CN1958911A - Stretchable nonwovens - Google Patents

Abstract

A nonwoven material which can be elongated and which will partially recover. The material comprises a web of fibers comprising polymeric chains which fibers are entangled with one another. The fibers are stretched in a first direction at a temperature wherein the fibers are aligned in a first direction and the polymeric chains within the fiber are also orientated in such first direction. The fibers are then cooled and demonstrate an ability to elongate and partially recover in a second direction that is different from the first direction.

Description

Stretchable bondedfibre fabric

Technical field

The present invention relates in general to a kind of bondedfibre fabric, more specifically relates to a kind of method of making bondedfibre fabric, bondedfibre fabric can be had stretch and recovery characteristic.Be used for producing the method for the stretchable bondedfibre fabric of this kind, particularly useful when 0.01 to 1.0dtex continuous multicomponent filaments is also bonded for fiber number.

Background technology

Bondedfibre fabric is widely used in various application, medical products for example, personal hygiene product, Work Clothes, motion and easy suit, shoes inner cloth, bed linen and carpet backing and installation system.Fabric of this type and woven fabric or knitted fabric difference are directly to be stacked mutually in irregular mode by each fiber to form fiber mat, have saved the rapid yarn preparation of multistep in the conventional fabrics manufacture process and weave or knitting production process.The fiber of fabric or the entanglement of long filament provide quite high-caliber globality for fabric.

The manufacturing of bondedfibre fabric is the technology of a high development.Usually, nonwoven web and manufacturing thereof comprise and form long filament or fiber and they are deposited on the conveyer belt by this way, that is, make long filament or fiber stack into the pad of required grammes per square metre.The bonding of this pad can reach by entanglement or alternate manner, for example uses adhesive, heating and/or pressurization, or only pressurization sometimes.

The formation that can in all sorts of ways of bondedfibre fabric or fiber web, meltblown for example, spun-bond process, bonded carded fibrous web method, and nearest melt spinning method (melt spinning process).

In meltblown, extruder of thermoplastic resin feeding, the temperature that melts and be heated to suitable formation fiber there.Extruder is with special melt injection die of resin feeding of fusing.Normally linearly aligned several minor diameter capillaries of die head.Resin is expressed into high velocity air from die orifice with the line that melts, normally in the air.Air attenuates polymer and enters in the fine fibre air-blast device, and these fine fibres are collected in and are positioned on the preceding screen cloth of air-blast device.When fiber dropped on the screen cloth, their tangle to form obvolvents fibre web together, made a complete fiber to be removed usually to come out from other fiber or followed the trail of a fiber from the beginning to the end.

Spun-bond process also is used to produce bondedfibre fabric.Had various spunbond technologies, but all comprised basic step: extrude continuous filament yarn, quenched filaments, by the high-velocity fluid elongate filaments or long filament is attenuated, with on filament collection to a surface to form fiber web.Spun-bonded fibre net can have the sense of touch more comfortable than meltblown fiber web, because spun-bonded fibre net is more near the DENIER number of textile filament and therefore drapability and feel are also more approaching.

During from homopolymers production bondedfibre fabric, single component filaments or fiber are known, and the use of multicomponent " easily division " fiber or long filament has more advantage to some occasion.Such easy devillicate or long filament comprise a plurality of subfractions, typically comprise two or more different polymeric materials, and subfraction is arranged with side by side relationship along long filament or fibre length.Various concrete cross-sectional configuration are known, many sectors pie for example, fabric of island-in-sea type, flower type, parallel type, and various other special tectonic.

Easily the subfraction of devillicate or long filament can technical point enough various chemistry or machinery from.For example, the each several part of multicomponent fibre or long filament can be handled by heating, acupuncture or water thorn and separate.For the multicomponent fibre or the long filament of some types, suitable chemical treatment can be dissolved some parts wherein, thereby the subfraction of defibre or long filament at least in part.

Though the feel that woven fabric and knitted fabric provide, drapability and draftability are excellent than most bondedfibre fabrics, these advantages are owing to offseted by certain degree ground in order to the expensive and complexity of the weaving processing method of producing woven fabric and knitted fabric.There had been many trials to improve the stretching and the recoverability of bondedfibre fabric, to utilize the low advantage of its production cost.These are included in the fiber web and use more expensive elastomeric fibre, and additional processing step lamination or coat other material on fiber web for example, and some fiber of mechanical flexing.

Transfer the U.S. Patent No. 4426420 of E.I.Du Pont Company, the name be called " spunlaced nonwoven fabrics that comprises elastomer ", relate to Hydroentangled spunlaced nonwoven fabrics, its through Overheating Treatment to give improved tensile property.Two types of fibers comprises cotton-shaped hard fibre (polyester, polyamide etc.) and elastomeric fibre (polybutylene terephthalate (PBT)-copolymerization of preferred 10-25%-poly-(tetramethylene oxygen) terephthalate).

Transfer the U.S. Patent No. 4820572 of Kimberly-Clark Corporation (Kimberly-Clark corp), name is called " compound elastomeric polyethers block acid amides nonwoven web ", relate to a kind of elastomer nonwoven web, it forms by melting and spraying the adhesive matrix that forms preferably the microfiber of being made up of polyester block amide copolymer.

Transfer the U.S. Patent No. 5151320 of Dexter company, name is called " water stings spunbond composite fabric and technology thereof ", relate to a kind of water and sting spunbond composite fabric, by the spun-bonded fibre base net material that will form by continuous artificial filament in width 5% of its original size at least that stretches, the described material width direction percentage elongation under the surrounding environment but this width stretches when stretching.But put on the fiber base that is stretched on the net to form sandwich construction by the cover layer that the water loosen collagen fibre is formed, this structure engages each layer through the water thorn.Put on the fiber base that is stretched on the net to form sandwich construction, this structure engages each layer through the water thorn.

Transfer the U.S. Patent No. 5227224 of Chisso company, name is called " but stretched non-woven fabric and manufacture method thereof ", the fiber web that relates to a kind of homogeneous, comprising the heat of 70-100 weight % polypropylene matrix can bonding composite fibre and other organic fiber (polyamide of 0-30%, polyester), the percent thermal shrinkage of 120 ℃ of fiber webs is 50% or higher.The uniform mat of fiber and since further the result that gives of heat treatment (non-tension state) fully tangle and " contraction ", the fabric that obtains extends 80% or have 30% elastic recovery when higher at the longitude and latitude both direction.

Transfer the U.S. Patent No. 5540976 of Kimberly-Clark Corporation, name is called " having the nonwoven layered article that width is upheld performance ", relates to a kind of layered article that comprises three layers.Two skins of spunbond nonwoven web are made by the fiber that maybe can curl that is curled, and internal layer is an elastomer polymer layer.These layers preferably are bonded together by the water thorn.

Transfer the U.S. Patent No. 5549964 of Asahi Kasei Kogyo Kabushiki Kaisha, name is called " stretchable bondedfibre fabric and manufacture method thereof ", but relates to the stretched non-woven fabric that a kind of block copolymer that uses hydrogenation is made.This copolymer comprises vinyl aromatic compounds, conjugated diene compound and polyolefin, and melted and sprayed.

Transfer the U.S. Patent No. 5534335 of Kimberly-Clark Corporation, name is called " by the bondedfibre fabric of multicomponent fibre generation ", relates to a kind of bondedfibre fabric, and it comprises at least two kinds of thermoplastic polymers and a kind of compatibility agent.A kind of thermoplastic polymer provides (for example polypropylene) with main continuous phase, and another kind provides (for example polyamide or polyester) with discontinuous phase.The melt temperature of discontinuous phase polymer preferably is lower than at least 30 ℃ of the melt temperatures of continuous phase polymer.This fiber can be melted and sprayed or be spunbond.

Transfer the U.S. Patent No. 5814390 of Kimberly-Clark Worldwide Inc (Kimberly-Clark Worldwide), name is called " have and stretch and the wrinkle bondedfibre fabric of recovery ", relates to a kind of by using cross one another roller to wrinkle the bondedfibre fabric that predecessor (precursor) and HEAT SETTING wrinkle are made.This fabric preferably includes the predecessor fiber web that comprise thermoplastic fibre of a stiff olefin polymer for the basis.

U.S. Patent No. 5910224, name is called " method that forms a kind of elasticity constriction-jointing material ", also be to transfer Kimberly-Clark Worldwide Inc, but the method that relates to a kind of manufacturing elastomeric compositions, by but a kind of elastomer predecessor is applied on the neckable material, but this shrinkable material of constriction-stretching and be in this elastomer of heating predecessor under the constriction state in neckable material.This predecessor can comprise latex or thermo-setting elastomer.But this neckable material can preferably include microfiber, for example polyester, polyamide and polyolefin by spunbond or melt and spray formation.

Transfer the U.S. Patent No. 5997989 of BBA nonwoven fabric Simpson Wei Li company (BBA Nonwovens Simpsonville.Inc.), name is called " lofty nonwoven fibre web and method for making thereof ", relate to a kind of spun-bonded type elastic non-woven fabric (and production technology), comprise the fiber web that a kind of thermoplastic fibre that is made by thermoplastic elastomer (TPE) is bonding and form.Slit stretch spunbond technology make fiber web in fabric extension 30% and the RMS that has at least 75% (MD and CD) after stretching once can recover elongation.

Transfer the U.S. Patent No. 6689703 of You Nijia company, name is called " but elasticity stretched non-woven fabric and make its used fabric ", but relate to a kind of elasticity stretched non-woven fabric, it comprises the thermoplastic elastomer (TPE) long filament, this long filament by thermal welding and/or mechanical interlocking to the bondedfibre fabric that has flexing and non-flex region together with formation.The flexing rate is 50 times/cm or higher.Flexing by blow facing to extrudate hot-air, blow temperature facing to long filament subsequently or cold wind (at least than low 20 ℃ of the melting temperature of long filament) form, make long filament be stretched and reduced and by uneven cooling, become to the small part flexing.But long filament then by thermal welding or mechanical interlocking to obtain the stretched non-woven fabric.

Transfer the U.S. Patent No. 6692541 of Polymer Group Co., Ltd, name is called " method that manufacturing comprises the bondedfibre fabric of easy devillicate ", relate to a kind of method, wherein fabric is formed by easy division long filament or staple fiber with several subfractions, and this artificial staple fibre is separated into its subfraction at least in part by the water thorn.Use has the three-dimensional image transfer device of aperture profiled surface and comes during the water thorn picture on surface or image print on predecessor's fiber web clearly.This fiber web preferably before impression case or image by combing and overlapping.

Transfer the U.S. Patent application 2003/0064650 of E.I.Du Pont Company, name is called " Stretchable multiple-component spun-bonded fibre net and production technology thereof ", and relating to provides a kind of height three-dimensional spiral flexing, utilizes draw roll so that high orientation to be provided.Long filament keeps under amorphous state by mechanical stretching at polymers compositions.The method comprises the continuous filament yarn of melt-spun, and this long filament comprises at least the first and second different melt-spinnable polymers, and wherein these two kinds of polymer are arranged on the filament cross in the fixing basically diverse location, is eccentric relation and extends along the filament length direction.Long filament is by quenching, and with its heat treatment (from amorphous state to the hypocrystalline state), stretching also discharges to form the helical form flexing through a series of rollers.

Summary of the invention

Therefore need a kind of bondedfibre fabric that can stretch and reply, it is improved on prior art, and it can easily be made according to the present invention.

Therefore one object of the present invention is to provide a kind of bondedfibre fabric, and it can be by spunbonded materials production, and can be extended, and for example percentage elongation is about 5-70%.

The present invention's purpose more specifically is to provide the thorn of water arbitrarily thermoplastic filament bondedfibre fabric (spunbond or its composite), and it can be stretched and can improve and stretch and recovery characteristic.

Another object of the present invention is to provide a kind of spunbond bondedfibre fabric, comprise filament web, wherein be exposed to that long filament that outer filament web comprises can be tangled each other and/or interlocking, and under selected temperature, in first preferential direction, stretch then, it provides the tensile property that is different from first direction in second direction.

In one embodiment, the invention discloses a kind of non-woven material, it can stretch in preferential direction, comprise one by the fibrous fiber web that comprises polymer chain, fiber is entangled to each other, it is characterized in that fiber is stretched in first direction under a temperature, wherein fiber in described first direction, arrange and described fiber in described polymer chain directed in described first direction.Fiber is cooled under the described temperature then, wherein fibrous thus fiber web demonstrates the ability that can stretch in being different from the second direction of described first direction, and wherein said fiber also can partly be replied in the described stretching from described second direction.

In second alternative embodiment, the present invention points to the technology that a kind of manufacturing has the non-woven material of tensile property, comprises from polymer filaments forming fibroreticulate step, and wherein long filament is entangled to each other, and described polymer filaments has Tm.Then under a temperature at first direction this fiber web that stretches, wherein said temperature is lower than Tm, so that described fiber arranges at described first direction, and makes the described polymeric chain of described fiber directed in described first direction.Be lower than the described fiber of cooling under the described temperature then, wherein said non-woven material can elongate in being different from the second direction of described first direction, and the described elongation from described second direction is partly replied.Selectively, this technology can comprise such additional step, and wherein said non-woven material can further extend in the second direction of crossing the described width of described fiber web, and can reply from described elongated portion ground.

Description of drawings

Above-mentioned and other purpose, the feature and advantage of the present invention will become clearer according to explanatory note and accompanying drawing, wherein

Fig. 1 is the illustration of the one-step technology of manufacturing Stretch material of the present invention.

Fig. 2 is the illustration of the two-step process of manufacturing Stretch material of the present invention.

Fig. 3 is the orientation of fiber before stretching and the chart of orientation angle.

Fig. 4 is the orientation of back fiber and the chart of orientation angle of stretching.

The specific embodiment

In first preferred embodiment, the present invention discloses a kind of non-woven material that can be elongated at preferential direction, comprises one by the fibrous fiber web that comprises polymer chain, and this fiber is entangled to each other.

Preferably, comprise a fine filament bondedfibre fabric by described fiber web, it has 30 to the weight of 150g/m2 with greater than the tearing strength of 40N/5cm, this bondedfibre fabric is made up of continuous multicomponent filaments, this filament linear-density is 1.5 to 5dtex, through melt-spun, stretching and direct lay and form bondedfibre fabric, wherein continuous multicomponent filaments at least 80% division is 0.01 to 1.0dtex a continuous fine filament and bonding to form fiber number.

More preferably, continuous multicomponent filaments can comprise the continuous bicomponent filament that comprises two kinds of polymer.These two kinds of polymer can comprise first the polymer for example polyester and second polymer, and second polymer can comprise the polymer that is selected from polyamide, polyolefin and mixture thereof.

In a particularly preferred embodiment, bondedfibre fabric can be Evolon by Freudenberg Nonwovens production and the trade mark of selling^TMThe material manufacturing, it is a kind of textiles of being made by fine filament.It is said it from polymer chips to the finished product fabric by a continuous processing production, spinning becomes the fiber web form preferably to interosculate with the long filament lay during this continuous processing.Water stings the bonding Evolon that is made up of continuous fine filament that formed then^TMMaterial.

According to Fig. 1 herein, fibrous fiber web is unfolded at 10 places and is fed into relative roller, and preheated and stretch at 12 and 14 places, provides length direction to stretch like this and the contraction of unconfined width.Preferably, heating is such, that is, the fibrous fiber web that is formed by polymeric chain defines a fusing point Tm, and pre-warmed temperature mentioned above is lower than Tm, more preferably for being lower than Tm0.1 to 20.0 ℃.In addition, consider that these polymer have glass transition temperature or Tg, pre-warmed temperature can be set at and be higher than Tg and be lower than Tm.Preferably as graphic, fiber is arranged in the length direction direction, and polymer chain is also directed in this direction.

In addition, according to Fig. 3, the orientation of fiber before stretching (% frequency) is marked and drawed with orientation angle, thereby a fiber alignment distribution view (FOD) is provided.And in Fig. 4, the orientation of fiber after stretching (% frequency) is marked and drawed with orientation angle.Comparison diagram 3 and 4, clearly, the back that stretches that is oriented in of fiber changes to the direction that fabric is stretched.Before stretching, this structure relatively presents isotropism, and can see more anisotropic feature after stretching.

Turn back to Fig. 1 now, can see that selectively applying width at 16 places stretches, width can be set to required size like this, by using for example stenter.Those skilled in the art will know that stenter can be with fabric tension to its original width.In any case, the result of method for optimizing shown in Figure 1 is by also reeling in the quenching of 18 places, find to obtain a kind of fiber web, it shows the ability that stretches in the second direction different with first direction (length direction), and partly replys during wherein from then on fiber can extend.According to this production method, have been found that at the percentage elongation of second direction and can partly reply simultaneously up to about 70%.

Note Fig. 2 now, illustrate the two-step process that is used for production Stretch material of the present invention herein.Can see at 20 place's fiber webs being unfolded and feeding, then at 22 and 24 places by using the preheated and length direction of roller to be stretched, and temperature required by using described roller to be heated to, as described in this article.By this way, the fabric that is stretched at 26 places is by quenching and reeled, and can be used with this form.Selectively, as shown in the figure, also can launched and be fed into 28 places once more, make that applying width when passing between the roller stretches to reach required width at 30 places by the quenching and the output of back of reeling at 26 places, then at 32 places by quenching and coiling.

Can find that according to the present invention but people can prepare a kind of stretched non-woven material uniquely, it can use the occasion of utilizing the advantage of non-woven material of the present invention multiple, and so, this bondedfibre fabric has stretching and replys feature simultaneously.

Although describe the present invention, should be appreciated that theme of the present invention is not limited to these certain embodiments according to specific preferred embodiment.Theme of the present invention comprises all equivalents that fall in following claims scope.

Claims (15)

1. the non-woven material that can be stretched at preferential direction comprises

(a) by the fibrous fiber web that comprises polymer chain, described fiber tangles mutually, it is characterized in that:

(i) described fiber is stretched at first direction under a temperature, and wherein said fiber is arranged at described first direction, and the described polymer chain in the described fiber is directed at described first direction; And

(ii) described fiber is cooled to below described temperature;

Wherein said fiber web demonstrates the ability that stretches in the second direction different with described first direction, and wherein said fiber also can part be replied from the stretching the described second direction.

2. bondedfibre fabric according to claim 1 is characterized in that described polymer chain has fusing point Tm, and described temperature is lower than Tm.

3. bondedfibre fabric according to claim 2 is characterized in that being lower than the temperature of Tm for hanging down about 0.1 to 20 ℃ than Tm.

4. bondedfibre fabric according to claim 1 is characterized in that described polymer chain has Tg and Tm, and described temperature is Tg or is higher than Tg and is lower than Tm.

5. bondedfibre fabric according to claim 1 is characterized in that the described tensile fiber rate in described second direction also can partly be replied up to about 70%.

6. bondedfibre fabric according to claim 1 is characterized in that described second direction is basically perpendicular to described first direction.

7. bondedfibre fabric according to claim 1 is characterized in that described fiber web comprises a kind of fine filament bondedfibre fabric, and it has 30 to 150g/m²Weight and greater than the tearing strength of 40N/5cm, this bondedfibre fabric is made by continuous multicomponent filaments, this filament linear-density is 1.5 to 5dtex, form bondedfibre fabric through melt-spun, stretching and direct lay, wherein said continuous multicomponent filaments is divided at least 80%, is 0.01 to 1.0dtex continuous fine filament and bonding to form fiber number.

8. bondedfibre fabric according to claim 7 is characterized in that described continuous multicomponent filaments is made of the continuous bicomponent filament that comprises two kinds of polymer.

9. bondedfibre fabric according to claim 8 is characterized in that one of described polymer comprises polyester polymers, and another comprises a kind of polymer that is selected from by in polyamide, polyolefin and the mixture thereof described polymer.

10. but method for preparing the non-woven material with stretch characteristic comprises following steps:

(a) form a fiber web of being made up of polymer filaments, these polymeric filaments are entangled to each other, and wherein said polymeric filaments has Tm;

(b) the described fiber web of stretching under a temperature, wherein said temperature is lower than Tm so that described fiber is arranged at described first direction, and makes the described polymer chain in the described fiber directed in described first direction;

(c) described fiber is cooled to below the described temperature, wherein said non-woven material can stretch in being different from the second direction of described first direction, and partly replys in the described elongation from described second direction.

11. method according to claim 10 is characterized in that described temperature is for hanging down about 0.1 to 20 ℃ than Tm.

12. method according to claim 10 is characterized in that the stretching of described fiber in described second direction is up to about 70% and can partly reply.

13. but a method for preparing the non-woven material with stretch characteristic comprises following steps:

(a) form a fiber web of being made up of polymer filaments, these polymer filaments are entangled to each other, and wherein said polymer filaments has a Tm, and described fiber web has length and width;

(b) the described fiber web that under a temperature that is lower than Tm, in the first direction consistent, stretches with described fibroreticulate length direction, so that described fiber is arranged at described first direction, and make the described polymer chain in the described fiber directed in described first direction, and wherein said fibroreticulate described reduced width;

(c) described fiber is cooled to below the described temperature, wherein said non-woven material can with second direction across described width in stretch, and can from described stretching, partly reply.

14. method according to claim 13, it is characterized in that comprising an additional step, wherein said fiber web is further being stretched across described fibroreticulate described width, and wherein said non-woven material can stretch in across the second direction of the described width of described fiber web and can be from described stretching partly reply.

15. method according to claim 13 is characterized in that fiber web being placed on the stenter comprising across the described stretching step in the direction of described fibroreticulate described width.

Images