TWI798985B - Melt-blown non-woven fabric - Google Patents

Abstract

A melt-blown non-woven fabric includes a plurality of melt-blown fibers, and each of the melt-blown fiber includes 90 parts by weight to 95 parts by weight of a high-fluidity polyester and 5 parts by weight to 10 parts by weight of a high-fluidity modified polyester. A melt index of the high fluidity polyester at a temperature of 230°C is between 350 g/10min and 550 g/10min, and a melt index the high fluidity modified polyester at a temperature of 230°C is between 200 g/10min and 400 g/10min.

Description

Melt blown nonwoven

The present disclosure relates to a nonwoven fabric, in particular to a melt blown nonwoven fabric.

In the textile industry, since non-woven fabrics can be formed without weaving, issues related to non-woven fabrics have gradually become the focus of development. In addition, due to the advantages of short process time, high output, low cost and wide source of raw materials, non-woven fabrics are suitable for use in the consumer market. A broad definition of a nonwoven can be a cloth-like thing formed by pressure or by stickiness. However, the manufacturing process of non-woven fabrics can have considerable variation, and as the manufacturing process changes, the properties of non-woven fabrics will also change.

Generally speaking, compared with the meltblown process, the nonwoven fabric formed by the electrospinning process usually has finer fibers. However, due to the limitation of electrospinning equipment, its production speed is relatively slow compared with the meltblown process. Therefore, how to manufacture a non-woven fabric with low fiber fineness and high fiber distribution uniformity through the melt-blown process is a very important issue at present.

The present disclosure provides a melt-blown nonwoven fabric, which can have low fiber fineness and high fiber distribution uniformity.

According to some embodiments of the present disclosure, the melt-blown nonwoven fabric includes a plurality of melt-blown fibers, and the melt-blown fibers include 90 to 95 parts by weight of high-fluidity polyester and 5 to 10 parts by weight of high-fluidity modified polyester ester. The high flow polyester has a melt index between 350 g/10 min and 550 g/10 min at a temperature of 230°C. The high fluidity modified polyester has a melt index between 200g/10min and 400g/10min at a temperature of 230°C.

In some embodiments of the present disclosure, the high fluidity modified polyester includes low melting point polyester, and the melting point of the low melting point polyester is between 150°C and 155°C.

In some embodiments of the present disclosure, the high fluidity modified polyester includes low melting point polyester, and the melting point of the low melting point polyester is between 160°C and 165°C.

式(1)。 In some embodiments of the present disclosure, the high fluidity modified polyester includes a soft chain polyester, and the soft chain polyester has a structure represented by formula (1):

Formula 1).

式(2)。 In some embodiments of the present disclosure, the high fluidity modified polyester includes a soft chain polyester, and the soft chain polyester has a structure represented by formula (2):

Formula (2).

式(3)，其中x為介於1至12間的正整數，且y為介於1至12間的正整數。 In some embodiments of the present disclosure, the high fluidity modified polyester includes a soft chain polyester, and the soft chain polyester has a structure represented by formula (3):

Formula (3), wherein x is a positive integer between 1 and 12, and y is a positive integer between 1 and 12.

In some embodiments of the present disclosure, the weight average molecular weight of the high fluidity modified polyester is between 8000 g/mole and 11000 g/mole.

In some embodiments of the present disclosure, the intrinsic viscosity of the high fluidity modified polyester is between 0.9 dL/g and 1.3 dL/g.

In some embodiments of the present disclosure, more than 50% of the melt-blown fibers have a fiber diameter between 0.5 μm and 1.5 μm.

In some embodiments of the present disclosure, more than 75% of the melt-blown fibers have a fiber diameter between 0.5 μm and 1.0 μm.

According to the above-mentioned embodiments of the present disclosure, since the melt-blown fibers in the melt-blown nonwoven fabric include a specific proportion of high-fluidity polyester and high-fluidity modified polyester, and the high-fluidity polyester and high-fluidity modified polyester each have A specific range of melt index, so the melt-blown fibers can have low and concentrated fiber fineness, so that they can be evenly distributed in the melt-blown nonwoven fabric, so that the melt-blown nonwoven fabric of the present disclosure can have high fiber distribution uniformity.

A plurality of implementations of the present disclosure will be disclosed in the following diagrams. For the sake of clarity, many practical details will be described together in the following description. However, it should be understood that these practical details should not be used to limit the present disclosure. That is to say, in some embodiments of the present disclosure, these practical details are unnecessary, and thus should not be used to limit the present disclosure. In addition, for the sake of simplifying the drawings, some well-known structures and components will be shown in a simple and schematic manner in the drawings. In addition, for the convenience of readers, the size of each element in the drawings is not drawn according to actual scale.

Herein, the structure of a polymer or a group is sometimes represented by a skeleton formula. This notation can omit carbon atoms, hydrogen atoms, and carbon-hydrogen bonds. Of course, if an atom or an atomic group is clearly drawn in a structural formula, the drawn one shall prevail.

It should be understood that although the terms "first", "second" and "third" etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, and/or or parts thereof shall not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section from each other. Thus, a "first element," "component," "region," "layer" or "section" hereinafter could also be termed a second element, component, region, layer or section without departing from the teachings herein. .

The present disclosure provides a melt-blown nonwoven fabric, which includes a plurality of melt-blown fibers formed by a melt-blown process. By adjusting the properties and proportions of each material in the melt-blown fiber, the melt-blown fiber can have low and concentrated fiber fineness, thereby overcoming the limitation of the traditional melt-blown process. In this way, the melt-blown fibers can be evenly distributed in the melt-blown non-woven fabric, thereby obtaining a melt-blown non-woven fabric with high fiber distribution uniformity.

The melt-blown nonwoven fabric of the present disclosure includes a plurality of melt-blown fibers, and the melt-blown fibers include 90 to 95 parts by weight of high-fluidity polyester and 5 to 10 parts by weight of high-fluidity modified polyester. The high-fluidity polyester and the high-fluidity modified polyester falling within the above ratio range can make the polyester mixture formed by mixing the high-fluidity polyester and the high-fluidity modified polyester have both Good fluidity and molecular flexibility are conducive to reducing the fiber fineness of the formed melt-blown fibers, and can make the fiber fineness of multiple melt-blown fibers tend to be concentrated. In addition, each of the high-fluidity polyester and the high-fluidity modified polyester has a suitable melt index, so that they each have good fluidity during the melt-blowing process, thereby reducing the fiber fineness of the melt-blown fibers. Specifically, the temperature of the melt-blowing process can be between about 250°C and 300°C, and the high-fluidity polyester of the present disclosure has a melt index between 350g/10min and 550g/10min at a temperature of 230°C ( Melt Index, MI), and the high fluidity modified polyester of the present disclosure has a melt index between 200g/10min and 400g/10min at a temperature of 230°C.

The meltblown fibers include 90 to 95 parts by weight of high flow polyester. In some embodiments, the high flow polyester may be polybutylene terephthalate (PBT). In some embodiments, the weight-average molecular weight of the high-flow polyester can be between 20,000 g/mole and 60,000 g/mole, so as to ensure that the melt index of the high-flow polyester is maintained in the above range, thereby facilitating the formation of fiber fineness Low meltblown fibers.

The melt-blown fibers include 5 to 10 parts by weight of high-fluidity modified polyester. In some embodiments, the high flow modified polyester may include a low melting point polyester, which may enhance the flow of polyester blends (including high flow polyester and high flow modified polyester) during the melt blowing process . In some embodiments, the high flow modified polyester can include a soft chain polyester, which can enhance the molecular softness of the polyester blend during the melt blowing process. Overall, the high-fluidity modified polyester can improve the fluidity and molecular softness of the polyester mixture during the melt-blowing process, thereby improving the spinning ductility of the polyester mixture, which is conducive to the formation of melt-blown fibers with low fiber fineness fiber.

For the low-melting-point polyester, the melting point of the low-melting-point polyester can be adjusted according to actual needs, so that the polyester mixture has proper fluidity. In some embodiments, the low melting point polyester can be a first low melting point polyester, a second low melting point polyester or a combination thereof, wherein the melting point of the first low melting point polyester can be between 150°C and 155°C, and the second low melting point polyester can be The melting point of the di-low melting polyester can be between 160°C and 165°C. In some embodiments, the weight-average molecular weight of the low-melting polyester may be between 8000 g/mole and 11000 g/mole, so as to ensure that the melting point of the low-melting polyester is maintained within the aforementioned range.

式(1)。在一些實施方式中，第二軟鏈聚酯可具有以式(2)表示的結構：

式(2)。在一些實施方式中，第三軟鏈聚酯可具有以式(3)表示的結構：

式(3)，其中x可為介於1至12間的正整數，且y可為介於1至12間的正整數。由於在以式(1)及式(2)表示的結構中具有直鏈烷鏈段，因此其可提供軟鏈聚酯良好的分子柔軟性。由於在以式(3)表示的結構中具有醚基，因此其可進一步提升軟鏈聚酯的柔韌性，從而有利於提升聚酯混合物的抽絲延展性。在一些實施方式中，軟鏈聚酯的重量平均分子量可介於8000g/mole至11000g/mole間，以確保軟鏈聚酯具有足夠長的鏈段，從而具有良好的分子柔軟性。 For the soft-chain polyester, the segment hardness of the soft-chain polyester can be adjusted according to actual needs, so that the polyester mixture has suitable molecular softness. For example, the segment length and the number of branches of the soft chain polyester can be adjusted so that the soft chain polyester has a suitable segment hardness. In some embodiments, the soft chain polyester may be, for example, a derivative formed by modifying polybutylene terephthalate (PBT). In some embodiments, the soft chain polyester may be the first soft chain polyester, the second soft chain polyester, the third soft chain polyester or any combination thereof. In some embodiments, the first soft chain polyester may have a structure represented by formula (1):

Formula 1). In some embodiments, the second soft chain polyester may have a structure represented by formula (2):

Formula (2). In some embodiments, the third soft chain polyester may have a structure represented by formula (3):

Formula (3), wherein x can be a positive integer between 1 and 12, and y can be a positive integer between 1 and 12. Since the structures represented by the formulas (1) and (2) have straight-chain alkane segments, they can provide good molecular flexibility of the soft-chain polyester. Since there is an ether group in the structure represented by formula (3), it can further improve the flexibility of the soft-chain polyester, thereby helping to improve the spinning ductility of the polyester mixture. In some embodiments, the weight average molecular weight of the soft chain polyester can be between 8000 g/mole and 11000 g/mole, so as to ensure that the soft chain polyester has a long enough chain segment to have good molecular flexibility.

In some embodiments, when the temperature is between 260°C and 280°C, the intrinsic viscosity of the high-fluidity modified polyester can be between 0.9dL/g and 1.3dL/g, so that the polyester mixture can be melt-blown Good flow during the process facilitates the formation of meltblown fibers with low fiber fineness. In detail, if the intrinsic viscosity of the high-flow modified polyester is greater than 1.3 dL/g, the fluidity of the high-flow modified polyester will be too low to provide good pumping of the polyester mixture during the melt blown process. The ductility of the silk cannot effectively reduce the fiber fineness of the melt-blown fiber; if the intrinsic viscosity of the high-fluidity modified polyester is less than 0.9dL/g, the fluidity of the high-fluidity modified polyester will be too high, which is not conducive to Controlling the formation of meltblown fibers. In some embodiments, based on the good fluidity of the polyester mixture, the diameter of the discharge hole of the melt blown equipment can be configured to be about 0.15 mm to 0.30 mm, and the ratio of the length of the discharge hole to the diameter of the hole can be configured to be about 20, so that Helps form meltblown fibers with low fiber fineness.

In some embodiments, the formed melt-blown fibers can have low fiber fineness by adjusting the operating parameters of the melt-blown process and the calendering process. Specifically, the melt-blown fibers can be made to have low fiber fineness by adjusting the air temperature, air volume, fiber throughput, and web speed of the melt-blown process, as well as the hot-press temperature, line pressure, and line speed of the calendering process. The specific ranges of the operating parameters of the meltblown process and the calendering process are shown in Table 1.

Table I Operating parameters of the meltblown process Wind temperature(℃) Air volume(m ³ /min) Fiber throughput (g/(hole×min)) Undertake network speed (m/min) 220~280 5.0~8.0 0.02~0.50 0.2~20 Operating parameters of the calendering process Hot pressing temperature (℃) Line pressure (kg/cm) Linear speed(m/min) 120~200 10~120 0.5~2.0

In the following description, the fiber diameters of the melt-blown fibers in the melt-blown nonwoven fabrics of various comparative examples and various embodiments are measured to verify the effectiveness of the present disclosure. The relevant descriptions of the melt-blown nonwoven fabrics of each comparative example and each embodiment are shown in Table 2.

Table II Components and the proportion of each component in the melt-blown fiber (parts by weight) Average fiber diameter (μm) Proportion of the number of fibers with a fiber diameter of 0.5 μm to 1 μm (%) Proportion of the number of fibers with a fiber diameter of 0.5 μm to 1.5 μm (%) high flow polyester High flow modified polyester Comparative example 1 Use conventional PBT (100) 2.35 1~2 18 Comparative example 2 PBT (100) none 2.09 4 36 Example 1 PBT (95) PEAT (5) 1.54 14 54 Example 2 PBT (90) LTm2 (10) 1.69 16 51 Example 3 PBT (95) LTm2 (5) 1.55 16 60 Example 4 PBT (90) PBST (10) 1.54 20 56 Example 5 PBT (90) PEAT (10) 1.66 twenty three 56 Example 6 PBT (90) PBST+LTm2 (5+5) 1.66 28 52 Example 7 PBT (95) LTm1 (5) 1.44 30 64 Example 8 PBT (90) PBAT+LTm2 (5+5) 1.62 31 55 Example 9 PBT (90) PBST+LTm1 (5+5) 1.50 41 63 Example 10 PBT (90) PBST+LTm1 (3+7) 1.24 42 79 Example 11 PBT (90) PEAT+LTm1 (3+7) 1.31 44 68 Example 12 PBT (90) LTm1 (10) 1.33 48 67 Example 13 PBT (90) PEAT+LTm1 (5+5) 1.34 53 73 Example 14 PBT (90) PBAT+LTm1 (5+5) 0.89 69 94 Example 15 PBT (90) PBAT+LTm1 (3+7) 0.91 76 90 Note 1: When the temperature is 230°C, the MI value of conventional polyester is 100g/10min; the MI value of high fluidity polyester PBT is 350 g/10min~550 g/10min; the MI value of high fluidity modified polyester The value is 200 g/10min~400 g/10min. Note 2: LTm1 represents the first low melting point polyester; LTm2 represents the second low melting point polyester. Note 3: PBST stands for the first soft chain polyester; PBAT stands for the second soft chain polyester; PEAT stands for the third soft chain polyester.

From the measurement results in Table 2, it can be seen that the average fiber diameter of the melt-blown fibers of the melt-blown nonwoven fabrics of each example is significantly smaller than the average fiber diameter of the melt-blown fibers of the melt-blown nonwoven fabrics of each comparative example. From the measurement results of all examples, it can be seen that the fiber diameter of more than 50% of the melt-blown fibers is between 0.5 μm and 1.5 μm, and the fiber diameter of more than 14% of the melt-blown fibers is between 0.5 μm Between 1.0 μm, it is shown that the meltblown fibers of the various examples can have low and concentrated fiber fineness. From Examples 13 to 15, it can be seen that when a specific proportion of the second or third soft chain polyester and the first low melting point polyester are used to match the high fluidity polyester, the fiber diameter of the meltblown fiber is as high as 73% or more. Between 0.5 μm and 1.5 μm, and as high as 53% of the fiber diameter of the melt-blown fiber is between 0.5 μm and 1.0 μm, wherein it can be seen from Example 15 that the amount of up to 75% of the The fiber diameter of the melt-blown fibers is between 0.5 μm and 1.0 μm, which shows that the melt-blown fibers of Examples 13-15 can have extremely low and concentrated fiber fineness.

According to the above-mentioned embodiments of the present disclosure, since the melt-blown fibers in the melt-blown nonwoven fabric include a specific proportion of high-fluidity polyester and high-fluidity modified polyester, and the high-fluidity polyester and high-fluidity modified polyester each have A specific range of melt index, so the melt-blown fibers can have low and concentrated fiber fineness, so that they can be evenly distributed in the melt-blown nonwoven fabric, so that the melt-blown nonwoven fabric of the present disclosure can have high fiber distribution uniformity. In addition, by adjusting the weight-average molecular weight and viscosity of the high-fluidity modified polyester, it also helps to form melt-blown fibers with low and concentrated fiber fineness.

Although this disclosure has been disclosed as above in the form of implementation, it is not intended to limit this disclosure. Anyone who is familiar with this technology can make various changes and modifications without departing from the spirit and scope of this disclosure. Therefore, the protection of this disclosure The scope shall be defined by the appended patent application scope.

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Claims (10)

A melt-blown nonwoven fabric comprising: A plurality of melt-blown fibers, the melt-blown fibers comprising: 90 to 95 parts by weight of high flow polyester, wherein the high flow polyester has a melt index between 350g/10min and 550g/10min at a temperature of 230°C; and 5 to 10 parts by weight of high fluidity modified polyester, wherein the high fluidity modified polyester has a melt index between 200g/10min and 400g/10min at a temperature of 230°C. The melt-blown nonwoven fabric according to claim 1, wherein the high-fluidity modified polyester includes a low-melting point polyester, and the melting point of the low-melting point polyester is between 150°C and 155°C. The melt-blown non-woven fabric according to claim 1, wherein the high-fluidity modified polyester includes a low-melting point polyester, and the melting point of the low-melting point polyester is between 160°C and 165°C. The melt-blown nonwoven fabric as claimed in item 1, wherein the high fluidity modified polyester comprises a soft chain polyester, and the soft chain polyester has a structure represented by formula (1):

Formula 1). The melt-blown nonwoven fabric as claimed in item 1, wherein the high fluidity modified polyester comprises a soft chain polyester, and the soft chain polyester has a structure represented by formula (2):

Formula (2). The melt-blown nonwoven fabric as claimed in item 1, wherein the high fluidity modified polyester comprises a soft chain polyester, and the soft chain polyester has a structure represented by formula (3):

Formula (3), wherein x is a positive integer ranging from 1 to 12, and y is a positive integer ranging from 1 to 12. The melt-blown nonwoven fabric according to claim 1, wherein the weight average molecular weight of the high-fluidity modified polyester is between 8000 g/mole and 11000 g/mole. The melt-blown nonwoven fabric according to claim 1, wherein the intrinsic viscosity of the high-fluidity modified polyester is between 0.9dL/g and 1.3dL/g. The melt-blown nonwoven fabric according to claim 1, wherein more than 50% of the melt-blown fibers have a fiber diameter between 0.5 μm and 1.5 μm. The melt-blown nonwoven fabric according to claim 1, wherein more than 75% of the melt-blown fibers have a fiber diameter between 0.5 μm and 1.0 μm.