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CN1068390C - 热熔自粘复合纤维及其生产工艺和由此获得的熔结织物或表面材料 - Google Patents

热熔自粘复合纤维及其生产工艺和由此获得的熔结织物或表面材料 Download PDF

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CN1068390C
CN1068390C CN95115526A CN95115526A CN1068390C CN 1068390 C CN1068390 C CN 1068390C CN 95115526 A CN95115526 A CN 95115526A CN 95115526 A CN95115526 A CN 95115526A CN 1068390 C CN1068390 C CN 1068390C
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CN1128305A (zh
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石泽整
铃木正康
寺田博和
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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Abstract

本发明揭示了热熔自粘复合纤维，在复合纤维相互交叉点熔结的复合纤维无纺织物；及卫生用品诸如卫生巾和纸尿布等表面材料。复合纤维含有一种聚丙烯作为第一组分及一主要包括聚乙烯的聚合物作为第二组分，其中第二组分连续存在于沿纤维长度方向的至少部分纤维表面上；具有4-16/英寸三维卷曲；具有单丝旦数1.0-2.0，及具有表现切断长度20-40mm。

Description

热熔自粘复合纤维及其生产工艺和由此获得的熔结织物或表面材料
本发明涉及热熔自粘复合纤维及生产该复合纤维的方法。进一步，本发明涉及含这种复合纤维且具有高强度，压缩后的高体积回复性。良好的不成结(细纤维聚集体)成形特性及柔软手感的部分熔结的织物。更进一步，本发明涉及含有该部分熔结织物的卫生用品等表面材料，诸如卫生巾和纸尿布。
近年，用于卫生用品诸如卫生巾和尿布等表面材料的无纺织物要求的性能已经提高并多样化；而且特别要求这种无纺织物在尽可能小的基重下保持高强度，压缩后具有高体积回复性，作为织物的成形特性具有有限数目的丝结(细纤维聚集体)，并具有柔软手感。
为满足这些要求，在已审查的日本专利公开No.1-37505中提出了一种生产膨体无纺织物的工艺。其中热熔自粘复合纤维部分熔结。在生产这种纤维中，第一组分的Q值。预热温度，拉伸比，卷曲数，及卷曲弹性是特定的。
然而，无纺织物作为卫生用品等表面材料仍不令人满意，并且具体说该专利公开’505中得到的无纺织物存在问题，在粗梳步骤出现麻烦；许多丝结的形成而使织物的性能变差，体积回复率低；强度低且手感差。因此，人们强烈要求开发一种解决上述这些问题的无纺织物。
作为对含有热熔自粘复合纤维的无纺织物的性能及其生产工艺勤奋研究的结果，人们发现下面提出的发明已经解决了先有技术中存在的缺陷：
本发明提供了含有包括结晶聚丙烯的第一组分和主要包括聚乙烯的第二组分，两组分以并列或偏心鞘-芯关系设置的热熔自粘复合纤维，其中第二组分连续存在于纤维长度方向的至少部分纤维的表面上，具有4-16英寸三维卷曲，单丝旦数为1.0-2.0，且表观长度为20-40mm。
本发明复合纤维可通过下列步骤的实施而生产：
利用纺制并列或偏心鞘-芯型复合纤维的喷丝板的聚合物组分纺丝步骤，
在高于90℃，低于130℃的温度，以最大拉伸比率的0.6-0.85倍拉伸比率下拉伸如此获得的未拉伸丝的拉伸步骤，
冷却该拉伸丝至一低于预热温度的温度下并进行丝的卷曲处理步骤，及
在高于80℃，但低于120℃的温度下进行的丝的热定型步骤。
进一步，本发明是要提供一种含有50％wt以上的上述热熔自粘复合纤维或按照上述工艺加工得到的纤维的部分熔结织物。在本发明的织物中，复合纤维的相互交叉点是通过复合纤维中第二组分的熔融而相互连接的。
更进一步，本发明是要提供一种卫生用品所用表面材料，厚度大于1mm，且含有上述部分熔结的织物。
图一所示为本发明复合纤维的截面图。
用作本发明复合纤维第一组分的结晶聚丙烯通常指含有聚合的丙烯作为主要组分的一种结晶聚合物，不仅包括丙烯均聚物，而且包括丙烯与乙烯，丁烯-1，或4-甲基戊烯的共聚物。
在本发明复合纤维中主要用作第二组分的聚乙烯通常指含有聚合的乙烯作为主要组分的聚合物，诸如中或低压聚乙烯和高压聚乙烯，它不仅包括乙烯均聚物，而且包括乙烯与丙烯，丁烯-1或醋酸乙烯酯的共聚物(EVA)。聚乙烯的熔点最好低于作为第一组分的结晶聚丙烯的熔点20℃或更多。
上述的结晶聚丙烯和聚乙烯在不至于达不到本发明目的这一范围内可含有各种通常用于聚烯烃纤维的添加剂，诸如稳定剂，填充剂及颜料。
本发明中的热熔自粘复合纤维是通过一纺制并列型或偏心鞘-芯型复合纤维的喷丝板挤出纺丝而成。第二组分必须连续存在于纤维长度方向的至少部分纤维表面上，而且第二组分最好尽可能广地复盖纤维表面。因为热融自粘复合纤维是利用两组分弹性收缩的不同产生卷曲，图一所示偏心鞘-芯结构最好是处于该复合纤维具有鞘-芯型结构的情况，且芯组分的中心最好偏离鞘组分中心的5-15％(基于鞘-芯复合纤维的直径)。
本发明复合纤维可利用纺制并列型复合纤维或偏心鞘-芯型复合纤维的常规方法而得到，其中第二组分用作为鞘组分，对复合纤维中的两组分的比率没有特别限制，但第二组分最好为40-70％wt。
本发明的热熔自粘复合纤维具有三维卷曲。复合纤维在热处理制备无纺织物时最好不要产生卷曲，换句话说，本发明的复合纤维最好不要产生后卷曲。当纤维热处理时基本上不产生后卷曲时，产生卷曲导致的纤维收缩在热处理制备无纺织物时可避免。
本发明热熔自粘复合纤维的卷曲数通常为4-16/英寸，且最好为6-14/英寸。当卷曲数少于4/英寸，它导致在粗梳机筒上纤维的缠绕。当卷曲数超过16/英寸时，孔隙变差，并导致无纺织物制备时丝结形成。
本发明热熔自粘复合纤维必须具有单丝旦数1.0-2.0。当旦数低于1.0，卷曲变得太细并导致丝结的形成。当旦数超过2.0，存在一种手感变硬且压缩后无纺织物的体积回复性下降的趋势。
本发明的热熔自粘复合纤维的表观切断长度通常为20-40mm，且最好为25-35mm。当它低于20mm时，纤维在粗梳机上的传输性能低下，且它成为纤维缠辊问题的原因。当它超过40mm时，纤维的缠结是显而易见的且成为丝结形成的一个原因。
本发明的热熔自粘复合纤维的表观切断长度对切断长度的比率最好为50-70％。当比率低于50％时，纤维在粗梳机上的传输性能低下，纤维缠辊导致丝结的形成。当比率超过70％时，纤维的缠结变得很强烈，导致纤维在喂入辊上的缠绕，而且粗梳步骤本身变得不可能。
本发明热熔自粘复合纤维的生产方法包括：
通过一纺制并列或鞘-芯型复合纤维的喷丝板的聚合物组分纺丝步骤，
在高于90℃，但低于130℃的温度下，以0.6-0.85倍最大拉伸比率的拉伸比对如此得到的未拉伸丝进行拉伸步骤，
冷却拉伸丝至一低于预热温度的温度并进行丝的卷曲处理步骤，及
在高于80℃，但低于120℃的温度下进行纤维的热定型步骤。
在纺丝步骤中，包括一结晶聚丙烯的第一组分和主要包括一聚乙烯的第二组分通过一纺制并列或鞘-芯型复合纤维的喷丝板挤出而制成长丝以使第二组分连续存在于至少一部分纤维表面上。
在拉伸步骤，挤出的未拉伸丝预热至一拉伸温度。当拉伸温度低于90℃时，卷曲变得太细。当拉伸温度超过130℃时，复合纤维聚乙烯发生相互间的明显熔结而不利。
当拉伸比率低于最大拉伸比率的0.6倍时，两组分弹性回复的差别变小且因此卷曲不能产生。当拉伸倍数超过最大拉伸比率的0.85倍时，两组分弹性回复的差别变得太大且卷曲环变小。其后果不仅卷曲数变多，而且纤维表观切断长度变得太短而不利。最大拉伸比率是指当拉伸比率逐渐上升时，丝条开始出现毛丝时的拉伸比率。
在卷曲处理中，拉伸丝在低于拉伸温度的温度下冷却，丝束用一导辊诸如压料辊的卷取轮在张力条件下卷取，且随后丝束松驰产生卷曲。当卷曲处理在超过拉伸温度的温度下进行时，卷曲的产生不充分。
在热定型步骤中，卷曲处理中产生了卷曲的丝束在高于80℃，低于120℃的温度下进行热定型0.5-30分钟。当热定型温度低于8℃，存在在制备无纺织物步骤中产生不利的后卷曲的可能。当热定型温度高于120℃时，由于两组分弹性回复差别产生的卷曲伸直且纤维表观切断长度变长而不利。
从无纺织物加工简便的观点考虑，本发明热熔自粘复合纤维常常切成预定长度并用作短纤维。
本发明的部分熔结的织物可含有50wt％以上，及直至100wt％的上述热熔自粘复合纤维。部分熔结的无纺织物可利用常规的粗梳法，气体熔喷法，或干浆法将热熔自粘复合纤维转变为一无纺织物并使该无纺织物进行热处理以使织物部分熔结而获得。部分熔结的无纺织物可含有50wt％以下的聚酯，聚酰胺，聚丙烯，聚乙烯，或其它的合成纤维、天然纤维诸如棉和羊毛，或再生纤维如人造丝，作为不同于热熔自粘复合纤维的纤维。在这一步骤，热熔自粘复合纤维必须在织物中掺混50wt％或更多的用量。当热熔自粘复合纤维的含量低于50wt％，不仅得不到高无纺强度的织物，因为织物中纤维相互交联部分较少，而且预期的压缩后织物的高膨松性和高体积回复性也不能得到。
作为部分熔结热熔自粘复合纤维的方法，通过使用一加热空气干燥机或吸气式带式干燥机的方法作为示例。通过将这些方法利用于织物，复合纤维相互交叉部分通过第二组分的熔融而相互熔结形成织物。熔结温度通常高于第二组分的熔点，但低于第一组分的熔点，优选为120-155℃。以干燥机为例，熔结时间通常长于5秒。
本发明卫生用品等表面材料是利用部分熔结的无纺织物制取的，且通常厚度大于1mm。当膨松特性大于1mm，且特别是压缩后的弹性回复高于50％时表面材料是符合要求的。当厚度小于1mm且回复性低于50％，材料不能得到柔软手感。
本说明书中所指的厚度是指对材料施加50gf/cm2负载24小时后，让材料在无负载下静置lhr以恢复它的厚度并随后在2gf/cm2负载下测定厚度而确定的厚度值(mm)。压缩后的弹性回复是指换算为百分数(％)后的表面材料施加50kgf/cm2负载24hr后测定的厚度与同一表面材料在无负载下使之静置1hr后以恢复它的厚度后测定的厚度差值。
按照本发明，可以生产具有高体积回复性，良好成形特性，高强度且同时具有柔软手感的热融自粘复合纤性，并因此用作卫生用品等表面材料，特别是，本发明的部分熔结织物可广泛应用于卫生巾和纸尿布。
实施例
参照实施例，本发明将得到更具体的说明。然而，必须明白这些具体实施例决不能限制本发明。实施例中的物理性能值通过如下方法测定：
卷曲数：热熔自粘复合纤维的卷曲数按照JIS L1015(化学纤维短纤维测试法)7.12.1测定。
单丝旦数：热熔自粘复合纤维的单丝旦数按照JIS L1015(化纤短纤维测试法)7.5.1-A测定。
表观切断长度：热熔自粘复合纤维的表观切断长度是在无张力下不使短纤维的卷曲伸直并且未施加额外的力作用于短纤维下测定纤维的长度(mm)而确定。得到30次测量的平均值。
体积回复：部分熔结的无纺织物的体积回复是通过测定对织物施加50gf/cm2负载24hr后样品织物的厚度(A)，使织物在无负载下静置1hr以恢复它的体积，在负载2gf/cm2下测定织物厚度(B)，并按照下面的等式计算体积回复率而得到：
Figure C9511552600091
在评价结果时，具有50％以上体积回复率的织物被认为是可接受的，而其它织物认为是不可接受的。可接受的织物设定为A，不可接受的织物设定为C。
无纺织物强度：部分熔结的无纺织物的强度按照JIS L1085(无纺织物夹层布的测试)而测定。其中在夹持距离为10cm及拉伸速度为30±2cm/min的条件下通过拉伸测定5cm宽样品物沿织物方向的强度(MD)及垂直于织物方向的强度(CD)。评价结果时，具有MD强度2500g/5cm以上的织物认为是可接受的，而低于2500g/5cm则认为是不可接受的；具有CD强度500g/5cm以上的织物认为是可接受的，而低于500g/5cm则认为是不可接受的。可接受的织物设为A，不可接受的织物设为C。
丝结数目：部分熔结的无纺织物的丝结数通过计数1cm2样品织物上的丝结数且换算为个数/m2而确定。在评介结果时，具有1个或无丝结的部分熔结的无纺织物认为是可接受的，而2个以上的丝结则认为是不可接受的。可接受的织物设定为A，不可接受的织物设定为C。
手感：部分熔结的无纺织物的手感通过5个质检员进行感觉测试而确定。当所有的质检员判断样品织物柔软，织物被认为是“优良”；当三个以上的质检员判定织物柔软，织物被认为“良好”；当三个以上的质检员判定样品织物柔软感觉不充分，织物被认为“差”。优良的织物设定为A，良好的织物设定为B，而差的织物设定为C。
织物收缩：部分熔结的无织物的收缩可通过将样品织物切成大小为25cm2，用干燥机在无负载下，于145℃下加热5min，测定沿织物方向的三个点上的收缩，通过计算得到平均值。评价时，具有低于10％的收缩的织物认为是可接受的，而具有10％以上收缩的织物认为是不可接受的。可接受织物设为A，不可接受织物设定为C。
实施例1-4和比较例1-9
表1所示的每种热熔自粘复合纤维短纤维是通过一具有350孔，直径0.6mm，用于纺制鞘-芯或偏心并列型复合纤维的喷丝板挤出聚丙烯作为第一组分和聚乙烯作为第二组分以形成丝束，及在表1所示的条件下拉伸丝束，并将拉伸丝切成短纤维而得到。由此得到的纤维物理性能示于表1。
由此得到的每种热熔自粘复合纤维的短纤维利用粗梳机制成基重为20-30g/m2的织物，并且在135-140℃的预定温度用一吸气式带式干燥机进行织物的热处理5秒钟以得到一纤维相互交叉部分相互熔结的无纺织物。无纺织物的特性示于表2。在表2的实施例4和比较例9中，使用实施例1中和比较例3中的短纤维。
                                      表1
                                      热熔自粘复合纤维物理性能
第一组分 第二组分 复合结构   复合比率第一/第二组分 拉伸温度(℃) 冷却温度(℃) 热定型温度℃
实施例1    PP2)    PE3)   偏心鞘-芯    50/50     115     50     100
比较例1     ＂     ＂   偏心鞘-芯      ＂     ＂      ＂ 130
比较例2     ＂     ＂   偏心鞘-芯      ＂     ＂      ＂     100
比较例3     ＂     ＂   偏心鞘-芯      ＂     ＂      ＂      ＂
比较例4     ＂     ＂   偏心鞘-芯      ＂     110     80     80
比较例5     ＂     ＂   偏心鞘-芯      ＂     ＂      ＂      ＂
比较例6     ＂     ＂   偏心鞘-芯      ＂     115     50     100
实施例2     ＂   LL4)   偏心鞘-芯     40/60     95     40     80
比较例7     ＂     ＂   偏心鞘-芯      ＂      ＂      ＂      ＂
实施例3     ＂   PE3)     并列     50/50     110     100     100
比较例8     ＂     ＂     并列      ＂      ＂     60     60
2)PP：结晶聚丙烯3)PE：高密度聚乙烯4)LL：线性低密度聚乙烯
                                              表1(续)
                                           热熔自粘复合纤维物理性能′
 实际拉伸比率  最大拉伸比率   MS比9  卷曲数/英寸   卷曲形态 单丝旦数  切断长度mm  表观切断长度mm
实施例1     4.0     4.8    0.83      11.3 三维     1.5    51     34
比较例1     ＂      ＂      ＂      3.5     三维      ＂     ＂     43
比较例2     4.4      ＂    0.92      18.2     三维      ＂     ＂     21
比较例3     4.0      ＂    0.83      12.7     机械5)      ＂     ＂     29
比较例4     3.2     3.5    0.91      16.0 三维     0.8 ＂     22＂
比较例5     2.0      ＂    0.57      3.1     三维     1.5     ＂     43
比较例6     4.0     4.8    0.83      11.3     三维      ＂     64     44
实施例2      ＂     5.1    0.78      13.3     三维     2.0     51     28
比较例7     3.3      ＂    0.64      13.9     三维     3.0     ＂     25
实施例3     3.4     3.9    0.87      6.5     三维     1.0     38     26
比较例8      ＂     3.8    0.89      15.1     三维      ＂     ＂     17
1)MS比：实际拉伸比÷最大拉伸比5)机械：利用填塞箱获得的卷曲形态。
                                                  表2
                                熔结的无纺织物物理性能
   含量％ 基重g/m2                  膨松性         强度特性
 厚度(mm)  体积回复性(％)    评价   MD g/5cm    评价
实施例1    100    25     2.0        61      A     2840     A
比较例1                            比较例1的纤维不能形成无纺织物
比较例2    100    25     1.9        68      A     2520     A
比较例3     ＂    ＂     0.7        38      C     3150     A
比较例4     ＂    ＂     1.7        57      A     2720     A
比较例5                            比较例5的纤维不能形成无纺织物
比较例6    100    25     1.6        60      A     2670     A
实施例2     ＂    30     2.2        53      A     3200     A
比较例7     ＂    ＂     1.4        32      C     2200     C
实施例3     ＂    20     1.3        55      A     2610     A
比较例8     ＂    ＂     1.0        62      A     2550     A
实施例4    506)    25     1.3        51      A     2950     A
比较例9    307)    ＂     1.0        45      C     3030     A
6)实施例1的纤维(50％)与比较例3的纤维(50％)掺混。7)实施例1的纤维(30％)与比较例3的纤维(70％)掺混。
                                                  表2(续)
                                 熔结的无纺织物物理性能
         强度特性                       成型特性 手感
  CDg/5cm    评价      Naps丝结(个/m2)   评价   织物收缩率(％)   评价
实施例1     610     A        0     A     3.1     A    A
比较例1                            (比较例1的纤维不能开成无纺织物)
比较例2     590     A       13     C     4.7     A    B
比较例3     780     A        0     A     2.9     A    C
比较例4     510     A       38     C     6.3     A    B
比较例5                            (比较例5的纤维不能形成无纺织物)
比较例6     500     A        9     C     3.2     A    B
实施例2     630     A        1     A     2.0     A    A
比较例7     450     C        0     A     1.8     A    C
实施例3     550     A        0     A     2.9     A    A
比较例8     540     A       57     C     13.1     C    B
实施例4     640     A        0     A     2.8     A    A
比较例9     660     A        0     A     2.8     A    B

Claims (4)

1．热熔自粘复合纤维含有包括一结晶聚丙烯的第一组分和主要包括一聚乙烯的第二组分，组分以并列型或偏心鞘-芯型关系设置，其中第二组分连续存在于沿纤维长度方向的至少部分纤维表面上，具有4-16/英寸三维卷曲和具有单丝旦数1.0-2.0，且具有表观切断长度20-40mm。
2．一种生产权利要求1所述热熔自粘复合纤维的方法，包括利用一纺制并列或偏心鞘-芯型复合纤维的喷丝板进行聚合物组分的纺丝步骤，在高于90℃，但低于130℃下，以最大拉伸比率的0.60-0.85倍的拉伸比率下对如此得到的未拉伸丝进行拉伸步骤，冷却拉伸丝使其为低于预热温度的温度并进行丝的卷曲处理步骤，及在高于80℃，但低于120℃下进行丝的热定型步骤。
3．一种部分熔结的含有50％wt以上的按照权利要求1的热熔自粘复合纤维或通过按照权利要求2的方法得到的纤维的无纺织物，复合纤维的相互交叉点通过复合纤维中的第二组分熔融而相互连接。
4．一种卫生用品的表面材料，其厚度大于1mm，含有按照权利要求3的部分熔结的无纺织物。
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EP0696655B1 (en) 1998-06-03
DE69502775T2 (de) 1998-10-29
JP3569972B2 (ja) 2004-09-29
CN1128305A (zh) 1996-08-07
JPH0860441A (ja) 1996-03-05
DE69502775D1 (de) 1998-07-09
KR100350175B1 (ko) 2002-12-26
KR960007849A (ko) 1996-03-22
BR9503626A (pt) 1997-09-16
EP0696655A1 (en) 1996-02-14

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