TWI631245B - 熱黏合複合纖維及其製作方法以及使用其不織布 - Google Patents
熱黏合複合纖維及其製作方法以及使用其不織布 Download PDFInfo
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- TWI631245B TWI631245B TW103119005A TW103119005A TWI631245B TW I631245 B TWI631245 B TW I631245B TW 103119005 A TW103119005 A TW 103119005A TW 103119005 A TW103119005 A TW 103119005A TW I631245 B TWI631245 B TW I631245B
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- composite fiber
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Classifications
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Abstract
本發明之目的在於提供一種熱黏合複合纖維以及使用其的不織布。上述熱黏合複合纖維確保即使在處於纖維伸長的狀態下也可維持其捲曲構造穩定性,且可賦予不織布纖維其膨鬆性與柔軟性纖維。本發明提供之熱黏合複合纖維包括含有聚酯類樹脂之第一成分以及含有聚烯烴類樹脂之第二成分。上述聚烯烴類樹脂具有較上述聚酯類樹脂之熔點還低的熔點,其中上述第二成分佔特定範圍之外部纖維周長且具有並列或偏心鞘-芯結構,且熱黏合複合纖維具有特定伸長率、特定範圍之三維顯現捲曲與特定範圍之捲曲模數。
Description
本發明是有關於一種熱黏合複合纖維,且特別是有關於一種可從而獲得具有優良的柔軟性之不織布或其類似物之熱黏合複合纖維。更具體而言,本發明是有關於一種可從而獲得例如具有優良的柔軟性且適於多種應用之不織布的熱黏合複合纖維以及使用其而具有優良的柔軟性之不織布。上述應用例如為吸水性物品,用於諸如尿布、餐巾和襯墊之清潔材料、醫療及衛生材料、生活相關材料、一般醫學材料、墊層材料、過濾材料、護理產品以及寵物產品。
傳統上,藉由利用熱能(諸如熱空氣與加熱輥(heated roll))的熱熔融可形成的熱黏合複合纖維可輕易地提供具有優良的膨鬆性與柔軟性的不織布。因此,上述熱黏合複合纖維被廣泛地用於諸如尿布、餐巾和襯墊之清潔材料、生活用品以及諸如過濾器之
工業材料中。其中,由於清潔材料與人體皮膚直接接觸或需要迅速地吸收諸如尿液和月經血的液體,故清潔材料之膨鬆性與柔軟性是非常重要的。獲得膨鬆性的代表技術為使用高剛性(rigid)樹脂的方法與使用具有高纖度(fineness)纖維的方法。然而,在這些情況下,所獲得的不織布之柔軟性低且對皮膚造成強烈的物理性刺激。另一方面,當以抑制對皮膚的刺激性的柔軟性為優先時,則大幅地降低所得到之不織布的膨鬆性(特別是在緩衝作用(cushioning effect)上),故表現出不佳的流體吸收特性。
為了解決這些問題,已提出了許多方法來獲得各自能夠同時滿足膨鬆性與柔軟性的纖維與不織布。舉例而言,專利文獻1提出了一種具有優異膨鬆回復性的捲曲複合纖維,此捲曲複合纖維是由鞘-芯複合纖維所組成,且此鞘-芯複合纖維使用聚對苯二甲酸丙二酯類樹脂(polytrimethylene terephthalate-based resin)作為芯成分,並使用聚烯烴類樹脂作為鞘成分。此外,專利文獻2中提出一種高膨鬆性的熱黏合複合纖維。此熱黏合複合纖維具有優異的捲曲構造穩定性且由鞘-芯複合纖維所組成,此鞘-芯複合纖維是使用聚酯類樹脂作為芯成分,並使用聚烯烴類樹脂作為鞘成分。
專利文獻
[專利文獻1]JP-A-2003-3334(本文所用的術語“JP-A”表示「未經審查的日本專利申請公開」)
[專利文獻2]JP-A-2008-274448
然而,這些方法是專門針對膨鬆性或膨鬆回復性,而不織布的柔軟性卻有待改進。
本發明之目的在於提供一種熱黏合複合纖維以及使用其的不織布。上述熱黏合複合纖維確保即使在處於纖維伸長的狀態下也可維持其捲曲構造穩定性,且可賦予不織布纖維其膨鬆性與柔軟性。
本發明人已作了很多深入的研究,以解決上述問題。因此,已發現當使用由包含聚酯類樹脂之第一成分以及包含聚烯烴類樹脂之第二成分所組成的複合纖維,並調整其拉伸(drawing)條件、賦予機械捲曲(mechanical crimp-imparting)條件與乾燥條件(下文中有時稱為「熱處理條件」。此外,進行「乾燥」的步驟有時稱為「乾燥步驟」或「熱處理步驟」),以提供即使在纖維處於伸長的狀態下仍可防止由加熱導致的剛性降低之顯現捲曲熱黏合複合纖維時,可達到上述目的。本發明已基於上述發現而完成。
即,本發明有以下的態樣。
[1]一種熱黏合複合纖維,其包括含有聚酯類樹脂之第一成分以及含有聚烯烴類樹脂之第二成分。上述聚烯烴類樹脂具有
較上述聚酯類樹脂之熔點還低15℃或低更多之熔點。第二成分在與纖維長度方向交叉的纖維剖面中佔30%或更多的外部纖維周長且具有並列或偏心鞘-芯結構。上述熱黏合複合纖維具有50%至120%之伸長率、10至20波峰(crests)/2.54公分之三維顯現捲曲以及85%至100%之捲曲模數。
[2]如上述[1]中所述的熱黏合複合纖維,其中上述聚酯類樹脂是由聚乙烯對苯二甲酸酯(polyethylene terephthalate)、聚丙烯對苯二甲酸酯(polypropylene terephthalate)、聚丁烯對苯二甲酸酯(polybutylene terephthalate)、聚乳酸、聚丁烯琥珀酸酯(polybutylene succinate)以及聚己二酸/聚丁烯共聚對苯二甲酸酯(polybutylene adipate terephthalate)所組成的群組中所選出的至少一者。
[3]如上述[1]或[2]中所述的熱黏合複合纖維,其中上述聚烯烴類樹脂是由聚乙烯、聚丙烯以及主成分為丙烯之共聚物所組成的群組中所選出的至少一者。
[4]如上述[1]至[3]中任一者所述的熱黏合複合纖維,其中熱黏合複合纖維之纖度從0.9dtex至8.0dtex。
[5]如上述[1]至[4]中任一者所述的熱黏合複合纖維,其中熱黏合複合纖維包含無機微粒,且基於熱黏合複合纖維的質量而言,此無機微粒之含量從0.1質量%至10質量%。
[6]一種如上述[1]至[5]中任一者所述的熱黏合複合纖維的製作方法,其包括:獲得未拉伸纖維的步驟,使包含聚酯類樹脂之第一成分
以及包含聚烯烴類樹脂之第二成分經熔融紡絲(melt-spinning)具有第二成分佔外部纖維周長的30%或更多的並列或偏心鞘-芯剖面形狀,上述聚烯烴類樹脂具有較聚酯類樹脂之熔點還低15℃或低更多之熔點;拉伸步驟,將上述得到的未拉伸纖維拉伸至拉伸比為未拉伸纖維斷裂時的拉伸比之75%至95%;以及加熱步驟,將上述得到的拉伸纖維加熱以藉由熱收縮賦予其三維顯現捲曲。
[7]如上述[6]中所述的熱黏合複合纖維的製作方法,其中在拉伸步驟後,得到的拉伸之纖維經機械捲曲以賦予二維捲曲,此二維捲曲具有許多5至10波峰/2.54公分之捲曲。
[8]一種不織布,其是使用上述[1]至[5]中任一者所述的熱黏合複合纖維所得到。
[9]如上述[8]中所述的不織布,其中不織布的比體積為80至130立方公分/克。
本發明之熱黏合複合纖維雖然具有良好的特定纖維伸長率,其仍可維持三維顯現捲曲形狀。因此,即使在製程中熱黏合成不織布時,仍可維持捲曲構造穩定性,而可製作有高柔軟性以及優異膨鬆性的不織布。
圖1A是實例1的剖面形狀的示意圖;圖1B是實例2的剖面形狀的示意圖;圖1C是實例3的剖面形狀的示意圖;圖1D是實例4的剖面形狀的示意圖;圖1E是實例5的剖面形狀的示意圖;圖1F是實例6的剖面形狀的示意圖;圖2A是比較例1的剖面形狀的示意圖;圖2B是比較例2的剖面形狀的示意圖;圖2C是比較例3的剖面形狀的示意圖;圖2D是比較例4的剖面形狀的示意圖;圖2E是比較例5的剖面形狀的示意圖。
下文更詳細地說明本發明。
本發明之熱黏合複合纖維為包括含有聚酯類樹脂之第一成分以及含有聚烯烴類樹脂之第二成分的熱黏合複合纖維。上述聚烯烴類樹脂具有較上述聚酯類樹脂之熔點還低15℃或低更多的熔點。第二成分在與纖維長度方向交叉的纖維剖面中佔30%或更多的外部纖維周長且具有並列或偏心鞘-芯結構。
構成本發明的熱黏合複合纖維(下文有時簡稱為「複合纖維」)之第一成分的聚酯類纖維可藉由二醇和二羧酸的縮聚(condensation)得到。
在聚酯類樹脂之縮聚中使用的二羧酸包括對苯二甲酸(terephthalic acid)、間苯二甲酸(isophthalic acid)、2,6-萘二羧酸(2,6-naphthalenedicarboxylic acid)、己二酸(adipic acid)、癸二酸(sebacic acid)等。所用的二醇包括乙二醇(ethylene glycol)、二乙二醇(diethylene glycol)、1,3-丙二醇(1,3-propanediol)、1,4-丁二醇(1,4-butanediol)、新戊二醇(neopentyl glycol)、1,4-環己烷二甲醇(1,4-cyclohexanedimethanol)等。
作為用於本發明中的聚酯類樹脂,較佳可使用芳香族聚酯,其諸如聚乙烯對苯二甲酸酯、聚丙烯對苯二甲酸酯以及聚丁烯對苯二甲酸酯。除了芳香族聚酯之外,也可使用脂肪族聚酯。較佳的脂肪族聚酯樹脂包括聚乳酸以及聚丁烯琥珀酸酯。
這些聚酯類樹脂可以不僅是均聚物(homopolymer),其也可為共聚合的聚酯(共聚聚酯(copolyester))。同時,可將二羧酸成分(諸如己二酸、癸二酸、鄰苯二甲酸(phthalic acid)、間苯二甲酸以及2,6-萘二羧酸)、二醇成分(諸如二乙二醇以及新戊二醇)以及光學異構物(諸如L-乳酸)用作為共聚成分。舉例而言,上述共聚物包括聚己二酸/聚丁烯共聚對苯二甲酸酯(polybutylene adipate terephthalate)。此外,這些聚酯類樹脂可混合兩種或更多種使用。
考慮到例如原料成本或所得纖維之熱穩定性,第一成分
更佳為僅由聚乙烯對苯二甲酸酯組成的未改性聚合物。
第一成分未受到特別限定,只要其含有聚酯類樹脂,然聚酯類樹脂較佳的含量為80質量%或更多,且聚酯類樹脂更佳的含量為90質量%或更多。此外,若有需要的話,只要本發明的效果未受到抑制,則可適當地加入添加劑,其諸如抗氧化劑、光穩定劑、紫外線吸收劑、中和劑、成核劑、環氧穩定劑(epoxy stabilizer)、潤滑劑(lubricant)、抗菌劑、阻燃劑、抗靜電劑(antistatic agent)、顏料以及塑化劑(plasticizer)。
構成本發明之複合纖維的第二成分的聚烯烴類樹脂並不受到特別限定,只要其滿足熔點較構成第一成分之聚酯類樹脂的熔點還低15℃或低更多的條件即可。
舉例而言,可使用聚乙烯、聚丙烯、聚丁烯-1、聚己烯-1、聚辛烯-1、聚4-甲基戊烯-1(poly 4-methylpentene-1)、聚甲基戊烯、1,2-聚丁二烯以及1,4-聚丁二烯。在這樣的均聚物中,除了構成上述均聚物之單體之外,在此條件下,可含有作為共聚成分的α-烯烴,其諸如乙烯、丙烯、丁烯-1、己烯-1、辛烯-1以及4-甲基戊烯-1(4-methylpentene-1)。此外,可含有作為共聚成分的其他乙烯類不飽和單體,其諸如丁二烯、異戊二烯、1,3-戊二烯(1,3-pentadiene)、苯乙烯以及α-甲基苯乙烯。
也可將這些聚烯烴類樹脂的兩種或更多種混合使用。關
於這些樹脂,不僅較佳可使用以傳統的齊格勒-納塔催化劑(Ziegler-Natta catalyst)聚合的聚烯烴類樹脂,也可使用以茂金屬(metallocene)催化劑聚合的聚烯烴類樹脂及兩者之共聚物。此外,適用之聚烯烴類樹脂的熔融質量流動速率(以下簡稱為MFR(Melt Mass Flow Rate))並未受到特別限定,只要其在可紡絲(spinnable)的範圍內即可,然MFR較佳從1至100克/10分鐘,更佳從5至70克/10分鐘。
構成本發明之複合纖維的第二成分的聚烯烴類樹脂較佳為從以下族群中選出的至少一種聚烯烴類樹脂,所述族群由聚乙烯、聚丙烯以及包括作為主成分之丙烯的共聚物所組成。其實例包括高密度聚乙烯、線性低密度聚乙烯、低密度聚乙烯、聚丙烯(丙烯均聚物)、以丙烯為主成分的乙烯-丙烯共聚物與以丙烯為主成分的乙烯-丙烯-丁烯-1(ethylene-propylene-butene-1)共聚物。本文使用的「包括丙烯為主成分之共聚物」是指在構成共聚物的共聚成分中,其丙烯單元佔最大量的共聚物。
在第一成分為兩種或更多種聚酯類樹脂混合物及/或第二成分為兩種或更多種聚烯烴類樹脂混合物的情形下,「構成第二成分的聚烯烴類樹脂具有較構成第一成分之聚酯類樹脂還低15℃或低更多之熔點」是指在構成第二成分的聚烯烴類樹脂混合物中具有最高熔點之樹脂的熔點較構成第一成分之聚酯類樹脂混合物中具有最低熔點之樹脂還低15℃或低更多。
除了MFR以外,聚烯烴的物性未受到特別限定,只要聚
合物滿足本發明之要求即可。舉例來說,上述除了MFR以外的物性諸如Q值(重量平均分子量/數均分子量(number average molecular weight))、洛式硬度(Rockwell hardness)以及甲基支鏈數。
只要其中含有聚烯烴類樹脂,則第二成分未受到特別限定,然聚烯烴類樹脂較佳含量為80質量%或更多,且聚烯烴類樹脂更佳含量為90質量%或更多。若需要的話,只要本發明的效果未受到抑制,可以適當地含第一成分所例示的添加劑。
本發明之複合纖維的第一成分與第二成分的組合未受到限定,只要構成第二成分的聚烯烴類樹脂滿足熔點較構成第一成分之聚酯類樹脂之熔點還低15℃或低更多之條件即可,且可使用選自上述第一成分與第二成分中之成分組合。
第一成分/第二成分之組合特定實例包括聚乙烯對苯二甲酸酯/聚丙烯、聚乙烯對苯二甲酸酯/高密度聚乙烯、聚乙烯對苯二甲酸酯/線性低密度聚乙烯以及聚乙烯對苯二甲酸酯/低密度聚乙烯。在這些組合中,較佳為聚乙烯對苯二甲酸酯/高密度聚乙烯。
在本發明之複合纖維具有偏心鞘-芯結構的情況下,纖維可為偏心實心鞘-芯複合纖維或偏心中空鞘-芯複合纖維。偏心鞘-芯類型是指在與纖維長度方向交叉的纖維剖面之芯側重心不同於
鞘側重心。有鑑於可紡性(spinnability)或三維顯現捲曲(下文有時簡稱「顯現捲曲」)發展性(developability),偏心率(eccentricity ratio)較佳從0.05至0.50,更佳從0.15至0.30。本文所用的偏心率以JP-A-2006-97157中描述的下式表示:偏心率=d/R
其中d以及R如下:d為複合纖維中心點與構成芯之第一成分中心點之間的距離,而R為複合纖維半徑。
芯側之剖面形狀可不僅僅是圓形,其也可以是不規則形狀。不規則形狀之實例包括星形、橢圓形、三角形、四邊形、五邊形、多葉形(multifoliate)、陣列(array)、T-形以及馬蹄形。然而,有鑑於三維顯現捲曲發展性,芯側剖面形狀較佳為圓形、半圓形或橢圓形,而有鑑於不織布強度,更佳為圓形。
在本發明之複合纖維具有並列(平行)結構的情況下,在與纖維長度方向交叉的纖維剖面中,第二成分佔外部纖維周長的30%或更多。歸因於此比例,可改善三維顯現捲曲發展性。具體而言,第二成分較佳佔外部纖維周長的30%至70%,更佳為從40至60%。
本發明之複合纖維具有三維顯現捲曲,且捲曲數為從10至20波峰/2.54公分。
三維顯現捲曲是指具有三維捲曲形狀,例如螺旋形或歐
姆形(波峰/波谷(trough)非呈銳角而為圓角且三維扭曲的形狀),且可由單獨一個捲曲來提供三維捲曲形狀或由混合的捲曲來提供三維捲曲形狀,此未受到特別限定。藉由具有這種三維捲曲形狀,可容易得到體積大且柔軟的不織布。
三維顯現捲曲中的捲曲數從10至20波峰/2.54公分,較佳從12至16波峰/2.54公分。在製作不織布的過程中,具有在此範圍內的捲曲數可穩定梳理(carding)步驟的梳理通過性(card passability),且可容易得到體積大且柔軟的不織布。
關於本發明之複合纖維捲曲形狀,以三維顯現捲曲為主,但可與藉由機械捲曲而設有平面鋸齒輪廓(彎曲輪廓)的二維捲曲混合在一起。在具有機械捲曲的情況下,三維顯現捲曲較佳佔50%或更多,更佳80%或更多。
在本發明複合纖維之與長度方向交叉的纖維剖面中,第一成分以及第二成分的複合率較佳為10/90至90/10體積%,更佳為30/70至70/30體積%,再更佳為40/60至50/50體積%。具有在此範圍內的複合率,很可能會發展出藉由加熱而成的顯現捲曲。在上述說明中,複合率單位為體積%。
本發明之複合纖維纖度未受到特別限定,較佳從0.9dtex至8.0dtex。具體而言,在為用於清潔材料或耗材之纖維的情況下,纖度較佳為1.0dtex至8.0dtex,更佳為1.7dtex至6.0dtex,再更佳為2.6dtex至4.4dtex。具有在此範圍內的纖度,可輕易實現膨鬆性與柔軟性兩者。
本發明之複合纖維強度未受到特別限定,但例如在用於清潔材料或耗材之纖維的情況下,強度較佳從1.5cN/dtex至4.0cN/dtex,更佳從2.0cN/dtex至3.0cN/dtex。具有在此範圍內的強度,可滿足纖維的構造穩定性與膨鬆性兩者。
本發明之複合纖維伸長率為50%至120%,較佳為70%至100%。具有在此範圍內的伸長率,可賦予不織布柔軟性。
本發明所用的伸長率是根據JIS L 1015(2010)進行拉伸試驗,使用拉伸試驗機並將夾具(clamp)距離設為20mm。定義樣品斷裂時的伸長率為纖維伸長率。
本發明之複合纖維捲曲模數為85%至100%,較佳為90%至97%。JIS L 2080中所定義的捲曲模數為「基於拉直長度與原始長度之間的差異,當捲曲被拉直時的纖維長度與鬆開纖維並靜置一段預定時間後的纖維長度之間的差異百分率」。特定量測方法提供於JIS L 1015(2010)中。具有85%或更多的捲曲模數,可在不織布製作過程中維持顯現捲曲構造穩定性,進而可賦予不織布膨鬆性與柔軟性。
在本發明之複合纖維中,為了提供來自其本身重量或光滑質地的懸垂效果(draping effect),或為了藉由於纖維內部或外部產生空氣間隙(諸如空隙或裂縫)以獲得具有優良柔軟性之纖維,可視需要適當地加入無機微粒。基於本發明之複合纖維質量,纖維中無機微粒的添加量較佳從0至10質量%,更佳從0.1至10質量%,再更佳從1至5質量%。
無機微粒未受到特別限定,只要其為具有高的比重(specific gravity)且不易在熔融樹脂材料中造成聚集(aggregation)即可。舉例而言,上述材料包括氧化鈦(比重:3.7至4.3)、氧化鋅(比重:5.2至5.7)、鈦酸鋇(barium titanate)(比重:5.5至5.6)、碳酸鋇(比重:4.3至4.4)、硫酸鋇(比重:4.2至4.6)、氧化鋯(比重:5.5)、矽酸鋯(比重:4.7)、氧化鋁(alumina)(比重:從3.7至3.9)、氧化鎂(比重:3.2)以及具有與上述材料實質相同比重之材料。在上述材料之中,較佳使用氧化鈦。為了掩蔽(masking)、抗菌、除臭等目的,一般習知會在纖維中加入使用這些無機微粒。所用無機微粒較佳具有不會造成問題(諸如於紡絲步驟或拉伸步驟中的紗線(yarn)斷裂)的粒徑或形狀。
無機微粒之加入方法例如包括:將無機微粒粉末直接加入第一成分或第二成分中的方法;以及將無機微粒揉合進樹脂,以製作母料(masterbatch),並將此母料加入第一成分或第二成分中的方法。關於製作母料的樹脂,最佳使用與第一成分或第二成分相同的樹脂。然此樹脂未受到特別限定,只要其滿足本發明之要求即可,且也可使用與第一成分以及第二成分不相同的樹脂。
以下說明本發明之複合纖維之製作方法。
複合纖維可製作如下。首先,將會變成本發明之複合纖維原料的聚酯類樹脂配置為第一成分,將熔點較第一成分之熔點
還低15℃或低更多的烯烴類樹脂配置為第二成分,並將這些樹脂加工成並列或偏心鞘-芯之未拉伸纖維,在與纖維長度方向交叉的纖維剖面中,第二成分佔外部纖維周長的30%或更多。
可藉由習知並列紡絲噴嘴(side-by-side spinning nozzle)或習知偏心鞘-芯紡絲噴嘴(sheath-core spinning nozzle)熔融紡絲原料,以構成並列或偏心鞘-芯剖面形狀,而產生具有上述結構之未拉伸纖維。
熔融紡絲的溫度條件未受到特別限定,然紡絲溫度較佳為250℃或更多,更佳為280℃或更多,再更佳為300℃或更多。紡絲溫度較佳為250℃或更多,這是因為於紡絲期間的紗線斷裂數減少,且同時得到使維持其拉伸後伸長率成為可能的未拉伸紗線。紡絲溫度更佳為280℃或更多,這是因為有更高強度的上述效果。再更佳300℃或更多,這是因為有再更高強度的上述效果。溫度上限為可使紡絲成功之溫度且未受到特別限定。
此外,紡絲速率未受到特別限定,然較佳從300至1500公尺/分鐘,更佳從600至1000公尺/分鐘。紡絲速率較佳為300公尺/分鐘或更高,這是因為可以增加獲得具有任意紡絲纖度之未拉伸紗線時的單孔排出量,以提供滿意的生產率。
將在上述條件下得到的未拉伸紗線於拉伸步驟中拉伸。
拉伸溫度較構成第一成分之聚酯類樹脂的玻璃轉換溫度還高30℃至70℃,且拉伸溫度同時低於構成第二成分之聚烯烴類樹脂的熔點。拉伸溫度較佳是較上述聚酯類樹脂的玻璃轉換溫
度還高40℃至60℃且低於上述聚烯烴類樹脂的熔點。
本文使用的拉伸溫度表示在拉伸起始位置之纖維溫度。拉伸溫度較佳不低於「作為第一成分之聚酯類樹脂的玻璃轉換溫度+30℃」,這是因為可維持高的纖維伸長率且可允許維持拉伸後之伸長率。當拉伸溫度為較高的溫度時,即使是在高應變速率(strain rate)(亦即高拉伸比)下拉伸,其仍有利於得到上述效果。然而,若拉伸溫度過高時,第一成分會發生冷結晶(cold crystallization)直到未拉伸纖維被拉伸,且剩餘(remaining)伸長率受到抑制。就此觀點而言,將拉伸溫度設為不高於「作為第一成分之聚酯的玻璃轉換溫度+70℃」。此外,拉伸溫度需要低於作為第二成分之烯烴類樹脂的熔點,以抑制在拉伸過程中纖維彼此熔接(fusion)所致的不穩定性。
舉例而言,將玻璃轉換溫度為70℃之聚乙烯對苯二甲酸酯配置為第一成分,並將熔點為130℃之高密度聚乙烯配置為第二成分,在此情況下拉伸未拉伸纖維,則將拉伸溫度設為從100℃至低於130℃。當拉伸溫度為100℃或更高時,纖維之熱量(heat quantity)增加,且聚乙烯對苯二甲酸酯與高密度聚乙烯之間的可拉伸性(drawability)差異變小,因此在不織布的製作過程中,在梳理期間造成鞘-芯分離的風險降低。
拉伸比為未拉伸纖維斷裂時的拉伸比之75%至95%,較佳為從80%至95%,更佳為從85%至90%。斷裂時的拉伸比是指在拉伸未拉伸纖維之過程中發生纖維斷裂時的拉伸比。當拉伸比
為斷裂時的拉伸比之75%或更高時,可抑制加熱導致的剛性降低。當拉伸比為斷裂時的拉伸比之95%或更低時,將降低伴隨著由潛伏捲曲(latent crimp)的顯現(actualization)所造成之拉伸所產生之顯現捲曲的可展性(developability),其中潛伏捲曲的顯現是由於本發明之複合纖維的複合結構及施於第一成分與第二成分之應力-應變的差異所造成的。因此,在隨後之乾燥步驟(熱處理步驟)中,可提昇由纖維複合結構以及第一成分與第二成分之間的熱收縮性差異所造成之潛伏捲曲的顯現所產生之顯現捲曲的發展性(development)。
接著,將於拉伸步驟中得到的拉伸纖維乾燥,以賦予三維顯現捲曲。
在本發明中,顯現捲曲是在纖維的乾燥步驟(熱處理步驟)中所形成的。顯現捲曲的發展性是來自於本發明之複合纖維的複合結構以及複合成分之間的熱收縮性差異,且顯現捲曲的發展是存在於纖維中的潛伏捲曲顯現的結果。
與在拉伸步驟中所形成的顯現捲曲相比,在乾燥步驟中所形成的顯現捲曲具有大的捲曲直徑,且顯現捲曲數落在適當的範圍內。在本發明中,形成具有10至20波峰/2.54公分之三維顯現捲曲,且較佳形成具有12至16波峰/2.54公分之顯現捲曲。具有上述範圍中的顯現捲曲數目,可減少由顯現捲曲造成的纖維纏結(entanglement),且可改善後續梳理步驟中的梳理通過性。
在本發明中,可在乾燥步驟之前賦予機械捲曲。藉由進
行機械捲曲,可增加梳理步驟中的梳理通過穩定性。在進行機械捲曲的情況下,較佳賦予5至10波峰/2.54公分的機械捲曲,更佳為從7至9波峰/2.54公分。
若在乾燥步驟中形成的顯現捲曲的直徑是小的(捲曲細微),則纖維與使用纖維所得到的不織布會具有堅硬的質地。然而,當賦予5至10波峰/2.54公分之機械捲曲時,纖維在賦予機械捲曲時會承受熱與強大的應力,且其熱力學/物理效果為經記憶/經固定為纖維內部的纖維形狀。
在乾燥步驟中,潛伏捲曲被顯現同時保持預先記憶/固定於纖維內部的熱力學/物理效果。因此,與未賦予機械捲曲的情況相比,在這樣的記憶/形狀的影響下,很可能發展出具有大捲曲直徑之顯現捲曲。捲曲直徑增加導致纖維柔軟性提昇,憑藉著在機械捲曲步驟中預先承受熱力學/物理作用,在乾燥步驟中得到的纖維可成為特別在顯現捲曲構造穩定性方面優良的纖維。
若有需要時,在賦予機械捲曲前,也可在諸如濕熱與蒸汽的氛圍(atmosphere)下施加退火處理,以在熱處理步驟中改善熱歷程(heat history)、抑制應力鬆弛並精細地調整熱收縮。
舉例而言,乾燥步驟(熱處理步驟)較佳在低於第二成分之熔點但不低於其熔點超過15℃的溫度下使用熱風乾燥機(hot air dryer)或其類似物進行,且較佳在低於第二成分之熔點但不低於其熔點超過10℃的溫度下進行。此處理促進顯現捲曲的發展與結晶,進而可得到具有適當伸長率與大捲曲直徑並柔軟且構造穩定
性優良的捲曲。顯現捲曲的可展性也可藉由在賦予機械捲曲前之拉伸比、機械捲曲數或熱歷程來控制。
藉由在乾燥步驟(熱處理步驟)中之潛伏捲曲的顯現而得到的三維顯現捲曲之捲曲數為10至20波峰/2.54公分,較佳為12至16波峰/2.54公分。得到的捲曲具有三維顯現捲曲形狀,然可保持源自機械捲曲的平面鋸齒捲曲(二維捲曲)。
本發明之複合纖維製作方法的精髓在於,在拉伸步驟中進行拉伸,且拉伸比足夠低以使纖維伸長而抑制或壓制潛伏捲曲的發展,而隨後於後步驟(亦即纖維熱處理步驟,特別是在形成不織布前的纖維乾燥步驟)中發展纖維之顯現捲曲。
此外,在乾燥步驟前的步驟中,較佳賦予纖維捲曲數量相對較少的機械捲曲,具體為5至10波峰/2.54公分。
其後,可將纖維切成短纖維。可根據使用用除選擇短纖維之纖維長度,而其未受到特別限定。然而,在進行梳理加工的情況下,纖維長度較佳從20至102mm,更佳從30至51mm。
藉由使用本發明之複合纖維,可適當地得到比體積為80立方公分/克或更大之大體積不織布。具體而言,可適當地得到80至130立方公分/克之不織布。加工成不織布之條件未受到特別限定,然舉例而言,一種方法是將使用軋輥梳理機(roller carding machine)得到的梳理網於130℃至145℃下進行加熱處理,以製
得基重為20至30克/平方公尺之不織布。熱處理方法未受到特別限定,然較佳為透氣(through-air)加工等,這是因為可製作出有良好柔軟性的不織布。
可將使用本發明之複合纖維製作的不織布應用於需要膨鬆性與耐壓縮性的多種纖維產品中,其例如吸水性材料(諸如尿布、餐巾以及失禁襯墊)、醫療與衛生材料(諸如袍以及手術衣)、室內裝修材料(諸如中空板、窗戶紙與地板材料)、日常生活有關的材料(諸如蓋布、清洗擦拭器與廚房垃圾蓋)、洗浴用品產品(諸如拋棄式馬桶(disposable toilet)以及馬桶墊)、寵物產品(諸如寵物被單、寵物尿布以及寵物巾)、工業用材料(諸如擦拭材料、過濾器、緩衝材料(cushioning material)、油吸附劑以及墨槽吸附劑)、一般的醫療材料、鋪墊材料以及護理產品。
下文參照實例來說明本發明,然本發明未受到這些實例的限定。在各個實例中,物理評價是通過後述的方法進行。
使用以下樹脂作為構成複合纖維之熱塑性樹脂。樹脂1:高密度聚乙烯(縮寫:PE),其密度為0.96克/立方公分,MFR(190℃,負載(load):21.18 N)為16克/10分鐘,熔點為130℃;樹脂2:聚丙烯晶體(縮寫:PP),其MFR(230℃,負載:21.18 N)為5克/10分鐘,熔點為162℃;樹脂3:聚乙烯對苯二甲酸酯(縮
寫:PET),其本徵黏度為0.64,玻璃轉換溫度為70℃。
使用以下的方法作為將無機微粒加入複合纖維之方法。
將無機微粒粉末加工成母料,接著,將其加入第一成分及/或第二成分。用來形成母料的樹脂與作為第一成分或第二成分之樹脂相同。
使用表1或表2中所示的熱塑性樹脂,並分別將第一成分與第二成分分別配置在芯側與鞘側,以與表中所示相似的擠壓溫度(extrusion temperature)、複合率(體積率)與剖面形狀進行紡絲。在紡絲期間,藉由油輥法(oiling roll)的手段使含有烷基磷酸酯鉀鹽(alkyl phosphate K salt)作為主成分之纖維處理劑與紡纖維接觸,以將纖維處理劑附著於纖維上。
在表1或表2中所示的條件下,使用拉伸機並將拉伸溫度(熱輥表面溫度)設為90至125℃,使所得之未拉伸纖維經受拉伸步驟與捲曲(機械捲曲)賦予步驟。隨後,使用熱風循環式乾燥機,於表1或表2中所示的乾燥溫度(熱處理溫度)下施加乾燥步驟(熱處理步驟)5分鐘,以得到熱黏合複合纖維。
隨後,使用切割器將纖維切成短纖維,使用此纖維作為樣品纖維。
將熱黏合複合纖維設置於軋輥梳理機上,對網取樣,並
使用熱風循環式熱處理機於138℃之處理溫度下對網進行加熱處理,以使鞘成分(sheath component)熱黏合,從而可得到基重為約25克/平方公尺之不織布。
根據JIS K 7210(1999)量測熔融質量流動速率。此處,MI遵照表1之附錄A的條件D(測試溫度:190℃,負載:2.16公斤)來量測,而MFR遵照條件M(測試溫度:230℃,負載:2.16公斤)來量測。
根據JIS L 1015(2010),量測樣品纖維的纖度與拉伸強度/伸長率。
量測當將初始負載0.18mN/tex施加於25毫米(或20毫米)之樣品纖維時的長度,對此時的捲曲數進行計數,並判定每25毫米(或20毫米)的捲曲數。
量測當將初始負載0.18mN/tex施加於25毫米(或20毫米)之樣品纖維時的長度。此外,量測當施加負載4.41mN/tex時的長度。然後,移除所有負載。在讓樣品靜置2分鐘之後,藉由施加初始負載來量測長度,並計算捲曲模數(%)。
使用數位指示器(Digimatic Indicator)(由三豐公司
(Mitutoyo Corporation)製作),於負載3.5克/平方公分下量測不織布的厚度,並使用以下數學公式由所量測到的厚度計算比體積:不織布比體積(立方公分/克)=不織布的厚度(毫米)/不織布基重(平方公尺/克)×1000
從得到的比體積值評價膨鬆性。
將以不織布的製作方法所得到的四張不織布堆疊,以製得樣品100克/平方公尺,並準備三組。預先量測各樣品的厚度,將測得值用於量測功數量(work amount)並計算負載。以卡尺(caliper)對每個樣品的四個部分進行樣品的厚度量測,並使用其算術平均值。
使用加藤科技(Kato Tech)有限公司製作之壓縮試驗機(KES-G5),以壓力板(2平方公分的盤)在0.4毫米/秒的速率下壓縮每個樣品,直到樣品厚度降至50%,並量測此時的功數量。
將得到的功數量除以50%之樣品厚度(壓縮距離),可計算得到負載(克力/平方公分(gf/cm2))。
平均負載是從三個樣品組計算出的算術平均值所判定的。
由得到的平均負載值來評價柔軟性。
從上面的結果可以明顯看出,在根據本發明之實例1至6中,其纖維伸長率從50至120%,且同時,捲曲模數提高,這顯示了即使在處於纖維伸長的狀態下,也能夠確保捲曲構造穩定性。還可理解的是,可提昇使用本發明之複合纖維製作之不織布的膨鬆性(由比體積評估)與柔軟性(由平均負載評估)。
在比較例3之複合纖維中,可看出其纖維伸長率為非常高的值(136%),這顯示了使用此複合纖維製作的不織布柔軟性被提昇,然與實例相比,其膨鬆性則不佳。
雖然參照本發明之特定實施例詳細地說明本發明,所屬領域具有通常知識者可理解的是,可對其作各種變化與修飾而不會脫離本發明之精神與範疇。
本申請是基於2013年5月31號申請的日本專利申請第2013-115739號,其全文以引用的方式併入本文中。本文引用的所有參考文獻皆全文併入本文中。
本發明之熱黏合複合纖維在處於纖維伸長的狀態下,可維持其捲曲構造穩定性,且因此上述熱黏合複合纖維可製作出有高柔軟性與優異膨鬆性之不織布。從本發明之熱黏合複合纖維得到的不織布具有優良的柔軟性與膨鬆性,因此上述不織布可用於需要膨鬆性與柔軟性兩者的應用中,例如是需要膨鬆性與柔軟性的多種纖維產品的應用,舉例而言,吸水性材料(諸如尿布、餐巾
以及失禁襯墊)、醫療與衛生材料(諸如袍以及手術衣)、室內裝修材料(諸如中空板、窗戶紙與地板材料)、日常生活有關的材料(諸如蓋布、清洗擦拭器與廚房垃圾蓋)、洗浴用品產品(諸如一次性馬桶以及馬桶蓋)、寵物產品(諸如寵物被單、寵物尿布以及寵物巾)、工業用材料(諸如擦拭材料、過濾器、緩衝材料、油吸附劑以及墨槽吸附劑)、一般的醫療材料、鋪墊材料以及護理產品。
Claims (9)
- 一種熱黏合複合纖維,包括含有聚酯類樹脂之第一成分以及含有聚烯烴類樹脂之第二成分,所述聚烯烴類樹脂具有較所述聚酯類樹脂之熔點還低15℃或低更多之熔點,其中所述第二成分在與纖維長度方向交叉的纖維剖面中佔30%或更多的外部纖維周長且具有並列或偏心鞘-芯結構,且所述熱黏合複合纖維具有50%至120%之伸長率、10波峰/2.54公分至20波峰/2.54公分之三維顯現捲曲以及85%至100%之捲曲模數。
- 如申請專利範圍第1項所述的熱黏合複合纖維,其中所述聚酯類樹脂是由聚乙烯對苯二甲酸酯、聚丙烯對苯二甲酸酯、聚丁烯對苯二甲酸酯、聚乳酸、聚丁烯琥珀酸酯以及聚己二酸/聚丁烯共聚對苯二甲酸酯所組成的群組中所選出的至少一者。
- 如申請專利範圍第1項或第2項所述的熱黏合複合纖維,其中所述聚烯烴類樹脂是由聚乙烯、聚丙烯以及主成分為丙烯之共聚物所組成的群組中所選出的至少一者。
- 如申請專利範圍第1項所述的熱黏合複合纖維,其中所述熱黏合複合纖維之纖度為0.9dtex至8.0dtex。
- 如申請專利範圍第1項所述的熱黏合複合纖維,其中所述熱黏合複合纖維中含有無機微粒,且基於所述熱黏合複合纖維之質量,所述無機微粒之含量為0.1質量%至10質量%。
- 一種熱黏合複合纖維的製作方法,用於製作如申請專利範圍第1項所述的熱黏合複合纖維,所述熱黏合複合纖維的製作方 法包括:獲得未拉伸纖維的步驟,使包含所述聚酯類樹脂之所述第一成分以及包含所述聚烯烴類樹脂之所述第二成分經熔融紡絲而具有所述第二成分佔所述外部纖維周長的30%或更多的並列或偏心鞘-芯剖面形狀,所述聚烯烴類樹脂具有較所述聚酯類樹脂之熔點還低15℃或低更多之熔點;拉伸步驟,將獲得的所述未拉伸纖維拉伸至拉伸比為所述未拉伸纖維斷裂時的拉伸比之75%至95%;以及加熱步驟,將所得到的拉伸纖維加熱以藉由熱收縮賦予所述拉伸纖維三維顯現捲曲。
- 如申請專利範圍第6項所述的熱黏合複合纖維的製作方法,其中在所述拉伸步驟後,對所得到的所述拉伸纖維進行機械捲曲,以賦予所述拉伸纖維捲曲數為5波峰/2.54公分至10波峰/2.54公分的二維捲曲。
- 一種不織布,使用如申請專利範圍第1項所述的熱黏合複合纖維得到。
- 如申請專利範圍第8項所述的不織布,其中所述不織布之比體積為80立方公分/克至130立方公分/克。
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