TWI607126B - Nonwoven fabric and method for manufacturing the same - Google Patents

Description

Non-woven fabric and its making method

The present invention relates to a nonwoven fabric and a method of making the same.

Wet wipes have been widely used in general life due to ease of use. For example, in a hot and humid climate, many people are used to wiping sticky skin with a wet tissue. However, in recent years, there have been reports that wet wipes have additives. For example, commercially available wet wipes have been detected to be likely to be doped with various chemical additives such as surfactants or sodium carbonate, which are used to strengthen or fix the wet. The structure of the paper towel. In other words, wet wipes that are generally emphasized for hygiene may be potentially dangerous.

On the other hand, among the commercially available wet tissues, in order to make the wet tissue have wet strength characteristics and water dissipability, a chemical treatment agent of a water-soluble adhesive or a wet strength agent is also added to the wet tissue. The user will have a greasy discomfort when wiping, and further, the chemical treatment agent will cause environmental impact and burden on the public sewage sewer after being flushed.

An embodiment of the present invention provides a non-woven fabric, including the first The one fiber layer and the two second fiber layers are configured by the material of the first fiber layer and the second fiber layer, and the non-woven fabric can have a certain dry strength/wet strength, so that the non-woven fabric can provide a wiping function. In addition, since the non-woven fabric of the present invention has a flushable property to water, the used non-woven fabric can be directly thrown into an aqueous environment, and since the composition of the non-woven fabric does not require the addition of an additional chemical treatment agent, it is generated after being discarded to the environment. The impact and burden are also relatively small.

One embodiment of the present invention provides a nonwoven fabric comprising a first fibrous layer and two second fibrous layers. The first fibrous layer is comprised of a first fibrous material, wherein the first fibrous material comprises fibrillar fibers. Two layers of second fiber layers are respectively disposed on opposite surfaces of the first fiber layer. The second fibrous layer is composed of a first fibrous material mixed with a second fibrous material, wherein the second fibrous material comprises staple fibers, and the first fibrous material has a swelling coefficient greater than a swelling coefficient of the second fibrous material.

In some embodiments, the first fibrous material is a rayon fiber and the second fibrous material is a pulp fiber.

In some embodiments, the ratio of the basis weight of the first fibrous layer to the total basis weight of the two second fibrous layers is 0.5 to 0.6.

In some embodiments, the ratio of the weight of the first fibrous material to the second fibrous material in the second fibrous layer is from 0.5 to 1.

In some embodiments, a portion of at least one of the two layers of the second fibrous layer extends into the first fibrous layer.

In some embodiments, a portion of one of the two layers of the second fibrous layer extends through the first fibrous layer and into the other of the two second fibrous layers.

One embodiment of the present invention provides a method of fabricating a nonwoven fabric, comprising the following steps. A first fibrous layer is formed using the first fibrous material, wherein the first fibrous material comprises fibrillar fibers. Using the first fibrous material and the second fibrous material to form a second fibrous layer on opposite surfaces of the first fibrous layer, wherein the second fibrous material comprises staple fibers, and the first fibrous material has a swelling coefficient greater than that of the second fibrous material Swelling coefficient.

In some embodiments, the method of making the nonwoven fabric further comprises applying pressure to the second fibrous layer such that a portion of the second fibrous layer extends into at least the first fibrous layer.

In some embodiments, the step of providing pressure to the second fibrous layer can be accomplished through a hydroentanglement process.

In some embodiments, the first fibrous layer and the second fibrous layer are formed by one of a wet papermaking process and an airlaid process.

100‧‧‧nonwoven

110‧‧‧First fiber layer

120, 122‧‧‧ second fibrous layer

130‧‧‧Water column

140A, 140B‧‧‧ fiber

S10-S30‧‧‧Steps

FIG. 1A is a schematic side view showing a nonwoven fabric according to an embodiment of the present invention.

Fig. 1B is a flow chart showing a method of manufacturing the nonwoven fabric of Fig. 1A.

FIG. 1C is a schematic side view showing the hydroentanglement process of the non-woven fabric of FIG. 1A.

FIG. 1D is a schematic side view showing the non-woven fabric of FIG. 1C after the completion of the hydroentanglement process.

The embodiments of the present invention are disclosed in the following drawings, and the details of However, it should be understood that these practical details are not intended to limit the invention. That is, in some embodiments of the invention, these practical details are not necessary. In addition, some of the conventional structures and elements are shown in the drawings in a simplified schematic manner in order to simplify the drawings.

Since commercially available wet wipes have a chemical treatment agent, when the wet tissue is discarded, it will have an impact and burden on the environment. In view of this, an embodiment of the present invention provides a non-woven fabric that does not require the addition of an additional chemical treatment agent, which has a relatively small environmental impact and burden after disposal. In more detail, the non-woven fabric of the present invention comprises a first fibrous layer and two second fibrous layers, and the non-woven fabric can have a certain dry strength/wet strength by the material arrangement of the first fibrous layer and the second fibrous layer, so that The non-woven fabric has a wiping function and water dissipative properties.

FIG. 1A is a side elevational view of a nonwoven fabric 100 in accordance with an embodiment of the present invention. The nonwoven fabric 100 includes a first fibrous layer 110 and two second fibrous layers 120 and 122. The first fibrous layer 110 is comprised of a first fibrous material, wherein the first fibrous material comprises fibrillar fibers. The two second fiber layers 120 and 122 are respectively disposed on opposite surfaces of the first fiber layer 110, that is, in the three-layer structure of the non-woven fabric 100, the first fiber layer 110 is used as an intermediate layer, and the two layers are second. The fibrous layers 120 and 122 are used as an outer layer with the first fibrous layer 110 sandwiched therebetween. Each of the second fibrous layers 120 or 122 is composed of a first fibrous material mixed with a second fibrous material, wherein the second fibrous material comprises staple fibers, and the length of the staple fibers is less than the length of the long fibers. this Additionally, the swelling coefficient of the first fibrous material is greater than the swelling coefficient of the second fibrous material.

Since the strength of the long fiber is greater than the strength of the staple fiber, the strength of the first fiber material comprising the long fiber may be greater than the strength of the second fiber material of the staple fiber. In other words, the first fibrous material is less susceptible to permanent deformation or breakage than the second fibrous material. In this regard, since the first fibrous layer 110 is substantially composed of the first fibrous material, and the two second fibrous layers 120 and 122 are formed by mixing the first fibrous material and the second fibrous material, the first fibrous layer 110 is thus formed. The strength may be relatively greater than the respective strengths of the second fibrous layers 120 and 122. On the other hand, since the swelling coefficient of the first fiber material is greater than the swelling coefficient of the second fiber material, when the nonwoven fabric 100 absorbs a large amount of moisture, the degree of swelling of the first fiber layer 110 is greater than that of the second fiber layers 120 and 122, respectively. The degree of swelling.

In the configuration of the first fibrous material and the second fibrous material of the nonwoven fabric 100, the first fibrous material may be a rayon fiber, and the second fibrous material may be a pulp fiber. By this configuration, the nonwoven fabric 100 may be used, for example, as a wet tissue. Please see the instructions below.

Since the yttrium fiber has strong fiber strength, the ruthenium fiber of the first fiber layer 110 and the two second fiber layers 120 and 122 can be used as the structural skeleton of the non-woven fabric 100, and since the pulp fiber has adhesive properties, two The second fibrous layers 120 and 122 of the layer are permeable to the first fibrous layer 110 by the pulp fibers, thereby fixing the structure and shape of the nonwoven fabric 100. Further, since the pulp fibers have water absorbing characteristics, moisture can be stored in the two second fiber layers 120 and 122 when the nonwoven fabric 100 is used as a wet tissue. In other words By this configuration, the nonwoven fabric 100 can have a certain degree of wet strength (the maximum tensile force that the moisture absorbing cloth can withstand without breaking or permanent deformation), so that the nonwoven fabric 100 can be used as a wet tissue.

On the other hand, in the nonwoven fabric 100 formed in this configuration, since the swelling coefficient of the ray fiber is larger than the swelling coefficient of the pulp fiber, when the nonwoven fabric 100 absorbs a large amount of moisture, a swelling effect is generated, in which the swelling of the first fiber layer 110 is performed. The extent will be greater than the degree of swelling of the two layers of second fibrous layers 120 and 122. Through the swelling effect, the structure of the nonwoven fabric 100 can cause degradation and dissolution. In other words, when the nonwoven fabric 100 absorbs a large amount of moisture, the structure of the nonwoven fabric 100 is disintegrated and becomes a plurality of chips. With this configuration, the nonwoven fabric 100 can produce a flushable property against water without using a chemical treatment agent. Therefore, when the non-woven fabric 100 is used as a wet tissue, since the wet tissue does not have a chemical treatment agent, the user will not have a similar greasy discomfort when wiping. Moreover, since the wet tissue does not have a chemical treatment agent, the impact or burden on the environment is relatively small, so that the used wet tissue can be directly thrown into the aqueous environment to be dispersed, for example, thrown into the flush toilet. .

In addition, the ratio of the basis weight (unit: gsm) of the first fiber layer 110 to the total basis weight of the two second fiber layers 120 and 122 is 0.5 to 0.6. Further, in the second fiber layer 120 or 122, the ratio of the weight of the first fiber material and the second fiber material is 0.5 to 1. A method of manufacturing the nonwoven fabric 100 will be described below.

Please refer to FIG. 1A and FIG. 1B simultaneously, wherein FIG. 1B is a flowchart of a method of manufacturing the nonwoven fabric 100 of FIG. 1A. The manufacturing method of the nonwoven fabric 100 includes steps S10, S20, and S30. Step S10 is to use the first fiber The dimensional material forms a first fibrous layer 110, wherein the first fibrous material comprises long fibers. Step S20 is to form a second fiber layer 120 and 122 on the opposite surfaces of the first fiber layer 110 by mixing the first fiber material and the second fiber material, wherein the second fiber material comprises the staple fiber, and the first fiber material is swollen. The coefficient is greater than the swelling coefficient of the second fibrous material.

In the manufacturing method of the nonwoven fabric 100, the first fiber layer 110 and the two second fiber layers 120 and 122 may be formed by one of a wet papermaking process and an airlaid process. For example, the first fiber layer 110 and the two second fiber layers 120 and 122 may be separately completed by a wet papermaking process, and then the two second fiber layers 120 and 122 are disposed on the opposite sides of the first fiber layer 110. surface. For example, two layers of the second fiber layers 120 and 122 are disposed on opposite surfaces of the first fiber layer 110 by a bonding process.

Moreover, in order to enhance the structural strength of the nonwoven fabric 100, the method of fabricating the nonwoven fabric 100 further includes providing pressure to at least one of the second fibrous layers 120 and 122 such that a portion of the second fibrous layer 120 or 122 extends at least to the first fibrous layer 110. The fibers in the nonwoven fabric 100 are thereby entangled with each other as shown in step S30.

For example, please see FIG. 1C, in which FIG. 1C is a side view showing a hydroentanglement process of the non-woven fabric 100 of FIG. 1A. In Fig. 1C, the structure of the nonwoven fabric 100 is such that pressure is applied to the second fibrous layer 120 through the hydroentangled process, so that the fibers in the nonwoven fabric 100 can be entangled with each other. The hydroentanglement process uses a high-pressure water (for example, a water pressure of 40 to 120 kg/cm ² ) to produce a fine water column such as a needle (for example, a water column having a diameter of 0.1 mm). Next, the generated water column is directly sprayed toward the nonwoven fabric 100 so that the fibers in the nonwoven fabric 100 are entangled with each other.

In the manufacturing method of the non-woven fabric 100, after the two second fiber layers 120 and 122 are disposed on the opposite surfaces of the first fiber layer 110, at least one of the second fiber layers 120 and 122 can be provided through the hydroentanglement process. pressure. For example, the second fibrous layer 120 is pressurized by the jetting water column 130.

Please refer to FIG. 1D again, wherein FIG. 1D is a side view showing the non-woven fabric 100 of FIG. 1C after the completion of the hydroentanglement process. In the nonwoven fabric 100, a portion of at least one of the two layers of the second fibrous layers 120 and 122 may extend into the first fibrous layer 110 when the hydroentanglement process is completed. For example, the fibers 140A of the second fibrous layer 120 sprayed by the water column 130 (see FIG. 1C) may extend into the first fibrous layer 110 and entangle with the fibers in the first fibrous layer 110 to enhance the first The fixing strength between a fiber layer 110 and the second fiber layer 120.

Alternatively, portions of one of the two layers of second fibrous layers 120 and 122 may extend through the first fibrous layer 110 and into the other of the two second fibrous layers 120 and 122. For example, the fibers 140B of the second fibrous layer 120 sprayed by the water column 130 (see FIG. 1C) will penetrate the first fibrous layer 110 and extend into the second fibrous layer 122, thereby making it the first The fibers in the fibrous layer 110 and the second fibrous layer 122 are entangled to enhance the overall fixing strength.

In other words, after the second fiber layer is pressurized by the hydroentanglement process, the fibers in the second fiber layer sprayed by the water column may be entangled with the first fiber layer or the second fiber layer on the opposite side to enhance the non-woven fabric. The structural strength allows the dry strength and/or wet strength of the nonwoven to be further enhanced. In addition, the non-woven fabrics depicted in Figures 1C and 1D are only for a second layer of fibers. The water supply column, however, in other embodiments, the hydroentanglement process can also provide a water column for both layers of the second fibrous layer.

The parameters of each layer of the non-woven fabric 100, the structural strength, and the flushability of water will be further described below in conjunction with Tables 1 and 2.

Please see Table 1 and Table 2, where Table 1 is the basis weight of the fibers in the layers of the comparative example and the plurality of experimental examples, and Table 2 is the dry strength/wet strength/water flush of the comparative example and the plurality of experimental examples. The measurement result of the divergence. The structure of Experimental Example 1-3 is the nonwoven fabric 100 shown in Fig. 1D, and the difference is that the basis weight of the fibers in each layer is different. Further, the first fibrous layers of Experimental Examples 1-3 were composed of yttrium fibers having a fiber length of 5 mm, and the second fibrous layers of Experimental Examples 1-3 were all rayon fibers having a fiber length of 5 mm and The pulp fibers are mixed to form.

The base fiber of the first fiber layer of Experimental Example 1 has a basis weight of 15 gsm, and the basis weight of the ruthenium fiber and the pulp fiber of each of the second fiber layers of each layer is 6 gsm and 9 gsm, respectively, so that the second fiber layer of each layer is The basis weight is 15 gsm, and the total weight of the two second fiber layers is 30 gsm. Therefore, the ratio of the basis weight of the first fiber layer of Experimental Example 1 to the total basis weight of the two second fiber layers was 0.5, and the yttrium fiber (first fiber material) in the second fiber layer of Experimental Example 1 and The ratio of the weight of the pulp fibers (second fiber material) was 2/3.

The base fiber of the first fiber layer of Experimental Example 2 has a basis weight of 18 gsm, and the basis weight of the ruthenium fiber and the pulp fiber of each of the second fiber layers of each layer is 6 gsm and 9 gsm, respectively, so that the two layers of the second fiber layer are The total basis weight is 30 gsm. Therefore, the ratio of the basis weight of the first fiber layer of Experimental Example 2 to the total basis weight of the two second fiber layers was 0.6, and the yttrium fiber (first fiber material) of the second fiber layer of Experimental Example 2 and the pulp The ratio of the weight of the fibers (second fiber material) was 2/3.

The base fiber of the first fiber layer of Experimental Example 3 has a basis weight of 15 gsm, and the basis weight of the ruthenium fiber and the pulp fiber of each of the second fiber layers of each layer is 5 gsm and 9 gsm, respectively, so that the two layers of the second fiber layer are The total basis weight is 28 gsm. Therefore, the basis weight of the first fiber layer 110 of Experimental Example 3 and the total of the two second fiber layers The basis weight ratio was about 0.54, and the ratio of the weight of the yttrium fiber (first fiber material) to the pulp fiber (second fiber material) of the second fiber layer of Experimental Example 3 was 5/9.

It can be seen from Table 1 that the non-woven fabrics formed in Experimental Examples 1-3 can have a certain degree of dry strength/wet strength and also have a good water dispersibility. In other words, when the non-woven fabric of Experimental Examples 1-3 is used as a wet tissue, the wet tissue can provide the user's wiping demand by using the dry strength/wet strength, and after the wet tissue is used, It has a better water dispersibility, and the wet tissue can be directly thrown into an aqueous environment to directly disintegrate its structure in water.

In summary, the material arrangement of the first fibrous layer and the second fibrous layer of the nonwoven fabric of the present invention can provide the nonwoven fabric with a certain degree of dry strength/wet strength so that the nonwoven fabric can provide a wiping function. In addition, since the formed non-woven fabric has a flushable property against water, the used non-woven fabric can be directly thrown into an aqueous environment. Moreover, since the composition of the non-woven fabric does not require the addition of an additional chemical treatment agent, its impact on the environment and the burden are relatively small. In addition, the non-woven fabric can be entangled with each other through the hydroentanglement process to enhance the structural strength of the nonwoven fabric, thereby further enhancing the wet strength.

While the invention has been described above in terms of various embodiments, it is not intended to limit the invention, and the invention may be modified and modified without departing from the spirit and scope of the invention. The scope of protection is subject to the definition of the scope of the patent application attached.

100‧‧‧nonwoven

110‧‧‧First fiber layer

120, 122‧‧‧ second fibrous layer

130‧‧‧Water column

140A, 140B‧‧‧ fiber

Claims (10)

A nonwoven fabric comprising: a first fibrous layer composed of a first fibrous material, wherein the first fibrous material comprises long-fiber fibers; and two second fibrous layers respectively disposed on opposite surfaces of the first fibrous layer, The second fibrous layer is composed of a mixture of the first fibrous material and a second fibrous material, the second fibrous material comprising staple fiber, wherein a swelling coefficient of the first fibrous material is greater than that of the second fibrous material Swelling coefficient. A non-woven fabric according to claim 1, wherein the first fibrous material is a rayon fiber and the second fibrous material is a pulp fiber. The non-woven fabric of claim 1, wherein a ratio of a basis weight of the first fibrous layer to a total basis weight of the two second fibrous layers is 0.5 to 0.6. The non-woven fabric of claim 1, wherein in the second fibrous layer, the ratio of the weight of the first fibrous material to the second fibrous material is 0.5 to 1. A non-woven fabric of claim 1, wherein a portion of at least one of the two of the second fibrous layers extends into the first fibrous layer. A non-woven fabric according to claim 5, wherein a portion of one of the two second fibrous layers extends through the first fibrous layer and extends into the other of the two second fibrous layers. A method of making a nonwoven fabric comprising: forming a first fiber layer using a first fiber material, wherein the first fiber material comprises a long fiber fiber; and mixing the first fiber material with the second fiber material to form a second fiber layer And opposite surfaces of the first fibrous layer, wherein the second fibrous material comprises staple fibers, and the first fibrous material has a swelling coefficient greater than a swelling coefficient of the second fibrous material. The method of fabricating the nonwoven fabric of claim 7, further comprising: applying pressure to the second fibrous layer such that a portion of the second fibrous layer extends into at least the first fibrous layer. A method of fabricating a nonwoven fabric according to claim 8 wherein the step of providing pressure to the second fibrous layer is completed by a hydroentanglement process. The method for fabricating a nonwoven fabric according to claim 7, wherein the first fibrous layer and the second fibrous layer are formed by one of a wet papermaking process and an airlaid process.