CN1054410C - 多组分聚合物丝条制成的非织造布及其用途 - Google Patents

多组分聚合物丝条制成的非织造布及其用途 Download PDF

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CN1054410C
CN1054410C CN93116477A CN93116477A CN1054410C CN 1054410 C CN1054410 C CN 1054410C CN 93116477 A CN93116477 A CN 93116477A CN 93116477 A CN93116477 A CN 93116477A CN 1054410 C CN1054410 C CN 1054410C
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D·C·施特拉克
L·A·康纳
S·W·格瓦尔尼
A·L·麦克科马克
S·E·肖弗
J·S·舒尔兹
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Abstract

一种由多组分聚合物丝条制成的非织造布包括一种包含在多组分聚合物丝条的一侧面或外鞘中的聚烯烃和乙烯丙烯酸烷基酯共聚物的共混物。这种布改进了耐磨性,强度,韧性和柔软性。本发明还揭示了包括将这种多组分材料粘合到在里面的熔喷网层的两侧面上的复合材料。

Description

多组分聚合物丝条制成的非织造布及其用途
本发明一般地是关于聚合物的织物,更具体说是关于多组分聚合物的非织造布。
非织造布用于制造各种产品,这种产品具有符合需要的特定的柔软性、强力、耐用性、均匀性、液体保持性,如吸液性,隔液性以及其他物理性能。这种产品包括毛巾、工业擦布、失禁用品、婴幼儿护理用品,如婴儿尿布、吸液性的妇女护理用品和服装,如医用服。这些产品常常由多层非织造布制成以得到所需的综合性能,例如,由非织造布做成的婴儿尿布可由贴近婴儿皮肤的柔软、有强力和多孔的里层,有强力、柔软不透水的外复盖层和柔软吸水的一层或多层蓄积液体的内层组成。
如上所述非织造布一般由热塑性材料熔纺制成。这种布称为纺粘材料,而制造纺粘聚合物材料的方法是众所周知的。Dorschner等人的美国专利4,692,618和Appel等人的美国专利4,340,563揭示了用热塑性材料制造纺粘非织造纤维网的方法,即挤压这种热塑材料通过喷丝孔,进而用高速气流拉伸这种被挤出的材料成长丝并在收集面上形成无定向纤维网。例如Dorschner等人的美国专利3,692,618公开了用非常高速的气流通过许多喷射器对高聚物长丝束进行拉伸的过程。Appel等人的美国专利4,340,563公开了热塑性长丝通过一个单头大喷嘴经高速气流进行拉伸的过程。下述专利也都揭示了一些典型的熔纺过程:Kinney的美国专利3,338,992;Kinney的美国专利3,341,394;Levy的美国专利3,502,538;Hartmann的美国专利3,502,763;Hartmann的美国专利3,909,009;Dobo等人的美国专利3,542,615以及Harmon的加拿大专利803714。
具有所需的综合物理性能的纺粘材料,特别是柔软性、强度和耐用性等综合性能的纺粘材料已经生产出来了,但还是有其局限性的。例如,对某些应用来说,一些聚合物材料如聚丙烯具有所需要的强度,但是不具备所需要的柔软性。另一方面,一些材料,如聚乙烯在某种情况下具有所需要的柔软性,但不具备所需要的强度。
在致力于生产具有所需综合物理性能的非织造材料的过程中,开发了多组分或双组分的非织造布。用于制造双组分非织造布的方法是众所周知的,并在一些专利中被揭示。如Stanistreet的美国专利4,068,036的重新颁布号30,955,Davies等人的美国专利3,423,266和Davies等人的美国专利3,595,731。一种双组分非织造布是由包含第一和第二种组分并保持各自特性的聚合物纤维或长丝制成的。这里所用的“长丝”是指该材料的连续丝条,“纤维”是指具有一定长度的切断的或不连续的丝条。实质上,多组分长丝的第一和第二组分在横跨长丝的横截面上排列在各自完全不同的区域里,并沿长丝长度方向连续延伸。有代表性的是一种组分显示出和另一种组分不同的性质,致使该长丝显示出二种组分的性质。例如,一种组分是聚丙烯,其强度相对地大,另一种组分是相对柔软的聚乙烯,其结果得到了既强又柔软的非织造布。
Davies等人的美国专利3,423,266,和Davies等人的美国专利3,595,731揭示了熔纺双组分长丝形成聚合物非织造布的方法。这种非织造纤维网可以通过切断熔纺长丝成短纤维,然后形成被粘合的梳理纤维网,或通过铺设连续的双组分长丝在一个成形表面上再粘合纤维网。
为了增加双组分非织造纤维网的膨松性,双组分纤维或长丝常常是被卷曲的。例如在Davies等人的美国专利3,595,731和3,423,266中揭示的双组分长丝可以机械卷曲。被卷曲的纤维形成非织造纤维网,或如果使用合适的聚合物,这种双组分纤维或长丝所产生的潜在的螺旋形卷曲通过形成的纤维网的热处理而得到活化,这种热处理是在纤维或长丝被制成非织造纤维网后用来活化纤维或长丝的螺旋形卷曲的。
特别对于外复盖层材料如用可弃婴儿尿布的外复盖层,需要改进聚合物非织造布的耐久性和柔软性。高聚物非织造布的耐久性可由增加布的耐磨损性得到改进。耐磨性的增加可随布的弹性(可弯性)增加而增加。例如,对由较柔软的组分如聚乙烯和高强度组分如聚丙烯组成的多组分布之间的多组分非织造布的粘合来说,当经受足够的负荷时丝条就会撕开。为了生产比较耐久的布,需要增加这些多组分聚合物丝条之间粘合的耐久性,增加多组分布和其他用于多组分布层压的聚合物材料层之间的粘合耐久性。
因此,需要增强柔软性和耐久性的聚合物非织造布,特别需要象用于吸水性的个人护理品和服装材料的外层复盖材料。
因此,本发明目的是提供改进的非织造布及其用途。
本发明的另一个目的是提供所需的综合物理性能,如柔软性、强度、耐久性、均匀性和吸水性的非织造布及其用途。
本发明的再一个目的是提供一种用于吸水性个人护理产品,如用于可弃婴儿尿布的既柔软又耐久的非织造外层复盖材料。
本发明的又一个目的是提供用于诸如医用服装的既柔软又耐久的非织造服装材料。
因此,本发明提供一种由多组分聚合物丝条组成的非织造布,其中,一种组分包括一种聚烯烃和乙烯丙烯酸烷基酯共聚物的共混物。乙烯丙烯酸烷基酯共聚物提供了布的丝条之间比较耐久的粘合,因而增强了布的耐磨性,更特别的是乙烯丙烯酸烷基酯共聚物增强了布的丝条在他们粘结点上的弹性(可弯性),从而使布有较好的弹性和较高的耐磨性。同时乙烯丙烯酸烷基酯共聚物增加了布的其他强力性能和改进了布的柔软性、悬垂性和顺应性。此外,乙烯丙烯酸烷基酯共聚物的加入增强了多组分丝条的天然螺旋卷曲,使布的膨松性增加。乙烯丙烯酸烷基酯共聚物的添加可使丝条在比较低的温度下被高度卷曲。较详细的解释见下面。本发明的非织造布在适当粘合时特别适用于做吸水性的个人护理品,如可用弃婴儿尿布等的外复层材料和做诸如医院用衣服等的服装材料。用作外复盖层或服装材料,本发明的布可以和聚合物薄膜层压,如和聚乙烯薄膜层压,可起到隔液作用。
较具体说,本发明的非织造布由挤压出的多组分聚合物的丝条组成,这种丝条包括第一和第二两种聚合物组分,排列在横跨多组分丝条的横截面上完全不同的区域里,并连续地沿着多组分丝条长度延伸。这种丝条最好是由纺粘技术形成的连续长丝。丝条的第二组分至少构成多组分丝条的一部分园周表面并连续地沿多组分丝条的长度方向延伸,且包括一种聚烯烃和乙烯丙烯酸烷基酯共聚物的共混物。多组分丝条之间的粘合可由热作用而形成。正如上面所解释的,添加乙烯丙烯酸烷基酯共聚物增强了多组分丝条之间粘合的耐久性。
更具体说,按重量计本发明多组分丝条的第一聚合物组分在丝条里约占20~80%,第二聚合物组分在丝条里约占80~20%。较好的是按重量计本发明的多组分丝条的第一聚合物组分在丝条里约占40~60%和第二聚合物组分在丝条里约占60~40%。此外,较可取的乙烯丙烯酸烷基酯共聚物在第二组分里所占的重量约为2~50%而聚烯烃在第二组分里所占的重量约为98~50%。更好是乙烯丙烯酸烷基酯共聚物在第二组分里所占的重量约为5~25%,而聚烯烃在第二组分里所占的重量约为95~75%。最好的是乙烯丙烯酸烷基酯共聚物在第二组分里所占的重量约为10~20%,聚烯烃在第二组分里所占的重量约为90~80%。
合适的乙烯丙烯酸酯共聚物包括乙烯丙烯酸丁酯、乙烯丙烯酸乙酯和乙烯丙烯酸甲酯共聚物。乙烯丙烯酸正丁酯是优选的共聚物。
按照本发明的另一个方面,提供了一种复合非织造布。本发明的这种复合布包括由被挤出的多组分聚合物丝条组成的第一纤维网。如上所述,这种纤维网包括在多组分丝条的第二组分里含有聚烯烃和乙烯丙烯酸烷基酯共聚物的共混物的多组分聚合物长丝。本发明的复合布还包括由被挤出的聚合物丝条组成的第二纤维网,第一和第二纤维网以面贴面的叠层关系铺放,并粘合在一起而形成一块整体布。在第一纤维网里的多组分丝条的第二组分里添加乙烯丙烯酸烷基酯共聚物增强了第一纤维网和第二纤维之间粘合的耐久性,这将改进整个复合物的耐磨性和弹性。
较具体说,本发明的复合布的第二纤维网的丝条可由传统的熔喷技术形成。更具体说,第二纤维网的丝条最好包括聚烯烃和乙烯丙烯酸烷基酯共聚物的第二种共混物。乙烯丙烯酸烷基酯共聚物在第一和第二纤维网里的存在增强了纤维网间的粘合和复合布总体的耐久性。
更详细地说,本发明的复合布最好进一步包括含被挤出的多组分聚合物丝条的第三纤维网,该网包括如在第一纤维网里一样排列的第一和第二聚合物组分,第二组分包含聚烯烃和乙烯丙烯酸烷基酯共聚物的第三种共混物。第一纤维网被粘合到第二纤维网的一面,第三纤维网被粘合到第二纤维网的背面。乙烯丙烯酸烷基酯共聚物的存在增强了三层纤维网间粘合的耐久性和复合布总体的耐久性。
最好,在本发明的多层布中,第一和第三纤维网的丝条是可以由纺粘技术形成的连续长丝,而第二或中间层纤维网的丝条可以由熔喷技术形成。本发明的复合布是一种仿布类材料,特别适用于服装用材料或用于个护理的吸水物品的外复盖材料。
本发明更进一步的目标和广泛的应用范围,对熟悉本技术的人看了后面详述后是很明白的。但必须理解,在此只是用一种例证方法对本发明的择优实施方法给予详细描述,因为在本发明范围和精神内的各种改进和改变对熟悉这方面技术的人看了下面详述后应该是显而易见的。
图1是用于本发明择优实例的生产线简图。
图2A是说明根据本发明择优实例用聚合物组分A和B以并列型排列制成的长丝横截面简图。
图2B是说明根据本发明择优实例用聚合物组分A和B以偏心的皮芯型排列制成的长丝横截面简图。
图2C是说明根据本发明择优实例聚合物组分A和B以同心的皮芯型排列制成的长丝横截面简图。
图3是根据本发明择优实例制得的多层布的点粘合样品掀开层面的局部透视图。
图4是图3多层布的横截面剖视图。
如上面所讨论的,本发明提供一种既柔软又耐久的由多组分聚合物丝条制成的仿布类非织造布。本发明的非织造布由挤出的多组分丝条组成,该丝条包括一种聚烯烃和乙烯丙烯酸烷基酯共聚物的共混物(作为其一个组分)。这种乙烯丙烯酸烷基酯共聚物使多组分丝条之间的粘合点具有某些弹性,从而使布能较好地分布应力,结果使本发明的布的抗拉伸伸长,抗拉能、耐磨性和柔软性得到改进。此外,这种乙烯丙烯酸烷基酯共聚物增加了多组分丝条的天然螺旋卷曲,并使得丝条在较低温度下被高度卷曲。
本发明的布特别适用于制造作为个人护理用品和服装材料的外复盖材料。适合的个人护理用品包括婴儿护理用品如用可弃婴儿尿布、儿童护理用品如训练裤,成人护理用品如失禁者用品和女性护理用品。合适的服装材料包括的项目如医用服、工作服和类似产品。对于用作服装材料的外复盖层,可使本发明的布和聚合物薄膜层压复合,如和聚乙烯薄膜层压复合后可以起到隔液作用。乙烯丙烯酸烷基酯共聚物增强了非织造布和聚合物薄膜之间粘合的耐久性。
合适的乙烯丙烯酸烷基酯共聚物包括乙烯丙烯酸丁酯、乙烯丙烯酸乙酯和乙烯丙烯酸甲酯共聚物。乙烯丙烯酸正丁酯是较可取的共聚物。
此外,本发明综合了一种复合非织造布,它包括含有如上所述的多组分聚合物丝条组成的非织造布的第一纤维网和由被挤出的聚合物丝条组成的第二纤维网。它以和第一纤维网里面贴面叠层关系粘合到第一种纤维网上。提据本发明择优实例,这种复合材料包括一个由被挤出的多组分聚合物丝条组成的第三纤维网,它粘合到第二纤维网的反面后形成三层复合材料。每一层都可含有一种聚烯烃和乙烯丙烯酸烷基酯共聚物的共混物,以改进复合材料的整体耐磨性。
在此所用的术语“丝条”是指聚合物通过一个成形孔,如模具,而形成的被拉伸的挤出物。丝条包括纤维(有一定长度的非连续丝条)和长丝(一种材料的连续丝条)。本发明的非织造布可以由多组分的短纤维构成。这种短纤维可以被梳理和粘合形成非织造布。本发明的非织造布最好是用连续的纺粘多组分长丝的构成,即被挤出、拉伸的长丝铺在传送成形面上构成。制造本发明的非织造布的择优工艺在下面详述。
在此所用术语“非织造纤维网”和“非织造布”可交换使用。意思是指不用织造过程即不是一种由各股纱以可识别的重复方式交织结构而形成的一种材料的纤维网。这种非织造纤维网可以采用各种工艺形成,如熔喷工艺法、纺粘加工法、缝隙成膜法和短纤维梳理加工法。
本发明的布由含有第一和第二聚合物组分的被挤出的多组分聚合物丝条组成。第一、二两种聚合物排列在横跨多组分丝条的横截面上完全不同的区域里并连续地沿多组分丝条长度方向延伸。多组分丝条的第二组分构成多组分丝条一部分园周表面,连续地沿多组分丝条的长度方向延伸,并含有聚烯烃和乙烯和丙烯酸烷基酯共聚物的共混物。
本发明的择优实例是一种由含有第一聚合物组分A和第二聚合物组分B的双组分长丝组成的聚合物非织造布。第一和第二组分A和B可以排列成如图2A所示的并列型排列,或如图2B所示的偏心皮/芯型排列,以致形成的长丝可以显示出高度的天然螺旋卷曲。在皮/芯型排列中,聚合物组分A是丝条的芯子,而聚合物组分B是丝条的外鞘。第一和第二组分还可形成如图2C所示同心皮/芯型排列或其他多组分排列形式。多组分聚合物丝条被挤出形成这种排列方式的方法对普通熟练本技术的人们是众所周知的。虽然实例里揭示的是双组分长丝,但是应该理解本发明的布可以由多于二种组分的丝条组成。
多组分丝条的第一组分A的熔点较好比第二组分B的熔点高。更好地,第一组分A包括一种聚烯烃,第二组分包括聚烯烃和乙烯丙烯酸烷基酯共聚物的共混物。对于第一组分A合适的聚烯烃包括聚丙烯,丙烯和乙烯的无规共聚物和聚4-甲基戊烯-1等。但必须理解第一组分A也可以含有其他热塑性聚合物,如聚酯或聚酰胺。对于第二组分B,合适的聚烯烃包括聚乙烯和丙烯与乙烯的无规共聚物。对于第二组分B,较好的聚乙烯是线性低密度聚乙烯和高密度聚乙烯。
用于组分A和B的聚合物的较好的组合包括(1)聚丙烯作为第一组分A,线性低密聚乙烯和乙烯丙烯酸正丁酯共聚物的共混物作为组分B;和(2)聚丙烯作为第一组分A,丙烯与乙烯的无规共聚物和乙烯丙烯酸正丁酯共聚物的共混物作为组分B。
适用于制备本发明的多组分丝条的原材料包括:得克萨斯州,休斯顿的Exxon公司生产的PD 3445聚丙烯,Exxon公司生产的丙烯和乙烯的无规共聚物;密执安州,Midlund的Dow化学公司生产的ASPUN6811A、6808A和6817牌号的线性低密度聚乙烯;Ohio(俄亥俄)州Cincinnati的USI部门的Quantum化学公司生产的ENA THENE720-009乙烯丙烯酸正丁酯共聚物。
本发明的多组分丝条的主要组分已在上面叙述过,这些聚合物组分还可以包括其他一些对本发明目的没有不利影响的材料。例如,聚合物组分A和B还可以包括,但不限于,颜料、抗氧化剂、稳定剂、表面活性剂、蜡、流动促进剂、固体溶剂、微粒以及可以增加组合物加工性能的添加材料等。
根据本发明的择优实例,多组分丝条包括按重量计约20%~约80%的第一聚合物组分A和约80~约20%的第二聚合物组分B。第二组分B较好含有按重量计约98-约50%的聚烯烃和约2~约50%的乙烯丙烯酸烷基酯共聚物,更好含有按重量计约95~约75%的聚烯烃和约5~约25%的乙烯丙烯酸烷基酯共聚物,最好含有按重量计约90-约80%的聚烯烃和约10-约20%的乙烯丙烯酸烷基酯共聚物。
根据本发明的一个择优实例,一种非织造布由连续纺粘法双组分长丝组成。该双组分长丝由并列型按重量计50%的聚合物组分A和50%的聚合物组分B组成,聚合物组分A按重量计含有100%的聚丙烯,而聚合物组分B按重量计含有85%聚乙烯和15%乙烯丙烯酸正丁酯共聚物。一个可供选择的实例中,第二聚合物组分B中聚乙烯用无规乙烯丙烯共聚物替代。
参看图1,可以看到一条用于本发明择优实例的加工线10。加工线10用来生产双组分连续长丝,但在此要指出,本发明包括用含有二个组分以上的多组分长丝制造的非织造布。例如,本发明的布可含有三个组分或四个组分的长丝制造而成。
本加工线10包括一对螺杆12a和12b用于分别挤出聚合物组分A和聚合物组分B。聚合物组分A由第一加料斗14a喂入螺杆12a,聚合物组分B由第二加料斗14b喂入螺杆12b。聚合物组分A和B经螺杆12a和12b挤到各自的聚合物管道16a和16b,再到喷丝板18。用来挤出双组分连续长丝的喷丝板,对于熟悉本技术的普通人员来说是众所周知的,在此不必详述。一般地说,喷丝板18包括装有纺丝组件的套架,纺丝组件包括多块带有花纹开口的板,一块堆砌在另一块的顶上,板上花纹开口的排列形成了熔体流通道,以引导聚合物组分A和B分别通过喷丝板。喷丝板18有很多孔,排列成一排或多排。当聚合物通过喷丝板挤出喷丝板孔时形成一向下延伸的长丝帘。喷丝板18最好排列成为用来形成并列型和偏心皮芯型构型双组分长丝,这种构型分别如图2a和2b中所示。
加工线10还包括冷却吹风20,其位置与通过喷丝头18挤出的长丝帘相邻,从冷却吹风20出来的空气使从喷丝头18挤出的长丝冷却。冷却空气可以向长丝帘的一侧吹,如图1所示,也可以向长丝帘的两侧吹。
位于喷丝头18下面的纤维拉伸装置或吸丝器22接受被冷却的长丝。如上所述,用于熔纺聚合物的纤维拉伸装置或吸丝器是众所周知的。用于本发明加工的合适的纤维拉伸装置包括一个在美国专利3,802,817中所示的这一类型的直型纤维吸丝器和在美国专利3,692,618和3,423,266中所示的这一类型的喷射器,在此引入这些专利作为参考。
一般来说,纤维拉伸装置22包括一个细长的垂直通道,长丝被从通道各个方面进入并通过此通道向下流动的抽吸空气拉伸。抽吸空气拉伸长丝和拉曳周围空气通过纤维拉伸装置。当需要长丝有高度的天然螺旋卷曲时,可用加热器24用来加热抽吸空气。
一个环形带孔的成形面26位于纤维拉伸器,22的下面,用来接受从纤维拉伸器出口下来的连续长丝。此成形面26绕导轮28运行。位于长丝堆积的成形面26下方的抽真空装置30抽吸对着成形面的长丝。
加工线10还包括可加热的压辊32。当纤维网离开成形面26时,压辊32与向前运动的导轮28一起接受该纤维网。此外,该加工线包括一对用于把双组分长丝粘接在一起并把纤维网结合在一起形成成品布的热点粘合辊34。最后,加工线还包括一个用于卷绕成品布的卷绕辊42。
为了操作加工线10,加料斗14a和14b分别充入聚合物组分A和B。聚合物组分A和B分别由螺杆12a和12b熔融挤出,通过导管16a和16b及喷咝板18。虽然熔融聚合物的温度随所用聚合物而异,但当聚丙烯和聚乙烯分别用作组分A和B时,较可取的聚合物温度范围为约370°F~约350°F,更可取的范围为约390°F-约450°F。
当被挤出的长丝在喷丝板18下面延伸时,来自冷却吹风器20的一股空气流至少部分地冷却该长丝。这种部分冷却可用来使长丝产生潜在螺旋卷曲。冷却气流最好以基本上垂直于长丝长度的方向流动,其温度为约45-约90°F,流速为约100-约400英尺/分。
冷却后,长丝由通过纤维拉伸装置的空气流拉进纤维拉伸装置22的垂直通道而被拉伸。纤维拉伸装置最好位于喷丝板18底部下面30-60英寸处。当只需要最小的天然螺旋卷曲的长丝时,只需用室温的抽吸空气就可以了。当需要高度卷曲的长丝时,就要把经过加热器24加热的空气送到纤维拉伸器22。对高卷曲而言,由加热器24供给的空气由于和随长丝拉曳出来后与比较低的室温空气混合后温度稍有降低,但是,此温度的空气也足以加热长丝到活化潜在卷曲所需的温度。活化长丝潜在卷曲的温度范围约110°F,到低于第二组分B的熔点的最高温度。为了得到不同程度的卷曲,加热器24加热的空气温度也即长丝被加热的温度可以变化。但是,还必须理解,为了达到所需的卷曲度,接触长丝的空气温度和许多因素有关,诸如长丝中的聚合物的类型和长丝的纤度等。
通常,较高的温度产生较高的卷曲数,长丝的卷曲度可以用控制在纤维拉伸器22中和长丝接触的混合空气的温度来控制。人们通过简单地调节在纤维拉伸装置里的空气温度,就可改变布的最终的密度,孔的大小分布和布的悬垂性。
被拉伸长丝通过纤维拉伸器22的外开口铺在运行的成形面26上,真空装置30抽吸对着成形面的长丝,形成一个未粘合的连续长丝非织造纤维网。该纤维网随后被压辊22轻度压缩,再经粘合辊34热点粘合。热点粘合技术对本技术中熟练的人们来说是熟知的,在此不评述。按照美国专利3,855,046的热点粘合技术是择优选择的,因此该文献在此列为参考。粘合花纹类型,根据所需强度要求可以不同。粘合温度也可根据诸如长丝的聚合物类型等因素而异,但较可取的温度为约240-255°F之间。如下面所述,在制造仿布类材料如婴儿尿布类吸水的个人护理用品的外复盖层和象医用服的服装材料时,最好采用热点粘结。一种热点粘结材料如图3所示。
最后,成品纤维网卷在卷绕辊42上,准备进一步处理或使用。当本发明的布用来制作吸液用品时,可以用传统的表面处理方法处理或含有一些传统的聚合物添加剂以增强布的吸湿性。例如,本发明的布可以用聚氧化亚烷基改性的硅氧烷和硅烷,如美国专利5,057,361所述的聚烷二氧撑改性聚二甲基硅氧烷。这种表面处理增强了布的吸湿性,从而使非织造布适合于作妇女护理的衬垫或来潮处理材料,婴幼儿护理品,儿童护理品和成人失禁用品等。本发明的布也可用其他处理方法处理,如抗静电剂,醇类防护剂和其他熟悉本技术的人们所熟悉的类似方法。
所得到的材料柔软而耐用,乙烯丙烯酸烷基酯共聚物的加入可以增强耐磨损性和织物的弹性而不减少布的柔软性,乙烯丙烯酸烷基酯赋予多组分长丝间粘结点比较好的弹性,以使布具有较好的应力分布。
本发明的布用作个人护理用品的外层复盖材料时,比较可取的单丝纤度约为1-12dpf(旦/单丝),更可取的单丝纤度约为2-3.5dpf。比较细的单丝纤度赋予非织造布较好的仿布触感性。这种外层复盖材料的基重可以不同,但较可取的范围约为0.4-3.0osy(盎司/平方码)。
虽然在图1中显示的粘结方法是热点粘结,但在此应该理解本发明的布也可用其他方法粘合,如用烘箱粘合、超声波粘合、水力缠结或用这些方法的组合方法制造仿布类非织造布。这些粘结技术对熟悉本技术的人来说是熟知的,在此不评述。如果需要比较蓬松的材料,那么本发明的布可用压缩方法粘合,如通气粘合。通气粘合方法对于热悉本技术的人来说是熟知的。一般来说,本发明的布可用通气粘合。也就是当布从带孔的罗拉上方通过时,使温度高于长丝第二组分B的熔融温度的空气强制通过布。热空气使比较低熔点聚合物组分B熔化并形成双组分长丝间的粘结而结合成纤维网。这种高膨松材料作为个人护理用品的流体处理层,如婴儿尿布的衬垫或来潮材料。
根据本发明的另一个方面,上述的非织造布可以层压到一层或多层聚合物层上形成复合材料。例如可以通过把上述的纺粘法热点粘结的非织造布层压到聚合物薄膜上来形成外复盖材料。聚合物薄膜可以起到隔液作用,比较可取的聚合物薄膜包括聚烯烃如聚丙烯或聚乙烯,其厚度最好小于约1密耳。低密度聚乙烯和相对柔软的聚丙烯特别可取,聚合物薄膜也可以是共挤出的薄膜,例如,这种共挤出的薄膜包括一层胶粘聚合物如乙烯丙烯酸甲酯共聚物作为非织造材料的相邻层;聚烯烃,如低密聚乙烯或聚丙烯作为外层。胶粘层最好是共挤出薄膜重量的约20%,外层是共挤出薄膜重量的约80%。
根据本发明的另一实例,如前所述方法由被挤出的多组分聚合物丝条组成的第一纤维网被粘到被挤出的聚合物丝条组成的第二纤维网上,第一和第二纤维网以面贴面叠层关系放置。第二纤维网可以是纺粘材料,但作为某些应用如医用服的服装材料,第二层可用众所周知的熔喷技术制得。熔喷层可起到隔液作用。这种熔喷技术,可以根据美国专利4,041,203得到,该专利的内容在此列为参考。美国专利4041203参考了下列有关熔喷技术的出版物,这些也列为参考。如在“工业和工程化学”中登载的题为“超细热塑性纤维”一文,第48卷第8期第1342-1346页叙述了在美国首都华盛顿海军研究实验室所做的工作;1954年4月15日海军研究实验报告111,437;美国专利3,715,251、3,704,198、3,676,242和3,595,245以及英国说明书1,217,892。
熔喷层实质上可由和构成第一纤维网的多组分丝条的第二组分B相同的组合物组成。这两层纤维网用热点粘合层粘合在一起形成仿布类材料。当第一和第二纤维网粘合在一起且第一和第二纤维网中多组分丝条的第二组分B含有乙烯丙烯酸烷基酯共聚物时,纤维网间的粘合比较耐久,从而增强了复合材料的耐磨性。
和第一纤维网一样,由多组分聚合物丝条组成的非织造布的第三层和已与第一纤维网粘合的第二纤维网的背面粘合。当第二纤维网是熔喷网层时,该熔喷网层象三明治一样夹在二层多组分材料之间。如图3和4所示这种材料50,由于它含有防液体渗透的中间层52和相对柔软的布层54和5在其二面,使布柔软和手感较好,因此用作医用服装材料有其优越性。材料50最好采用热点粘结法粘结。当采用热点粘结时,各层52、54和56在粘合点58处被熔合在一起。
这类复合材料可以分别形成,然后再粘合在一起,也可以连续加工形成,其中一层在另一层上面形成。这两种加工过程对于熟悉本技术的人来说都是热知的,在此不详述。上述美国专利4,041,203在此列为参考,它描述了制造这类复合材料的一个连续加工过程。
下述实例1-9用来说明本发明的具体实施方法并对熟悉本技术的一般人员讲授实施本发明的方法。对比实例1和2是用来说明本发明优点的,对熟悉本技术的人们来说应该理解,本发明的参数和下述实例中所提供的参数随所使用的具体工艺设备,环境条件的变化可以有所不同。
                              比较实例1
一种由连续双组分长丝组成的非织造布纤维网是由图1所示的上述工艺制得的。长丝为并列型构型,一侧对另一侧的重量比为1∶1。纺丝孔的几何形状为0.6mm直径,长径比L/D为4∶1的园孔,喷丝板有645孔,在机器方向以50孔/英寸排列。组分A的组成是按重量计为100%的由Texas州Houston的Exaon公司生产的PD-3445聚丙烯,组分B的组成是按重量计为100%的Aspuw6811A线性低密聚乙烯(由Michigan州Midlund的DOW化学公司生产)。纺丝组件的熔体温度是450°F,纺丝孔的吐出量为0.5克/孔·分。冷却气流流量是15scfm(立方英尺/每分钟),冷却空气温度为53°F。抽风器喂入温度是350°F,纺丝总管的压力是4.2(psi)磅/平方英寸。得到的纤维网用图案/砧进行热点粘合。粘合温度242/243°F。粘合图案为有规则地间隔的粘合区域,每平方英寸有250个粘合点,总粘合面积为15%。
                              实例1
一种由连续双组分长丝组成的非织造布纤维网是由图1所示的上述工艺制得的。长丝构型为并列型,一侧对另一侧的重量比为1∶1。纺丝孔的几何形状为0.6毫米直径,长径比(L/D)为4∶1的园孔,喷丝板有645个孔,在机器方向以每英寸50孔排列。组分A的组成是按重量计100%的PD-3445聚丙烯,(由德克萨新州休斯顿城的Exxon公司生产)组分B的组成是按重量计95%的ASPUN 6811A聚乙烯(由密执安州Midland的DOW化学公司生产)和按重量计5%的ENATHENE 720-009乙烯丙烯酸正丁酯共聚物(由Quantum公司生产)。纺丝组件的熔体温度为432°F,纺丝孔的吐出量为0.7GHM(克/孔·分)。冷却气流流量是16scfm(空间立方英尺/分),冷却空气温度是53°F,抽风器喂入温度是368°F,纺丝总管的压力是3.8磅/平方英寸。所得到的纤维网用图案/砧进行热点粘合,粘合温度为244/246°F,粘合图案为有规则地间隔的粘合区域,每平方英寸约有250个粘合点,总粘合面积为15%。
                           实例2
一种由连续双组分长丝组成的非织造布纤维网是由图1所示的上述的工艺制得的。长丝构型为并列型,一侧对另一侧的重量比为1∶1纺丝孔的几何形状为0.6毫米直径,长径比(L/D)为4∶1,喷丝板有645个孔,在机器方向上以每英寸50孔排列。组分A的组成是按重量计100%的PD-3445聚丙烯,(由德克萨斯州休斯顿城的Exxon公司生产)组分B的组成是按重量计90%的ASPUN 6811A聚乙烯(由密执安州Midland的DOW化学公司生产)和按重量计为10%的Quantum生产的ENATHENE720-009乙烯丙烯酸正丁酯共聚物。纺丝组件的熔体温度为431°F,纺丝孔的吐出量为0.7GHM(克/孔·分)。冷却气流流量是15scfm(空间立方英尺/分),冷却气流温度是53°F抽风器喂入温度是359°F,纺丝总管的压力为3.8磅/平方英寸。所得到的纤维网用图案/砧进行热点粘合,粘合温度为243/247°F,粘合花纹为有规则地间隔的粘合区域,每平方英寸约有250个粘合点,总粘合面积为15%。
                             实例3
一种由连续双组分长丝组成的非织造布纤维网是由图1所示的上述工艺制得的。长丝构型为并列型,一侧对另一侧的重量比为1∶1。纺丝孔的几何形状为0.6毫米直径,长径比(L/D)为4∶1,喷丝板有645个孔,在机器方向以每英寸50孔排列。组分A的组成是按重量计100%的PD-3445聚丙烯,(由德克萨斯州休斯顿城的Exxon公司生产)组分B的组成是按重量计85%的ASPUN 6811A聚乙烯(由密执安州的Midland的DOW化学公司生产)和按重量计为15%的Quantum生产的ENATHENE720-009乙烯丙烯酸正丁酯共聚物。纺丝组件的熔体温度为431°F,纺丝孔的吐出量为0.7GHM(克/孔·分)。冷却气流流量是15scfm(空间立方英尺/分)和冷却气流温度为53°F,抽风器喂入温度为359°F和纺丝总管的压力为3.8磅/平方英寸。所得到的纤维网在花纹/砧上以243/247°F粘合温度进行热点粘合,粘合花纹为有规则间隔的粘合区域,每平方英寸约有250个粘合点,总粘合面积为15%。
对比较实例1和实例1~3得到的布样进行测试以测定它们的物理性能。这些试验的数据列于表1中。抓样强力是根据美国材料试验标准ASTMD 1682测定的。悬垂硬挺度是根据美国材料试验标准ASTMD 1388测定的。
梯形试样撕破强力是在平行于样品长度施加一个桓定增加负荷时测定的布样撕破强力。梯形试样撕破强力是根据美国材料试验标准ASTMD 1117-14测定的,但有一点除外,即撕破强力负荷是按记录的第一个和最高峰值的平均值计算的,而不是按最低和最高峰值的平均值计算的。
耐磨性由双头旋转平台(Tabor)测试。Tabor试验是根据美国材料试验标准ASTMD-1175采用一个125克橡胶轮进行的。耐磨性是由拍照循环数测得的。
压杯试验(Cup crush test)通过测定用直径为4.5厘米的半球形压脚压破一块9″×9″的布做成的一个形如高6.5厘米直径6.5厘米倒置杯子所需的峰值负荷来评价布样的硬挺性。在此杯形布被一个约6.5厘米直径的园柱体环绕以保持杯形布的均匀变形。压脚和杯布要对准以避免杯壁和压脚接触而影响峰值负荷。采用500克范围FTD-G-500型载荷传悉器(新泽西州Tennsanken的Schaevits公司生产),当压脚以约0.25英寸/秒(15英寸/分)速度下降时,就可测得峰值负荷。
                              表1性    能                      比  较
                       实例1    实例1    实例2    实例3实际基重(盎司/平方码)                    1.34      1.43     1.29    1.38厚度(英寸)                 0.016     0.014    0.021   0.018单纤纤度(
Figure C9311647700331
/根长丝)                    2.3       2.8      2.8     2.8抓样强力纵向负荷峰值(磅)           5.54      7.3      7.5     8.4纵向应变%                 57        90.04    144.3   132.4纵向峰值能(英寸·磅)       6.3       13.0     20.1    19.12横向负荷峰值(磅)           5.50      6.5      5.2     5.1横向应变%                 100       153.1    262.3   251.4横向峰值能(英寸·磅)       11.0      18.2     19.3    21.8压杯负荷峰值(克)           40        27       10      13能(克·毫米)               736       417      115     180Tabor耐磨性( 循环)面                         5         12       90+     58砧                         5         9        53      24悬垂硬挺性(厘米)纵向                                 1.98     1.8     1.6横向                                 1.59     1.29    1.39
从表1数据可以看出,实例1~3布样的耐磨性比比较实例1的布样耐磨性大得多。这表明乙烯丙烯酸丁酯共聚物加入到多组分长丝的第二组分形成单层纤维网的影响。此外,表1还表示:沿机器方向测量的峰值负荷来看,乙烯丙烯酸丁酯共聚物的加入增加了布的强度;从%应变和峰值能的增加来看,乙烯丙烯酸丁酯共聚物的加入增加了布的韧性;从压杯负荷和能值的减小来看,它增加了布的柔软性和顺应性;从布样厚度增加来看,它还增加了布的蓬松性。
                               比较实例2
由图1所示的上述工艺制得一种由连续双组分长丝组成的第一非织造布纤维网。长丝的构型为同心皮芯型,外鞘对芯子的重量比为1∶1。纺丝孔几何形状是直径为0.6毫米,长径比L/D为4∶1。喷丝板有525孔。在机器方向上以每英寸50孔排列,芯子的组成按重量计为100%的PD 3445聚丙烯,(由德克萨斯州休斯顿的Exxon公司生产),外鞘的组成按重量计为100% ASPUN6811A线型低密度聚乙烯(由密执安州Midland的Dow化学公司生产)。纺丝组件的熔体温度是430°F,纺丝孔吐出量为0.7克/孔·分,冷却气流流量为22空间立方英尺/分和冷却空气的温度是55°F。抽风器喂入温度是55°F,纺丝总管的压力是5磅/平方英寸。本实例的纤维网被热点粘合到中间的熔喷非织造布纤维网层的背面,该熔喷纤维网是由按重量计100%的ASPUN6811A聚乙烯组成,是按照美国专利4,041,203的方法制成的,制成的复合材料在260°F的粘合温度下进行热点粘合。粘合图案为有规则间隔的粘合区域,每平方英寸约有270个粘合点,总粘合面积为18%。
                         实例4
由图1所示的上述工艺制得一种由连续双组分长丝组成的第一非织造布纤维网。长丝的构型为同心皮芯型,外鞘对芯子的重量比为1∶1。纺丝孔几何形状是直径为0.6毫米,长径比L/D为4∶1,喷丝板有525孔,在机器方向上以每英寸50孔排列,芯子的组成是按重量计为100%的PD3445聚丙烯,(由德克萨斯州休斯顿的Exxon公司生产),外鞘的组成是按重量计85%的密执安州Midlamd的Dow化学公司生产的ASPUN 6811A聚乙烯和按重量计15%的ENATHENE 720-009乙烯丙烯酸正丁酯共聚物(由俄亥俄州辛辛那提USI部门的Quantum化学公司生产)。纺丝组件的熔体温度是430°F,纺丝孔的吐出量是0.7克/孔·分,冷却气流流量是22scfm(空间立方英尺/分)和冷却空气的温度是55°F,抽风器喂入温度是55°F,纺丝总管的压力为5磅/平方英寸。第一纤维网被热点粘合到中间的熔喷非织造布纤维网层的反面,该熔喷纤维网是由按重量计为100%的ASPUN 6811A聚乙烯组成,是按照美国专利4,041,203的方法制成的。制成的复合材料在260°F粘合温度下进行热点粘合。粘合图案为有规则间隔的粘合区域,每平方英寸约有270个粘合点和总粘合面积为18%。
                                实例5
根据实例4所述的工艺生产一种复合非织造布,所不同的是熔喷网层是由Exxon公司按重量计100%的3495G聚丙烯组成的。
                                实例6
根据实例4所述的工艺生产一种复合非织造布,所不同的是组成纺粘网层的长丝的外鞘是由按重量计85%的25355高密度聚乙烯(由Dow化学公司生产)和按重量计15%的Quantum公司生产的ENATHENE720-009乙烯丙烯酸正丁酯共聚物组成。
                            实施例7
根据实例4所述工艺生产一种复合非织造布,所不同的是组成纺粘网层的长丝的外鞘是由按重量计85%的由Dow化学公司生产的25355高密度聚乙烯和按重量计15%的由Quantum公司生产的ENATHENE720-009乙烯丙烯酸正丁酯共聚物组成,熔喷网层由按重量计100%的Exxon公司生产的3495G聚丙烯组成。
                            实例8
根据实例4所述的工艺生产一种复合非织造布,所不同的是组成纺粘网层的长丝的外鞘是由按重量计85%的Dow化学公司生产的ASPUN 6808A聚乙烯和按重量计15%的由Quantum公司生产的ENATHENE 720-009乙烯丙烯酸正丁酯共聚物组成的。
                               实例9
根据实例4所述的工艺生产一种复合非织造布,所不同的是组成纺粘网层的长丝的外鞘是由按重量计85%的Dow化学公司生产的ASPUN 6808A聚乙烯和按重量计15%的由Quantum公司生产的ENATHENE 720-009乙烯丙烯酸正丁酯共聚物组成。熔喷网层由按重量计为100%的Exxon公司的3495G聚丙烯组成。
按比较实例2和实例4~9的马丁代尔(Martindale)磨损试验使用马丁代尔试验仪测定形成纤维绒球的阻力和在轻微压力下其他有关的布样表面变化。马丁代尔磨损是根据美国材料试验标准ASTM04970-89测定的,但有一点例外,即测得的数值是马丁代尔试验仪对在布样上产生一个0.5英寸的孔所需的循环次数。
                                       表2性    能         比较实例2    实例4    实例5    实例6    实例7    实例8    实例9实际基重          1.60        1.71     1.63     1.75     1.54     1.70     1.56抓样强力纵向/横向平均峰值能(英寸·磅)    32.00       36.03    22.62    36.07    18.21    36.22    25.61纵向/横向平均峰值负荷(磅)        9.77        14.12    10.31    11.73    6.99     14.51    11.14纵向梯形试样撕破强力(磅)          6.75        11.36    10.64    14.09    10.70    14.77    12.42横向梯形试样撕破强力(磅)          4.10        6.99     4.90     4.78     2.55     5.88     4.18马丁代尔磨损(循环数/0.5英寸孔)     175         524      592      291      222      885      826马伦织物顶坡强力(磅/平方英寸)     13.0        21.1     -        20.7     19.7     21.9     21.8纵向悬垂硬挺性(英寸)            2.34        3.15    4.03      2.40     3.47     2.52     3.31横向悬垂硬挺性(英寸)            1.72        1.74    1.85      1.51     1.61     1.66     1.41压杯/负荷峰值(克)              59          95      118       77       97       71       102压杯/总能(克/毫米)             1093        1690    2410      1395     1731     1328     1925
从表2可以看出,实例4~9试样的耐磨性比比较实例2的大得多,这表明乙烯丙烯酸丁酯共聚物加入到多组分长丝的第二组分的影响。实例4~9样品的强度和柔软性随在纺粘纤维网和熔喷纤维网中的聚烯烃而变化。直接对比较实例2和实例4进行比较,可以看出乙烯丙烯酸正丁酯共聚物的加入增加了复合布强力性能。但是不同于乙烯丙烯酸丁酯共聚物加入到多组分长丝形成一单层纤维网,其柔软性并没得到改进。
虽然本发明对一些特殊实例已作了详细说明,熟悉这方面技术的人们对前面所述获得理解后,就会很容易地设想出对这些实例的改进,变动和等效的方法。因此本发明的范围应按所附的权利要求和任何等效方法来确定。

Claims (75)

1.一种由包含有第一和第二聚合物组分的被挤出的多组分聚合物丝条组成的非织造布,多组分丝条具有横截面、长度和园周表面,第一和第二组分在横跨多组分丝条的横截面上完全特有的区域中排列,并连续地沿多组分丝条的长度方向延伸,第二组分构成多组分连续丝条的至少一部分园周表面,并连续地沿多组分丝条长度延伸,且包含一种聚烯烃和乙烯丙烯酸烷基酯共聚物的共混物。
2.一种如权利要求1所述的非织造布,其中,按重量计,乙烯丙烯酸烷基酯共聚物在第二组分中的含量约为2-50%,而聚烯烃在第二组分中的含量约为98-50%。
3.一种如权利要求1所述的非织造布,其中,按重量计,乙烯丙烯酸烷基酯共聚物在第二组分中的含量约为5-25%,而聚烯烃在第二组分中的含量约为95-75%。
4.一种如权利要求1所述的非织造布,其中,按重量计,乙烯丙烯酸烷基酯共聚物在第二组分中的含量约为10-20%,而聚烯烃在第二组分中的含量约为90-80%。
5.一种如权利要求1所述的非织造布,其中,按重量计,第一聚合物组分在丝条中的含量约为20-80%,第二聚合物组分在丝条中的含量约为80-20%。
6.一种如权利要求1所述的非织造布,其中,按重量计,第一聚合物组分在丝条中的含量约为40-60%,第二聚合物组分在丝条中的含量约为60-40%。
7.一种如权利要求1所述的非织造布,其中,丝条是连续长丝。
8.一种如权利要求1所述的非织造布,其中,乙烯丙烯酸烷基酯共聚物选自乙烯丙烯酸丁酯共聚物,乙烯丙烯酸乙酯共聚物或乙烯丙烯酸甲酯共聚物。
9.一种如权利要求1所述的非织造布,其中,第二组分的聚烯烃选自聚乙烯、聚丙烯或乙烯丙烯共聚物。
10.一种如权利要求1所述的非织造布,其中,第二组分的聚烯烃含有线型低密度聚乙烯。
11.一种如权利要求1所述的非织造布,其中,第一组分有一个第一熔点,第二组分有一个第二熔点,第二熔点低于第一熔点。
12.一种如权利要求1所述的非织造布,其中,第一组分有一个第一熔点,第二组分有一个低于第一熔点的第二熔点,第二组分含有聚乙烯。
13.一种如权利要求1所述的非织造布,其中,第一组分有一个第一熔点,第二组分有一个低于第一熔点的第二熔点,第二组分含有线型低密度聚乙烯。
14.一种如权利要求1所述的非织造布,其中,第一组分有一个第一熔点,第二组分有一个低于第一熔点的第二熔点,第一组分含有一种聚烯烃。
15.一种如权利要求1所述的非织造布,其中,第一组分有一个第一熔点,第二组分有一个低于第一熔点的第二熔点,第一组分选自聚乙烯或丙烯乙烯共聚物,第二组分含有聚乙烯。
16.一种如权利要求1所述的非织造布,其中,第一组分有一个第一熔点,第二组分有一个低于第一熔点的第二熔点,第一组分选自聚丙烯或丙烯乙烯共聚物,第二组分含有线型低密度聚乙烯。
17.一种如权利要求1所述的非织造布,其中,第一组分有一个第一熔点,第二组分有一个低于第一熔点的第二熔点,第一组分含有聚丙烯,第二组分含有丙烯和乙烯的无规共聚物。
18.一种如权利要求1所述的非织造布,其中,按重量计,第一聚合物组分在丝条中的含量约为20-80%,第二聚合物组分在丝条中的含量约为80-20%;按重量计,乙烯丙烯酸烷基酯共聚物在第二组分中的含量约为2-50%,聚烯烃在第二组分中的含量约为98-50%。
19.一种如权利要求18所述的非织造布,其中,第一组分含有聚丙烯,第二组分含有聚乙烯。
20.一种如权利要求18所述的非织造布,其中,第一组分含有聚丙烯,第二组分含有线型低密度聚乙烯。
21.一种如权利要求1所述的非织造布,其中,按重量计,第一聚合物组分在丝条中的含量约为20-80%,第二聚合物组分在丝条中的含量约为80-20%;按重量计,乙烯丙烯酸烷基酯共聚物在第二组分中的含量约为5-25%,聚烯烃在第二组分中的含量约为95-75%。
22.一种如权利要求21所述的非织造布,其中,第一组分含有聚丙烯,第二组分含有聚乙烯。
23.一种如权利要求21所述的非织造布,其中,第一组分含有聚丙烯和第二组分含有线型低密度聚乙烯。
24.一种如权利要求1所述的非织造布,其中,按重量计,第一聚合物组分在丝条中的含量约为20-80%,第二聚合物组分在丝条中的含量约为80-20%;按重量计,乙烯丙烯酸烷基酯共聚物在第二组分中的含量约为10-20%,聚烯烃在第二组分中的含量约为90-80%。
25.一种如权利要求24所述的非织造布,其中,第一组分含有聚丙烯,第二组分含有聚乙烯。
26.一种如权利要求24所述的非织造布,其中,第一组分含有聚丙烯,第二组分含有线型低密度聚乙烯。
27.一种如权利要求1所述的非织造布,其中,丝条形成一个纤维网且进一步包含一层被粘合到该纤维网上的聚合物薄膜。
28.一种由连续多组分聚合物长丝组成的非织造布,按重量计,其长丝由约20-80%的第一聚合物组分和约80-20%的第二聚合物组分组成,该多组分长丝具有横截面、长度和园周表面,第一和第二组分在横跨多组分长丝的横截面上排列在完全不同的区里,并连续地沿多组分长丝的长度延伸,第二组分构成多组分连续长丝的至少一部分园周表面并连续地沿多组分长丝长度延伸,且包括一种按重计由约98-50%的聚烯烃和约2-50%的乙烯丙烯酸烷基酯共聚物组成的共混物。
29.一种如权利要求28所述的非织造布,其中,第一组分含有聚丙烯,第二组分含有聚乙烯。
30.一种如权利要求28所述的非织造布,其中,第一组分含有聚丙烯,第二组分含有线型低密度聚乙烯。
31.一种如权利要求28所述的非织造布,其中,乙烯丙烯酸烷基酯共聚物选自乙烯丙烯酸丁酯共聚物,乙烯丙烯酸乙酯共聚物或乙烯丙烯酸甲酯共聚物。
32.一种如权利要求28所述的非织造布,其中,长丝形成一纤维网,且进一步包含一层被粘合到该纤维网上的聚合物薄膜。
33.一种非织造布,它包含被挤出的含有第一和第二聚合物组分的多组分聚合物丝条的第一纤维网,该多组分丝条具有横截面、长度和园周表面,第一和第二组分在横跨多组分丝条的横截面上排列在完全不同的区域内,并连续地沿多组分丝条长度延伸,第二组分构成了多组分连续丝条的至少一部分园周表面,连续地沿多组分丝条长度延伸,且包括聚烯烃和乙烯丙烯酸烷基酯共聚物的第一共混物;该布还包含被挤出的聚合物丝条构成的第二纤维网,其中单一聚合物组分包含聚烯烃和乙烯丙烯酸烷基酯共聚物的第二共混物,然后第一和第二纤维网以面贴面的叠层关系放置并粘结在一起形成一块整体布。
34.一种如权利要求33所述的非织造布,其中,第二纤维网的丝条是熔喷的。
35.一种如权利要求33所述的包括由含有第一和第二聚合物组分的被挤出的多组分聚合物丝条构成的第三纤维网的非织造布,其中,多组分丝条具有横截面、长度和园周表面,第一和第二组分在横跨多组分丝条的横截面上排列在完全不同的区域内,并连续地沿多组分丝条长度延伸,第二组分构成了多组分连续丝条的至少一部分园周表面,连续地沿多组分丝条长度延伸,并包括聚烯烃和乙烯丙烯酸烷基酯共聚物的第三共混物,第一纤维网粘合到第二纤维网的一个面上,而第三纤维网则粘合到第二纤维网的另一面上。
36.一种如权利要求35所述的非织造布,其中,第二纤维网的丝条是熔喷的。
37.一种如权利要求33所述的非织造布,其中,按重量计,乙烯丙烯酸烷基酯共聚物在第一和第二共混物中的含量约为2-50%,聚烯烃在第一和第二共混物中的含量约为98-50%。
38.一种如权利要求33所述的非织造布,其中,按重量计,乙烯丙烯酸烷基酯共聚物在第一和第二共混物中的含量约为5-25%,聚烯烃在第一和第二共混物中的含量约为95-75%。
39.一种如权利要求33所述的非织造布,其中,按重量计,乙烯丙烯酸烷基酯共聚物在第一和第二共混物中的含量约为10-20%,聚烯烃在第一和第二共混物中的含量约为90-80%。
40.一种如权利要求33所述的非织造布,其中,第一纤维网的丝条是连续长丝。
41.一种如权利要求33所述的非织造布,其中,乙烯丙烯酸烷基酯共聚物选自乙烯丙烯酸丁酯共聚物、乙烯丙烯酸乙酯共聚物或乙烯丙烯酸甲酯共聚物。
42.一种如权利要求33所述的非织造布,其中,第一纤维网的第二组分的聚烯烃和第二纤维网的聚烯烃可选自聚乙烯、聚丙烯或乙烯和丙烯的共聚物。
43.一种如权利要求33所述的非织造布,其中,第一纤维网中的第二组分所含聚烯烃和第二纤维网中所含的聚烯烃包含线型低密度聚乙烯。
44.一种如权利要求33所述的非织造布,其中,第一组分有第一熔点、第二组分有低于第一熔点的第二熔点。
45.一种如权利要求33所述的非织造布,其中,第一组分有第一熔点、第二组分有低于第一熔点的第二熔点,第二组分包含聚乙烯。
46.一种如权利要求33所述的非织造布,其中,第一组分有第一熔点、第二组分有低于第一熔点的第二熔点,第二组分包含线型低密度聚乙烯。
47.一种如权利要求33所述的非织造布,其中,第一组分有第一熔点、第二组分有低于第一熔点的第二熔点,第一组分包含聚烯烃。
48.一种如权利要求33所述的非织造布,其中,第一组分有第一熔点、第二组分有低于第一熔点的第二熔点,第一组分可选自聚丙烯或丙烯和乙烯的共聚物,第二组分包含聚乙烯。
49.一种如权利要求33所述的非织造布,其中,第一组分有第一熔点、第二组分有低于第一熔点的第二熔点,第一组分可选自聚丙烯或丙烯和乙烯的共聚物,第二组分包含线型低密度聚乙烯。
50.一种如权利要求33所述的非织造布,其中,第一组分有第一熔点、第二组分有低于第一熔点的第二熔点,第一组分包含聚丙烯,第二组分包含丙烯和乙烯无规共聚物。
51.一种如权利要求33所述的非织造布,其中,第一聚合物组分,按重量计,在丝条中的含量约为20-80%,第二聚合物在丝条中的含量约为80-20%;乙烯丙烯酸烷基酯共聚物按重量计在第二组分中的含量约为2-50%,聚烯烃按重量计在第二组分中的含量约为98-50%。
52.一种如权利要求51所述的非织造布,其中,第一组分包含聚丙烯,第二组分包含聚乙烯。
53.一种如权利要求51所述的非织造布,其中,第一组分包含聚丙烯,第二组分包含线型低密度聚乙烯。
54.一种如权利要求33所述的非织造布,其中,第一聚合物组分,按重量计,在丝条中的含量约为20-80,第二聚合物组分在丝条中的含量约为80-20%;乙烯丙烯酸烷基酯共聚物按重量计在第二组分中的含量约为5-25%,聚烯烃在第二组分中的含量约为95-75%。
55.一种如权利要求54所述的非织造布,其中,第一组分包含聚丙烯,第二组分包含聚乙烯。
56.一种如权利要求54所述的非织造布,其中,第一组分包含聚丙烯,第二组分包含线型低密度聚乙烯。
57.一种如权利要求33所述的非织造布,其中,第一聚合物组分,按重量计,在丝条中的含量约为20-80%,第二聚合物组分在丝条中的含量约为80-20%;按重量计,乙烯丙烯酸烷基酯共聚物在第二组分中的含量约为10-20%,聚烯烃在第二组分中的含量约为90-80%。
58.一种如权利要求57所述的非织造布,其中,第一组分包含聚丙烯,第二组分包含聚乙烯。
59.一种如权利要求57所述的非织造布,其中,第一组分包含聚丙烯,第二组分包含线型低密度聚乙烯。
60.一种非织造布,它包含含有第一和第二聚合物组分的多组分聚合物连续长丝的第一纤维网,该多组分长丝具有横截面、长度和园周表面,第一和第二组分在横跨多组分长丝的横截面上排列在完全不同的区域内,并连续地沿多组分长丝长度延伸,第二组分构成了多组分长丝的至少一部分园周表面,连续地沿多组分长丝长度延伸且包括聚烯烃和乙烯丙烯酸烷基酯共聚物的第一共混物;
该布还包含由被挤出的聚合物丝条构成的第二纤维网,其中,一个聚合物组分含有聚烯烃和乙烯丙烯酸烷基酯共聚物的第一共混物;和
该布还包含含有第一和第二聚合物组分的多组分聚合物连续长丝的第三纤维网,该多组分长丝具有横截面、长度和园周表面,第一和第二组分在横跨多组分长丝的横截面上排列在完全不同的区域内,并连续地沿多组分长丝长度延伸,第二组分构成了多组分长丝的至少一部分园周表面并连续地沿多组分长丝长度延伸且包括聚烯烃和乙烯丙烯酸烷基酯共聚物的第三共混物;
第一、第二和第三纤维网以面贴面叠层关系放置,第一纤维网粘到第二纤维网的一面,第三纤维网粘合到第二纤维网的另一面形成一块整体布。
61.一种如权利要求60所述的非织造布,其中第二纤维网的丝条是熔喷的。
62.一种如权利要求60所述的非织造布,其中长丝中第一聚合物组分的含量按重量计约为20%-80%,长丝中第二聚合物组分的含量按重量计约为80%-20%;按重量计,乙烯丙烯酸烷基酯在第一和第三纤维网的第二组分中的含量和在单组分的第二纤维网中的含量约为2%-50%,聚烯烃在第一和第三纤维网的第二组分中的含量和在单组分的第二纤维网中的含量约为98%-50%。
63.一种如权利要求60所述的非织造布,其中乙烯丙烯酸烷基酯共聚物可选自乙烯丙烯酸丁酯共聚物、乙烯丙烯酸乙酯共聚物或乙烯丙烯酸甲酯共聚物。
64.一种如权利要求63所述的非织造布,其中第一和第三纤维网的第一组分包含聚丙烯,第一、第三纤维网的第二组分及单组分的第二纤维网包含聚乙烯。
65.一种如权利要求63所述的非织造布,其中第一和第三纤维网的第一组分包含聚丙烯,第一,第三纤维网的第二组分及单组分的第二纤维网包含线型低密度聚乙烯。
66.一种非织造布,它包含被挤出的含有第一和第二聚合物组分的多组分聚合物丝条的第一纤维网,该多组分丝条具有横截面、长度和园周表面,第一和第二组分在横跨多组分丝条的横截面上排列在完全不同的区域内并连续地沿多组分丝条长度延伸,第二组分构成了多组分丝条的至少一部分园周表面,连续地沿多组分丝条长度延伸且包括聚烯烃和乙烯丙烯酸烷基酯共聚物的第一共混物;
该布还包含由被挤出的聚合物丝条构成的第二纤维网,第一和第二纤维网以面贴面的叠层关系铺放并粘合在一起形成一块整体布。
67.一种如权利要求66所述的布,其中,乙烯丙烯酸烷基酯共聚物可选自乙烯丙烯酸丁酯共聚物、乙烯丙烯酸乙酯共聚物或乙烯丙烯酸甲酯共聚物。
68.权利要求1所述的非织造布用于制造个人护理用品。
69.一种如权利要求68所述的用途,其中乙烯丙烯酸烷基酯共聚物可选自乙烯丙烯酸丁酯共聚物,乙烯丙烯酸乙酯共聚物或乙烯丙烯酸甲酯共聚物。
70.一种如权利要求68所述的用途,其中丝条形成纤维网且进一步包含一层聚合物薄膜与该纤维网粘合。
71.权利要求33所述的非织造布用于制造服装。
72.一种如权利要求71所述的用途,其中第二纤维网的丝条是熔喷的。
73.一种如权利要求71所述的用途,其中非织造布层包含被挤出的含有第一和第二聚合物组分的多组分聚合物丝条的第三纤维网,该多组分丝条具有横截面、长度和园周表面,第一和第二组分在横跨多组分丝条的横截面上排列在完全不同的区域内,并连续地沿多组分丝条长度延伸,第二组分构成了多组分丝条的至少一部分园周表面,连续地沿多组分丝条长度延伸且包括聚烯烃和乙烯丙烯酸烷基酯共聚物的第三共混物;第一纤维网粘合到第二纤维网的一个面上而第三纤维网粘合到第二纤维网的另一面上。
74.一种如权利要求73所述的用途,其中第二纤维网的丝条是熔喷的。
75.一种如权利要求71所述的用途,其中乙烯丙烯酸烷基酯共聚物可选自乙烯丙烯酸丁酯共聚物、乙烯丙烯酸乙酯共聚物或乙烯丙烯酸甲酯共聚物。
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KR940004117A (ko) 1994-03-14
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CA2084255A1 (en) 1994-02-27
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BR9303033A (pt) 1994-03-15
DE69307229T2 (de) 1997-04-24
PH30005A (en) 1996-10-29
AU4478193A (en) 1994-03-03
DE69307229D1 (de) 1997-02-20
CN1085972A (zh) 1994-04-27
ES2097406T3 (es) 1997-04-01
TW216809B (en) 1993-12-01
ZA934767B (en) 1994-01-20
US5336552A (en) 1994-08-09
EP0586936B1 (en) 1997-01-08
KR100236629B1 (ko) 2000-03-02
AU668973B2 (en) 1996-05-23

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