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TWI387531B - 各向異性可延長非織物 - Google Patents

各向異性可延長非織物 Download PDF

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Publication number
TWI387531B
TWI387531B TW96115057A TW96115057A TWI387531B TW I387531 B TWI387531 B TW I387531B TW 96115057 A TW96115057 A TW 96115057A TW 96115057 A TW96115057 A TW 96115057A TW I387531 B TWI387531 B TW I387531B
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Taiwan
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machine direction
web
woven fabric
bonding
fibers
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TW96115057A
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English (en)
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TW200744842A (en
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Kenneth E Martin
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Invista Tech Sarl
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    • D04H13/00—Other 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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    • D04H1/74—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 orientated, e.g. in parallel (anisotropic fleeces)
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Description

各向異性可延長非織物
本發明係關於不織布，其中主要沿機器方向定向鋪列該紡織品之纖維。所產生非織物沿機器方向具有高拉伸強度及極低伸長率，但沿機器橫向具有相對較低的拉伸強度且可用相對較小力使其伸長。在形成該非織物之方法中，無需「固化(consolidation)」或「頸縮(necking)」之單獨步驟即可獲得所需纖維定向特性。
拉伸非織物在衛生行業中發展迅速。所用的大部分產品具有機器方向拉伸容量(例如Kimberly Clark Demique®及「Flex-All」產品)或機器橫向拉伸性(例如「Golden Phoenix」或「Tredegar」非編織-彈性薄膜層疊物)。然而，真正的多向拉伸非織物可為衛生相關產品以及開發新的最終用途(例如拉伸非織物服裝)提供有價值的功能。
商業生產商已藉由使用習用紡黏方法中之彈性熱塑性聚合物製成了完全彈性的多向紡黏非織物。然而，儘管該等產品呈現良好的彈性，但其亦具有令人不愉快的表徵彈性聚合物之橡膠樣手感。人們已習知藉由生產後「頸縮」或「固化」步驟(其中係於非織物初步生產後在單獨步驟中沿機器方向對其實施拉伸)用主要沿機器方向定向之纖維產生非織物。讓予University of Tennessee且關於該技術並部分揭示該技術之美國專利包括：美國專利第5,441,550號(1995年8月15日頒佈)； 美國專利第5,443,606號(1995年8月25日頒佈)；美國專利第5,486,411號(1996年1月23日頒佈)；美國再頒佈專利第35,206號(1996年4月16日頒佈；美國專利第5,244,482號之再頒佈)；美國專利第5,599,366號(1997年2月4日頒佈)；美國專利第5,730,923號(1998年3月24日頒佈)；美國專利第5,747,394號(1998年5月5日頒佈)；美國專利第6,030,906號(2000年2月29日頒佈)。
鑒於先前技術之揭示內容，人們已明瞭頸縮或固化製程為非編織產品提供至少期望的橫向延長性。該橫向延長性係在生產不織布後的第二步驟後獲得。該步驟給整個製程所增加的成本係該產品經濟可行路線的一個缺點。
本文所揭示的發明可提供直接生產而無需固化或頸縮步驟之橫向可延長不織布。
由本文所揭示製程提供之不織布在機器方向與機器橫向具有顯著不同的物理特性，其特徵在於該不織布具有至少約50%之橫向斷裂伸長率。顯著不同的物理特性至少係指沿機器方向及垂直方向之無破裂伸長率。
本文實施例中所提供之非織物具有約100-約200%之橫向斷裂伸長率。
本文實施例中所提供之非織物係選自包括經紡黏、熔噴、梳理熱黏結及射流噴網結構之群。
本文揭示內容提供一種製造在機器方向與橫向具有顯著 不同物理特性之非織物的方法，該方法包括以下步驟：鋪列纖維網，隨後黏結該網。所提供方法大體上沿機器方向排列非織物纖維並黏結所產生之網以使所產生材料具有橫向延長性，但具有足夠的橫向及機器方向相關性以允許隨後的轉換步驟。
本發明之一態樣提供一種製造可延長非織物之方法，該方法包括以下步驟：鋪列纖維網並藉由選擇包括少量黏結點之黏結圖案黏結該網，且其中沿垂直於機器方向之軸佈置之該等黏結點，較沿平行於該機器方向之軸佈置之黏結點間距更寬，且其中該等黏結點係由熱能提供。
本發明之一態樣提供一種製造可延長非織物之方法，該方法包括以下步驟：排列梳理纖維棉絮以使大部分該等纖維之纖維方向所達成之角度大體上平行於機器方向或在該機器方向+/-45°之範圍內並黏結該網。
定義
以下非限制性定義包括拉伸非織物技術術語表。該等定義意欲指導熟練技術人員瞭解本文所用的業內各術語之清晰而簡明的含義。
LYCRA®XA係INVISTA S.à r.1.,3 Little Falls Centre,2801 Centreville Road,Wilmington,Delaware,19808之注冊商標。LYCRA®纖維具體而言被設計為以黏著方式連接而非針織或編織在一起且用於尿片及成人大小便失禁產品。「XA」表示「格外黏附」或「格外黏著」。
分特及旦尼爾係紗線的相對厚度即線性密度。分特係 10,000米紗線之重量(以克表示)。旦尼爾係9,000米紗線之重量(以克表示)。
不織布之機器方向軸係平行於其中該紡織品通過機器前進之方向；即其中形成該紡織品之方向的方向。
不織布之橫向軸係垂直於其中形成該紡織品之方向的方向。
經固化非織物係可用相對較小力使其沿橫向(亦稱為「頸縮」方向)延長(拉伸)者。通常，經固化非織物於延長後具有較低的收縮力及較高的永久變形(形變)。經固化非織物係藉由牽拉方法(例如「the Kimberly Clark」技術)或牽拉加上加熱(the University of TennesseeTANDEC )方法自幾乎任何常用「製成狀態」非織物生產。經固化非織物通常沿機器方向具有高模數及拉伸強度，例如不破裂伸長率可達200%或250%。
可延長非織物係可用相對較低力使其沿橫向延長者。此等非織物可係經固化非織物或「製成狀態(as-made)」可延長非織物。「製成狀態」可延長非織物具有與經固化非織物類似之特徵，但通常具有較低的伸長率，此並非係由特殊頸縮或固化製程所致。
各向異性非織物係沿機器方向與橫向具有不同特性(例如伸長率及拉伸強度)者。各向異性非織物係「製成狀態」可延長非織物。
GSM即「克/平方米」係每單位面積非織物之重量或厚度的常用量度。通常，該等之範圍在較低端係紡黏及熔噴 非織物之10 GSM高至針刺非織物之100-400 GSM。舉例而言，「尿片覆蓋材料」非織物係介於15至25 GSM之間。
MDXA「機器方向XA」係LYCRA®斯潘德克斯(spandex)纖維與非織物或薄膜之層壓物(例如非織物/LYCRA®/非織物)。受到延長之LYCRA®係使用熱熔黏著劑黏結至非織物。當使該層壓物收縮時，其形成特徵褶皺圖案。MDXA族產品特性端視LYCRA®間隔、分特及非織物或薄膜之類型而顯著不同。
CDXA(亦稱為CDXA-I)即「橫向XA」係LYCRA®斯潘德克斯纖維夾在非織物層之間之層壓物，其中該等LYCRA®纖維係以「鋸齒形」圖案鋪列。當膠合時該等LYCRA®纖維延長，且當使其鬆弛時產品具有特徵褶皺外觀。該CDXA產品通常係沿機器方向呈剛性但沿橫向呈彈性(拉伸及恢復)之窄帶。其欲用於尿片及成人大小便失禁產品中之橫向可拉伸組件，例如腰帶、側板、彈性尿片護翼及封閉帶。
CDXA-III(所謂的「3形」及CDXA之後繼產品)，該產品係具有單層可延長非織物之層壓物，該可延長非織物係經硬鏈段及軟鏈段聚胺基甲酸酯聚合物(實質上與用來製備LYCRA®斯潘德克斯長絲之聚合物相同)浸漬。該具有高收縮力之經浸漬層壓物係藉由凝固塗佈製程產生之可延長非織物。該經浸漬層壓物之特徵在於沿機器方向呈剛性且沿橫向呈彈性。
EDXA即「各方向XA」，係具有多方向(機器方向及橫向) 拉伸及恢復之非織物。實例係由ADC(Advanced Design Concepts GmbH，德國)使用熱塑性彈性聚合物製成之紡黏非織物。
非織物生產技術：非織物生產可分成三個部分：「網形成、黏結及修整」。
網形成可分成以熱塑性聚合物碎片開始之「紡熔」製程，「閃紡」非織物係「紡熔」非織物之溶劑紡絲形式，且「梳理及氣流成網」非織物以短纖維開始。「紡熔」進一步分成「紡黏」及「熔噴」非織物。將紡黏非織物中之纖維熔紡至氣流延長室中，在該室中藉由「氣流拉細」製程對該等纖維實施拉伸以增加強度且隨後鋪列於移動帶上。在熔噴製程中，將聚合物熔融物擠至由氣流驅動之高剪切區域，藉此將該等纖維粉碎成小斷且同時在熔融狀態下將其拉伸成極細旦尼爾。紡黏係最常見的非編織製程，可生產強而耐用的廣泛用於衛生行業(例如尿片)中之不織布。熔噴紡織品通常較弱，但具有極細小及均勻的孔徑且常用於過濾。
紡黏、熔噴及閃紡非織物通常由熱黏結製程固化。混合非織物例如SMS或SMMS(紡黏/熔噴/紡黏)變得越來越常見。在閃紡非織物中，在一定壓力下使聚合物(通常聚乙烯及聚丙烯或混合物)溶於低沸點溶劑中，當壓力下降及自噴絲板擠出聚合物溶液後該溶劑立即汽化。最重要的閃紡非織物係得自E.I.Du Pont de Nemours and Co.公司(Wilmington,Delaware)之TYVEK®。
梳理或氣流成網非織物係以短纖維開始，該等短纖維係藉由習用梳理法或藉由其中藉由氣流將各纖維傳送至網中之氣流成網法形成網。梳理及氣流成網非織物係藉由採用熱、化學之製程或藉由機械黏結裝置實施黏結。
「網黏結」係用來將非編織網之纖維黏結在一起之製程。通常存在三種網黏結類型：「熱黏結」通常藉由具有浮雕圖案之砑光滾筒使纖維部分熔融在一起從而在紡織品之特定點(圓點)使網黏結在一起。「化學(或黏著)黏結」使用樹脂或黏著劑將纖維黏結在一起。「機械黏結」使用大量鋼針重複穿過紡織品以纏結纖維(亦稱為針刺)而達成。同樣，可使用高壓噴水器來達成纖維纏結且通常稱為射流噴網或水刺纏結非織物。得自E.I.Du Pont de Nemours and Co.公司(Wilmington,Delaware)之SONTARA®係射流噴網非織物之一個實例。射流噴網非織物與其他非織物相比更呈現三維及紡織品形式且通常視為非織物系列產品中之高品質者。
「網修整」係指修整或處理，通常將化學化合物施用於非織物以賦予某一特徵(通常親水性)。
根據本發明，具有布樣手感之完全彈性非織物係藉由紡黏、熔噴及該等兩種製程之混合組合使輕重量紡黏或熔噴硬纖維(例如聚丙烯、聚乙烯、聚酯或聚丙烯-聚乙烯摻合物)層包圍初始紡黏彈性非織物(例如以EXXON VISTAMAXX®為主之彈性聚丙烯)而提供。在該製程中， 將硬纖維層沈積於紡黏彈性體之任一側，該紡黏彈性體須足夠薄且足夠輕地黏結以不阻止中心彈性層之拉伸及恢復。彈性非織物係藉由將高品質熔紡彈性體用作初始彈性層而增強。
根據本發明之一態樣，提供了不織布，其中該布之纖維係主要沿機器方向以一定向進行有意圖的鋪列。所產生非織物沿機器方向具有高拉伸強度(tensile strength)及極低伸長率，但沿橫向具有相對較低的拉伸強度且可用相對較小力使其伸長。在製備該非織物之製程中，所需纖維定向特性無需單獨「固化」或「頸縮」步驟即可獲得。
沿橫向與機器方向具有顯著不同特性之非織物意指所產生非織物即下文「可延長非織物」沿機器方向呈剛性且具有高斷裂韌性。同時藉由施加相對較低力可容易地使該可延長非織物沿橫向延長而不破裂。相對較低力係50%伸長率時所施加之力小於1牛頓。
通常，應注意，在生產非織物中使纖維鋪列方向隨機化以產生沿各個方向皆具有相似物理特性(模數、百分伸長率及斷裂韌性)之薄片結構。然而，可延長非織物已顯示可用於製造多種沿橫向使用非織物薄片之材料。
儘管人們已熟知具有200%橫向拉伸之可延長非織物，但其係藉由非織物成形後轉化製程生產。關於該技術之專利揭示內容已讓予TANDEC (University of Tennessee Nonwovens Research Consortium)(Kimberly Clark)及BBA。根據美國再頒佈專利第35,206號之揭示內容，通常 稱為「頸縮」或「固化」之製程係以非織物尤其紡黏及梳理熱黏結非織物開始，隨後沿機器方向對其實施拉伸以大體上沿機器方向排列非織物纖維從而產生所期望特性。另外，由包括E.I.DuPont、Sheng Hung及BBA在內的多個生產商生產之射流噴網型(水刺纏結)非織物具有類似於所期望「可延長」非織物之特性，但伸長率通常小於100%。在本發明中，可延長非織物係在非織物成形製程期間直接生產而無需成形後處理且可由圖2A及2B之流程圖表示。
對於以纖維網為主之非織物(在圖1A中)，非織物之可延長特徵係藉由選擇下列而增強：具有相對較少數量黏結點20(在圖1A中)之黏結圖案及/或其中將黏結點佈置成使得沿垂直於機器方向之軸之黏結點20間隔較寬(例如，在圖1A中具有間距A)而沿平行於該機器方向之軸之彼等點間隔相對較近(例如，在圖1A中具有間隔B)者。一般而言，黏結點間距滿足關係A>B。更具體而言，對黏結點間距應加以選擇以使得至少A=1.1(B)，且更通常係A>2(B)。對於紡黏非織物，黏結點圖案係藉由在纖維鋪列點適當調整隨機化空氣射流以產生與上文針對梳理熱黏不織布所述相同的纖維鋪列且亦使用上述黏結圖案而實現。
對於以梳理網為主之非織物(在圖1B中)，將形成非織物之梳理棉絮排列成使得纖維方向大體上平行於機器方向或角度在機器方向+/-a(其中a係45°)之範圍內。如此形成之非織物之相關特徵係藉由使用習知黏結裝置進行黏結而增強。
測試方法
斷裂伸長率係根據ASTM D 5035-90測定。
MD‧‧‧機器方向
圖1A係具有複數個黏結點20之拉伸非織物10的一部分之示意圖。
圖1B係具有纖維200之拉伸非織物100的一部分之示意圖，其中纖維200排列於機器方向MD+/-α之角度範圍內。
圖2A係一用來提供本發明拉伸非織物之製程的流程圖。
圖2B係另一個用來提供本發明拉伸非織物之製程的流程圖。

Claims (6)

  1. 一種可延長不織布，其沿機器方向的物理特性與沿橫向的物理特性不同，其特徵在於：該不織布具有50%至200%間之橫向伸長率，且其中該不織布包括多數纖維，該等纖維形成一纖維網，在該纖維網中，該網中的大部分纖維具有一纖維方向，該纖維方向所達成之角度大體上平行於機器方向、或在該機器方向+/-45°之範圍內，且進一步包括多數黏結點，該等黏結點的配置方式，係使沿垂直於該機器方向之一軸的黏結點間距，比沿平行於機器方向之一軸的黏結點的間距寬。
  2. 如請求項1之可延長不織布非織物，其具有100%至200%之橫向伸長率。
  3. 如請求項1之可延長不織布，其係選自包括下列之群：經紡黏、熔噴、梳理熱黏結及射流噴網結構。
  4. 一種製造可延長不織布之方法，其中該不織布在製成狀態及在頸縮及固化前，沿機器方向的物理特性與沿橫向的物理特性大致不同，該方法包括以下步驟：鋪列多數纖維以形成一纖維網，而使該鋪列的纖維網中的大部分纖維具有一纖維方向，該纖維方向所達成之角度大體上平行於該網的機器方向、或在該網的機器方向+/-45°之範圍內，及之後，藉由選擇包括複數個黏結點之一黏結圖案將該網網黏結，該黏結圖案包括多數黏結點，其中沿垂直於機 器方向之一軸佈置之黏結點的間距，較沿平行於該機器方向之一軸佈置之黏結點間距更寬，且其中該等黏結點係藉由熱能提供。
  5. 一種製造可延長不織布之方法，其中該不織布為一梳理網，且其中該不織布在製成狀態及在頸縮及固化前，沿機器方向的物理特性與沿橫向的物理特性大致不同，該方法包括以下步驟：排列梳理纖維棉絮，以形成一網，其中該網中的大部分該等纖維之纖維方向所達成之角度大體上平行於機器方向或在該機器方向+/-45°之範圍內，及藉由選擇包括複數個黏結點之一黏結圖案來將該網網黏結，其中沿垂直於機器方向之一軸佈置之黏結點的間距，較沿平行於該機器方向之一軸佈置之黏結點間距更寬。
  6. 如請求項4之方法，其中該不織布為紡黏網，且其中該不織布是藉使用隨機化空氣射流鋪列一纖維網製成。
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JP2009535525A (ja) 2009-10-01
BRPI0710374A2 (pt) 2011-08-09
EP2010704B1 (en) 2013-12-25
CN101432477A (zh) 2009-05-13
JP5619417B2 (ja) 2014-11-05
ES2447041T3 (es) 2014-03-11
US20070254545A1 (en) 2007-11-01
WO2007127442A3 (en) 2008-03-13
EP2010704A2 (en) 2009-01-07
TW200744842A (en) 2007-12-16
KR20080111095A (ko) 2008-12-22
KR101497711B1 (ko) 2015-03-03
CN101432477B (zh) 2013-11-20

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