CN1177943A - 可横向拉伸的非织造层合物 - Google Patents

可横向拉伸的非织造层合物 Download PDF

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Publication number
CN1177943A
CN1177943A CN96192379A CN96192379A CN1177943A CN 1177943 A CN1177943 A CN 1177943A CN 96192379 A CN96192379 A CN 96192379A CN 96192379 A CN96192379 A CN 96192379A CN 1177943 A CN1177943 A CN 1177943A
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CN
China
Prior art keywords
laminated thing
elastomer
layer
fibre
polymer
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Granted
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CN96192379A
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English (en)
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CN1098770C (zh
Inventor
S·E·肖韦尔
L·W·科利尔四世
P·W·埃斯特伊
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Kimberly Clark Worldwide Inc
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/66—Additional nonwoven fabric is a spun-bonded fabric
    • Y10T442/663—Hydroentangled

Abstract

提供一种具有横向可拉伸性的非织造布层合物。该层合物由至少3层构成。外层是由卷曲或可卷曲纤维构成的纺粘非织造纤网。内层是弹性体聚合物层,后者本身可由一个或多个较薄的层组成。这些层优选的制法是,将它们顺序地沉积到移动的成型金属网上并采用除水力缠结以外的方法将它们粘合在一起,成为层合物。

Description

可横向拉伸的非织造层合物
发明背景
本发明涉及用于医用制品、个人护理用品、服装及户外用布料的非织造布领域。
许多用非织造布制作的产品的制造过程可能是涉及到许多不同裁切及结合步骤的非常复杂的一件事。例如，由非织造布制作手术罩衣要涉及在一大块材料上挖出袖窿及领口，裁出袖子料，然后把通常由两片构成的袖子彼此接到一起，再同罩衣的大身接起来。有些罩衣还带有加强部位(例如肘部)，为此还必须将附加的布片裁出、安放并结合。在罩衣的袖子、后片及前片上还可能要求开扣眼或其他固定或合拢方式的手续。这样一种制作过程要求将各种布片多次转动、翻身、折叠等等。
用于各种各样用途的某些类型非织造布的特性之一是弹性，即能够拉长，然后又大致恢复到其原来尺寸的能力。这种特性对于例如医用罩衣、尿布、训练裤以及成人失禁用品是有用的。
可拉伸非织造布已有生产，然而通常局限于沿机器方向(MD)拉伸，即布料被生产出来的方向。虽然这一特性是有用的，但是据发现，假如非织造布能够沿垂直于机器的方向(横向)(CD)拉伸，则将大大有利于许多制造过程。虽然看起来是件小事，但是加工期间反复翻转例如罩衣的非织造布料会导致布料的损伤、维护费用增加，以及当然还有原始购置加工生产线设备的基本投资的增加。横向可拉伸非织造布，由于免去在使用MD可拉伸材料时为了获得沿需要方向的可拉伸性而转动布料的步骤，将会大大简化制造过程。
据此，本发明的一个目的是提供一种沿至少横向可拉伸的非织造布层合物。
发明简述
本发明的目的是通过一种具有横向可拉伸性的多层层合物实现的，其中外层是卷曲或可卷曲纺粘聚合物纤网或布，它可以是双组分纤维的，而且该层合物还包括至少一个弹性体聚合物层的内层。各层在其整个生产及粘合为所述层合物期间均维持在未拉伸的状态。
发明详述
定义
这里所用的“非织造布或纤网”一词是指这样一种纤网，它具有由单根纤维或丝互相绞缠而成的，而不是如针织织物中那样以可辨认或规则重复的方式组成的结构。非织造布或纤网一向可采用多种方法成形，例如熔喷法、纺粘法以及粘合梳理纤网法。非织造布的单位重量通常以每平方码材料的盎司数(osy)或每平方米的克数(gsm)来表示，使用的纤维直径通常以微米表示。(注：要从osy换算到gsm，可用33.91乘上以osy表示的数值)。
这里所使用的“微纤维”一词是指平均直径不大于约50微米的细直径纤维，例如其平均直径约为0.5微米～约50微米，或者特别是，微纤维的平均直径为约2微米～约40微米。例如，一个按微米给出的聚丙烯纤维的直径数值可以通过将其乘方，然后将结果乘上0.00629，换算为旦数，比如，15微米聚丙烯纤维的旦数为约1.42(152×0.00629＝1.415)。
这里所使用的“纺粘纤维”一词是指这样的小直径纤维，其制取方法是：将熔融热塑性材料从一种纺丝板的通常为圆形的许多细孔中挤出成为一束丝，然后通过例如以下文献所述的方法使挤出丝的直径迅速变细：授予Appel等人的美国专利4,340,563及授予Dorschner等人的美国专利3,692,618、授予Matsuki等人的美国专利3,802,817、授予Kinney的美国专利3,338,992及3,341,394、授予Hartman的美国专利3,502,763、授予Levy的美国专利3,502,538，以及授予Dobo等人的美国专利3,542,615。纺粘纤维通常是连续的，其直径大于7微米，特别是常常介于约10微米～30微米之间。
这里所使用的“熔喷纤维”一词是指这样的纤维，其制取方法是：将熔融热塑性材料从许多细小的、通常为圆形的模板孔中以熔融丝或丝束的形式挤出到高速气体(例如空气)流中，气流将熔融热塑性材料的丝束拉细，以致可将其直径降低到微纤维直径的水平。此后，该熔喷纤维被高速气流夹带并沉积到收集表面上，形成由无规散落的熔喷纤维组成的纤网。这样一种方法例如公开在授予Butin的美国专利3,849,241中。熔喷纤维一般属于微纤维，其直径通常小于10微米。
这里所用的“聚合物”一词一般包括但不限于，均聚物、共聚物，例如嵌段、接枝、无规及交替共聚物、三元共聚物等，及其共混物和改性物。此外，除非另行限定，“聚合物”一词应涵盖材料的所有几何构型。这些构型包括但不限于，全同立构、间同立构、无规及随机对称构型(randomsymmetries)。
这里所用的“机器方向”或“MD”一词是指布料被生产出来的长度方向。“垂直机器的方向”、“横向”或“CD”是指布料的幅宽方向，即大体垂直于MD的方向。
这里所用的“双组分纤维”一词是指用来自分开的挤出机的至少两种聚合物，但共同纺成一种纤维时所制成的纤维。这些聚合物沿双组分纤维的横断面排列在基本固定的界限分明的区内，并沿该双组分纤维的长度连续地延伸。此种双组分纤维的配置例如可以是皮/芯排列的，其中一种聚合物被另一种聚合物包围着，或者可以是并排排列的，或是呈“海-岛”式排列的。双组分纤维公开在授予Kaneko等人的美国专利5,108,820、授予Strack等人的美国专利5,336,552以及欧洲专利0586924中。就双组分纤维而言，聚合物存在的比例可为75/25、50/50、25/75，或者任何希望的其他比例。
这里所用的“双成分纤维”一词是指从同一挤出机以共混物形式挤出的至少两种聚合物制成的纤维。“共混物”一词的定义见下文。双成分纤维不具备沿纤维的横断面内排列在相对固定位置的界限分明区内的不同聚合物组分，其不同聚合物通常不是沿纤维的全长连续延伸的，相反，它们通常形成无规地开始和结束的细纤。双成分纤维有时也叫做多成分纤维。这种大体类型的纤维例如见诸于授予Gessner的美国专利5,108,827中。双组分纤维和双成分纤维还见诸于教科书聚合物共混物及复合物，John A.Manson及Leslie H.Sperling编，Plenum出版社1976年出版，纽约Plenum出版公司一分支机构，IBSN 0-306-30831-2，273～277页。
这里所用的“共混物”一词是指两种或更多种聚合物的混合物，而“合金”一词是指共混物的一个子类，其中的成分不相混溶，但具有相容(共存)关系。“混溶性”和“不混溶性”的定义是分别具有负值和正值的混合自由能的共混物。进而，“相容化”的定义是改变不混溶的聚合物共混物的界面特性以制成合金的方法。
这里所用的“缩颈”或“缩颈拉伸”二词可互相通用地指一种将非织造布拉长的方法，一般是沿着机器方向，以便按控制的方式将其幅宽减少到希望的数值。控制拉伸可在冷态、室温或较高的温度下进行，拉伸的限度是使沿拉伸方向的总尺寸增加到最大不超过将布料拉破所需要的伸长值，多数情况下拉伸值介于约1.2～1.4倍。当松弛时，纤网朝着其原来的尺寸回缩。这样一种方法公开在例如授予Meitner和Notheis的美国专利4,443,513中，另一个是授予Morman的美国专利4,965,122。
这里所用的“缩颈软化”一词是指拉伸期间不对材料进行加热的缩颈拉伸。
这里所用的“可缩颈材料”一词是指任何可使之发生缩颈的材料。
这里所用的“缩颈材料”一词是指任何在至少一个方向上用诸如拉伸或收褶的方法使之颈缩了的材料。
这里所用的“恢复”一词是指由于施加位移力使材料伸长之后，一旦位移力消失，被拉长的材料产生的收缩。例如，一个松弛状态、未发生位移的、长度为1英寸的材料，假如由于被拉伸到1.5英寸的长度而伸长了50％，则该材料就应被拉长了50％并且应具有其松弛长度的150％的长度。假如该示范的拉伸材料发生了回缩，即在解除位移及拉伸力之后回缩到1.1英寸长，则该材料便恢复了其伸长值的80％(0.4英寸)。
这里所用的“解缩颈”一词是指施加于某种可逆缩颈的材料以使之伸长到至少其原来的、缩颈前尺寸的方法，这是通过沿纵向或垂直机器的方向施加了这样的拉伸力达到的：它能使材料在解除拉伸力之后恢复到其可逆缩颈尺寸的至少约50％以内。
这里所用的“缝编结合”一词是指例如按照授予Strack等人的美国专利4,891,957或授予Carey，Jr.等人的美国专利4,631,933将材料缝编结合的方法。
这里所用的“医用制品”一词是指手术罩衣及帘子、面罩、头罩、鞋罩、伤口敷裹物、绷带及消毒用包布。
这里所用的“个人护理制品”一词是指尿布、婴儿围涎、训练裤、吸收性内裤、成人失禁用品、抹布以及妇女卫生制品。
这里所用的“防护外罩”一词是指用于运输工具，例如汽车、卡车，船、飞机、摩托车、自行车、高尔夫小车等的外罩，经常放在户外的设备外罩，例如用于烧架、庭院及园艺设备(割草机、转轴式松土机等)以及草坪家具的外罩，直至地板覆盖物、桌布及野餐铺地布。
这里所用的“户外用布料”一词是指主要，虽不是唯一户外使用的布料。户外用布料包括用于防护外罩的布料、野营/拖车布料、帆布、篷帐布、华盖、帐篷、农用布(例如禾苗行的覆盖)以及户外服装，例如头罩、工业工作服及连衣裤防护服、裤子、衬衫、夹克、手套、袜子、鞋罩等。
测试方法
熔体流动速率：熔体流动速率(MFR)是聚合物粘度的度量。MFR采用规定载荷或剪切速率下在一段测量的时间内从已知尺寸的毛细管流出的物质重量来表示，根据例如ASTM试验1238，条件E，该值在230℃下进行测定，以克/10分钟为单位。
Grab拉伸试验：Grab拉伸试验是布料在夹具间单方向应力作用下破裂强度及伸长或应变的度量。Grab拉伸强度和Grab伸长的数值是在采用规定的布宽度、夹具宽度及恒定伸长速率的情况下获得的。该试样与夹具同宽，但比夹具的间距长，给出的结果代表处于夹持宽度内纤维的有效强度与布料中邻近纤维所贡献的附加强度之和。该结果逼真地模拟了实际使用当中布料的应力条件。结果以直至破裂的磅数及直至破裂的伸长百分数表示。总能量还可表示为断裂功。数值越高，布料越结实或可拉伸性越好。
循环试验：在循环试验中，让材料经受固定的伸长或固定的载荷，将结果画成图，以载荷为纵轴y，伸长为横轴x。该图生成一条曲线，其下方的面积叫做总吸收能量或“TEA”。对同一试样不同循环次数的TEA曲线的比例是一个独立于可与其他试样比较的材料、单位重量及试样宽度等参数的数值。
发明详述
本发明的层合布包括由夹在两层卷曲纤维或长丝的纺粘非织造布之间的至少一个热塑性弹性体聚合物层所组成的层状构造。该纺粘纤维可为双组分的。
用于实施本发明的热塑性弹性体聚合物层可由下列材料制成：苯乙烯嵌段共聚物、聚氨酯、聚酰胺、共聚多酯、乙烯-乙酸乙烯酯(EVA)等，且可以是熔喷纤网、纺粘纤网薄膜或泡沫体层，而且本身可以由一或多层较薄的热塑性弹性体聚合物层组成。一般而言，任何能成形为合适的弹性体纤维、薄膜或泡沫体的树脂或含此种树脂的共混物均可用来制作该弹性体纤维的非织造纤网、弹性体薄膜或弹性体泡沫体。
苯乙烯嵌段共聚物包括：苯乙烯/丁二烯/苯乙烯(SBS)嵌段共聚物、苯乙烯/异戊二烯/苯乙烯(SIS)嵌段共聚物、苯乙烯/乙烯-丙烯/苯乙烯(SEPS)嵌段共聚物、苯乙烯/乙烯-丁二烯/苯乙烯(SEBS)嵌段共聚物。例如，有用的形成弹性体纤维的树脂包括通式为A-B-A’或A-B的嵌段共聚物，其中A和A’每一个是含有苯乙烯部分的，例如聚(乙烯基芳烃)的热塑性聚合物端嵌段，而其中B是诸如共轭二烯或低级烯烃聚合物的弹性体聚合物中嵌段。A-B-A’型嵌段共聚物可以含有不同或相同A与A’嵌段的热塑性嵌段共聚物。而本发明的嵌段共聚物意在涵盖线型、支链及星形嵌段共聚物。就此而言，星形嵌段共聚物可表示为(A-B)m-X，其中X是多官能原子或分子，且其中每一个(A-B)m-以A作为端嵌段自X呈发射状伸出。在该星形嵌段共聚物中，X可为有机或无机多官能原子或分子，m是整数，其值与原来存在于X中的官能团数相同、它一般至少是3，常常是4或5，然而并不限于此。所以，在本发明中，“嵌段共聚物”，特别是“A-B-A’”及“A-B”嵌段共聚物一词意在涵盖所有含有这种橡胶嵌段以及上面讨论过的热塑性嵌段的嵌段共聚物，它们可挤出(例如通过熔喷)，且嵌段数目不受限制。
授予Wisneski等人的美国专利4,663,220公开一种纤网，包括含有至少约10％(重量)A-B-A’嵌段共聚物的微纤维，其中“A”和“A’”每一个是含有苯乙烯部分的热塑性端嵌段，且其中“B”是聚(乙烯-丁烯)弹性体中嵌段，以及大于0％(重量)直至约90％(重量)这样的聚烯烃：当与该A-B-A’嵌段共聚物掺混并受到高温与高压条件的有效组合的作用时适合以与A-B-A’嵌段共聚物的共混形式挤出。Wisneski等人所用的聚烯烃可以是聚乙烯、聚丙烯、聚丁烯、乙烯共聚物、丙烯共聚物、丁烯共聚物及其混合物。
此种弹性体共聚物的商品例子例如有：叫做KRATON材料的共聚物，生产者：壳牌化学公司，Houston，Texas。供应的KRATON嵌段共聚物有几种不同的配方，其中有许多种可见诸于美国专利4,663,220，该文收作本文的参考。特别合适的弹性体层可用例如如下的弹性体聚(苯乙烯/乙烯-丁烯/苯乙烯)嵌段共聚物制成，其商品名为KRATONG-1657，生产者：壳牌化学公司，Houston，Texas。
可用来制作弹性体层的其他范例弹性体材料包括：聚氨酯弹性体材料，例如商品名为ESTANE的材料，生产者：B.F.Goodrich公司；聚酰胺弹性体材料，例如商品名为PEBAX的材料，生产者：Rilsan公司；以及聚酯弹性体材料，例如商品名为HYTREL的材料，由杜邦公司生产。
用聚酯弹性体材料制作弹性体非织造布的方法例如公开在授予Morman等人的美国专利4,741,949中，该文收入本文作为参考。
弹性体层还可用乙烯与至少一种乙烯基单体，例如乙酸乙烯酯、不饱和脂族单羧酸及该单羧酸的酯等的弹性体共聚物制成。该弹性体共聚物及用这种弹性体共聚物制作弹性体非织造纤网的方法公开在，例如美国专利4,803,117中。尤其有用的熔喷热塑性弹性体纤网由公开在例如授予Boggs的美国专利4,707,398、授予Morman等人的美国专利4,741,949以及授予Wisneski等人的美国专利4,663,220中的材料的纤维构成。另外，熔喷热塑性弹性体聚合物层本身，还可以由一或多个借助技术上已知的方法一层盖一层地顺序沉积或层合在一起的较薄熔喷热塑性弹性体聚合物层构成。
热塑性共聚多酯弹性体包括通式如下的共聚多醚酯：
Figure A9619237900101
其中“G”选自聚(氧乙烯)-α，ω-二醇、聚(氧丙烯)-α，ω-二醇、聚(氧四亚甲基)-α，ω-二醇，“a”和“b”是包括2、4及6的正整数，“x”、“y”及“z”是包括1～20的正整数。该材料按ASTM D-638测定的断裂伸长值一般为约600％～750％，按ASTM D-2117测定的熔点为约350°F～约400°F(176～205℃)。此类共聚多酯材料的商品例子例如有商品名为ARNITEL的材料，原生产者：Akzo塑料公司，Amhem，荷兰，现生产者：DSM公司，Sittard，荷兰，或者商品名为HYTREL的材料，生产者：杜邦公司，Wilmington，Delaware。
合适泡沫体的例子包括由General Foam公司，Paramus，NJ，生产的泡沫体。此种泡沫体是商品名为“4000系列”的聚氨酯泡沫体。此种泡沫体见诸于授予Rautenberg等人的美国专利4,761,324，第6栏，53～68行，该公开收作本文的参考文献。
弹性体熔喷层可按照授予Strack等人的美国专利4,891,957的方法进行缝编。缝编使得缝编后的产品具备强度和耐用性，而本发明的缝编据信能提高层合物的耐磨性。虽然缝编通常用来将两种或多种材料结合在一起，但对本发明的该实施方案而言，弹性体熔喷层是单独进行缝编，然后再用于制作层合材料的。
纺粘非织造布可用技术上已知并在上面列举的大量参考文献中描述过的方法生产。扼要地说，纺粘法通常采用一个料斗向加热的挤出机供应聚合物。挤出机将熔融聚合物送至纺丝板，在此随着聚合物通过纺丝板中通常排列成一排或多排的细孔，它就变为纤维状，形成由丝束构成的幕。对丝束通常用低压空气进行骤冷，牵伸，一般靠气力，然后将其沉积在移动的多孔垫、带或“成形金属网”上，成形为非织造布。
用纺粘法生产出的纤维，其直径依工艺条件及由该纤维生产出的布料的预期最终用途而定，一般在约10～约30微米范围内。例如，提高聚合物分子量或降低加工温度，生产出的纤维直径就较粗。骤冷流体温度及气力牵伸压力的变化也会影响到纤维直径。
适用于纺粘法的聚合物，其加工熔体温度通常介于约350°F～约610°F(175℃～320℃)，如上面定义的熔体流动速率介于约10～约150，特别是在约10～50之间。合适聚合物的例子包括聚丙烯、聚乙烯及聚酰胺。
双组分纤维也可用于实施本发明。双组分纤维通常是聚丙烯和聚乙烯，按皮/芯、“海/岛”或并列的配置排列。合适的市售材料包括牌号为PP-3445的聚丙烯，生产者：Exxon化学公司，Baytown，Texas，ASPUN6811A；以及2553线型低密度聚乙烯，生产者：道化学公司，Midland，Michigan；25355及12350高密度聚乙烯，生产者：道化学公司；DURAFLEXDP 8510聚丁烯，生产者：壳牌化学公司，Houston，Texas；以及ENATHENE720-009乙烯-丙烯酸正丁酯，生产者：Quantum化学公司，Cincinnati，Ohio。
某些双成分纤维也可用于实施本发明。聚丙烯共聚物与聚丁烯共聚物按90/10的混合比的共混物，据发现是有效的。任何其他的共混物也可能是有效的，只要它们能够纺成丝而且能提供卷曲的或可卷曲的纤维。
用于实施本发明的纺粘层纤维必须是卷曲的或可卷曲的，因为本发明人发现，卷曲纤维的纤网，在层合到弹性体熔喷层上之后能够对拉伸作出足够的“贡献”，以致伸长至较大的尺寸而不会破裂。
纺粘纤维的卷曲可采用多种方法完成。一种方法是，向成形金属网表面纺制出一种纺粘纤网，然后令纤网通过两个具有不同表面的鼓或辊之间。辊在纤网纤维通过其间时将纤维折弯，从而生成所要的卷曲。在纤维中造成卷曲的另一种方法是将每根纤维进行机械拉伸。
当双组分纤维用于实施本发明时，卷曲可通过对纤维加热来达到。可选择具有不同膨胀系数的两种聚合物组成双组分纤维，以便加热后在纤维中产生卷曲。这种加热可在成形金属网上形成了纤网之后，在介于约110°F(43℃)至最高不超过低熔点纤维组分的熔点的温度范围内进行。这种加热可替代地，如同1994年3月16日发表的授予Pike等人的欧洲专利申请586,924中所述的那样，在纤维从纺丝板落到成形金属网的过程中进行，在Pike的方法中，被加热到约110°F(43℃)到最高不超过低熔点纤维组分的熔点之间的空气吹向正在下落的纤维，使得两种聚合物发生彼此不同程度的膨胀，从而使纤维发生卷曲。
本发明的层合布的制法可首先在成形金属网上沉积一层卷曲的纺粘纤维。在该卷曲纺粘纤维的表面沉积上一层弹性体熔喷纤维。最后，在该弹性体熔喷层上沉积上另一层卷曲纺粘纤维，而这层一般是预先成形好的。可以有一层以上的弹性体熔喷纤维。在包括粘合步骤在内的层合物生产过程中，没有任何一层在任何方向上受到拉伸。
替代地，所有的层可单独地生产出来，然后在一个分开进行的层合步骤中结合在一起。如果选择了这种制造方法，同样重要的是，各层在层合物制造过程中均不受拉伸。
在制造层合物期间布料不受拉伸的要求是指，布料不受任何超出通常用于生产层合物的那类机械所提供的正常拉伸力，即指不受超过使布料从层合前到层合以后沿着加工路线运动的滚筒、卷绕机所提供的正常拉伸力的任何附加或过分的拉伸力。本发明的布料不需要进行缩颈拉伸、缩颈软化或解缩颈来提供要求的拉伸性。
在加上最后一层卷曲纺粘纤维之后，将各层粘合起来，产生出层合物。粘合可借助诸如穿透空气粘合或采用花纹热轧辊的点粘合等方法完成。
穿透空气粘合或“TAB”见诸于授予Pike等人的欧洲专利申请586,924，该方法包括：将非织造双组分纤维纤网至少部分地绕到被封闭在柜子内的多孔滚筒上。热度足以使构成纤网纤维的聚合物之一发生熔融的空气被强制从柜子穿过纤网层并进入到多孔滚筒中。该空气的速度介于100～500英尺/分，其停留时间可长达6秒钟。聚合物的熔融及再凝固就造成了粘合。鉴于TAB要求至少一种组分发生熔融以实现粘合，它局限于用在双组分纤维纤网的生产上。
已开发出采用带有各种花纹的热轧辊的点热轧粘合方法。一个例子是如授予Hansen及Pennings的美国专利3,855,046中所公开的扩展的HansenPennings花纹，它具有约15％粘合面积以及约100粘合点/平方英寸。另一种常用的花纹是由重复然而稍许偏置的菱形组成的菱形花纹。
层合物的粘合可替代地采用超声粘合、印花粘合以及除水力缠结法之外的任何技术上已知的其他有效的方法完成。
本发明的布料可在层合之前对任何单独的层，或者在粘合之后对整个布料，按已知技术用各种化学品进行处理，以赋予其用于特定用途的性能。这类处理包括拒水剂、软化剂、阻燃剂、拒油剂、抗静电剂及其混合物等的处理。颜料也可以加入到布料中，作为粘合的后处理或者替代地，在制成纤维之前加入到选定层的聚合物中。
据发现，本发明的布料可沿横向拉伸至少约100％。
本发明的布料可用于个人护理制品、医用制品以及户外用布料。同时据信，此种布料可用于汽车上，例如作为车顶衬里。
对各种不同层合物的性能进行了比较。这些层合物的情况见诸于以下内容，其中各实例样是按本发明制作的层合物，而对比样则不是。
对比样
两个外表面层均为纺粘聚丙烯纤维，中间夹一层弹性体熔喷层。
该弹性体熔喷层系由壳牌公司的KRATONG-2740制成，其单位重量为约1.8osy(61gsm)。
纺粘纤维系由Exxon PD-3445聚丙烯构成，以0.7克/孔/分钟(ghm)的速率通过0.6毫米的孔挤出，生产出单位重量0.7osy(22gsm)的每一表面层。该布料是采用带有5％螺旋花纹的热轧辊粘合工艺在291°F的温度下粘合的。制造或粘合期间没有任何一层受到拉伸。
实例样1
二外表面层中均为纺粘纤维，中间夹一层弹性体熔喷纤维层。
该弹性体熔喷层系由壳牌公司的KRATONG-2740制成，其单位重量为约1.8osy(61gsm)。
该纺粘布是由带有交替排列的不同种纤维纺丝孔的纺丝组件生产的，生成的一层布或纤网中含有不同种类纤维组成的混合物，从而该纤网具有可卷曲性。一排纤维是Exxon PD-3445聚丙烯，紧挨着一排是由90％(重量)壳牌聚丙烯共聚物与10％(重量)壳牌Duraflex聚丁烯共聚物组成的共混物。该聚丙烯共聚物含有3.2％(重量)乙烯，而该聚丁烯共聚物含有6％(重量)乙烯。全部聚合物通过0.6毫米的纺丝孔以0.5克/孔/分(ghm)的速率挤出，每个表面层的单位重量为1.0osy(34gsm)。该布料是采用带有5％螺旋花纹的热轧辊粘合工艺在291°F的温度下粘合的。制造或粘合期间没有任何一层受到拉伸。
实例样2
二外表面层中均为双成分纺粘纤维，中间夹一层弹性体熔喷纤维层。
该弹性体熔喷层系由壳牌公司的KRATONG-2740制成，其单位重量为约1.8osy(61gsm)。
该纺粘布是由如实例样1所述的90％(重量)聚丙烯共聚物与10％(重量)聚丁烯共聚物组成的双成分共混物，通过0.6毫米的纺丝孔以0.7克/孔/分(ghm)的速率挤出，每个表面层的单位重量为1.0osy(34gsm)，制成一种可卷曲纤网  该布料是采用带有5％粘合面积方块花纹的热轧辊粘合工艺在270°F的温度下粘合的。制造或粘合期间没有任何一层受到拉伸。
实例样3
二外表面层中均为双成分纺粘纤维，中间夹一层弹性体熔喷纤维层。
该弹性体熔喷层系由壳牌公司的KRATONG-2740制成，其单位重量为约1.8osy(61gsm)。
该纺粘布是由如实例样1所述的90％(重量)聚丙烯共聚物与10％(重量)聚丁烯共聚物组成的双成分共混物，通过0.6毫米的纺丝孔以0.53克/孔/分(ghm)的速率挤出，每个表面层的单位重量为0.7osy(24gsm)，制成一种可卷曲纤维。该布料是采用带有5％粘合面积方块花纹的热轧辊粘合工艺在291°F的温度下粘合的。制造或粘合期间没有任何一层受到拉伸。
实例样4
二外表面层中均为卷曲双组分纺粘纤维，中间夹一层弹性体熔喷纤维层。
该弹性体熔喷层系由壳牌公司的KRATONG-2740制成，其单位重量为约1.8osy(61gsm)。
该卷曲纺粘纤维是Exxon PD-3445聚丙烯与Dow Aspun6811A聚乙烯并列型纤维，它是通过0.6毫米的纺丝孔以0.65克/孔/分(ghm)的速率挤出的，每个表面层的单位重量为0.8osy(27gsm)。该布料是采用穿透空气粘合工艺在258°F的温度下粘合的。制造或粘合期间没有任何一层受到拉伸。
实例样5
二外表面层中均为卷曲双组分纺粘纤维，中间夹一层弹性体熔喷纤维层。
该弹性体熔喷层系由壳牌公司的KRATONG-2740制成，其单位重量为约1.8osy(61gsm)。
该卷曲纺粘纤维是Exxon PD-3445聚丙烯与Dow Aspun6811A聚乙烯并列型纤维，它是通过0.6毫米的纺丝孔以0.65克/孔/分(ghm)的速率挤出的，每个表面层的单位重量为0.4osy(13gsm)。该布料是采用穿透空气粘合工艺在258°F的温度下粘合的。制造或粘合期间没有任何一层受到拉伸。
就上述层合物的横向可拉伸性及可恢复性在Instron Sintech机器上进行了测试。峰值载荷及峰值应变采用了3英寸宽的试样及300毫米/分的拉伸速度。峰值伸长或应变用百分率表示。峰值载荷用克表示。循环试验伸长值用百分率表示。循环伸长中的第一循环载荷(A)用克表示。试样的性能载于下面的表1中。
表1
    峰值应变  峰值载荷    循环伸长    A对比样     79       3690         50      2690实例样1    130      3682         80      3720实例样2    190      1420         125     1210实例样3    125      2980         75      2230实例样4    101      2970         55      2290实例样5    25       1060         50      1420
本发明人相信，尽管其循环试验数据是较好的，但卷曲双组分纤维(实例4及5)的数据如采用不同的粘合方法，本可有所改善。所采用的方法，即穿透空气粘合法，由于带来许多粘合斑点，因而很可能导致可拉伸性的损失，故不是优选的。其他的实例样及对比样未使用穿透空气粘合。
该数据表明，本发明的布料在比不可卷曲聚丙烯纺粘布低的载荷下能提供优异的横向可拉伸性。这是极为有用的性能，它简化了用这种布料制造诸如尿布及手术罩衣等许多产品的制造过程。

Claims (20)

1.一种具备横向可拉伸性的层合物，包括：
可卷曲纺粘聚合物纤网的第一层；
弹性体聚合物的第二层；
可卷曲纺粘聚合物纤网的第三层；
其中所述各层借助除水力缠结法以外的方法粘合在一起，形成层合物，其中所述各层在其整个生产及粘合为所述层合物期间均维持在未拉伸的状态。
2.权利要求1的层合物，其中每个纺粘层可独立地选自可卷曲双组分纤维、可卷曲双成分纤维及不同种类纤维的可卷曲混合物。
3.权利要求1的层合物，其中所述各层在未拉伸状态下用选自热粘合、超声粘合、印刷粘合及粘合剂粘合的方法互相粘合在一起。
4.权利要求1的层合物，其中所述弹性体聚合物层选自弹性体熔喷纤网、弹性体纺粘纤网、弹性体薄膜及弹性体泡沫体。
5.权利要求4的层合物，其中弹性体聚合物层由一个或多个较薄的层构成。
6.权利要求4的层合物，其中所述弹性体层在被结合到层合物当中去之前经过缝编加工。
7.权利要求4的层合物，其中所述弹性体层包括：至少约10％(重量)A-B-A’嵌段共聚物，其中“A”和“A’”每一个是含有苯乙烯部分的热塑性端嵌段，且其中“B”是弹性体聚(乙烯-丁烯)中嵌段，以及大于0％(重量)直至约90％(重量)这样的聚烯烃，当它与该A-B-A’嵌段共聚物掺混并受到高温与高压条件的有效组合的作用时，适合以与A-B-A’嵌段共聚物的共混形式进行挤出加工。
8.权利要求4的层合物，其中弹性体聚合物层的聚合物选自苯乙烯嵌段共聚物、聚氨酯、聚酰胺、其聚多酯、共聚多醚酯以及乙烯-乙酸乙烯酯。
9.权利要求5的层合物，其中所述聚合物是A-B-A’嵌段共聚物与聚丙烯的混合物。
10.权利要求5的层合物，其中所述弹性体聚合物层包括嵌段共聚物弹性体纤维。
11.权利要求10的层合物，其中所述聚醚酯的通式为：其中“G”选自聚(氧乙烯)-α，ω-二醇、聚(氧丙烯)-α，ω-二醇、聚(氧四亚甲基)-α，ω-二醇，“a”和“b”选自包括2、4及6的正整数，“x”、“y”及“z”选自包括1～20的正整数。
12.权利要求1的层合物，其中至少一层用选自拒水剂、软化剂、阻燃剂、拒油剂及其混合物的化学品处理过。
13.权利要求1的层合物，其中所述可卷曲纺粘纤维纤网由皮/芯排列的双组分纤维构成，其中聚丙烯是芯层，聚乙烯是皮层。
14.权利要求1的层合物，其中所述层的单位重量为约0.25～3osy.。
15.权利要求1的层合物，存在于选自医用制品、个人护理用品及户外用布料的产品之中。
16.权利要求15的层合物，其中所述产品是个人护理用品，而所述个人护理用品是尿布。
17.权利要求15的层合物，其中所述产品是个人护理用品，而所述个人护理用品是妇女卫生制品。
18.权利要求15的层合物，其中所述产品是医用制品，而所述医用制品是手术罩衣。
19.权利要求15的层合物，其中所述产品是医用制品，而所述医用制品是面罩。
20.权利要求15的层合物，其中所述产品是医用制品，而所述医用制品是抹布。
CN96192379A 1995-01-11 1996-01-11 可横向拉伸的非织造层合物 Expired - Fee Related CN1098770C (zh)

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CN100378261C (zh) * 2001-12-21 2008-04-02 因维斯塔技术有限公司 可拉伸多组分非织造布及其制备方法
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CN107780047B (zh) * 2017-08-23 2020-06-12 山东恒鹏卫生用品有限公司 弹性无纺布的制备方法、弹性无纺布及其应用
CN110528171A (zh) * 2019-09-12 2019-12-03 苏州市兴丰强纺织科技有限公司 防水透气tpu薄膜加工工艺

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KR100413571B1 (ko) 2004-04-21
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MX9705020A (es) 1997-10-31
AR000701A1 (es) 1997-08-06
KR19980701328A (ko) 1998-05-15
PL321276A1 (en) 1997-11-24
DE69620576D1 (de) 2002-05-16
DE69620576T2 (de) 2002-08-08
CN1098770C (zh) 2003-01-15
US5540976A (en) 1996-07-30
BR9606751A (pt) 1998-01-06
TW324034B (en) 1998-01-01
ZA96167B (en) 1996-08-19
EP0802857A1 (en) 1997-10-29
AU705709B2 (en) 1999-05-27
CA2209472A1 (en) 1996-07-18
EP0802857B1 (en) 2002-04-10
AU4655796A (en) 1996-07-31

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