EP2616580B1 - Highly functional spunbonded fabric made from particle-containing fibres and method for producing same - Google Patents

Highly functional spunbonded fabric made from particle-containing fibres and method for producing same Download PDF

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Publication number
EP2616580B1
EP2616580B1 EP20110767163 EP11767163A EP2616580B1 EP 2616580 B1 EP2616580 B1 EP 2616580B1 EP 20110767163 EP20110767163 EP 20110767163 EP 11767163 A EP11767163 A EP 11767163A EP 2616580 B1 EP2616580 B1 EP 2616580B1
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EP
European Patent Office
Prior art keywords
fibers
functional
web
spunbonded web
functional additives
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EP20110767163
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German (de)
French (fr)
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EP2616580A1 (en
Inventor
Yvonne Ewert
Frank-Günter NIEMZ
Marcus Krieg
Bernd Riedel
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Thueringisches Institut fuer Textil und Kunststoff Forschung eV
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Thueringisches Institut fuer Textil und Kunststoff Forschung eV
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Application filed by Thueringisches Institut fuer Textil und Kunststoff Forschung eV filed Critical Thueringisches Institut fuer Textil und Kunststoff Forschung eV
Priority to PL11767163T priority Critical patent/PL2616580T3/en
Priority to SI201130159T priority patent/SI2616580T1/en
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Classifications

    • 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
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • 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
    • D01D5/12—Stretch-spinning methods
    • D01D5/14—Stretch-spinning methods with flowing liquid or gaseous stretching media, e.g. solution-blowing
    • 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
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • 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
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/724—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged forming webs during fibre formation, e.g. flash-spinning
    • 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
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • 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
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • 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
    • Y10T442/609—Cross-sectional configuration of strand or fiber material is specified
    • Y10T442/61—Cross-sectional configuration varies longitudinally along strand or fiber material

Definitions

  • the invention relates to highly functional spunbonded nonwovens as textile fabrics which can be produced directly from dissolved polymers by means of known spunbonding processes and which are constructed from fibers filled with liquid and / or solid functional additives.
  • the fibers consist of more than 40 wt.%, Based on the total weight of the fibers, from functional additive, their average fiber diameter is 0.1 to 500 microns and the diameter variations within a fiber or each other is at least 30%.
  • the spunbonded fabric is characterized by a high degree of functionality as a result of very high concentrations of the functional additives and can be used in a variety of ways, for example as a lining material, for hygiene applications, for wound dressings, as support materials, as construction and transport material, as a cosmetic material or as a filter.
  • Filled textile fabrics e.g. those with thermo-regulating, antimicrobial or absorbing properties are already known.
  • the materials hitherto used in the prior art are structures which have been processed into a textile surface after the production of functional fibers by at least one additional process step and / or contain only small amounts of functional particles.
  • the additive components are limited to zinc white (ZnO and ZnS), whereby their proportion is limited to a maximum of 30% and particle sizes are smaller than 15 ⁇ m. It is mentioned that for Fleece applications, the particle content may also be higher, but there is no teaching taught how such nonwovens are produced.
  • the aim was not a functional nonwoven with high particle content, but washable and dyeable bactericidal bodies / fibers with controlled release of the active ingredients with prescribed washing permanence.
  • the melts can be processed into a spunbonded, for example in the EP 1 199 393 A2 , This is a spunbond made of thermoplastic polymers with hydrophobic additives.
  • the aim is an enrichment of the hydrophobic additives on the fiber surface. This is achieved by the fact that the fiber is warped by the air flow so far that the mean fiber diameter is equal to the particle diameter or is reduced to at most half of the particle diameter.
  • the proportion of masterbatches with the additives is between 10 and 20 wt .-% and may not be higher, so as not to affect the further processing to roofing membranes or use in sanitary napkins.
  • Particle-containing filaments or fibers can not be stably spun in a very high proportion of functional particles from 40% in normal filament or fiber spinning processes, since frequent breaks would result.
  • fiber materials with functional added value for the end user, which should also be inexpensive to produce and easy to process.
  • Areas of application of such fiber materials are, for example, in the clothing industry as an insert material, in technical textiles, for example hygiene applications, for wound dressings, as support materials, as construction and transport material, as a cosmetic material or as a filter, for example for the filtration of wastewater or exhaust air and binding of air and water ingredients.
  • Fabrics with functional additives can be prepared in principle either by the surface formation along a textile value chain or web formation from each provided with functional additives fibers, the coating of flat textile structures with additive dispersions or the incorporation of solid or liquid functional additives in already produced nonwoven structures.
  • Fibers with a content of functional additives of more than 40% by weight can not be stably spun in normal fiber spinning processes, since frequent fiber breaks are the result. Although this disadvantage can be partially compensated by the use of functional fibers which are produced by solution spinning processes, the downstream textile surface forming processes also require at least one additional processing step in each case.
  • the materials hitherto produced in the prior art are structures that have been processed into a textile surface by at least one additional process step after separate production of functional fibers and / or only small amounts of functional particles include. Due to the separate nonwoven production process, the highly filled fibers are additionally stressed and thereby damaged and only meet lower quality requirements in terms of functionality or mechanical resistance.
  • the aim of the present invention is to provide a versatile sheet of particulate filaments and fibers having high functional utility for various applications, Depending on the nature of the functional particles to make available, wherein the particulate filaments or fibers consist of more than 40 wt .-% of functional additives and have an average diameter of 0.1 to 500 microns.
  • the fabrics are said to have already reached such a level of stability immediately after being deposited that they are suitable for further processing or for direct use. Due to the high content of functional additives, these fabrics should have such functional properties as are otherwise achieved only by additional process steps such as coating or surface finishing.
  • the subject of the present invention is accordingly a highly functional spunbonded non-meltable polymer-based fiber containing one or more functional additives characterized in that the fibers are intertwined and entangled, have a different length with aspect ratios above 1,000 and a solid one Form nonwoven composite, wherein the fibers have a middle Diameters of 0.1 to 500 micrometers and diameter variations within a fiber and / or with each other of at least 30% and wherein the fibers in addition to the non-meltable polymer more than 40 wt .-%, based on the total weight of the fibers, of functional additives in solid and / or liquid form, which are finely distributed in the fibers
  • the textile fabrics which can be used for various fields of application, depending on the type of functional additives are composed of additives containing more than 40% by weight and up to 96% by weight, optionally even more, in each case based on the total weight of the fibers, of functional additive contained and have a mean diameter 0.1 to 500 microns.
  • the proportion of functional additives is more than 40 wt .-% up to 90 wt .-%, based on the total weight of the fibers.
  • the incorporated and permanent functions of the additives range from, for example, electrically conductive, absorbing, ion-exchanging, antibacterial, temperature-regulating to flame-retardant, abrasive or caring or combinations thereof.
  • the functional additives are, in particular, activated carbon, superabsorbents, ion exchange resins, PCM, metal oxides, flame retardants, abrasives, zeolites, sheet silicates, such as bentonites, or modified sheet silicates, cosmetics or mixtures thereof.
  • liquid lipophilic substances such as paraffins, waxes or oils, can be introduced as a functional additive.
  • one or more component (s) can be introduced in lower concentrations, for example nanosilver or dyes or even active substances, for example pharmaceutical substances or insecticides.
  • the volume fraction of the functional additives (in the context of the present invention also referred to as functional particles or functional materials) in the spinning mixture is preferably chosen such that it makes up the main volume component in the non-woven air-moist filaments or fibers with more than 50%.
  • the diameter of the functional particles in about 1/4 of the average filament or fiber diameter of the air-damp spunbonded fabric, it is achieved that the individual particles in the filaments or fibers have points of contact and so the functional properties in can train advantageously.
  • the production of the additive-containing fabrics from particle-containing filaments or fibers is effected by a spunbonding process.
  • a doped polymer-containing spinning solution is used in the fiber-forming process, wherein the direct solvent is preferably an aprotic solvent.
  • Particularly suitable as direct solvents, especially for cellulose are N-methyl-morpholine-N-oxide or N-methyl-morpholine-N-oxide-monohydrate, ionic liquids, such as 1-ethyl-3-methylimidazolium-acetate, 3- Ethyl 1-methylimidazolium chloride or 3-butyl-1-methylimidazolium chloride, dimethylformamide, dimethylacetamide or dimethyl sulfoxide mixed with lithium chloride or NaOH-thiourea-water or possibly also mixtures thereof.
  • the spinning solution with the functional particles and the dissolved polymer is extruded, wherein the nozzle bores have a diameter of 0.1 to 1.1 mm, preferably from 0.3 to 0.7
  • the strands thus generated are immediately after leaving the nozzles by its own weight and / or an obliquely from the rear acting air flow whose intensity is adapted to the reduced by the functional particles thread creep of the spinning mixture, within a short distance in the longitudinal direction into filaments and fibers with aspect ratios greater than 1,000, preferably greater than 5,000, and most preferably greater than 40,000, tapered.
  • the resulting fiber cracks do not lead to a termination of the process and do not adversely affect the process of web formation. They lead to fibers of different lengths and varying diameters being present in a nonwoven.
  • the fibers are subsequently stabilized in their shape (during the transition into the stress-free space) before the onset of longitudinal relaxation.
  • the fibers or filaments are deposited on a wire belt or a screen drum to form a nonwoven, which may also be layered, and compressed by suction.
  • the solvent-enriched excess water is separated off, the remaining solvent rinsed by washing several times and then optionally the resulting nonwoven can be dried, wherein the functional particles in the non-woven filaments and / or fibers by the taking place swelling of the polymer property determining mutually reinforced touch and connect.
  • the directly dissolved and the particle-binding polymer is a non-melting polymer, ie a polymer in which the softening point is above the decomposition point.
  • a non-melting polymer ie a polymer in which the softening point is above the decomposition point.
  • It is preferably a member of the group of natural polymers, for example the polysaccharides, particularly preferably cellulose, the polysaccharide derivatives or the proteins or protein derivatives and / or from the group of solution-formable synthetic polymers, for example polyacrylonitrile, polyvinyl alcohol, Polyethylene oxide, polysulfone, meta-aramid or their copolymers.
  • the wet spunbonded fabric obtained in this way can be consolidated, finished and shaped by textile processes (needle punching, hydroentanglement, chemical bonding), the solidification and refinement of the nonwoven fabric being able to take place before or after drying. Aftertreatment by, for example, lubricants, impregnations or with ionic active substances may follow.
  • a spunbond web is understood to mean a web of fibers and continuous fibers laid down directly in random orientation after the extrusion, in which case it is also possible to lay several layers one above the other.
  • the mixture of fibers and continuous fibers is caused by fiber breaks after the nozzle, resulting from the high particle content, but do not lead to an interruption of the process.
  • the spunbonded nonwoven not only consists of fibers of different lengths, but the fibers themselves have different fiber thicknesses over their length or with each other. The fiber thickness is determined by various factors, such as the concentration of the solution, the rate of blowing, the type of polymer, the particle size, as well as interaction of the additives to other components of the solution and content of additives.
  • Characteristic features are the irregularities in the mean diameter of the fibers due to the high particle content, the size of the particles and the fiber breaks, which are visually very easily discernible under a microscope.
  • the highly functional spunbonded nonwoven has a basis weight of 2 to 1000 g / m 2 , preferably of 5 to 500 g / m 2 and a thickness of 0.01 to 20 mm, preferably from 0.05 to 5 mm. It has incorporated and permanent additional functions, such as electrically conductive, absorbent, ion-exchanging, antibacterial, temperature-regulating, flame-retardant, abrasive, caring or combinations thereof.
  • particulate pore formers for example Glauber's salt
  • the pore formers then lead, during the washing process, to a spunbonded web of highly porous fibers and filaments, which have a much larger surface area in comparison with area-like sponges.
  • a highly functional spunbond web of particulate filaments or fibers ranges from apparel materials, such as heat-trapping or active ingredient release liners, to technical textiles with high functional utility for various applications - depending on the type of functional particles, for example for hygiene applications, as wound dressings, as carrier materials for active ingredients or as support materials in composites, as Construction and transport material, as a cosmetic material or as a filter, for example for the filtration and binding of air and water ingredients such as phosphates, nitrates and ammonium-nitrogen compounds. Due to the special characteristics of the functional properties, due to the high concentration of additives, these nonwovens are also suitable for layered composites with other fabrics. This can happen by producing the highly functional spunbonded fabric on another, already introduced fabric during spunbonding production.
  • Some of the resulting fiber cable pieces were completely freed of solvent and cut, as far as possible, to a staple length of 40 mm, with the described bonds sorted out as far as possible.
  • the fibers were treated with a 1% sodium chloride solution and dried at 55 ° C to constant weight. A secondary spinning to the yarn was not possible. A fleece formation was only partially possible, while a large number of short fibers and extreme shortening of the fibers was observed. The irregular loose fleece sections could not be further processed or used. A consolidation by needling for stabilization was not possible because the fleece was completely destroyed and fell apart.
  • a cellulose solution prepared according to Example 1 was solidified by melt-blown spinning (solution blowing) at a solution temperature of 95 ° C, blowing with 80 ° C warm air, and spraying with a water mist directly at the exit of the nozzle blower unit and depositing on a screen belt deformed into a direct web.
  • the deformation process was stable and the resulting nonwoven fabric could be used after complete extraction of the solvent and drying at 60 ° C without difficulty as an ion exchange nonwoven.
  • the functional fleece was mechanically stable enough to be cut to size and fed into the water treatment plant. An additionally performed moderate needling and thus further compaction was also possible without the fleece was destroyed.

Description

Die Erfindung betrifft hochfunktionelle Spinnvliese als textile Flächengebilde, die direkt aus gelösten Polymeren mittels bekannter Spinnvliesverfahren herstellbar und die aus mit flüssigen und/oder festen Funktionaladditiven gefüllten Fasern aufgebaut sind. Die Fasern bestehen zu mehr als 40 Gew.%, bezogen auf das Gesamtgewicht der Fasern, aus Funktionaladditiv, ihr mittlerer Faserdurchmesser beträgt 0,1 bis 500 Mikrometer und die Durchmesserschwankungen innerhalb einer Faser bzw. untereinander betragen mindestens 30%. Das Spinnvlies zeichnet sich durch eine hohe Funktionalität infolge sehr hoher Konzentrationen der Funktionaladditive aus und lässt sich vielseitig verwenden, beispielsweise als Einlagestoff, für Hygieneanwendungen, für Wundauflagen, als Trägermaterialien, als Bau- und Transportmaterial, als kosmetisches Material oder als Filter.The invention relates to highly functional spunbonded nonwovens as textile fabrics which can be produced directly from dissolved polymers by means of known spunbonding processes and which are constructed from fibers filled with liquid and / or solid functional additives. The fibers consist of more than 40 wt.%, Based on the total weight of the fibers, from functional additive, their average fiber diameter is 0.1 to 500 microns and the diameter variations within a fiber or each other is at least 30%. The spunbonded fabric is characterized by a high degree of functionality as a result of very high concentrations of the functional additives and can be used in a variety of ways, for example as a lining material, for hygiene applications, for wound dressings, as support materials, as construction and transport material, as a cosmetic material or as a filter.

Mit Füllstoffen versehene textile Flächengebilde, z.B. solche mit thermoregulierenden, antimikrobiellen oder absorbierenden Eigenschaften, sind bereits bekannt.Filled textile fabrics, e.g. those with thermo-regulating, antimicrobial or absorbing properties are already known.

Bei den im Stand der Technik bislang eingesetzten Materialien handelt es sich, soweit textile Flächen beschrieben wurden, um Gebilde, die nach der Herstellung von Funktionsfasern durch mindestens einen zusätzlichen Prozessschritt zu einer textilen Fläche verarbeitet wurden und/oder nur geringe Mengen an Funktionspartikel enthalten. Zum Beispiel sind in DE 10 2008 045290 A1 Fasern offenbart aus denen dann Textilien, Wundauflagen, Filter usw. hergestellt werden. Die Additivanteile beschränken sich ausschließlich auf Zinkweiß (ZnO und ZnS), wobei deren Anteil auf maximal 30 % begrenzt ist und Partikelgrößen kleiner als 15 µm sind. Es wird erwähnt, dass für Vliesanwendungen der Partikelgehalt auch höher sein kann, es wird aber keine Lehre vermittelt, wie solche Vliesstoffe herstellbar sind. Ziel war nicht ein funktionelles Vlies mit hohem Partikelgehalt, sondern waschbare und färbbare bakterizide Formkörper/Fasern mit kontrollierter Freisetzung der Wirkstoffe bei vorgeschriebener Waschpermanenz.As far as textile surfaces have been described, the materials hitherto used in the prior art are structures which have been processed into a textile surface after the production of functional fibers by at least one additional process step and / or contain only small amounts of functional particles. For example, in DE 10 2008 045290 A1 Fibers from which then textiles, wound dressings, filters, etc. are produced. The additive components are limited to zinc white (ZnO and ZnS), whereby their proportion is limited to a maximum of 30% and particle sizes are smaller than 15 μm. It is mentioned that for Fleece applications, the particle content may also be higher, but there is no teaching taught how such nonwovens are produced. The aim was not a functional nonwoven with high particle content, but washable and dyeable bactericidal bodies / fibers with controlled release of the active ingredients with prescribed washing permanence.

Oft werden thermoplastisch verarbeitbare Polymere als Trägermaterial verwendet, deren Schmelzen zu einem Spinnvlies verarbeitet werden können, zum Beispiel in der EP 1 199 393 A2 . Hier handelt es sich um ein Spinnvlies hergestellt aus thermoplastischen Polymeren mit hydrophoben Zusätzen. Ziel ist eine Anreicherung der hydrophoben Zusätze an der Faseroberfläche. Erreicht wird das dadurch, dass die Faser durch den Luftstrom soweit verzogen wird, dass der mittlere Faserdurchmesser gleich dem Partikeldurchmessers ist oder bis höchstens zur Hälfte des Partikeldurchmessers verringert wird. Der Anteil an Masterbatches mit den Zusatzstoffen liegt zwischen 10 und 20 Gew.-% und darf auch nicht höher liegen, um die weitere Verarbeitung zu Dachbahnen oder die Verwendung in Damenbinden nicht zu beeinträchtigen.Often thermoplastically processable polymers are used as carrier material, the melts can be processed into a spunbonded, for example in the EP 1 199 393 A2 , This is a spunbond made of thermoplastic polymers with hydrophobic additives. The aim is an enrichment of the hydrophobic additives on the fiber surface. This is achieved by the fact that the fiber is warped by the air flow so far that the mean fiber diameter is equal to the particle diameter or is reduced to at most half of the particle diameter. The proportion of masterbatches with the additives is between 10 and 20 wt .-% and may not be higher, so as not to affect the further processing to roofing membranes or use in sanitary napkins.

Partikelhaltige Filamente bzw. Fasern lassen sich bei einem sehr hohen Anteil an Funktionspartikeln ab 40 % in normalen Filament- bzw. Faserspinnprozessen nicht stabil erspinnen, da häufige Abrisse die Folge wären.Particle-containing filaments or fibers can not be stably spun in a very high proportion of functional particles from 40% in normal filament or fiber spinning processes, since frequent breaks would result.

In verschiedenen Bereichen der Textilindustrie besteht ein hoher Bedarf an Fasermaterialien mit funktionellem Zusatznutzen für den Endverbraucher, die zudem preiswert herzustellen und leicht zu verarbeiten sein sollen. Anwendungsbereiche solcher Fasermaterialien sind zum Beispiel in der Bekleidungsindustrie als Einlagematerial, bei den technischen Textilien, beispielsweise Hygieneanwendungen, für Wundauflagen, als Trägermaterialien, als Bau- und Transportmaterial, als kosmetisches Material oder als Filter, zum Beispiel für die Filtration von Abwasser oder Abluft und Bindung von Luft- und Wasserinhaltsstoffen.In various areas of the textile industry, there is a high demand for fiber materials with functional added value for the end user, which should also be inexpensive to produce and easy to process. Areas of application of such fiber materials are, for example, in the clothing industry as an insert material, in technical textiles, for example hygiene applications, for wound dressings, as support materials, as construction and transport material, as a cosmetic material or as a filter, for example for the filtration of wastewater or exhaust air and binding of air and water ingredients.

Flächengebilde mit Funktionaladditiven lassen sich grundsätzlich entweder durch die Flächenbildung entlang einer textilen Wertschöpfungskette oder Vliesbildung jeweils aus mit Funktionaladditiven versehenen Fasern, die Beschichtung flächiger Textilstrukturen mit Additiv-Dispersionen oder die Einarbeitung fester oder flüssiger Funktionaladditive in bereits erzeugte Vliesstrukturen herstellen.Fabrics with functional additives can be prepared in principle either by the surface formation along a textile value chain or web formation from each provided with functional additives fibers, the coating of flat textile structures with additive dispersions or the incorporation of solid or liquid functional additives in already produced nonwoven structures.

Fasern mit einem Anteil an Funktionaladditiven von mehr als 40 Gew.-% lassen sich in normalen Faserspinnprozessen nicht stabil erspinnen, da häufige Faserabrisse die Folge sind. Obgleich sich dieser Nachteil bei der Nutzung von Funktionsfasern, die mittels Lösungsspinnverfahren gefertigt werden, teilweise ausgleichen lässt, erfordern die nachgeordneten textilen Flächenbildungsprozesse auch in jedem Fall mindestens einen zusätzlichen Verarbeitungsschritt.Fibers with a content of functional additives of more than 40% by weight can not be stably spun in normal fiber spinning processes, since frequent fiber breaks are the result. Although this disadvantage can be partially compensated by the use of functional fibers which are produced by solution spinning processes, the downstream textile surface forming processes also require at least one additional processing step in each case.

Bei den im Stand der Technik bislang erzeugten Materialien handelt es sich also, soweit funktionale textile Flächen beschrieben wurden, um Gebilde, die nach einer separaten Herstellung von Funktionsfasern durch mindestens einen zusätzlichen Prozessschritt zu einer textilen Fläche verarbeitet wurden und/oder nur geringe Mengen an Funktionspartikel beinhalten. Durch den separaten Vliesherstellungsprozess werden die hochgefüllten Fasern zusätzlich beansprucht und dadurch geschädigt und genügen nur qualitativ geringeren Ansprüchen bezüglich Funktionalität bzw. mechanischer Beständigkeit.So far as far as functional textile surfaces have been described, the materials hitherto produced in the prior art are structures that have been processed into a textile surface by at least one additional process step after separate production of functional fibers and / or only small amounts of functional particles include. Due to the separate nonwoven production process, the highly filled fibers are additionally stressed and thereby damaged and only meet lower quality requirements in terms of functionality or mechanical resistance.

Ziel der vorliegenden Erfindung ist es, ein vielseitig verwendbares Flächengebilde aus partikelhaltigen Filamenten und Fasern mit hohem funktionellem Nutzen für verschiedene Anwendungsbereiche, je nach Art der Funktionspartikel, zur Verfügung zu stellen, wobei die partikelhaltigen Filamente bzw. Fasern zu mehr als 40 Gew.-% aus Funktionsadditiven bestehen und einen mittleren Durchmesser von 0,1 bis 500 Mikrometer aufweisen. Die Flächengebilde sollen direkt nach der Ablage bereits eine solche Festigkeit erreicht haben, dass sie zur Weiterverarbeitung bzw. zum direkten Einsatz geeignet sind. Aufgrund der hohen Anteile an funktionellen Zusätzen sollen diese Flächengebilde solche funktionellen Eigenschaften besitzen, wie sie sonst nur durch zusätzliche Verfahrensschritte wie dem Beschichten oder Oberflächenausrüstung erreicht werden.The aim of the present invention is to provide a versatile sheet of particulate filaments and fibers having high functional utility for various applications, Depending on the nature of the functional particles to make available, wherein the particulate filaments or fibers consist of more than 40 wt .-% of functional additives and have an average diameter of 0.1 to 500 microns. The fabrics are said to have already reached such a level of stability immediately after being deposited that they are suitable for further processing or for direct use. Due to the high content of functional additives, these fabrics should have such functional properties as are otherwise achieved only by additional process steps such as coating or surface finishing.

Diese Aufgaben werden erfindungsgemäß dadurch gelöst, dass direkt im Spinnprozess kontinuierlich aus einer mit einem oder mehreren funktionalen Zusatzstoffen dotierten Lösung von nichtschmelzbaren Polymeren in Direktlösungsmitteln mit Hilfe eines Spinnvliesprozesses ein hochfunktionales textiles Flächengebilde erzeugt wird. Überraschenderweise lassen sich textile Flächengebilde mit mehr als 40 Gew.-% Additivgehalt sicher und reproduzierbar ohne zusätzliche Prozessschritte herstellen, die eine permanente Funktionalität über den gesamten Lebenszyklus des textilen Flächengebildes besitzen. Ebenso wurde gefunden, dass die erfindungsgemäßen Vliesstofffasern Durchmesserschwankungen innerhalb einer Faser bzw. untereinander von mindestens 30% aufweisen und dadurch überraschend ein hohes Selbstbindungsvermögen durch Verhakungen und Verschlingungen aufweisen.These objects are achieved according to the invention in that directly in the spinning process a highly functional textile fabric is continuously produced from a solution of non-meltable polymers doped with one or more functional additives in direct solvent with the aid of a spunbonding process. Surprisingly, textile fabrics with more than 40% by weight of additive content can be produced safely and reproducibly without additional process steps which have permanent functionality over the entire life cycle of the textile fabric. It has likewise been found that the nonwoven fibers according to the invention have diameter fluctuations within a fiber or of at least 30% with respect to one another and thus surprisingly have a high self-binding capacity due to entanglements and entanglements.

Gegenstand der vorliegenden Erfindung ist demgemäß ein hochfunktionelles Spinnvlies aus Fasern auf Basis von nichtschmelzbaren Polymeren, die einen oder mehrere Funktionaladditive enthalten, das dadurch gekennzeichnet ist, dass die Fasern in sich verschlungen und verhakt sind, eine unterschiedliche Länge aufweisen mit Aspektverhältnissen über 1.000 und einen festen Vliesverbund bilden, wobei die Fasern einen mittleren Durchmesser von 0,1 bis 500 Mikrometer sowie Durchmesserschwankungen innerhalb einer Faser und/oder untereinander von mindestens 30% aufweisen und wobei die Fasern neben dem nicht-schmelzbaren Polymer mehr als 40 Gew.-%, bezogen auf das Gesamtgewicht der Fasern, an Funktionaladditiven in fester und/oder flüssiger Form enthalten, die in den Fasern fein verteilt sindThe subject of the present invention is accordingly a highly functional spunbonded non-meltable polymer-based fiber containing one or more functional additives characterized in that the fibers are intertwined and entangled, have a different length with aspect ratios above 1,000 and a solid one Form nonwoven composite, wherein the fibers have a middle Diameters of 0.1 to 500 micrometers and diameter variations within a fiber and / or with each other of at least 30% and wherein the fibers in addition to the non-meltable polymer more than 40 wt .-%, based on the total weight of the fibers, of functional additives in solid and / or liquid form, which are finely distributed in the fibers

Die je nach Art der Funktionaladditive für verschiedene Anwendungsbereiche einsetzbaren textilen Flächengebilde sind aus additivhaltigen Fasern aufgebaut, die mehr als 40 Gew.-% und bis zu 96 Gew.-%, gegebenenfalls auch noch mehr, jeweils bezogen auf das Gesamtgewicht der Fasern, an Funktionaladditiv enthalten und einen mittleren Durchmesser 0,1 bis 500 Mikrometer haben. Bevorzugt beträgt der Anteil der Funktionaladditive mehr als 40 Gew.-% bis zu 90 Gew.-%, bezogen auf das Gesamtgewicht der Fasern.The textile fabrics which can be used for various fields of application, depending on the type of functional additives, are composed of additives containing more than 40% by weight and up to 96% by weight, optionally even more, in each case based on the total weight of the fibers, of functional additive contained and have a mean diameter 0.1 to 500 microns. Preferably, the proportion of functional additives is more than 40 wt .-% up to 90 wt .-%, based on the total weight of the fibers.

Die inkorporierten und permanenten Funktionen der Additive reichen von beispielsweise elektrisch leitfähig, absorbierend, ionentauschend, antibakteriell, temperaturregulierend bis hin zu flammhemmend, abrasiv oder pflegend bzw. auch Kombinationen daraus.The incorporated and permanent functions of the additives range from, for example, electrically conductive, absorbing, ion-exchanging, antibacterial, temperature-regulating to flame-retardant, abrasive or caring or combinations thereof.

Bei den Funktionaladditiven handelt es sich insbesondere um Aktivkohle, Superabsorber, Ionentauscherharze, PCM, Metalloxide, Flammschutzmittel, Abrasiva, Zeolithe, Schichtsilikate, wie Bentonite, oder modifizierte Schichtsilikate, Kosmetika oder Mischungen daraus. Auch flüssige lipophile Substanzen, wie Paraffine, Wachse oder Öle, können als Funktionaladditiv eingebracht werden. Zusätzlich können eine oder weitere Komponente(n) in geringeren Konzentrationen eingebracht werden, beispielsweise Nanosilber oder Farbstoffe oder auch Wirkstoffe, z.B. pharmazeutische Substanzen oder Insektizide.The functional additives are, in particular, activated carbon, superabsorbents, ion exchange resins, PCM, metal oxides, flame retardants, abrasives, zeolites, sheet silicates, such as bentonites, or modified sheet silicates, cosmetics or mixtures thereof. Also liquid lipophilic substances, such as paraffins, waxes or oils, can be introduced as a functional additive. In addition, one or more component (s) can be introduced in lower concentrations, for example nanosilver or dyes or even active substances, for example pharmaceutical substances or insecticides.

Der Volumenanteil der Funktionaladditive (im Zusammenhang mit der vorliegenden Erfindung auch als Funktionspartikel oder Funktionsmaterialien bezeichnet) in dem Spinngemisch ist dabei bevorzugt so gewählt, dass dieser in den vliesbildenden luftfeuchten Filamenten bzw. Fasern mit über 50 % die Hauptvolumenkomponente ausmacht. In einer besonderen Ausführungsform, in welcher der Durchmesser der Funktionspartikel in etwa 1/4 des mittleren Filament- bzw. Faserdurchmessers des luftfeuchten Spinnvlieses beträgt, wird erreicht, dass die einzelnen Partikel in den Filamenten bzw. Fasern Berührungspunkte aufweisen und sich so die funktionellen Eigenschaften in vorteilhafter Weise ausbilden können.The volume fraction of the functional additives (in the context of the present invention also referred to as functional particles or functional materials) in the spinning mixture is preferably chosen such that it makes up the main volume component in the non-woven air-moist filaments or fibers with more than 50%. In a particular embodiment, in which the diameter of the functional particles in about 1/4 of the average filament or fiber diameter of the air-damp spunbonded fabric, it is achieved that the individual particles in the filaments or fibers have points of contact and so the functional properties in can train advantageously.

Die Herstellung der additivhaltigen Flächengebilde aus partikelhaltigen Filamenten bzw. Fasern erfolgt durch ein Spinnvliesverfahren. Es wird eine dotierte polymerhaltige Spinnlösung im Faserbildungsprozess verwendet, wobei es sich bei dem Direktlösungsmittel vorzugsweise um ein aprotisches Lösungsmittel handelt. Als Direktlösungsmittel geeignet, insbesondere für Cellulose, sind vor allem N-Methyl-morpholin-N-Oxid bzw. N-Methyl-morpholin-N-oxid-Monohydrat, ionische Flüssigkeiten, wie 1-Ethyl-3-methylimidazolium-acetat, 3-Ethyl-1-methylimidazolium-chlorid oder 3-Butyl-1-methylimidazolium-chlorid, Dimethylformamid, Dimethylacetamid oder Dimethylsulfoxid gemischt mit Lithiumchlorid oder NaOH-Thioharnstoff-Wasser oder ggf. auch deren Mischungen. Die Spinnlösung mit den Funktionspartikeln und dem gelöstem Polymer wird extrudiert, wobei die Düsenbohrungen einen Durchmesser von 0,1 bis 1,1 mm, vorzugsweise von 0,3 bis 0,7 mm aufweisen.The production of the additive-containing fabrics from particle-containing filaments or fibers is effected by a spunbonding process. A doped polymer-containing spinning solution is used in the fiber-forming process, wherein the direct solvent is preferably an aprotic solvent. Particularly suitable as direct solvents, especially for cellulose, are N-methyl-morpholine-N-oxide or N-methyl-morpholine-N-oxide-monohydrate, ionic liquids, such as 1-ethyl-3-methylimidazolium-acetate, 3- Ethyl 1-methylimidazolium chloride or 3-butyl-1-methylimidazolium chloride, dimethylformamide, dimethylacetamide or dimethyl sulfoxide mixed with lithium chloride or NaOH-thiourea-water or possibly also mixtures thereof. The spinning solution with the functional particles and the dissolved polymer is extruded, wherein the nozzle bores have a diameter of 0.1 to 1.1 mm, preferably from 0.3 to 0.7 mm.

Die so generierten Stränge werden sofort nach Verlassen der Düsen durch Eigengewicht und/oder einen schräg von hinten einwirkenden Luftstrom, dessen Intensität an das durch die Funktionspartikel reduzierte Fadenziehvermögen des Spinngemisches angepasst ist, innerhalb einer kurzen Wegstrecke in Längsrichtung zu Filamenten und Fasern mit Aspektverhältnissen größer 1.000, bevorzugt größer 5.000 und ganz bevorzugt größer 40.000, verjüngt. Dabei auftretende Faserrisse führen zu keinem Abbruch des Verfahrens und beeinträchtigen den Prozess der Vliesbildung nicht negativ. Sie führen dazu, dass in einem Vlies Fasern verschiedener Länge und mit variierendem Durchmesser vorliegen. Die Fasern werden nachfolgend (beim Übergang in den spannungsfreien Raum) noch vor dem Einsetzen der Längsrelaxation in ihrer Form stabilisiert. Das passiert durch Überführung des Lösungszustandes des Polymers in einen zumindest teilweise ungelösten Zustand, entweder durch Verdampfen des Lösungsmittels im temperierten Luftstrom oder mittels eines Stromes feiner Tröpfchen, insbesondere aus Wasser oder einer aprotischen Flüssigkeit, durch Gelierung und eventuell möglichen Austausch des Lösungsmittels. Nach Erreichen eines verklebungsfreien Zustandes werden die Fasern bzw. Filamente auf einem Siebband oder einer Siebtrommel zu einem Vlies abgelegt, welches auch geschichtet sein kann, und durch Absaugen verdichtet. Das mit Lösungsmittel angereicherte überschüssige Wasser wird abgetrennt, das restliche Lösungsmittel durch mehrfaches Waschen ausgespült und anschließend kann ggf. das erhaltene Vlies getrocknet werden, wobei sich die Funktionspartikel in den vliesbildenden Filamenten und/oder Fasern durch die dabei stattfindende Entquellung des Polymers eigenschaftsbestimmend gegenseitig verstärkt berühren und verbinden.The strands thus generated are immediately after leaving the nozzles by its own weight and / or an obliquely from the rear acting air flow whose intensity is adapted to the reduced by the functional particles thread creep of the spinning mixture, within a short distance in the longitudinal direction into filaments and fibers with aspect ratios greater than 1,000, preferably greater than 5,000, and most preferably greater than 40,000, tapered. The resulting fiber cracks do not lead to a termination of the process and do not adversely affect the process of web formation. They lead to fibers of different lengths and varying diameters being present in a nonwoven. The fibers are subsequently stabilized in their shape (during the transition into the stress-free space) before the onset of longitudinal relaxation. This occurs by transferring the solution state of the polymer into an at least partially undissolved state, either by evaporation of the solvent in the tempered air stream or by means of a stream of fine droplets, in particular water or an aprotic liquid, by gelling and possibly possible replacement of the solvent. After reaching a bonding-free state, the fibers or filaments are deposited on a wire belt or a screen drum to form a nonwoven, which may also be layered, and compressed by suction. The solvent-enriched excess water is separated off, the remaining solvent rinsed by washing several times and then optionally the resulting nonwoven can be dried, wherein the functional particles in the non-woven filaments and / or fibers by the taking place swelling of the polymer property determining mutually reinforced touch and connect.

Das direkt gelöste und die Partikel bindende Polymer ist ein nicht schmelzendes Polymer, also ein Polymer bei dem der Erweichungspunkt über dem Zersetzungspunkt liegt. Bevorzugt ist es ein Vertreter aus der Gruppe der natürlichen Polymere, beispielsweise der Polysaccharide, besonders bevorzugt Cellulose, der Polysaccharidderivate oder der Proteine bzw. Proteinderivate und/oder aus der Gruppe der lösungsverformbaren synthetischen Polymere, beispielsweise Polyacrylnitril, Polyvinylalkohol, Polyethylenoxid, Polysulfon, meta-Aramid oder deren Copolymere.The directly dissolved and the particle-binding polymer is a non-melting polymer, ie a polymer in which the softening point is above the decomposition point. It is preferably a member of the group of natural polymers, for example the polysaccharides, particularly preferably cellulose, the polysaccharide derivatives or the proteins or protein derivatives and / or from the group of solution-formable synthetic polymers, for example polyacrylonitrile, polyvinyl alcohol, Polyethylene oxide, polysulfone, meta-aramid or their copolymers.

Das so erhaltene nasse Spinnvlies kann durch textile Prozesse (Vernadelung, Wasserstrahlverfestigung, chemische Bindung) verfestigt, veredelt und verformt werden, wobei die Verfestigung und Veredelung des Vlieses vor oder nach der Trocknung erfolgen kann. Eine Nachbehandlung durch beispielsweise Avivagen, Imprägnierungen oder mit ionischen Wirkstoffen kann folgen.The wet spunbonded fabric obtained in this way can be consolidated, finished and shaped by textile processes (needle punching, hydroentanglement, chemical bonding), the solidification and refinement of the nonwoven fabric being able to take place before or after drying. Aftertreatment by, for example, lubricants, impregnations or with ionic active substances may follow.

Unter einem Spinnvlies wird ein direkt nach der Extrusion in Wirrlage abgelegtes Vlies aus Fasern und Endlosfasern verstanden, wobei auch mehrere Lagen übereinander gelegt werden können. Das Gemisch aus Fasern und Endlosfasern entsteht durch Faserabrisse nach der Düse, die aus dem hohen Partikelgehalt resultieren, die aber nicht zu einer Unterbrechung des Verfahrens führen. Zudem besteht das Spinnvlies nach dem erfindungsgemäßen Verfahren nicht nur aus Fasern unterschiedlicher Länge, sondern weisen die Fasern selbst über die Länge oder untereinander unterschiedliche Faserdicken auf. Die Faserdicke wird bestimmt durch verschiedene Faktoren, wie die Konzentration der Lösung, die Anblasgeschwindigkeit, die Art des Polymers, die Partikelgröße, sowie Wechselwirkung der Additive zu anderen Komponenten der Lösung und Gehalt an Additiven. Bei der Ablage bilden sich in sich verschlungene und verhakte Fasern und Filamente, die einen festen Vliesverbund bilden. Charakteristisch sind die durch den hohen Partikelgehalt, die Größe der Partikel und die Faserabrisse entstehenden Ungleichmäßigkeiten im mittleren Durchmesser der Fasern, die visuell unter einem Mikroskop sehr leicht zu erkennen sind.A spunbond web is understood to mean a web of fibers and continuous fibers laid down directly in random orientation after the extrusion, in which case it is also possible to lay several layers one above the other. The mixture of fibers and continuous fibers is caused by fiber breaks after the nozzle, resulting from the high particle content, but do not lead to an interruption of the process. In addition, according to the method of the invention, the spunbonded nonwoven not only consists of fibers of different lengths, but the fibers themselves have different fiber thicknesses over their length or with each other. The fiber thickness is determined by various factors, such as the concentration of the solution, the rate of blowing, the type of polymer, the particle size, as well as interaction of the additives to other components of the solution and content of additives. When filing entangled and entangled fibers and filaments form, which form a solid nonwoven composite. Characteristic features are the irregularities in the mean diameter of the fibers due to the high particle content, the size of the particles and the fiber breaks, which are visually very easily discernible under a microscope.

Der Vorteil der Herstellung des Flächengebildes aus Lösungen von Polymeren im Vergleich zur Herstellung aus Polymerschmelzen besteht darin, dass der Partikelgehalt ungleich höher sein kann, da in der Ausgangslösung neben Polymer und Additiv auch das Lösungsmittel vorhanden ist, welches zu einem späteren Zeitpunkt dann entfernt wird. Es wird ausgenutzt, dass die Kohäsionskräfte so groß sind, dass es nur selten zu einem Abriss kommt, gleichzeitig das Netzwerk des gelösten Polymers aber seine Gleitwirkung behält, damit die Partikel bei der Extrusion und Verstreckung aneinander abgleiten können. Zudem können verschiedene Gelzustände der Fasern und Filamente, die durch den Austausch des Lösungsmittels mit Wasser entstehen, für die weitere Verarbeitung ausgenutzt werden.The advantage of producing the sheet from solutions of polymers in comparison with the production from polymer melts is that the particle content is much higher can, since in addition to the polymer and additive, the solvent is present in the starting solution, which is then removed at a later date. It is exploited that cohesive forces are so great that demolition rarely occurs, but at the same time the network of the dissolved polymer retains its lubricating action, allowing the particles to slide off each other during extrusion and drawing. In addition, various gel states of the fibers and filaments that result from the replacement of the solvent with water can be exploited for further processing.

Das hochfunktionelle Spinnvlies besitzt eine Flächenmasse von 2 bis 1000 g/m2, vorzugsweise von 5 bis 500 g/m2 und eine Dicke von 0,01 bis 20 mm, vorzugsweise von 0,05 bis 5 mm. Es besitzt inkorporierte und permanente Zusatzfunktionen, wie beispielsweise elektrisch leitfähig, absorbierend, ionentauschend, antibakteriell, temperaturregulierend, flammhemmend, abrasiv, pflegend oder Kombinationen daraus.The highly functional spunbonded nonwoven has a basis weight of 2 to 1000 g / m 2 , preferably of 5 to 500 g / m 2 and a thickness of 0.01 to 20 mm, preferably from 0.05 to 5 mm. It has incorporated and permanent additional functions, such as electrically conductive, absorbent, ion-exchanging, antibacterial, temperature-regulating, flame-retardant, abrasive, caring or combinations thereof.

In einer besonderen Ausführungsform können in die Polymerlösung auch partikelförmige Porenbildner, beispielsweise Glaubersalz, integriert werden. In dem hergestellten Spinnvlies führen die Porenbildner dann während des Waschprozesses zu einem Spinnvlies aus hochporösen Fasern und Filamenten, die im Vergleich zu flächenartigen Schwämmen eine sehr viel größere Oberfläche aufweisen.In a particular embodiment, particulate pore formers, for example Glauber's salt, can be integrated into the polymer solution. In the produced spunbonded fabric, the pore formers then lead, during the washing process, to a spunbonded web of highly porous fibers and filaments, which have a much larger surface area in comparison with area-like sponges.

Die Verwendung eines hochfunktionellen Spinnvlieses aus partikelhaltigen Filamenten bzw. Fasern reicht von Bekleidungsmaterialien, beispielsweise wärmespeichernden oder wirkstofffreisetzenden Einlagestoffen, bis zu technischen Textilien mit hohem funktionellen Nutzen für verschiedene Anwendungsbereiche - je nach Art der Funktionspartikel, beispielsweise für Hygieneanwendungen, als Wundauflagen, als Trägermaterialien für Wirkstoffe oder als Trägermaterialien in Verbundwerkstoffen, als Bau- und Transportmaterial, als kosmetisches Material oder als Filter, zum Beispiel für die Filtration und Bindung von Luft-und Wasserinhaltsstoffen wie Phosphaten, Nitraten und Ammonium-Stickstoff-Verbindungen. Aufgrund der besonderen Ausprägung der funktionellen Eigenschaften, bedingt durch die hohe Konzentration an Additiven, sind diese Vliese auch geeignet für geschichtete Verbundwerkstoffe mit anderen Flächengebilden. Das kann passieren, indem man das hochfunktionelle Spinnvlies auf einem anderen, schon vorgelegten Flächengebilde während der Spinnvliesherstellung erzeugt.The use of a highly functional spunbond web of particulate filaments or fibers ranges from apparel materials, such as heat-trapping or active ingredient release liners, to technical textiles with high functional utility for various applications - depending on the type of functional particles, for example for hygiene applications, as wound dressings, as carrier materials for active ingredients or as support materials in composites, as Construction and transport material, as a cosmetic material or as a filter, for example for the filtration and binding of air and water ingredients such as phosphates, nitrates and ammonium-nitrogen compounds. Due to the special characteristics of the functional properties, due to the high concentration of additives, these nonwovens are also suitable for layered composites with other fabrics. This can happen by producing the highly functional spunbonded fabric on another, already introduced fabric during spunbonding production.

Die nachfolgenden Beispiele dienen zur Illustration der Erfindung. Prozente sind darin als Gewichtsprozente zu verstehen soweit nicht anders angegeben oder aus dem Zusammenhang unmittelbar ersichtlich.The following examples serve to illustrate the invention. Percentages are to be understood as weight percentages unless otherwise stated or immediately apparent from the context.

(Vergleichs)Beispiel 1:(Comparative) Example 1:

In 1,5 kg einer 9 %-igen Celluloselösung in N-Methylmorpholin-N-oxid-Monohydrat (NMMO-Monohydrat) wurden 0,1 kg eines gemahlenen Ionenaustauscherharzes (stark basischer Anionenaustauscher) mit einem Partikeldurchmesser von D99 = 14,8 µm dispergiert und bei 90 °C 30 Minuten homogenisiert. Die Spinnlösung wurde anschließend mittels Zahnrad-Spinnpumpe bei 95 °C einer Spinndüse (1.200 Loch mit einem Durchmesser von 0,3 mm) zugeführt und versponnen. Eine sichere Verformung über einen Luftspalt (1 = 10 mm) war jedoch nicht möglich, es kam am Düsenaustritt zu Verklebungen der austretenden Lösungsstrahlen. Einige der entstandenen Faserkabelstücke wurden vollständig vom Lösungsmittel befreit und, soweit möglich, auf eine Stapellänge von 40 mm geschnitten, wobei die beschriebenen Verklebungen, soweit es ging, aussortiert wurden. Die Fasern wurden mit einer 1 %-igen Natriumchloridlösung behandelt und bei 55 °C bis zur Gewichtskonstanz getrocknet. Eine Sekundärspinnung zum Garn war nicht möglich. Eine Vliesbildung war nur bedingt möglich, wobei dabei eine große Anzahl an Kurzfasern und extreme Einkürzung der Fasern beobachtet wurde. Die unregelmäßigen lockeren Vliesabschnitte konnten nicht weiter verarbeitet bzw. genutzt werden. Eine Verfestigung mittels Vernadelung zur Stabilisierung war nicht möglich, da das Vlies dabei vollständig zerstört wurde und auseinanderfiel.In 1.5 kg of a 9% strength cellulose solution in N-methylmorpholine N-oxide monohydrate (NMMO monohydrate), 0.1 kg of a ground ion exchange resin (strongly basic anion exchanger) having a particle diameter of D 99 = 14.8 microns dispersed and homogenized at 90 ° C for 30 minutes. The spinning solution was then fed by means of a gear spinning pump at 95 ° C a spinneret (1200 holes with a diameter of 0.3 mm) and spun. However, a secure deformation over an air gap (1 = 10 mm) was not possible, it came at the nozzle exit to bonding of the exiting solution jets. Some of the resulting fiber cable pieces were completely freed of solvent and cut, as far as possible, to a staple length of 40 mm, with the described bonds sorted out as far as possible. The fibers were treated with a 1% sodium chloride solution and dried at 55 ° C to constant weight. A secondary spinning to the yarn was not possible. A fleece formation was only partially possible, while a large number of short fibers and extreme shortening of the fibers was observed. The irregular loose fleece sections could not be further processed or used. A consolidation by needling for stabilization was not possible because the fleece was completely destroyed and fell apart.

Beispiel 2:Example 2:

Eine gemäß Beispiel 1 hergestellte Celluloselösung wurde mittels Melt-blown Spinnprozess (Lösungsverblasung) bei einer Lösungstemperatur von 95 °C, einer Anblasung mit 80°C warmer Luft und Besprühung mit einem Wassernebel unmittelbar am Austritt der Düsen-Blaseinheit verfestigt und durch Ablage auf einem Siebband zu einem Direktvlies verformt. Der Verformungsprozess lief stabil und der erhaltene Vliesstoff konnte nach vollständiger Extraktion des Lösungsmittels und Trocknung bei 60 °C ohne Schwierigkeiten als Ionentauschervlies genutzt werden. Das Funktionsvlies war mechanisch so stabil, dass es zugeschnitten und in die Wasserbehandlungsanlage eingebracht werden konnte. Eine zusätzlich durchgeführte moderate Vernadelung und somit weitere Verdichtung war ebenfalls möglich, ohne dass das Vlies dabei zerstört wurde.A cellulose solution prepared according to Example 1 was solidified by melt-blown spinning (solution blowing) at a solution temperature of 95 ° C, blowing with 80 ° C warm air, and spraying with a water mist directly at the exit of the nozzle blower unit and depositing on a screen belt deformed into a direct web. The deformation process was stable and the resulting nonwoven fabric could be used after complete extraction of the solvent and drying at 60 ° C without difficulty as an ion exchange nonwoven. The functional fleece was mechanically stable enough to be cut to size and fed into the water treatment plant. An additionally performed moderate needling and thus further compaction was also possible without the fleece was destroyed.

Claims (12)

  1. A high-functionality spunbonded web of fibers based on nonmeltable polymers containing one or more functional additives, characterized in that the fibers are intertwined and interhooked, have a differing length with aspect ratios above 1000 and form a firmly interbonded web, wherein the fibers have an average diameter of 0.1 to 500 micrometers and also diameter fluctuations of at least 30 % within and between fibers and wherein the fibers in addition to the nonmeltable polymer contain more than 40 wt%, based on total fiber weight, of functional additives in solid and/or liquid form which are finely distributed in the fibers.
  2. The spunbonded web as claimed in claim 1, characterized in that the functional additives are solid or liquid, preferably lipophilic substances, more preferably activated carbon, superabsorbents, ion exchange resins, piezoelectric materials, phase change materials, specifically paraffins, metal oxides, flame retardants, abrasives, zeolites, sheet-silicates, modified sheet-silicates and/or cosmetics.
  3. The spunbonded web as claimed in claim 1 or 2, characterized in that the nonmeltable polymer binding the functional additives is a natural polymer, preferably a polysaccharide, more preferably cellulose, a polysaccharide derivative and/or a protein or protein derivative, and/or in that it is a solution-formable synthetic polymer, preferably polyacrylonitrile or a copolymer with acrylonitrile units, polyvinyl alcohol, polyethylene oxide, polysulfone and/or meta-aramid.
  4. The spunbonded web as claimed in one or more of the preceding claims, characterized in that it has a coated construction built from intertwined mechanically bonded filaments/fibers.
  5. The spunbonded web as claimed in one or more of the preceding claims, characterized in that it has a basis weight of 2 to 1000 g/m2 and preferably of 5 to 500 g/m2.
  6. The spunbonded web as claimed in one or more of the preceding claims, characterized in that it has a thickness of 0.1 to 20 mm and preferably of 0.5 to 5 mm.
  7. The spunbonded web as claimed in one or more of claims 1 to 6, characterized in that the fraction of functional additives is more than 40 wt% up to 96 wt%, optionally even more, based on total fiber weight.
  8. A process for producing a high-functionality spunbonded web as claimed in one or more of claims 1 to 7, characterized in that
    - the spinning solution, consisting of one or more functional additives, solvent and polymer dissolved therein, is extruded from the spinneret die, wherein
    the die holes have a diameter of 0.1 to 1.5 mm and preferably of 0.3 to 0.7 mm,
    - the resulting polymeric strands are pulled, immediately upon leaving the dies, by their own weight and/or an obliquely downwardly directed blasting stream, the intensity of which is adapted to the reduced thread-pulling capacity of the spun mixture due to the functional additives, within a short path, in the longitudinal direction, into filaments and/or fibers,
    - these are subsequently, on transitioning into the tensionless space, even before the onset of longitudinal relaxation, stabilized in their shape via a stream of temperature-controlled air and/or fine water droplets by consolidation/gelation and partial replacement of the solvent with water, wherein in spatial terms the stabilization can take place more or less offset to the die exit and webs with more or less interadhered gel-state fibers are thus obtainable,
    - after reaching this stabilized state these are laid down on a foraminous belt or drum to form a web, the remaining solvent is rinsed out by repeated washing and the web can subsequently be dried if desired.
  9. The process as claimed in claim 8, characterized in that the solvent comprises or consists of an aprotic solvent.
  10. The process as claimed in claim 8 or 9, characterized in that the high-functionality spunbonded web is further consolidated, refined and formed by textile processes, and in that the consolidating and refining of the web is effected before or after drying.
  11. The process as claimed in one or more of claims 8 to 10, characterized in that the high-functionality spunbonded web is stabilized by needling or water jet consolidation and/or additionally subjected to chemical crosslinking.
  12. The use of a high-functionality spunbonded web comprising functional additive-containing filaments/fibers as claimed in claims 1 to 7 for production of apparel textiles, especially interlinings, and also of industrial textiles, especially for hygiene applications, for wound dressings, as carrier materials for active ingredients or carrier materials for composites, as building and transportation material, as cosmetic material or as filters, with high functional benefit for various application sectors - depending on the type of functional additives.
EP20110767163 2010-09-14 2011-09-13 Highly functional spunbonded fabric made from particle-containing fibres and method for producing same Active EP2616580B1 (en)

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AU2011301355A1 (en) 2012-05-31
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DE112011100474A5 (en) 2012-12-13
RU2522186C2 (en) 2014-07-10
KR101497360B1 (en) 2015-03-02
BR112012017019A2 (en) 2016-04-05
EP2616580A1 (en) 2013-07-24
CN102753746A (en) 2012-10-24
AU2011301355B8 (en) 2014-02-20
DE112011100474B4 (en) 2021-12-09
AU2011301355B2 (en) 2014-02-06
SI2616580T1 (en) 2014-06-30
RU2012130176A (en) 2014-01-27
PL2616580T3 (en) 2014-08-29
US20120215148A1 (en) 2012-08-23
JP2013515869A (en) 2013-05-09
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KR20120113288A (en) 2012-10-12
AU2011301355A8 (en) 2014-02-20

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