CN1615380A - High elongation, low denier fibers using high extrusion rate spinning - Google Patents
High elongation, low denier fibers using high extrusion rate spinning Download PDFInfo
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- CN1615380A CN1615380A CN02827320.6A CN02827320A CN1615380A CN 1615380 A CN1615380 A CN 1615380A CN 02827320 A CN02827320 A CN 02827320A CN 1615380 A CN1615380 A CN 1615380A
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Images
Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/08—Melt spinning methods
- D01D5/098—Melt spinning methods with simultaneous stretching
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
- D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
- D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2904—Staple length fiber
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
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- Y10T428/2913—Rod, strand, filament or fiber
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2915—Rod, strand, filament or fiber including textile, cloth or fabric
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/601—Nonwoven fabric has an elastic quality
- Y10T442/602—Nonwoven fabric comprises an elastic strand or fiber material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
- Y10T442/626—Microfiber is synthetic polymer
Abstract
Low denier, high extensible fibers, soft extensible nonwoven webs comprising such fibers, and disposable articles comprising such nonwoven webs are obtained by spinning a polymer composition through small diameter holes.
Description
Invention field
The present invention relates to low dawn, high extensible fibers, comprise the soft extensible nonwoven webs of these fibers, and the disposable product that comprises this non-woven web.
Background of invention
By the nonwoven extrusion molding for example the non-woven web that forms of meltblown and spun-bond process can be made into product and product component, can be regarded as only using once or disposable products several times to such an extent as to the cost of manufacture of these products and product component is so cheap.The representational example of this product comprises disposable absorbent article, as diaper, incontinence briefs, training pant, feminine, cleaning piece etc.
The non-woven material that uses in the consumer wants disposable products can be sent flexibility and ductility.Soft non-woven material is to the skin milder, and provides an aesthetic feeling of garment-like more for diaper.The non-woven material that under low relatively external force effect, has a high ductibility can be used for for product for example disposable diaper sustained subsides and property are provided, for example as the part of elastomeric compositions, and facilitate as stretching, perforation etc. for the use of different mechanical post-treatments.Extensible material is defined as in this article and can extends, but is not to recover strain all or that part applies.And elastomeric material according to definition, then must recover the major part of its elongation after unloading.
This area has used several diverse ways to make extending non-woven material:
World patent application WO 00/04215 discloses a kind of being designed for and has produced high extensibility bondedfibre fabric, is the concrete bonding patterns for skin-core polypropylene staple fibers specifically.Described bonding patterns has bonding position staggered in adjacent lines, and it makes that they can be not overlapping in manufacturing vertical (MD).The area that is shaped as quadrangle and covers whole bonding zone of preferred node is less than 20%.Can be not bonding when they disclose fiber and vertically become 35-55 °, therefore allow bigger horizontal manufacture elongation.
Often use fiber preparation to obtain ductility.United States Patent (USP) 5,804,286 and 5,921,973 disclose polyethylene and polyacrylic mixture, contain or do not contain the copolymer of miscible ethylene-propylene, and described mixture can be produced softness, the high-intensity non-woven material with extensibility that hanging down fluffs becomes reconciled.World patent application WO 00/31385 discloses polypropylene and ethylene copolymer mixture, with United States Patent (USP) 6,015,317 disclose two kinds of differing ethylene mixture of polymers, these two kinds of mixtures all can improve bonding and fabric extension, keep good spinning properties simultaneously.United States Patent (USP) 5,616,412 disclose the filament of poly-third ethene (every fiber is the 2-4 dawn) of polypropylene and higher molecular weight, have the two filament and only have polyacrylic filament to compare to show to have higher extensibility.United States Patent (USP) 5,322,728 disclose the soft nonwoven with good elongation that comprises ethylene copolymer, however United States Patent (USP) 4,769,279 discloses the soft nonwoven with good elongation that comprises ethylene acrylic acid co polymer.United States Patent (USP) 4,804,577 and 4,874,447 disclose the elastocopolymer extending meltblown nonwoven of the mixture of isobutylene-isoprene copolymer for example that comprises polyolefin, isoalkene and conjugated diene.United States Patent (USP) 5,349, but 016 drawn fibers that discloses the grafted propylene polymer (as be grafted on the polypropylene backbone styrene or methylmethacrylate), it has higher bending recovery and coefficient, and elongation has surpassed the virgin pp tester in some cases.United States Patent (USP) 6,080,818 disclose the fiber of the non-woven material that comprises isotactic polypropylene and irregular flexible poly alkene mixture, and its percentage elongation is higher than the situation that does not comprise flexible polymeric.
All these obtainable formulation methods can be increased to the ductility that is moderate to low dawn fiber to a certain degree, but can not reach degree disclosed in this invention.In addition, they relate generally to the higher cost mixtures of material, and can relate to the specific blend requirement to guarantee the correct distribution in mixture.
This method that non-woven web is shaped also can be used to make the tensile property maximization.United States Patent (USP) 5,494,736 disclose the height elongation combing non-woven material from high elongated fibers, and the placement of described fiber is horizontal orientation more than conventional carded fiber.Claimed bonded areas is in 8 to 25% scope.
In current textile industry, satisfy obtaining to have a kind of like this demand of extending non-woven material that is moderate to low dawn fiber yet, this fiber can be by conventional resin manufacture, and does not need expensive particular polymers or elastomeric polymer.As everyone knows, take out long speed when increasing when spinning, the directionality of molecule increases but the elongation of fiber rate reduces.For high-intensity low dawn fiber, this is not a problem, remains a great challenge but produce the low dawn fiber with high elongation rate.Therefore, an object of the present invention is openly to be used to make the method for low dawn fiber with high elongation at tear.Another object of the present invention is the non-woven web that openly comprises the soft extensible of this low dawn, high elongation rate fiber.Another object of the present invention is the disposable product that openly comprises this soft extensible nonwoven webs.
Summary of the invention
The invention discloses the method for producing low dawn fiber with high extension at break.By changing the nozzle design of fiber on capable, make it have little capillary diameter keeping the high spinning speed of hope, the combination of availability, but to compare with the high draw ratio of conventional spinning technique, its generation is moderate to low draw ratio.Specific embodiments of the present invention comprises the fiber of diameter in 5 to 25 micrometer ranges, this fiber is produced by the solution spinning of polymeric blends, for example draw ratio is less than 400, and the quality output is every hole per minute 0.01 to 2.0 gram, and spinnerette diameters is less than 200 microns.Alternate embodiment of the present invention comprises the fiber of diameter in 5 to 25 micrometer ranges, this fiber is produced by the solution spinning of polymeric blends, for example draw ratio is less than 400, and the fibrous fracture percentage elongation is greater than 400%, and spinnerette diameters is less than 200 microns.
Without being limited by theory, it is believed that low draw ratio causes fiber to have less directionality, therefore keeps higher residue elongation at break.Make and to produce the high homogeneous fabric that comprises thin diameter, high elongated fibers in this way.Non-woven web with this performance combination is particularly useful for disposable absorbent article, as diaper, incontinence briefs, training pant, feminine hygiene underwear, Wiping article etc., because they can be used as the part of goods equally, wherein ductility and flexibility can increase the comfort level and the overall performance of goods.
Summary of drawings
Fig. 1 shows the capillary that uses 86 micron diameters and the capillary of 570 micron diameters, and 400 melt flow rates are with the polyacrylic elongation at break of every hole per minute 0.2 gram melt spinning.
Detailed Description Of The Invention
Term used herein " absorbent article " refers to absorb and hold the device of body excretions, has more Say body, refer to be close to or contiguous wearer's body is placed to absorb and held various body excretions Device.
Term used herein " disposable " refers to not plan wash, recovers or be heavy as absorbent article The multiple absorbent article that uses (that is, their designs abandon after disposable use, preferably with its with ring The compatible mode in border is recycled, compost treatment or carry out other processing). " one " absorbs system Product refer to be formed common physical and be coupled to each other the absorbent article that forms by independent sector, and they do not have like this Need independent processing section, such as independent holder and liner.
Term used herein " non-woven web " is meant a kind of like this net, and it has individual fibers or silk thread structure in the middle of inserting, but is not in any regularly repeating mode.Non-woven web ins all sorts of ways in the past and makes, and for example gas is paved into net method, melt blown webbing method, spunbond one-tenth net method, carding method, comprises bonding carding method.
Term used herein " microfiber " is meant that average diameter is not more than about 100 microns, L/D ratio greater than about 10 small diameter fibers.This area was subjected to the personnel of training will know that the fibre diameter that comprises non-woven web influences its overall flexibility and comfort level, and than fine count fiber usually relatively coarse denier fiber can produce soft more and comfortable product more.For fiber of the present invention, in order to obtain suitable flexibility and comfort level, preferred diameter in about 5 to 25 microns scope, more preferably diameter in about 10 to 25 microns scope, even more preferably diameter in about 10 to 20 microns scope.Fibre diameter can be determined with the light microscope of 10 microns counting line calibrations by for example using.
Term used herein " meltblown fibers " is meant the fiber that forms with following method: with molten thermoplastic material by a plurality of thin and be generally circular capillary die and be extruded as fusion silk thread or filament, flowing down the filament that makes molten thermoplastic at high-speed gas (as air) then elongates, so that its diameter reduces, even may diminish to the microfiber diameter.Thereafter, meltblown fibers is by high velocity air delivery and deposit to and collect on the surface, forms the knitmesh that the meltblown fibers by random distribution constitutes.
Term used herein " spun-bonded fibre " refers to by molten thermoplastic being extruded as the small diameter fibers that filament forms, fiber come from a plurality of thin be generally circular and with extrude the spinning head capillary that filament has same diameter, elongate in the drawing of conventional seal wire reel system or the drawing of convection current air then that its diameter reduces rapidly under the effect of device.If the application godet system, can also by after extrude tractive and reduce fibre diameter.
Term used herein " fixed " and " fixed " are meant a part of fiber of non-woven web at least the most closely gathered and form a bond locations or a plurality of bond locations, compare with non-consolidated web, these bond locations can increase that the external power effect of non-woven material is is for example worn and torn and the resistance of tension force." fixed " can refer to for example make at least a portion fiber the most closely in conjunction with the whole non-woven web of making by the heat bonding method.Such net can be thought " consolidated web ".On another meaning, tight coupling concrete fiber zone of dispersion, as independent thermal bond site, can be described as is " fixed ".
Can obtain fixedly by several different methods, these methods comprise fiber web are applied heat and/or pressure, for example thermal potential (that is point) bonding.Can be by fiber web be realized thermal point bond by the pressure nip that two rolls form, wherein a roll be heated and its surface on a plurality of raised points are arranged, authorize 3,855,046 description of United States Patent (USP) of people such as Hansen as described above.Consolidation method also can include, but not limited to ultrasonicly strong close, the convection current air is bonding, resin-bonding and water entanglement method.Water entanglement method typically relates to uses high pressure water jets processing fiber web to make net fixed, and the method is to twine (friction) by mechanical fiber in the fixed zone of needs, and bond locations forms in the zone that fiber twines.Fiber can carry out water with the method that following United States Patent (USP) proposes and twine: authorized the United States Patent (USP) 4 of Kalwaites on May 3rd, 1977, authorized people's such as Contrator United States Patent (USP) 4,024 on May 24th, 021,284 and 1977,612, two patents are incorporated herein by reference in view of the above.
Though non-woven web of the present invention as disposable product for example the component of diaper have useful purposes, its purposes is not limited to disposable absorbent article.Non-woven web of the present invention can in officely be what is the need for and be used in the goods of wanting or benefit from flexibility and extensibility, and these goods comprise for example cleaning piece, polishing cloth, furniture wadding, durable clothes etc.
Extensible soft nonwoven of the present invention can be the form of laminated material.Laminated material can adopt any adhesive method well known to those skilled in the art to carry out combination, these adhesive methods comprise, but be not limited to, thermal, include but not limited to spray adhesive, hot-melt adhesive, based on the adhesive of latex adhesive etc. in conjunction with, velocity of sound and ultrasonic bond and extrude lamination, extruding lamination is that polymer casts directly on another non-woven material, and when also being in partially molten state and the one side of non-woven material bonding or directly meltblown fibers is deposited on the non-woven material.The United States Patent (USP) 6 of authorizing people such as Wu that the proper method of the making laminated material of these and other was announced on January 11st, 2000,013, be described in the United States Patent (USP) of announcing on August 3rd, 151 and 1,999 5932,497 of authorizing people such as Morman, these two patents all are incorporated herein by reference.
The term " polymer " composition that the present invention uses " generally comprise, but be not limited to, homopolymers, copolymer are for example with block, grafting, form and mutual copolymer, terpolymer etc., and their mixture or modifier at random.In addition, unless otherwise specifically limited, term " polymer " composition " should comprise all possible geometrical configuration of described material.These configurations include, but not limited to isotaxy, syndiotaxy and symmetrical at random.The embodiment that is suitable for thermoplastic polymer that uses in the present invention comprises, but be not limited to, polyethylene, polypropylene, polyethylene-polypropylene copolymer, polyvinyl alcohol, polyester, nylon, polyactide, polyhydroxyalkanoatefrom, aliphatic (acid) ester condensation polymer, and their mixture.Preferred polymeric compositions comprises polyolefin for example polyethylene and polypropylene, or polyester for example poly-(ethylene terephthalate), and their copolymer.Preferred other polyester comprises, but be not limited to, poly-(lactic acid) (Lacea of Mitsui Chemicals for example, or the EcoPLA of DowCargill), poly-(caprolactone) (for example ToneP787 of Union Carbide), poly-(butylene succinate) (for example Bionolle 1000 series of Showa Denko), poly-(ethene succinate) (for example Lunare SE of Nippon Shokubai), poly-(butylene succinate adipate ester) (for example Bionolle 3000 series of Showa Denko), poly-(ethene succinate adipate ester), aliphatic polyester based polyurethanes (the Morthane PN03-204 of MortonInternational for example, PN03-214 and PN3429-100), the adipic acid copolyesters, terephthalic acid (TPA) and 1,4-butanediol (for example the Eastar Bio of Eastman Chemical Company and the Ecoflex of BASE), polyesteramide (for example BAK series of Bayer Corporation), water-disintegrable aromatics/aliphatic copolyester (for example Biomax of DuPont), cellulose esters (cellulose ethanoate for example, and their composition and copolymer etc. the cellulose acetate root propionate of cellulose acetate root butyrate and Eastman ChemicalCompany).
Polymer composition also can comprise various non-polymeric components, comprising stabilizing agent, antioxidant, pro-oxygenic agent additive, pigment, filler etc. before nucleator, anticaking agent, antistatic additive, slip agent, the heating.These components can use with convention amount, but in order to obtain the favourable combination of flexibility and ductility, do not need these additives in the composition usually.
The melt flow rate that those skilled in the art will appreciate that polymer composition is suitable for interested fibre manufacture, for example melt spinning or meltblown.The melt flow rate of polymer composition can use the method for summarizing among the ASTM D1238 for example to determine.
Term used herein " extending " is meant under the bias force effect, the extending bust that do not cause at least about 400% of arbitrary fiber, more preferably extending at least 600% and do not cause bust, even more preferably extending at least 800% and do not cause bust.Elongation at break can use the method for summarizing among the ASTM D3822 for example to determine and the development length when being defined as fracture deducts the initial testing gauge length and multiply by 100 divided by the initial testing gauge length.
Continuous fibers, staple fiber, doughnut, shaped fibers, for example leafy shape fiber and multicomponent fibre can the application of the invention method prepare.In this article, component is defined as a unitary part of fiber, and another part of itself and fiber has spatial relationship.Multicomponent fibre is generally bicomponent fiber, can be parallel type, core-skin type, the cake type of cutting apart, band shape or day starlike configuration.Crust can be continuously or discontinuously around core.Fiber of the present invention can have different geometries, comprises circle, ellipse, star, rectangle and other multiple eccentric shape.Fiber of the present invention also can be a splittable fibers.The rheological property difference of polymer can produce division, and mechanical system and/or fluid induced distortion also can produce division.The diameter of noncircular cross section fiber used herein is the equivalent diameter with circle of same cross-sectional area.
In the melt spinning technology of routine, fiber speed and spinning speed can use continuity equation to calculate mostly and obtain:
V wherein
xBe total fiber speed, Q is the quality output of each spinneret orifice, ρ
FiberBe the density of fiber, d is the diameter (or equivalent diameter) of fiber.Total fiber speed comprises two key components
(2)V
x＝V
o+V
A
V wherein
oBe the speed that fiber is extracted out from spinning head, V
AFor taking out the apparent speed of the fiber of long correlation with filament.For definite V
AInfluencing the most significant is inertia, resistance and rheology educational level.V
APower is the power that produces direction in filament.
The extraction speed of fiber can be calculated according to equation 3, and only depends on the diameter (or equivalent diameter) of Q and capillary D
Wherein density p is melted in and is polymer melt density in this case.For given Q, D is unique variable, therefore extracts the diameter that speed only depends on the lousiness pipe out.
Higher fiber is taken out long speed V
ACause the higher orientation of fiber, and produce and have more high strength but the small diameter fibers of lower elongation.Without being limited by theory, for high elongated fibers, preferably in fiber, keep being moderate to little diameter to obtain comfort level and flexibility than the directionality of low degree and maintenance simultaneously.In other words, take out long speed V
A=V
x-V
o, or alternatively, draw ratio V
x/ V
oShould be low.In order to keep small diameter fibers to obtain uniformity, coverage and flexibility, this requires to reduce output Q usually.Yet the total output that this can reduce material causes not too gratifying economic impact.Usually, for this area trained personnel, the quality output of about 0.01 gram of every hole per minute is thought minimum.This area was also understood by the personnel of training, and the quality output that restrains greater than every approximately hole per minute 2.0 can cause the flow instability of mould, for example, and the slip of melt fracture or wall, the difficulty that causes handling or collecting the appropriate mass product.Therefore, preferably the quality output is in 0.01 to 2.0 grams per minute per hole, more preferably in 0.2 to 1.0 grams per minute per hole, even more preferably in the scope of 0.6 to 0.8 grams per minute per hole.The quality output in every hole can be determined, for example, by in preset time, collect extrudate then with the value of the gross mass collected divided by acquisition time at interval again divided by the hole count in the spinning head of extracting fiber out.
Use method of the present invention, (V when fiber is drawn out of the spinning head capillary
o), increase fiber speed and can reduce draw ratio V
x/ V
oOr take out long speed V
A, but can not reduce output.This can finish by using less capillary diameter.Following formula has provided the useful typical spun yarn number that comprises most present disclosures.
Similar with draw ratio, spinning number S
xValue low be preferred.
Be not subjected to the restriction of embodiment, for example, for the quality output of given 0.52 grams per minute per hole (is typical for conventional high speed melt spinning system) and the standard capillary diameter of 0.6mm, the extraction speed V of melt spinning grade polypropylene filament
oTo be about 2.5 meters/minute.Usually, for the even bondedfibre fabric of producing, conventional high speed melt spinning system must be equal to or higher than about 2000 meters/minute fiber speed V
xFollowing operation, draw ratio V then
x/ V
oWill be for about 800, spinning number S
xWill for about 7980 microns/(grams per minute per hole), this bondedfibre fabric performance relevant with this fiber (for example, high directionality and low extensibility).For identical spinning conditions, if replace the capillary diameter of using 0.07mm, the extraction speed of filament will be very high, is about 183 meters/minute, V
x/ V
oWill be much lower, for about 11, S
xWill be much lower, for about 403 microns/(grams per minute per hole).The fiber of gained will have lower directionality and higher residual elongation.
This area will be understood by the personnel of training, and the fibre diameter that comprises non-woven web influences overall pliability and comfort level, and the product that fine count fiber is produced is generally more soft and more comfortable than the product that coarse denier fiber is produced.For fiber of the present invention, in order to obtain suitable flexibility and comfort level, preferred diameter in about 5 to 25 microns scope, more preferably diameter in about 10 to 25 microns scope, even more preferably diameter in about 10 to 20 microns scope.In order to keep small diameter fibers to obtain uniformity, coverage and flexibility, this will need to reduce output Q routinely.Yet this will reduce the total output of material, cause not too gratifying economic impact.Usually, for the personnel that those this areas were subjected to training, it is minimum that the quality output of about 0.01 grams per minute per hole is considered to.This area will further be understood by the personnel of training, and the quality output that restrains greater than every approximately hole per minute about 2.0 can cause the flow instability of mould, for example, and the slip of melt fracture or wall, the difficulty that causes handling or collecting the appropriate mass product.Therefore, preferably the quality output is in the scope of 0.01 to 2.0 grams per minute per hole, more preferably in the scope of 0.2 to 1.0 grams per minute per hole, even more preferably in the scope of 0.6 to 0.8 grams per minute per hole.In addition, those this areas will be understood by the personnel of training, in order to obtain good even non-woven web, fiber speed V on older melt spinning system
xUsually must be greater than about 500 meters/minute, on newer middling speed system, fiber speed usually must be greater than about 2000 meters/minute, and on newer high-speed spinning system, fiber speed generally must be greater than about 3000 meters/minute.
In addition, this area will further be understood through the personnel of special training, low draw ratio V
x/ V
oHigher residual fiber extension at break will be caused usually.We find, the draw ratio less than about 400 is enough to make the fiber with the extension at break that is suitable for making soft extensible non-woven material of the present invention usually, and more preferably draw ratio is less than about 150, in addition more preferably draw ratio less than about 50.In order to obtain these low draw ratios and high fiber speed within the scope of the invention, we find just enough usually less than about 200 microns spinnerette diameters, more preferably spinnerette diameters is less than about 150 microns, in addition more preferably spinnerette diameters less than about 100 microns.In addition, term used herein " extending " is meant can extend any fiber that bust does not take place at least about 400% under the effect of bias force, more preferably elongation at least 600% and bust does not take place, even preferred the elongation at least 800% and fiber of bust does not take place.
The following example will further illustrate product of the present invention and method.
Embodiment 1
The demonstrated melt spinning of acrylic resin of the present invention of this embodiment.Specifically, poly-propyl ester resin (DE with 400 melt flow rates, the Valtech HH441 of the Basell PolyolefinsCompany of Wilmington) use vertical single screw extrusion machine to carry out spinning, this extruder be installed in can the platform of lifting on, and single hole capillary die and the about 86 microns capillary of diameter are housed.Utilize height-adjustable vapour lock equipment pull that the silk thread of fusing is retracted to about 25 ℃ air from capillary die, described equipment uses the compressed air under the high pressure to produce air-flow, and described air flow centers on and the pull filament.The output quantity of extruder is held constant at about 0.2 grams per minute per hole relatively, distance between mould outlet and the air gun remains about 41 inches (104.2cm), air gun and the distance of collecting between the screen cloth remain about 25 inches (63.5cm), the temperature of extruder and set of molds is as follows-regional 1=380 (193 ℃), 2=400 (204.4 ℃) in zone, 3=420 (215.5 ℃) in zone, die adapter=425 (218.3 ℃), mould=420 (215.5 ℃), and in order to obtain and to collect diameter less than about 25 microns fiber, the pressure of air gun is adjustable.Under these conditions, collected the fiber samples of diameter in 10 to 30 microns preferable range.This example shows that the standard fibers shaping resin is that fusion is spinnable according to the present invention.
Embodiment 2
This embodiment shows high extensibility of fibers produced according to the invention.Specifically, according to ASTM standard D3822 the fiber samples of embodiment 1 is tested.Test is carried out on MTS synergie 400 cupping machines (MN, the MTS Systems Corporation of Eden Prairie), this equipment 10 newton's load cell and pneumatic type anchor clamps.Crosshead speed is that the filament sample of 1 inch (2.54cm) is tested with the speed of per minute 2 inches (5.08cm) to gauge length.Sample is stretched to fracture, is recorded under the identical gun pressure elongation at break of 10 test specimens collecting and averages.The elongation at break of gained wherein utilizes the fibre diameter of microscope measurement can calculate spinning speed according to equation (1) as shown in Figure 1.This embodiment shows that when making according to the present invention, minor diameter (about 10 to 20 microns) fiber also can have high elongation at break (＞600%).
Comparing embodiment 3
This embodiment compares the elongate fiber of embodiment 2 and the elongate fiber of those use stock size spinnerette.Specifically, acrylic resin uses the about 570 microns capillary of diameter among the embodiment 1, and is spun into fiber according to the technology and the condition fusion of embodiment 1 general introduction, and determines elongation at break according to the method for embodiment 2 general introductions.The elongation at break of gained as shown in Figure 1, the fibre diameter that wherein utilizes microscope to measure can calculate the speed of spinning according to equation (1).This embodiment shows, when coming spinning fibre according to the present invention, can compare the ductility that fibre diameter or spinning speed can obtain to strengthen.
All patents of mentioning in this manual, patent application (with any patent at its announcement, and the foreign patent application of any corresponding publication) and the disclosure of publication all are incorporated herein by reference.Yet, do not admit clearly that any document that is incorporated herein by reference proposes or disclose the present invention.
Although illustrated and described the present invention with specific embodiments, it is evident that those skilled in the art can make many other variation and modifications in the case of without departing from the spirit and scope of protection of the present invention.Therefore appending claims is intended to comprise all these variation and modifications within the scope of the present invention.
Claims (9)
1. by the fiber of diameter in 5 to 25 micrometer ranges of melt spinning polymer composition production, it makes described quality output in the scope of every hole per minute 0.01 to 2.0 gram, and described draw ratio is less than 400, and described spinnerette diameters is less than 200 microns.
2. by the fiber of diameter in 5 to 25 micrometer ranges of melt spinning polymer composition production, it makes described fibrous fracture percentage elongation greater than 400%, and described draw ratio is less than 400, and described spinnerette diameters is less than 200 microns.
3. the fiber of claim 2, wherein said fibrous fracture percentage elongation is preferably greater than 800% greater than 600%.
4. each fiber in the claim 1 to 3, the diameter of wherein said fiber is in 10 to 20 micrometer ranges.
5. each fiber in the claim 1 to 4, wherein said draw ratio is less than 150, preferably less than 50.
6. each fiber in the claim 1 to 5, wherein said spinnerette diameters is less than 150 microns, preferably less than 100 microns.
7. each fiber in the claim 1 to 6, wherein said polymer composition comprises one or more polymer that is selected from polyolefin and polyester.
8. non-woven web is characterized in that, it comprises in the claim 1 to 7 each fiber.
9. disposable product is characterized in that, it comprises the non-woven web of claim 8.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US34060101P | 2001-12-14 | 2001-12-14 | |
| US60/340,601 | 2001-12-14 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN1615380A true CN1615380A (en) | 2005-05-11 |
Family
ID=23334109
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN02827320.6A Pending CN1615380A (en) | 2001-12-14 | 2002-12-03 | High elongation, low denier fibers using high extrusion rate spinning |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US20030124348A1 (en) |
| EP (1) | EP1461479A1 (en) |
| JP (1) | JP2005513279A (en) |
| CN (1) | CN1615380A (en) |
| AU (1) | AU2002352998A1 (en) |
| CA (1) | CA2470378A1 (en) |
| WO (1) | WO2003052179A1 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040152815A1 (en) * | 2002-11-17 | 2004-08-05 | Morin Brian G. | High speed spinning procedures for the manufacture of low denier polypropylene fibers and yarns |
| MXPA06008385A (en) * | 2004-01-27 | 2006-08-25 | Procter & Gamble | Soft extensible nonwoven webs containing multicomponent fibers with high melt flow rates. |
| US20050273958A1 (en) * | 2004-06-14 | 2005-12-15 | Dillon John J | Sponge and cloth cleaning device |
| DE102005025055B4 (en) * | 2005-05-30 | 2007-12-06 | Fiberweb Corovin Gmbh | A process for producing a high extensibility nonwoven fabric from polymer blends comprising amphiphilic block copolymers, high extensibility nonwoven web and use, and polymer blends for producing a high extensibility nonwoven web |
| EP2813611A1 (en) * | 2009-09-14 | 2014-12-17 | Idemitsu Kosan Co., Ltd. | Spun-bonded nonwoven fabric and fiber product |
| DE102017003340A1 (en) * | 2017-04-05 | 2018-10-11 | Bio-Tec Biologische Naturverpackungen Gmbh & Co. Kg | Biodegradable film |
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| CA948388A (en) * | 1970-02-27 | 1974-06-04 | Paul B. Hansen | Pattern bonded continuous filament web |
| US4021284A (en) * | 1972-11-13 | 1977-05-03 | Johnson & Johnson | Nonwoven fabric and method and apparatus for producing the same |
| US4013816A (en) * | 1975-11-20 | 1977-03-22 | Draper Products, Inc. | Stretchable spun-bonded polyolefin web |
| US4024612A (en) * | 1976-04-02 | 1977-05-24 | E. I. Du Pont De Nemours And Company | Process for making an apertured nonwoven fabric |
| JPS5488316A (en) * | 1977-12-21 | 1979-07-13 | Toray Ind Inc | Method of melt spinning of extremely fine fiber |
| JPS5747912A (en) * | 1980-09-03 | 1982-03-19 | Teijin Ltd | Undrawn polyester yarn and its production |
| DE3151322C2 (en) * | 1981-12-24 | 1983-11-10 | Fa. Carl Freudenberg, 6940 Weinheim | "Process for the production of spunbonded polypropylene nonwovens with a low coefficient of fall" |
| EP0156234B2 (en) * | 1984-03-17 | 2001-01-03 | Asahi Kasei Kogyo Kabushiki Kaisha | Heat-resistant non-woven fabric having a high elongation at break |
| US4551378A (en) * | 1984-07-11 | 1985-11-05 | Minnesota Mining And Manufacturing Company | Nonwoven thermal insulating stretch fabric and method for producing same |
| JPS61194247A (en) * | 1985-02-18 | 1986-08-28 | 株式会社クラレ | Composite fiber cloth |
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| JP2577977B2 (en) * | 1988-10-28 | 1997-02-05 | チッソ株式会社 | Stretchable nonwoven fabric and method for producing the same |
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| US6770356B2 (en) * | 2001-08-07 | 2004-08-03 | The Procter & Gamble Company | Fibers and webs capable of high speed solid state deformation |
-
2002
- 2002-12-03 CA CA002470378A patent/CA2470378A1/en not_active Abandoned
- 2002-12-03 AU AU2002352998A patent/AU2002352998A1/en not_active Abandoned
- 2002-12-03 JP JP2003553045A patent/JP2005513279A/en not_active Withdrawn
- 2002-12-03 EP EP02789964A patent/EP1461479A1/en not_active Withdrawn
- 2002-12-03 CN CN02827320.6A patent/CN1615380A/en active Pending
- 2002-12-03 WO PCT/US2002/038381 patent/WO2003052179A1/en not_active Application Discontinuation
- 2002-12-13 US US10/319,021 patent/US20030124348A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| JP2005513279A (en) | 2005-05-12 |
| EP1461479A1 (en) | 2004-09-29 |
| CA2470378A1 (en) | 2003-06-26 |
| AU2002352998A1 (en) | 2003-06-30 |
| WO2003052179A1 (en) | 2003-06-26 |
| US20030124348A1 (en) | 2003-07-03 |
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