CN104981344B - 生产水刺气流法纤维网的方法和由其获得的产品 - Google Patents

生产水刺气流法纤维网的方法和由其获得的产品 Download PDF

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CN104981344B
CN104981344B CN201380069791.7A CN201380069791A CN104981344B CN 104981344 B CN104981344 B CN 104981344B CN 201380069791 A CN201380069791 A CN 201380069791A CN 104981344 B CN104981344 B CN 104981344B
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R·诺尔森
E·玛丽安妮
K·D·彼德森
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Abstract

提供制备具有良好的MD和CD强度且水中一次性的非织造纤维网的方法。该方法包括水刺不小于50wt％纤维长度不大于3.5mm的天然纤维素纤维和不大于50wt％纤维长度不小于8.0mm的短纤维的气流法纤维。该气流法纤维网没有铺设在前体纤维网上，且没有使用粘接剂，粘合剂或热粘结纤维。以连续的操作进行气流成网和水刺。根据本发明的方法可获得满足市政能冲洗掉的指导原则的产品。

Description

生产水刺气流法纤维网的方法和由其获得的产品
相关申请的交叉参考
本申请要求2012年12月13日提交的美国临时申请No.61/736837的优先权，其公开内容在本文中通过参考全文引入。
发明领域
本发明涉及制备一次性的非织造纤维网的连续方法，该方法使用最小数量的操作，并提供可用作能冲洗掉的或一次性制品，例如一次性的擦拭布或刷子的经济产品。
发明背景
一次性的非织造基底用于生产通常使用一次并丢弃的宽泛的各种消费产品。这种产品包括一次性的清洁擦拭布，一次性的尿布，一次性的成人失禁产品，典型地在医院中使用以供吸收体液的一次性的垫子，和从角质基底上除去化妆品和其他材料的化妆工具或化妆垫。
这种商业产品构成了具有日益增加的增长潜力和功效扩大的工业。然而，由于实质上所有这种产品通过垃圾填埋或污水系统潜在地进入环境，因此需要一次性的非织造材料，它生产简单，含有最小或者不含生物降解性差的化学组分，例如粘接剂，粘合剂或热塑性聚合物，且仍然具有性能所要求的良好的湿拉伸强度。另外，寻求一种产品，该产品被构造为具有最小的棉绒含量且满足分类为市政和私人污水系统可接受的能冲洗掉的制品的条形码，同时生产经济。
常规地，可借助工业上称为“气流法”和“液压纺丝(hydraspun)”方法的两种基本技术之一，生产非织造的一次性擦拭布产品。基于打算的最终用途和可获得的生产设备，不同的生产商可变化地进行这些技术，但保持基本的操作原理。
气流法在非织造的载体层或前体基非织造纤维网之上结合沉积人造短纤维和木浆纤维的气流法纤维网的操作，并且水刺(hydroentangling)气流法层与非织造的载体。这一技术描述于Ouellette的U.S.8,250,719和在其内描述的参考文献中。除了使用载体纤维网以外，Ouellette还描述了用炽热的空气或喷洒的粘合剂粘结气流法纤维。
根据Manning等人在U.S.4,755,421中描述的"液压纺丝"方法，水刺纸浆和人造纤维的湿法成网的纤维网并干燥。然而，Viazmensky等人的U.S.5,292,581指明这种产品遭受差的湿强度的缺点，且描述了添加粘合剂显著改进强度。最近，Annis等人的U.S.7,732,357描述了对于当加热时，通过至少部分熔融变得活化的非织造片材，使用粘合剂纤维，并形成纤维与纤维的粘结。粘合剂纤维含有聚乙烯，聚丙烯，聚对苯二甲酸乙二酯及其混合物。
因此，仍然需要制备非织造纤维网的方法，所述非织造纤维网不含粘接剂，粘合剂，或粘合剂纤维，方便且经济地进行，并提供具有良好的性能强度的可分散的非织造纤维网，同时作为能冲洗掉的产品用于市政污水和私人感染系统是可接受的。
发明概述
因此，本发明的目的是提供生产非织造纤维网的方法，所述非织造纤维网包括最小的加工操作，不使用粘合剂，粘接剂或粘结纤维，并提供具有充足的湿拉伸强度以供用作擦拭布的非织造纤维网。本发明的另一目的是提供用作擦拭布的具有充足的湿强度的非织造纤维网，这对于一次性的污水和感染系统来说是可接受的。
根据本发明，实现了这些和其他目的，本发明的第一实施方案包括生产非织造纤维网的方法，该方法包括：制备天然纤维素纤维和人造短纤维的混合物；气流成形该混合物，获得至少一个均匀的气流法纤维网；水刺该气流法纤维网，在至少一面上固结纤维网；和干燥水刺纤维网，获得非织造纤维网；其中气流成形和水刺在连续操作中进行，在纤维的混合物内天然纤维素纤维的含量不小于50wt％，和人造短纤维的含量不大于50wt％，没有使用粘接剂，粘合剂或热粘结纤维，天然纤维素纤维中纤维的长度不大于3.5mm，人造短纤维中纤维的长度不小于8.0mm，非织造纤维网的基重为20g/m2-100g/m2，和非织造纤维网的厚度为0.25mm-2mm。
在第一实施方案的优选实施方案中，气流法纤维网直接在气流成形器的载体上成形，且没有预成形前体纤维网或者掺入连续的长丝纤维网。
在进一步高度优选的实施方案中，没有施加粘合剂，粘接剂或粘接剂纤维到非织造纤维网上，且在纵向上的拉伸强度与同纵向垂直的方向上的拉伸强度之比(MD/CD)小于3。
进一步在一个实施方案中，本发明提供通过任何一个上述方法的实施方案中的方法获得的非织造纤维网；其中非织造纤维网包括75wt％木浆；和25wt％Lyocell纤维。根据这一实施方案的非织造纤维网的基重为40g/m2-60g/m2，MD/CD之比小于3，CD湿拉伸强度为至少5N/5cm，和根据EDANA 2009年7月版的Guidance Document for Assessing theFlushability of Nonwoven Consumer Products(评估非织造消费产品的能冲洗掉的性的指导文件)，非织造纤维网是能冲洗掉的的产品。
在另一实施方案中，本发明提供通过任何一种上述方法的实施方案中的方法获得的非织造纤维网；其中非织造纤维网包括：约50wt％木浆；和约50wt％粘胶纤维；其中非织造纤维网的基重为40g/m2-60g/m2，MD/CD之比小于3，CD湿拉伸强度为至少12N/5cm。
附图简述
图1示出了根据本发明的一个实施方案的水刺单元中水的射流布局的示意图。
图2示出了与可商购的擦拭布相比，根据本发明的可分散和不可分散的非织造纤维网的对比数据。
本发明的详细说明
根据下述说明，所描述的所有数值范围包括所有子范围和在其间的所有数值，除非另有说明。所有重量含量值基于总重量。下述说明提供本发明的一般说明和具体的优选实施方案。然而，本领域普通技术人员会意识到，在没有脱离本发明的主旨下，本发明的许多变化可以是可能的。本说明书和下述权利要求意欲包括所有这种变化。
在第一实施方案中，本发明提供生产非织造纤维网的方法，该方法包括：制备天然纤维素纤维和人造短纤维的混合物；气流成形该混合物，获得至少一个均匀的气流法纤维网；水刺该气流法纤维网，在至少一面上固结纤维网；和干燥水刺纤维网，获得非织造纤维网；其中在连续操作下进行气流成形和水刺，在纤维的混合物中天然纤维素纤维的含量不小于50wt％，优选不小于60％，和最优选至少75wt％。人造短纤维的含量不大于50wt％，优选不大于40％，和最优选不大于25％。在本发明的气流成形和水刺操作中，没有使用粘接剂，粘合剂或热粘结纤维。
天然纤维素纤维的长度不大于3.5mm，优选1.5mm-3.5mm，最优选2.5-3.5mm。可使用任何天然纤维素纤维作为混合物中的短纤维。在一个实施方案中，所描述的长度的木浆可以是短纤维，和在优选的实施方案中，南方松木牛皮纸可以是天然纤维素纤维。由亚硫酸盐制浆工艺获得的木浆可另外作为天然纤维素纤维的来源。可使用天然纤维素纤维的混合物。天然纤维素纤维可以在锤磨机中脱纤维(defibrate)，形成单独的松散纤维的混合物。
短纤维可以是长度不小于8.0mm，优选8.0-100mm，最优选8mm-25mm的任何非热塑性的人造纤维。优选地，人造短纤维是粘胶纤维或Lyocell纤维。可使用非热塑性纤维的混合物。
形成气流法纤维网的方法一般地描述于Laursen等人的U.S.4,640,810中。共混短切和脱纤维的天然纤维素纤维成均匀的混合物，和同时在输送到分配器单元中的空气物流内承载。分配器单元含有穿孔有小孔、狭缝或设计为允许纤维在有小孔的载体上通过的其他合适地成型的孔隙的旋转圆柱或转鼓。转鼓的构造和孔隙的结构与尺寸可以随待使用且获得的独特纤维网构造的纤维混合物的特征而变化。在空气流，在转鼓内的机械搅拌和来自载体下方的抽吸的任何组合的影响下，将纤维导引经过穿孔的转鼓的开口，并在载体表面上形成均匀的纤维网。可借助工艺变量的控制，其中包括纤维的含量和尺寸，转鼓的孔隙尺寸与形状，空气流的流速，从载体底部施加的抽吸程度，和载体速度，改变使干燥纤维网消光(matting)的高度和程度。也可改变其他设备控制，提供独特的消光构造。
纤维网的宽度取决于所使用的空气成型器设备的类型，且可从1m变化到6m。常规的商业单元，例如由Dan-Web,Oerlikon和Anpap Oy供应的宽度范围为2到5m。
根据本发明，所形成的气流法纤维网被直接且连续地输送到水刺单元或者水刺单元中，其中用一系列的高压水射流冲击气流法垫子，机械缠结或固结纤维，并形成非织造纤维网。射流可垂直于载体表面取向，或者成角度，以提供纤维网独特性能。可定位射流，从一面，优选从顶面，或者从顶面和底面二者处固结纤维网。射流的压力可以是0.04bar/kg/h/m-15bar/kg/h/m，优选0.1bar/kg/h/m-10bar/kg/h m，和最优选0.3bar/kg/h/m-4bar/kg/h/m。
在图1中图示了一个实施方案，该实施方案显示出射流的布局，从两面固结纤维网。正如图1所示的，从空气成型器中直接取出的气流法纤维网沿着一系列的载体带通过，并暴露于以数字顺序表示的高压射流下。射流11,12和13撞击纤维网的顶部，同时射流21和22冲击对面或底面。示意的射流代表在横跨纤维网的宽度上的射流排，可定位并排列射流排，以赋予纤维网上变化的交缠完全度。因此，交缠可被构图或者随机，这取决于非织造纤维网所打算的最终用途。
可通过高压射流传递的能量，和通过纤维网行进通过设备的速度，来控制非织造纤维网的悬垂度，柔软度和舒适的手感。根据本发明，通过控制水压和纤维网行进通过水刺设备的速度以及不存在粘合剂，粘接剂或粘结纤维，可获得具有变化程度的强度，吸收度，柔软度和厚度的非织造纤维网。
水刺或水刺单元获自Fleissner GmbH(德国)和Andritz Perfojet(法国)。
在以上基本实施方案的一个变体中，可制备多个气流法纤维网并堆叠，之后水刺，以便可生产较厚的非织造纤维网。堆叠的各层可以具有相同的纤维组成，或者可具有针对非织造纤维网所打算的最终用途而选择的不同的纤维组成。在每一个这样可能的实施方案中，可通过改变水的射流压力，和纤维网行进通过水刺单元的速度，来实现交缠。不使用粘接剂，粘合剂或粘结纤维。
在水刺之后，可干燥湿的非织造纤维网并缠绕以供运输和储存。在进一步的实施方案中，在干燥之前，可或者通过水力压花工艺，或者通过热压花工艺，压花交缠的纤维网。
对于厚度为0.25mm-2mm的非织造纤维网来说，非织造纤维网的基重可以是20g/m2-100g/m2，优选40g/m2-80g/m2。然而，当堆叠多个气流法纤维网时，基重和厚度可以不在这些范围内。可通过控制针对气流法和水刺操作二者描述的工艺变量，和通过本发明技术领域的技术人员常规地已知的其他工艺变量，来改变基重。
根据本发明的非织造纤维网具有比一些常规地可获得的非织造纤维网更加无定向的强度曲线。在纵向(MD)上的拉伸强度与横向(CD)上的湿拉伸强度小于3。如图2的表所示，不具有粘合剂，粘接剂或粘结纤维的根据本发明的产品JHI的基重比对比的可商购的擦拭布显著较低，但仍然具有类似数值的MD和CD拉伸强度。这种性能是特别令人惊奇的，因为已知在满足能冲洗掉的性的标准指导原则的产品中难以获得CD湿拉伸强度。
在特别优选的实施方案中，根据本发明，采用约75wt％长度小于或等于3.5mm的脱纤维的木浆纤维和25wt％纤维大于或等于8mm的Lyocell纤维的组成，制造能冲洗掉的的产品。在0.35bar/kg/h/m-2.1bar/kg/h/m的射流压力下水刺气流法纤维网。非织造纤维网的CD湿拉伸强度为至少5.0N/5cm，和MD/CD之比小于3。这一非织造纤维网满足EDANA于2009年7月出版的Guidance Document for Assessing the Flushability of NonwovenConsumer Products(评估非织造消费产品的能冲洗掉的指导文件)中列出的关于能冲洗掉的测试标准。重要的是，这一产品通过了市政污水泵送试验，其中在60块擦拭布总计5个轮次的测量中小于10％的所有数据点各自可具有大于10％的力量(power)增加，和优选小于10％引起力量增加10％。
在另一特殊的实施方案中，根据本发明的方法，采用约50wt％长度小于或等于3.5mm的脱纤维的木浆纤维和约50wt％纤维大于或等于8mm的粘胶纤维，制造非织造纤维网。在0.3bar/kg/h/m-15bar/kg h/m，优选0.4bar/kg/h/m-6bar/kg/h/m的射流压力下水刺气流法纤维网。非织造纤维网的CD湿拉伸强度为至少12N/5cm，和MD/CD之比小于3。值得注意的是，这一产品的脱落纤维性能显著低于目前用作婴儿擦拭布或者硬表面清洁擦拭布的商业产品。

Claims (20)

1.生产非织造纤维网的方法，该方法包括：
制备脱纤维的天然纤维素纤维和人造短纤维的均匀干燥混合物；
使均匀干燥混合物通过穿孔的圆柱到有小孔的载体上，气流成形该混合物以获得至少一个均匀的气流法纤维网；
在有小孔的载体上水刺该气流法纤维网以在至少一面上固结纤维网；和
干燥该水刺的纤维网以获得非织造纤维网；
其中
气流成形和水刺在连续操作中进行，在纤维的混合物内天然纤维素纤维的含量不小于50wt％，且人造短纤维的含量不大于50wt％，
没有使用粘接剂、粘合剂或热粘结纤维，
天然纤维素纤维中纤维的长度不大于3.5mm，
人造短纤维中纤维的长度不小于8.0mm，
非织造纤维网的基重为20g/m2-100g/m2，且
非织造纤维网的厚度为0.25mm-2mm。
2.根据权利要求1所述的方法，其中混合物中天然纤维素纤维的含量为至少75wt％，且人造短纤维的含量为小于或等于25wt％。
3.根据权利要求1所述的方法，其中基重为40g/m2-60g/m2。
4.根据权利要求1所述的方法，其中天然纤维素纤维是木浆，且人造短纤维是粘胶纤维或Lyocell纤维。
5.根据权利要求4所述的方法，其中木浆是通过亚硫酸盐制浆法获得的亚硫酸盐纸浆。
6.根据权利要求1所述的方法，其中水刺该气流法纤维网，以在两面上固结纤维网。
7.根据权利要求1所述的方法，其中水刺所施加的压力为0.04bar/kg/h/m-15bar/kg/h/m。
8.根据权利要求7所述的方法，其中水刺所施加的压力为0.3bar/kg/h/m-4bar/kg/h/m。
9.根据权利要求1所述的方法，进一步包括：
压花该水刺的纤维网；其中压花操作与气流成形和水刺是连续的。
10.根据权利要求1所述的方法，其中在单一的气流成形器内进行气流法纤维网的气流成形。
11.根据权利要求1所述的方法，其中在大于一个气流成形器内进行气流法纤维网的气流成形，且每一纤维网中纤维的含量相同。
12.根据权利要求1所述的方法，其中在大于一个气流成形器内进行气流法纤维网的气流成形，且至少一个纤维网中的纤维含量不同于另一纤维网中的纤维含量。
13.根据权利要求1所述的方法，其中没有施加粘接剂、粘合剂或热粘结到非织造纤维网上。
14.根据权利要求1所述的方法，其中在没有预成形前体纤维网或者掺入连续长丝纤维网的情况下，在气流成形器的载体上直接形成气流法纤维网。
15.根据权利要求1所述的方法，其中气流法纤维网的水刺的压力为0.35bar/kg/h/m-15bar/kg/h/m。
16.根据权利要求15所述的方法，其中没有施加粘接剂、粘合剂 或粘合剂纤维到非织造纤维网上，且在纵向上的拉伸强度与纵向垂直的方向上的拉伸强度之比小于3。
17.通过根据权利要求1所述的方法获得的非织造纤维网。
18.根据权利要求17所述的非织造纤维网，其中该非织造纤维网包括：
75wt％木浆；和
25wt％Lyocell纤维；
其中
非织造纤维网的基重为40g/m2-60g/m2，
纵向上的拉伸强度与纵向垂直的方向上的抗伸强度之比小于3，
CD湿拉伸强度为至少5N/5cm，且
该非织造纤维网是根据2009年7月出版的EDANA的评价非织造消费产品的可冲洗的指导文件定义的能冲洗掉的产品。
19.根据权利要求17所述的非织造纤维网，其中该非织造纤维网包括：
约50wt％木浆；和
约50wt％粘胶纤维；
其中
非织造纤维网的基重为40g/m2-60g/m2，
纵向上的拉伸强度与纵向垂直的方向上的抗伸强度之比小于3，
CD湿拉伸强度为至少12N/5cm。
20.一种清洁擦拭布，它包括：
根据权利要求18所述的非织造纤维网；和
选自清洁剂、灭菌剂、除味剂、消毒剂、增湿剂和卸妆剂中的至少一种。
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