CN86100105A - 有涂层的织物及其制造方法 - Google Patents

有涂层的织物及其制造方法 Download PDF

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CN86100105A
CN86100105A CN8686100105A CN86100105A CN86100105A CN 86100105 A CN86100105 A CN 86100105A CN 8686100105 A CN8686100105 A CN 8686100105A CN 86100105 A CN86100105 A CN 86100105A CN 86100105 A CN86100105 A CN 86100105A
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保罗·西奥多·范冈普尔
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Abstract

一种有涂层的织物，系由纤维织物，如聚丙烯无纺织物等一类无纺纤维织物的基布所构成，其上粘合着一层如乙烯-丙烯酸甲酯膜的一种热塑膜。基布上有加密部与非加密部，加密部划定基布涂覆面有加密区，热塑膜被加热粘合于涂覆面的至少在加密部分上。制造有涂层织物的方法包括将处于热软化状态的热塑膜贴合于基布的涂覆面上，然后令其冷却。

Description

本发明涉及一种有热塑膜涂层的织物，尤其涉及一种有热塑膜涂层的纤维织物，这种织物很适于制作控制大小便失禁用的衬垫，外科手术服、床单及包扎用品，以及妇女卫生用品。本发明还涉及制造此类有热塑膜涂层织物的方法。
将热塑膜粘覆于纤维织物（包括无纺的合成纤维织物），这种技术在现有专利中已有报道。例如，美国专利4275105号公开了一种稳定的吸水性人造丝织品，它由一种连续丝的纺粘布或由一种人造丝短纤维经气法成网、湿法成网或梳整而成的织品所构成，从该织品的底表面熔入一种有许多网眼的热塑膜，其熔入深度达织品厚度的10～40%。该专利还公开了若干种热塑膜，包括聚乙烯、聚丙烯、聚酯及乙烯-丙烯酸甲酯共聚物膜。
美国专利4367112号公开了一种双轴取向的聚丙烯膜，声称具有改善了的热密封强度和良好的光学透明度，其特征在于至少在其一个表面上有一层乙烯-丙烯酸甲酯的共聚物的连续涂覆层。美国专利4076895类似地公开了一种用乙烯-丙烯酸共聚物或乙烯-丙烯酸酯共聚物（如乙烯-丙烯酸乙酯、乙烯-丙烯酸甲酯共聚物）的挤压涂层涂覆于透明的聚合物膜（诸如取向的聚丙烯、赛璐玢、聚酯、尼龙膜等）上，其目的在于增加由这种方法制作的多层复合膜的透明性。美国专利4416937也公开了类似的内容，声称各种有一定极性的合成热塑聚合物（如乙烯-丙烯酸或乙烯-甲基丙烯酸的无规共聚物）对各种金属和非金属基材具有相当好的粘着力。
本发明提供了一种有涂层的织物，它包括由纤维织物构成的基布，较好的为无纺织物，其上具有加密部和非加密部，加密部划定在基布的至少一个表面（称为涂覆面）上有许多加密区;它还包括至少在涂覆面的加密区上有一层热粘合的热塑膜。
此项发明的内容之一在于：基布的加密部的纤维密度至少是非加密部的1 1/4 倍;加密部划定基布中加密部的重复图案;加密部最好与涂覆面齐平或高出涂覆面。
此项发明的内容之二在于：纤维材料系聚烯烃纤维，较好的为聚丙烯纤维。热塑膜可以选自下列一组聚合物：聚丙烯、乙烯-丙烯酸甲酯共聚物、乙烯-醋酸乙烯酯共聚物、聚乙烯、丁二烯-苯乙烯嵌段共聚物、乙烯-丙烯酸乙酯共聚物、乙烯-甲基丙烯酸甲酯共聚物，以及上述两种或几种单体的相容共聚物。较好的热塑膜是乙烯-丙烯酸酯共聚物膜，更好的是乙烯-丙烯酸甲酯共聚物膜，最好的是将后者涂覆于由无纺聚丙烯纤维织物构成的基布上。
此项发明的内容之三在于提供了一种有涂层的织物，包括无纺聚烯烃纤维织物构成的一种基布，其上具有加密部与非加密部，在基布的至少一个表面（称为涂覆面）上划定有加密区与非加密区相间的图案;并且至少在涂覆面的加密区有一层热粘合的热塑膜，该膜渗入基布的深度以能在基布的涂覆面上形成一层热塑膜涂层为度。
此项发明的内容之四在于：基布可包括聚丙烯、聚乙烯、聚乙烯涂覆的聚丙烯、聚酯、人造丝、尼龙等纤维以及这些纤维的混合物。
本发明还提供了一种制造有涂层的织物的方法，包括：将热塑膜加热粘合于纤维织物的基布上（最好用无纺纤维织物），基布上具有加密部与非加密部，加密部分布于基布的至少一个表面（称为涂覆面）上;热粘合时将加热软化的热塑膜的一面贴于基布的涂覆面，然后令其冷却。
该方法内容之一在于控制热塑膜的温度和该膜与基布的接触压力，使得该膜渗入基布的深度小于基布自身的厚度，并在基布的涂覆面上形成一层表面涂层。
该方法内容之二包含在基布上形成加密部与非加密部相间图案的予加工步骤。
该方法内容之三在于优选的热软化薄膜系乙烯-丙烯酸甲酯共聚物膜，其与基布粘合的初始温度约为275～315℃，最好约为293～315℃;基布最好为无纺聚丙烯织物。
该方法内容之四包括使用一种或几种上述材料作为本发明之有涂层的织物的原料。
本发明还提供了一种多层的、控制大小便失禁用的衬垫，其最外层系本发明的织物，而该织物的基布面向外。
本发明之有涂层的织物具有若干用途，包括用作控制大小便失禁的衬垫，外科手术服、床单和包扎用品，以及妇女卫生用品。至少在本发明优选的实施例中，有涂层织物的特征在于：在基布的无涂层一侧具有柔软的布感，而凭借热塑膜又可防止液体的渗透。
基布可以包括任何一种适宜的纤维织物。所谓“纤维织物”系指由纤维制作的织物，无论是纺织的或无纺的。当然在本发明中我们发现无纺的纤维织物，尤其是无纺的聚烯烃纤维织物具有特殊价值。品种繁多的其它纤维，如人造丝、尼龙、聚酯纤维等也可通过适当技术制成可用的织物。例如，本发明中可用由短纤维经纺粘或梳整干法成网及湿法成网而成的无纺织物。做基布用的纤维材料显然可包括不同长度的混合纤维，或由两种或两种以上不同材料制成的、长度相同或不同的混合纤维。例如，可以使用尼龙-聚乙烯、人造丝-聚丙烯或其它适宜的纤维组合物制作混合的无纺织物。适用于本发明的无纺纤维织物系由聚丙烯纤维制作的无纺织物，有市售产品，十分廉价经济，极适于做可处理的制品。所谓“可处理的制品”系指一次性使用之后可被处理掉，而不是洗涤后再使用的制品。某些无纺纤维织物具有柔软的布感，从而改善了由这类织物制成的服装或其它制品的纹理和外观。当然，这类无纺织物由于具有多孔结构，故可透气透湿。
在许多用途（如用作控制大小便失禁的衬垫）中需要一种不透湿的材料，以便阻留或防止液体（如尿或其它生理流体）透过。热塑膜（如聚烯烃膜、尤其是聚丙烯膜）是用于此目的一种熟知的膜。例如，可处理的尿布通常包括能渗液的上层、能吸湿的中间毡垫或单片层及由聚丙烯膜构成的外层或底层。虽然这种结构的制品很有用且在商业上获得极为广泛的市场，但是由于聚丙烯或其它热塑膜外层显然缺乏柔软的布感或纹理，故缺乏美感。
除了美观上的因素外，也许希望在纤维织物（如无纺聚烯烃纤维织物）上粘附一层多孔性或无孔性的热塑膜。如前述的美国专利（275105）所指示的，通过将热塑膜熔入无纺织物层（其渗入深度不超过无纺布本身的厚度）的方法可将多孔性热塑膜与无纺纤维织物复合在一起。试图将热塑膜复合于纤维织物上，尤其是低密度的无纺纤维织物表面上，其困难之一在于因不能将热塑膜充分地熔入无纺纤维织物的基体之中（如上述专利所要求的那样），故常常很难达到防止分层所需的足够粘结强度。避开任何理论的约束，我们设想：若单位体积的纤维织物具有相对低的纤维体积密度（纤维并加上纤维之间的空隙），则在纤维与热塑膜之间必然只有相对小的粘着或粘结面积;当希望将热塑膜仅粘合于纤维织物的一个表面上而不是使其熔入纤维织物基体之中时，这就成为一个突出的问题。显然，即使仅将热塑膜粘合于纤维织物的一个表面上，热塑膜对纤维织物也必有某种程度的渗透。但是，倘若希望在有涂层的织物另一面保持不被热塑膜所渗透的那种纤维织物的纹理和手感，则可用于粘合热塑膜的纤维体积必定受到限制，这将导致低的粘结力或低的粘合强度，尤其当使用一种难粘合的膜和纤维织物时更是如此。
我们现已发现，在纤维织物上制造加密部可以大大增强热塑膜与纤维织物之间的粘合强度，热塑膜与加密部的热粘合强度可以大大超过其与非加密部之间的热粘合强度。我们相信，由于加密区中单位体积的纤维织物具有较大的纤维体积密度，故对于一定的渗透深度而言，热塑膜所能接触的纤维的总面积必定增大，从而具有较高的粘合强度。避开任何理论的约束，我们还相信：在纤维织物的加密部由于具有较大的物质密度，有利于热量从处于热粘合状态的、热的热塑膜上传走，从而使纤维织物加密区中的纤维比之非加密区中的纤维的热软化程度高，换言之，使之更易于粘合。一般来说，我们相信由于在热的热塑膜与加密部之间的热传导速度增大，其结果使得加密部比之非加密部具有较高的温度，从而增强粘合强度。我们还相信，无纺纤维织物的加密部除了为热塑膜提供相当光滑、致密而又大的粘附表面外，还从机械上改善了织物的抗张和抗撕强度。另一方面，纤维织物的非加密部（在下文及权利要求书中有时称作“基布”）仍较好保持未涂覆基布的原有手感、纹理及弯曲模量。因此，通过改变基布中相间的加密部与非加密部的面积（基布涂覆面上的表面积）及其比例，可以任意改变有涂层织物的手感、纹理及柔韧性。
纤维织物的加密部可按某种适宜的方法制作。例如，可直接将无纺纤维织物压花制成所需的加密部的图案。采用常规的压花技术，即将基布送入一对夹辊（其中的一个辊刻有凸纹图案，另一个辊为表面裹有象皮的压力辊）中，即可压制出加密图案。另一种方法中，一个辊刻有凸纹图案，另一个辊刻有相应的凹纹图案（如现有技术中所采用的）。或者，可采用任何其它适宜的技术，如压延法和（或）超声波焊接法，以便在纤维织物上造出适宜的加密图案。无纺织物上形成的加密部一般会透入其整个厚度层，并在纤维织物的双面上都会显现出来。不过，织物的一面所产生的阴纹与其背面的阳纹相对应。例如，织物通过有华夫饼干形的图案的压花机压制后形成了加密图案，从而也就形成了加密区与非加密区相间的图案。显然，可以采用任何一种合适的图案，如菱形、棋盘格形、条形、八角形图案等。于是各个加密区与非加密区的形状可以是正方形、矩形、椭圆形、八角形、圆形等等。较好的方案是：至少在织物的一个表面上有阳纹的加密图案，且选此表面做涂覆面。所谓“阳纹图案”系指加密区或与涂覆面的平面齐平或高出该平面，而不是低于该平面。
织物的加密部为热塑膜与无纺织物之间产生高强度的粘合提供了粘结区，而且通常希望基布上分散着的加密部与非加密部以小面积的形式相间出现。例如，基布上分散着的每小块加密部的面积约为1～8平方毫米，相间图案中夹杂着的每小块非加密部的面积约1/4～25平方毫米。无纺织物基布表面上形成的每小块加密部较合适的面积约1～8平方毫米，各小块加密部之间间隔的直线距离约1/2～5毫米，较合适的是1/2～3毫米。因此，假如加密区与非加密区的图案是正方形、矩形或棋盘格形的，则每小块非加密区的面积将是1/4～25平方毫米，较合适的为1/4～9平方毫米。这些相关的面积值也适用于非矩形图案。我们发现，通过改变加密部与非加密部面积的相对尺寸和比例，即可任意改变无纺织物基布的纹理。加密区与非加密区的精细图案不仅为织物提供了波纹状的外观，而且还为热塑膜与基布涂覆面之间提供了高粘合强度，即热塑膜可涂覆于基布的涂覆面上而无需使热塑膜大部或全部地熔入无纺织物的深层。热塑膜若熔入无纺织物的基体内部必将使织物变得僵硬，失去柔软性和布感，这是因为无纺织物内部会充满光滑而又相对僵硬的热塑膜。
适用于本发明的一种纺粘的无纺织物是由摆动式喷丝机喷纺而成的，该喷丝机的摆速、传输机的进速、纤维的袋数和单丝的支数均可改变，从而生产出品种繁多的织物（如现有专利中所公开的），例如聚丙烯无纺织物。生产无纺织物的另一种方法是使用如聚丙烯的短纤维，其长度约1/4～2吋，较合适者约3/4～1.5吋，其袋数约1.5～15，较合适的约3。可通过梳整干法成网技术（如现有专利中所公开的）制作所需的织物重的无纺织物。例如，可以生产一种具有约0.35～2盎司/平方码织物重、较合适的为约0.68盎司/平方码织物重（按ASTM    D-3376-79方法测定）的无纺聚丙烯纤维织物。无纺聚丙烯织物可具有的厚度约6～12密耳，较合适的为9.5密耳（按ASTM    D-1774-64中的类似方法测定）。
上述无纺聚丙烯纤维织物可通过压花或其它技术制成加密图案，从而提供了一种加密区与非加密区相间的图案。在正文及权利要求书中所指的基布的“加密部”系指基布中的这样一些部分，即通常用物理方法进行形变压实（如用压花法），使这些部分变得密实。换言之，经加工后使厚度减小，从而获得较高的单位体积的物质密度。例如密度为0.6克/立方厘米的无纺聚丙烯织物，其加密部的密度可达0.9克/立方厘米。
必须控制热粘合的条件，不得使热塑膜完全熔入并渗透基布的纤维材料中。换言之，必须控制热粘合的温度和接触压力，使热塑膜涂覆于纤维织物的涂覆面时其透入深度不超过纤维织物自身的厚度，最好不超过纤维织物厚度的一半。
优选的一种热塑膜为（或含有）乙烯-丙烯酸酯树脂的热塑膜，而优选的复合织物系无纺的聚丙烯纤维织物（如上所详述者），其表面上热粘合着一层由（或含）乙烯-丙烯酸酯（最好是乙烯-丙烯酸甲酯）共聚物制成的热塑膜。乙烯-丙烯酸甲酯共聚物中含约5%～80%（最好为10%～30%）的丙烯酸甲酯和95%～20%（最好为90%～70%）的乙烯。
本发明优选的一种加工方法系将乙烯-丙烯酸甲酯在螺杆温度为约275～315℃（最好至少为293℃）的条件下挤出成膜，较合适的膜厚约为0.4～10密耳，最好为0.4～2密耳。当挤出的膜尚处于热软化状态时即进行拉伸，并与无纺聚丙烯纤维织物（最好用以上详述的无纺织物）的基布贴合，然后将两者送入一对夹辊中加压，同时对夹辊进行冷却，使得热塑膜与基布粘合在一起。
例如，直接与热塑膜接触的那个辊子最好用水冷却至约25～80°F（约-3.89～26.7℃），更合适的温度约为50°F（约10℃）。冷却辊的表面可以是抛光的、粗糙的或刻有花纹（以便为热塑膜提供一种所需的花纹）。另一夹辊的表面可以包裹橡皮。辊压约为60～120磅/平方吋（约4.22～8.44公斤/平方厘米），较合适的为约80磅/平方吋（约5.62公斤/平方厘米）。当用乙烯-丙烯酸甲酯热塑膜涂覆于无纺聚丙烯纤维织物基布上时，由于聚丙烯纤维的熔点远高于热塑膜的熔点，因此不会产生热塑膜或纤维降解的问题。假如热塑膜的挤出温度超过上述指定的温度，而它却仍要经受同样的接触压力，则热塑膜就会完全流动并渗入基布中，结果制成的是一种热塑膜嵌入无纺聚丙烯纤维织物基体中的高粘合强度的复合织物。然而，如此实施本发明所制得的有涂层的织物，其未涂覆的一面将丧失布料的柔软特性，从而成为一种僵硬的、塑料状的复合织物。假如挤压机的温度远低于上述指定的温度，则热软化了的热塑膜在基布纤维上的流动性不够好，导致低的粘合强度，因而基布易从热塑膜上剥离下来。在上述指定的温度范围内，热塑膜至少与基布的加密部之间可获得高的粘合强度。显然，对于不同基布与不同热塑膜的各种不同的复合则可能要求不同的挤出温度范围和接触压力。
本发明优选的一种实施例中，挤压成膜用的乙烯-丙烯酸甲酯共聚物固体切片23℃下的比重通常至少为0.94，较合适者约0.91～0.97（按ASTM    D-792所述的类似方法测定）。热塑膜中可含有常见的添加剂，如可添加色料以使热塑膜呈现所需的颜色。
在本发明优选的实施例中，无纺基布的原料系压成纤维毡的聚丙烯纤维。通常采用23℃下的比重为至少0.9（较合适者为约0.90～0.96）、且熔点在160～172℃之间的固体聚丙烯切片来加工这种纤维。无纺聚丙烯织物基布最好具有至少10/平方米（较合适者约为10～40克/平方米）的基布重量。
如上所述，按照本发明生产的有涂层的织物具有广泛用途。例如，它可用于制作各种要求有不透湿衬层的制品，而这种衬层的一面又需具有布感。这种布感使得这类织品适于做控制大小便失禁的衬垫（如可处理的尿布）、训练裤等，以及外科手术服和床单。本发明之有涂层的织物可制成一种热塑涂层向里而纤维基布无涂层的一面向外的织物制品，热塑层成为液体阻隔层，无涂层的具有类似布感和布的外观。例如，一种可处理的尿布或训练裤可以由一渗湿的内层、一吸湿的毡垫或单片中间层及一外支撑层构成;外支撑层系由本发明之有涂层的织物所制，其有热塑涂层的一面向里，无涂层的一面向外。
当我们以优选的实施例对本发明作了详尽阐述之际，那些谙熟本技术领域的人们在阅读并理解本文的基础上不难明白：上述内容的各种变更和改进并不偏离本发明的公开说明及所附之权利要求书的精神和范围。
Figure 86100105_IMG1

Claims (28)

1、一种有涂层的织物，系由具有加密部和非加密部的若干纤维织物基布(加密部划定基布的至少一个表面一称为涂覆面一上有许多加密区)和热粘合于其至少在加密区的涂覆面上的热塑膜所构成；
2、权利要求1的织物，其特征在于基布是一种无纺织物;
3、权利要求2的织物，其特征在于基布的加密部的纤维密度至少是非加密部密度的1.25倍左右，且加密部划定基布上加密部的重复图案;
4、权利要求2的织物，其特征在于加密部与涂覆面齐平或高出涂覆面;
5、权利要求2的织物，其特征在于纤维材料系一种聚烯烃纤维材料;
6、权利要求5的织物，其特征在于热塑膜选自下列一组聚合物：聚丙烯、乙烯-丙烯酸甲酯共聚物、乙烯-醋酸乙烯酯共聚物、聚乙烯、丁二烯-苯乙烯嵌段共聚物、乙烯-丙烯酸乙酯共聚物、乙烯-甲基丙烯酸甲酯共聚物以及上列的两种或几种相容的共聚物;
7、权利要求5的织物，其特征在于热塑膜系一种乙烯-丙烯酸甲酯膜，基布系聚丙烯纤维织物;
8、权利要求2的织物，其特征在于基布的纤维选自下列一组纤维：聚丙烯纤维、聚乙烯纤维、聚乙烯涂覆的聚丙烯纤维、聚酯纤维、人造丝、尼龙纤维以及上列的两种或多种纤维之混合物;
9、一种有涂层的织物，包括：
具有加密部与非加密部的无纺聚烯烃纤维织物的基布，加密部与非加密部划定基布的至少一个表面（称为涂覆面）上有加密区与非加密区相间的图案;
热粘合于涂覆面的至少在加密区上是一种热塑膜，要控制膜透入基布的深度，使热塑膜恰成为基布涂覆面的一表面涂层;
10、权利要求9的织物，包括涂覆面上划定分立着的非加密小区的非加密部，每一小块的非加密小区的面积约1/4～25平方毫米;还包括涂覆面上划定分立着的加密小区的加密部，每一小块加密区的面积约1～8平方毫米;加密区与非加密区彼此相间;
11、权利要求10的织物，其特征在于热塑膜选自下列一组单体的聚合物：丙烯、乙烯-丙烯酸甲酯、乙烯-醋酸乙烯酯、乙烯、丁二烯-苯乙烯嵌段共聚物、乙烯-丙烯酸乙酯、乙烯-甲基丙烯酸甲酯以及上述两种或几种的相容的共聚物;
12、权利要求11的织物，其特征在于热塑膜系一种乙烯-丙烯酸酯膜;
13、权利要求12的织物，其特征在于热塑膜系一种乙烯-丙烯酸甲酯膜;
14、权利要求9的织物，其特征在于基布系聚丙烯纤维织物，其织物重约为0.35～2盎司/平方码，厚度约6～12密耳;热塑膜系乙烯-丙烯酸甲酯膜，其膜厚约0.4～10密耳;
15、一种制造有涂层织物的方法，包括：
将热塑膜热粘合于纤维织物的基布上;基布具有加密部和非加密部;加密部布满基布的至少一个表面（称为涂覆面）上;
通过下列步骤完成热粘合：将处于热软化状态的热塑膜表面与基布的涂覆面贴合，然后令其冷却;
16、权利要求14的方法，其特征在于基布系一种无纺纤维织物;
17、权利要求16的方法，包括控制热塑膜的温度及热塑膜与基布的接触压力，使膜透入基布的深度小于基布自身的厚度，使得在基布涂覆面上形成一个表面涂层;
18、权利要求16的方法，包括在基布上制作加密部与非加密部图案的予加工步骤;
19、权利要求16的方法，其特征在于基布系聚烯烃纤维织物;
20、权利要求19的方法，其特征在于基布系聚丙烯纤维织物;
21、权利要求20的方法，其特征在于热塑膜选自下列一组单体的聚合物：丙烯-乙烯-丙烯酸甲酯、乙烯-醋酸乙烯酯、乙烯、丁二烯-苯乙烯嵌段共聚物、乙烯-丙烯酸乙酯、乙烯-甲基丙烯酸甲酯以及上列的两种或几种相容之共聚物;
22、权利要求20的方法，其特征在于系乙烯-甲基丙烯酸甲酯共聚物膜;
23、权利要求16的方法，其特征在于基布材料选自下列一组纤维：聚丙烯、聚乙烯、聚乙烯、涂覆的聚丙烯、聚酯、人造丝、尼龙以及上列的两种及几种纤维的混合物;
24、权利要求23的方法，其特征在于热软化膜最初与基布贴合的温度约为275℃～315℃;
25、权利要求24的方法，其特征在于热软化膜的温度至少约为293℃;
26、一种多层的控制大小便失禁的衬垫，其特征在于其最外层系权利要求1的织物，其基布面向外;
27、一种多层的控制大小便失禁的衬垫，其特征在于其最外层系权利要求9的织物，其基布面向外;
28、一种多层的控制大小便失禁的衬垫，其特征在于其最外层系权利要求13的织物，其基布面向外。
CN8686100105A 1985-01-10 1986-01-10 有涂层的织物及其制造方法 Pending CN86100105A (zh)

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CN105088811A (zh) * 2014-05-05 2015-11-25 江苏聚威新材料有限公司 一种提高面料表面柔韧性的组合物面料
CN104191756A (zh) * 2014-08-07 2014-12-10 安踏（中国）有限公司 一种防紫外线面料及一种防紫外线服装
CN113040457A (zh) * 2015-02-06 2021-06-29 罗纳地股份公司 组合的纺织产品
CN110959927A (zh) * 2019-11-21 2020-04-07 黄生林 一种抗过敏透气型腿围

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