CN101932763B - 包含稳定剂或粘合剂的高膨松非织造物 - Google Patents

包含稳定剂或粘合剂的高膨松非织造物 Download PDF

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CN101932763B
CN101932763B CN2008801262288A CN200880126228A CN101932763B CN 101932763 B CN101932763 B CN 101932763B CN 2008801262288 A CN2008801262288 A CN 2008801262288A CN 200880126228 A CN200880126228 A CN 200880126228A CN 101932763 B CN101932763 B CN 101932763B
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goods
fiber
polyurethane
dispersion
flossing
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CN101932763A (zh
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D·K·法默
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Invista Technologies SARL Switzerland
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Invista Technologies SARL Switzerland
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/641—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions characterised by the chemical composition of the bonding agent
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41C—CORSETS; BRASSIERES
    • A41C3/00—Brassieres
    • A41C3/12—Component parts
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41C—CORSETS; BRASSIERES
    • A41C5/00—Machines, appliances, or methods for manufacturing corsets or brassieres
    • A41C5/005—Machines, appliances, or methods for manufacturing corsets or brassieres by moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/005—Making three-dimensional articles by consolidation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/02—Cotton wool; Wadding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
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    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0002—Condition, form or state of moulded material or of the material to be shaped monomers or prepolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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    • B29L2031/48—Wearing apparel
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    • B29L2031/4885—Brassieres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2250/20—All layers being fibrous or filamentary
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2601/00—Upholstery
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2369—Coating or impregnation improves elasticity, bendability, resiliency, flexibility, or shape retention of the fabric
    • Y10T442/2377—Improves elasticity

Abstract

本发明涉及一种包含粘合剂或稳定剂的高膨松非织造物，所述粘合剂或稳定剂包含对非织造结构提供柔韧性和压缩恢复的聚氨酯-脲组合物。本发明包含聚氨酯-脲分散体作为稳定剂或粘合剂，其用于产生高膨松非织造结构的短长度纤维。本发明用作例如半球状乳罩的应用中的诸如聚氨酯泡沫之类的改良替换物。

Description

包含稳定剂或粘合剂的高膨松非织造物
发明背景
发明领域
本发明涉及一种包含粘合剂或稳定剂的高膨松非织造物，所述粘合剂或稳定剂包含对非织造结构提供柔韧性和压缩恢复的聚氨酯-脲组合物。本发明包含聚氨酯-脲分散体作为稳定剂或粘合剂，其用于产生高膨松非织造结构的短长度纤维。本发明用作例如半球状乳罩应用中诸如聚氨酯泡沫之类的改良替换物。
相关技术概述
大多数乳罩在罩杯中具有某种形式的衬垫。衬垫用于形状和尺寸增进和适度的目的。填絮纤维在过去用于形成乳罩衬垫，但由于纤维在罩杯内移动，特别是在洗涤期间，罩杯可能变得不合形或凹凸不平。
由于衬垫乳罩越来越受欢迎，乳罩制造商开始用聚氨酯(PU)泡沫作为填絮纤维的替代物。PU泡沫已大量替代填絮纤维。虽然PU泡沫软，轻，并且可通过模压成形，但PU泡沫具有的主要缺陷是由于氧化和/或光化学反应变黄。为了掩饰变黄，制造商以相当大代价(如使用多层织物)以例如隐藏PU泡沫的方式设计乳罩。另外，PU泡沫缺乏或具有差的透气性、渗透性和蒸汽透过特性。
授予Magidson等人的美国专利3,947,207号认识到与制备重复洗涤后保持形状的衬垫半球状乳罩相关的挑战。填絮纤维衬垫包含树脂粘合剂，这种树脂粘合剂在使衬垫形成所需形状的拉伸之前几乎完全固化。为了对此补偿，施用另外的聚氨酯树脂。其缺点是聚氨酯给予乳罩衬垫硬挺度，使穿戴者感觉不适。这种替代方案在商业上不可接受，这是转向PU泡沫的一个原因。
授予Huber等人的美国专利4,091,819号也公开了包含填絮纤维衬垫的衬垫半球状乳罩。将诸如丙烯酸类、聚酯、乙酸酯或其组合的树脂粘合剂加入衬垫以在洗涤期间增加外形保持性。认识到与衬垫硬挺度相关的问题并通过引入树脂后使衬垫穿孔来进行抵偿。虽然这增加柔韧性，但这是高成本步骤，并且对于舒适问题没有提供足够的解决方案。
授予Pittman等人的美国专利6,670,035号公开粘合剂纤维与包含低熔点粘合剂纤维的非织造纤维网。然而，这些组合物不适合模压应用，因为它们形成硬模压制品。
因此，需要一种替代性的高膨松非织造材料，这种材料不仅在洗涤后保持其外形，而且提供对于穿戴者的舒适度必不可少的柔韧性和压缩恢复益处。
发明概述
本发明的一些实施方式为一种制品，所述制品包含高膨松非织造组合物和克服稳定剂或粘合剂组合物缺陷的稳定剂。高膨松非织造物可包括填絮纤维，并与聚氨酯-脲组合物(如聚氨酯-脲分散体)组合。此组合提供了随时间经过的和在数次包括机洗的洗涤后的柔韧性、拉伸-恢复、压缩-恢复、透气性和颜色稳定性。
一些实施方式中利用聚氨酯-脲组合物与非织造物的另外益处是聚氨酯-脲给予拉伸恢复性质。使用诸如丙烯酸类和聚氨酯的常规粘合剂组合物时，不存在拉伸恢复。
本发明还包括一种利用稳定化的填絮纤维制造的半球状乳罩。稳定剂通过诸如聚氨酯-脲分散体的聚氨酯组合物提供。通过使用聚氨酯-脲含水分散体作为粘合剂用于高膨松非织造结构中的填絮纤维，可解决泡沫降解和填絮纤维移动的问题。用稳定化填絮纤维制造的半球状乳罩可比PU泡沫罩杯更透气，重量更轻，更易模压，且颜色更稳定。
本发明的另一个实施方式为一种制备制品的方法。这包括提供含填絮纤维的高膨松非织造物。该非织造物与聚氨酯-脲组合物接触。聚氨酯-脲组合物可以为含水分散体的形式。
发明详述
本文所用术语“含水聚氨酯分散体”是包含至少聚氨酯或聚氨酯-脲聚合物或预聚物(如本文所述的聚氨酯预聚物)的组合物，任选包含溶剂，所述组合物已分散于含水介质中(如水，包括去离子水)。
除非另外指明，本文所用术语“溶剂”是指非水介质，其中非水介质包括有机溶剂，包括挥发性有机溶剂(如丙酮)和略小挥发性有机溶剂(如N-甲基吡咯烷酮(NMP))。
本文所用术语“无溶剂”或“无溶剂系统”是指组合物或分散体，其中该组合物或分散组分的本体(bulk)未溶于或分散于溶剂中。
本文所用术语“模压的”制品是指一种结果，制品或成形制品的形状因该结果而改变，例如通过在模型中使制品干燥或响应加热和/或加压。
本文所用术语“填絮纤维”旨在包括无规地填充在一起以得到适合多种用途的密度的相对较短纤维。
用于一些实施方案的填絮纤维组合物可包括任意多种天然纤维和人造纤维。高膨松非织造织物的具体实例公开于授予Newkirk的美国专利4,883,707号，所述专利全文通过引用结合到本文中。天然纤维可以为动物、植物或矿物来源。人造纤维可以为人工纤维(如再生纤维或溶纺纤维)或合成纤维(如无机纤维和石化纤维)。具体实例包括棉、羊毛、丙烯酸类(acrylic)、聚酰胺(尼龙)、聚酯、斯潘德克斯纤维、再生纤维素、橡胶(天然的或合成的)、竹、丝绸、大豆及其组合，诸如如聚酯/棉混合物。聚酯填絮纤维为枕和乳罩衬垫使用的一般材料。
在填絮纤维组合物中也可包含双组分纤维。双组分纤维由于其卷曲性质而尤其适用于制备高膨松非织造物。可用的双组分纤维的实例为包括选自以下聚合物组合的那些纤维：聚乙烯/聚丙烯、聚乙烯/聚酯、聚丙烯/聚酯、共聚酯/聚酯及其组合。
聚氨酯-脲组合物可以为溶液、含水分散体或无溶剂含水分散体形式。所述组合物可以本领域的技术人员已知的任何方式施用，包括喷、浸轧、浸渍、浸没、涂覆(如利用单面给液法或凹版印刷法)及其组合。
在已提供填絮纤维组合物并将其与聚氨酯-脲组合物接触后，可另外处理所得制品。该制品可干燥或在室温下使其干燥。减少干燥时间的方法包括热的应用(包括强制热风、加热如在烘箱中)、微波的应用以及本领域的其它应用(amng others known in the art)。
也可模压制品。可在聚氨酯-脲组合物施用到高膨松非织造物之前或之后进行此模压。例如，可将高膨松非织造物放入模型中，随后施用聚氨酯-脲组合物。然后可干燥或加热该制品。或者，可制备高膨松非织造物，然后，在干燥之前或之后，可将其放入模型中，并任选加热。也可在模压过程中加压。
在一些实施方案中，高膨松非织造物可放在两个织物层之间，使其加热干燥，任选利用加压。织物-非织造物-织物提供多层制品，其也可被模压。以此方式的模压制品用于多种最终用途，包括塑身衣，如半球状乳罩，但也用于制备室内装饰和其他家庭和汽车物品。
如上提到，一些实施方案中包含高膨松非织造物与聚氨酯-脲组合物的组合的制品用于多种最终用途。这尤其包括织物、衣服、室内装饰、枕和窗处理物。
用于一些实施方案的含水聚氨酯-脲分散体可由具体氨基甲酸酯预聚物提供。预聚物包括多元醇和异氰酸酯的反应产物，然后，此反应产物经增链以形成嵌段聚氨酯-脲组合物。具体实例在美国专利7,240,371号和2007年7月20日提交的美国专利申请11/780,819号中提出，这些专利全文通过引用结合到本文中。或者可使用聚氨酯-脲溶液。这些溶液为本领域的技术人员所知，其包括用以制备斯潘德克斯纤维的那些溶液。
在一些实施方案中，用于制备聚氨酯-脲溶液或分散体的嵌段聚氨酯-脲包含a)数均分子量500至5000(如约600至4000和600至3500)的多元醇或多元醇共聚物或多元醇混合物，包括但不限于聚醚二醇、聚酯二醇、聚碳酸酯二醇、聚丁二烯二醇或其氢化衍生物和羟基封端的聚二甲基硅氧烷；b)多异氰酸酯，包括二异氰酸酯，如脂族二异氰酸酯、芳族二异氰酸酯和脂环族二异氰酸酯；和对于分散体，包含c)二醇化合物，其包含(i)能够与多异氰酸酯反应的羟基，和(ii)至少一个能够在中和时生成盐的羧酸基团，其中至少一个羧酸基团不能与多异氰酸酯反应；d)中和剂；e)增链剂，如水、二醇或二胺增链剂(包括脂族二胺增链剂或脂族二胺增链剂与一种或多种选自具有2至13个碳原子的脂族二胺和脂环族二胺的二胺的组合)或氨基封端的聚合物(polyer)；和f)任选的伯或仲单醇或单胺(monoalcohol or monoamine，primary or secondary)作为封端剂或链终止剂；和任选的具有至少三个伯或仲胺基的有机化合物或聚合物。
一些实施方案的氨基甲酸酯预聚物，也称为封端的二醇，一般可概念化为在预聚物分散于水并且增链前的多元醇、多异氰酸酯和能够在中和时生成盐的化合物的反应产物。这些预聚物可通常在一个或多个步骤中制备，可利用或不利用能够用于降低预聚物组合物粘度的溶剂。
根据预聚物是否溶于将保留在分散体中的较小挥发性溶剂(如NMP)，溶于可之后除去的挥发性溶剂，如丙酮或甲基·乙基酮(MEK)，或不使用任何溶剂而分散于水中，实际上可将分散方法分别分类为溶剂法、丙酮法或预聚物混合法。预聚物混合法具有环境和经济上的优点，并且可用于制备含水分散体而基本无需另外的溶剂。
在预聚物混合法中，重要的是利用或不利用溶剂稀释，预聚物的粘度低得足以在水中输送和分散。可使用由此预聚物得到聚氨酯-脲分散体，其满足此粘度要求并且不在预聚物或分散体中具有任何有机溶剂。
根据聚氨酯-脲分散体的所需作用，分散体中聚合物的重均分子量可以为约40,000至约250,000，包括约40,000至约150,000，约70,000至约150,000，约100,000至约150,000和约120,000至约140,000。
以下更详细描述一些实施方案的聚氨酯-脲组合物的组分：
多元醇
适合用作制备本发明的氨基甲酸酯预聚物的原料的多元醇组分为数均分子量约600至约3,500或约4,000的聚醚二醇、聚碳酸酯二醇和聚酯二醇。
可使用的聚醚二醇的实例包括具有两个或更多个羟基的二醇：由环氧乙烷、环氧丙烷、氧杂环丁烷、四氢呋喃和3-甲基四氢呋喃开环聚合和/或共聚得到的二醇或由在各分子中具有少于12个碳原子的多元醇(如二醇或二醇混合物)缩聚得到的二醇，所述多元醇如乙二醇、1，3-丙二醇、1，4-丁二醇、1，5-戊二醇、1，6-己二醇、新戊二醇、3-甲基-1，5-戊二醇、1，7-庚二醇、1，8-辛二醇、1，9-壬二醇、1，10-癸二醇和1，12-十二烷二醇。多元醇的具体实例包括约1,700至约2,100分子量的线性双官能聚醚多元醇和聚(四亚甲基醚)二醇，如具有2的官能度的
Figure GSB00000957786600061
1800(Invista)。
可使用的聚酯多元醇的实例包括具有两个或更多个羟基的酯二醇(ester glycol)，其通过在各分子中具有不多于12个碳原子的低分子量脂族多元羧酸和多元醇或其混合物缩聚制备。合适的多元羧酸的实例为丙二酸、琥珀酸、戊二酸、己二酸、庚二酸、辛二酸、壬二酸、癸二酸、十一烷二羧酸和十二烷二羧酸。制备聚酯多元醇的适合多元醇的实例为乙二醇、1，3-丙二醇、1，4-丁二醇、1，5-戊二醇、1，6-己二醇、新戊二醇、3-甲基-1，5-戊二醇、1，7-庚二醇、1，8-辛二醇、1，9-壬二醇、1，10-癸二醇和1，12-十二烷二醇。线性双官能聚酯多元醇可具有约5℃至约50℃的熔点。
可使用的聚碳酸酯多元醇的实例包括具有两个或更多个羟基的那些碳酸酯二醇，其由光气、氯甲酸酯、碳酸二烷基酯或碳酸二烯丙基酯和在各分子中具有不多于12个碳原子的低分子量脂族多元醇或其混合物缩聚制备。制备聚碳酸酯多元醇的合适的多元醇的实例为二乙二醇、1，3-丙二醇、1，4-丁二醇、1，5-戊二醇、1，6-己二醇、新戊二醇、3-甲基-1，5-戊二醇、1，7-庚二醇、1，8-辛二醇、1，9-壬二醇、1，10-癸二醇和1，12-十二烷二醇。线性双官能聚碳酸酯多元醇可具有约5℃至约50℃的熔点。
多异氰酸酯
合适的多异氰酸酯组分的实例包括二异氰酸酯，如1，6-二异氰酸基己烷、1，12-二异氰酸基十二烷、异佛尔酮二异氰酸酯、三甲基-六亚甲基二异氰酸酯、1，5-二异氰酸基-2-甲基戊烷、二异氰酸基-环己烷、亚甲基双(4-环己基异氰酸酯)、四甲基-二甲苯二异氰酸酯、双(异氰酸基甲基)环己烷、甲苯二异氰酸酯、亚甲基双(4-苯基异氰酸酯)、苯二异氰酸酯、二甲苯二异氰酸酯和这些二异氰酸酯的混合物。例如，二异氰酸酯可以为芳族二异氰酸酯，如苯二异氰酸酯、甲苯二异氰酸酯(TDI)、苯二亚甲基二异氰酸酯、联苯二异氰酸酯、萘二异氰酸酯、二苯基甲烷二异氰酸酯(MDI)及其组合。
适合用作制备本发明的氨基甲酸酯预聚物的另一种原料的多异氰酸酯组分可以为包含4，4’-亚甲基双(苯基异氰酸酯)和2，4’-亚甲基双(苯基异氰酸酯)的二苯基甲烷二异氰酸酯(MDI)的异构体混合物，4，4’-MDI与2，4’-MDI异构体之比为约65∶35至约35∶65，包括约55∶45至约45∶55和约50∶50范围。合适的多异氰酸酯组分的实例包括ML(Bayer)、
Figure GSB00000957786600072
MI(BASF)和
Figure GSB00000957786600073
50O，P’(DowChemical)。
二醇
适合用作制备本发明的氨基甲酸酯预聚物的另外原料的二醇化合物包括至少一种二醇化合物，其具有(i)能够与多异氰酸酯反应的两个羟基；和(ii)至少一个能够在中和时生成盐并且不能与上述多异氰酸酯(b)反应的羧酸基团。具有羧酸基团的二醇化合物的典型实例包括2，2-二羟甲基丙酸(DMPA)、2，2-二羟甲基丁酸、2，2-二羟甲基戊酸和由DMPA起始的己内酯(如
Figure GSB00000957786600074
HC 1060(Solvay))。
中和剂
用于使酸基转化成盐基的合适的中和剂的实例包括：叔胺(如三乙胺、N，N-二乙基甲基胺、N-甲基吗啉、N，N-二异丙基乙基胺和三乙醇胺)和碱金属氢氧化物(如氢氧化锂、氢氧化钠和氢氧化钾)。也可用伯胺和/或仲胺作为酸基的中和剂。中和度一般为约60％至约140％，例如在约80％至约120％酸基的范围内。
增链剂
用于本发明的增链剂包括二胺增链剂和水。可用增链剂的很多实例为本领域的技术人员所熟悉。合适的二胺增链剂的实例包括：1，2-乙二胺、1，4-丁二胺、1，6-己二胺、1，12-十二烷二胺、1，2-丙二胺、2-甲基-1，5-戊二胺、1，2-环己烷二胺、1，4-环己烷二胺、4，4’-亚甲基双(环己基胺)、异佛尔酮二胺、2，2-二甲基-1，3-丙二胺、四甲基间苯二甲胺和分子量小于500的
Figure GSB00000957786600081
(Texaco)。
表面活性剂
合适的表面活性剂(表面活性剂)的实例包括阴离子、阳离子或非离子分散剂或表面活性剂，如十二烷基硫酸钠、磺基琥珀酸二辛酯钠、十二烷基苯磺酸钠、乙氧基化烷基酚(如乙氧基化壬基苯酚)和乙氧基化脂肪醇、溴化月桂基吡啶鎓、聚醚磷酸酯和磷酸酯、改性的醇-乙氧基化物及其组合。
封端剂
用于异氰酸酯基的封端剂可以为单官能醇或单官能胺。封端剂可在生成预聚物之前、生成预聚物期间或生成预聚物之后的任何时间加入，包括在将预聚物分散进入含水介质(如去离子水)之前和之后。在一些实施方案中，封端剂是任选的，或者可以排除。在其他实施方案中，以预聚物重量计，可以约0.05％至约10.0％量包含封端剂，包括约0.1％至约6.0％和约1.0％至约4.0％。以最终分散体的重量计，封端剂可以约0.01％至约6.0％的量存在，包括约0.05％至约3％和约0.1％至约1.0％。
封端剂的加入允许对分散体中聚合物的重均分子量的控制以及提供对聚合物分子量分布的控制。封端剂提供此控制的效力取决于封端剂的类型和在制备分散体期间何时加入封端剂。例如，可在预聚物生成之前、预聚物生成期间或之后加入单官能醇。也可将单官能醇封端剂加入到预聚物分散进入的含水介质，或在将预聚物分散进入含水介质后立即加入。然而，在需要控制最终分散体中聚合物分子量和分子量分布时，如果在预聚物分散前加入并且作为预聚物的部分进行反应，单官能醇可最有效。如果在使预聚物分散期间或之后将单官能醇加入到含水介质，则由于竞争性增链反应而降低控制聚合物分子量的效力。
本发明可利用的单官能醇的实例包括至少一种选自具有1至18个碳的脂族和脂环族伯醇和仲醇、酚、经取代的酚、分子量小于约750(包括分子量小于500)的乙氧基化烷基酚和乙氧基化脂肪醇、羟基胺、羟基甲基和羟基乙基取代的叔胺、羟基甲基和羟基乙基取代的杂环化合物及其组合的成员，其包括包括糠醇、四氢糠醇、N-(2-羟基乙基)琥珀酰亚胺、4-(2-羟基乙基)吗啉、甲醇、乙醇、丁醇、新戊醇、己醇、环己醇、环己烷甲醇、苄醇、辛醇、十八烷醇、N，N-二乙基羟胺、2-(二乙基氨基)乙醇、2-二甲基氨基乙醇和4-哌啶乙醇及其组合。
在单官能胺化合物(如单官能二烷基胺)用作异氰酸酯基的封端剂时，也可在制备分散体期间的任何时间加入，理想的是在预聚物分散期间或之后将单官能胺封端剂加入到水介质。例如，可在预聚物分散后立即将单官能胺封端剂加入水混合物。
合适的单官能二烷基胺封端剂的实例包括N，N-二乙基胺、N-乙基-N-丙基胺、N，N-二异丙基胺、N-叔丁基-N-甲基胺、N-叔丁基-N-苄基胺、N，N-二环己基胺、N-乙基-N-异丙基胺、N-叔丁基-N-异丙基胺、N-异丙基-N-环己基胺、N-乙基-N-环己基胺、N，N-二乙醇胺和2，2，6，6-四甲基哌啶。在水中分散之前胺封端剂与预聚物的异氰酸酯基的摩尔比一般应为约0.05至约0.50的范围，例如约0.20至约0.40。可将催化剂用于去封端反应。
将任选至少一种每摩尔聚合物具有至少三个或更多伯氨基和/或仲氨基的聚合物组分(MW＞约500)在预聚物分散并且加入封端剂后向水介质中加入。合适的聚合物组分的实例包括聚乙烯亚胺、聚(乙烯基胺)、聚(烯丙基胺)和聚(酰氨基胺)树枝状大分子及其组合。
其他添加剂
合适的防沫剂或消泡剂或控泡剂的实例包括：添加剂65和添加剂62(购自Dow Corning的聚硅氧烷基添加剂)、
Figure GSB00000957786600101
I 300(购自Cognis的矿物油基无聚硅氧烷消泡剂)和SurfynolTM DF 110L(购自Air Products & Chemicals的高分子量炔二醇非离子表面活性剂)。
合适的流变改性剂的实例包括：疏水改性的乙氧基化物氨基甲酸酯(HEUR)、疏水改性的碱溶胀性乳液(HASE)和疏水改性的羟乙基纤维素(HMHEC)。
可任选在含水分散体或在预聚物中包含的其他添加剂包括：抗氧化剂、UV稳定剂、着色剂、颜料、交联剂、相变物质(例如，
Figure GSB00000957786600102
可购自Outlast Technologies，Boulder，Colorado)、抗菌剂、矿物(例如，铜)、微囊化的健康添加剂(microencapsulated well-being additive)(例如，芦荟、维生素E胶、芦荟、海草、烟碱、咖啡因、香水或香料)、纳米颗粒(例如，二氧化硅或碳)、碳酸钙、阻燃剂、防粘添加剂、抗氯降解添加剂、维生素、药物、芳香剂、导电添加剂和/或染料助剂。可加到预聚物或含水分散体的其他添加剂包括粘合促进剂、抗静电剂、防堵孔剂、防滑动剂、荧光增白剂、聚结剂、导电添加剂、发光添加剂、流动剂和流平剂、冻熔稳定剂、润滑剂、有机和无机填料、防腐剂、卷曲变形剂、热色添加剂、驱虫剂和湿润剂。
任选的添加剂可在预聚物分散之前、期间或之后加入到含水分散体。
可在加到非织造物之前或之后使涂料或分散体、薄膜或成形制品着色或染色。
本发明的特征和优点更完全通过以下实施例显示，这些实施例用于说明，不应解释为以任何方式限制本发明。
实施例
制造数个半球状乳罩，这些乳罩包含具有重均分子量为约120,000的聚氨酯-脲含水分散体。将聚酯填絮纤维毛絮(一般为枕填塞料)铺在长方形盘中，并喷以含水分散体。制备具有“轻”涂层、“中”涂层和“重”涂层的实例。在使样品干燥过夜后，“轻”涂层似乎用很小力就能拉开，表明分散体的量不足以粘合足够的纤维。“重”涂层似乎为橡胶状并且摸起来硬。“中”涂层显示有能够用最低试验过程达到的聚氨酯-脲分散体的最佳负荷。
将“中”涂毛絮的样品放在两个织物层之间，并放入常规泡沫罩杯模压(成形和加热)装置。将模压的罩杯从模压机移除，发现显示出用于模压半球状乳罩所需要的成形外观和压缩恢复。
作为比较，用常规粘合剂稳定化的数个普通填絮纤维毛絮也在泡沫罩杯模压装置中模压。这些样品从Kem-Wove，Inc.得到，这是一家位于10530 Westlake Drive，Charlotte，NC 28273的高膨松非织造物商业制造商。在经过模压时，所得罩杯显示出不适用于模压的半球状乳罩的硬挺性质。
虽然已描述了目前相信为本发明优选的实施方案，但本领域的技术人员应认识到，可在不脱离本发明的精神下进行变化和改进，且旨在包括落在本发明的真实范围内的所有这些变化和改进。

Claims (22)

1.一种制品，所述制品包含：
(a)包括填絮纤维的高膨松非织造物；和
(b)聚氨酯-脲分散体，作为所述高膨松非织造物结构中所述填絮纤维的粘合剂。
2.权利要求1的制品，其中所述填絮纤维是聚酯填絮纤维。
3.权利要求1的制品，其中所述填絮纤维包括双组分纤维，所述双组分纤维包括选自聚乙烯/聚丙烯、聚乙烯/聚酯、聚丙烯/聚酯、共聚酯/聚酯及其组合的聚合物组合。
4.权利要求1的制品，其中所述聚氨酯-脲分散体包括含水分散体。
5.权利要求4的制品，其中所述含水分散体包含聚合物和至少一种表面活性剂，所述聚合物为以下物质的反应产物：
(a)至少一种选自聚醚、聚酯、聚碳酸酯及其组合的多元醇，其中多元醇具有600至4000的数均分子量；
(b)多异氰酸酯，其包括选自芳族二异氰酸酯、脂族二异氰酸酯、脂环族二异氰酸酯及其组合的成员；
(c)至少一种二醇化合物，其包括(i)能够与多异氰酸酯反应的羟基，和(ii)至少一个能够在中和时生成盐的羧酸基团，其中所述至少一个羧酸基团不能与多异氰酸酯反应；
(d)中和剂；
(e)增链剂；
(f)用于异氰酸酯基的封端剂，所述封端剂包括至少一种单官能胺或单官能醇。
6.权利要求4的制品，其中所述分散体基本不含加入的溶剂。
7.权利要求5的制品，其中所述多异氰酸酯包括4，4’-和2，4’-亚甲基双(苯基异氰酸酯)即MDI的异构体的混合物，其中4，4’-MDI与2，4’-MDI异构体之比为65∶35至35∶65。
8.权利要求5的制品，其中所述二醇选自2，2-二羟甲基丙酸、2，2-二羟甲基丁酸、2，2-二羟甲基戊酸及其组合。
9.权利要求4的制品，其中所述分散体包含具有约40,000至约250,000的重均分子量的聚氨酯-脲聚合物。
10.权利要求4的制品，其中所述分散体包含具有约40,000至约150,000的重均分子量的聚氨酯-脲聚合物。
11.权利要求1的制品，其中所述制品经模压。
12.权利要求1的制品，其中将所述制品模压成半球状乳罩。
13.一种制备制品的方法，所述方法包括：
(a)提供包括填絮纤维的高膨松非织造物；
(b)使所述非织造物与聚氨酯-脲分散体接触，其中所述聚氨酯-脲分散体作为所述高膨松非织造物结构中所述填絮纤维的粘合剂。
14.权利要求13的方法，其中所述填絮纤维是聚酯填絮纤维。
15.权利要求13的方法，其中所述接触通过喷、浸轧、浸渍、浸没、涂覆及其组合来进行。
16.权利要求13的方法，其中所述聚氨酯-脲分散体包括含水分散体。
17.权利要求13的方法，所述方法进一步包括：
(c)干燥所述制品。
18.权利要求17的方法，其中所述干燥选自室温干燥、加热及其组合。
19.权利要求13的方法，所述方法进一步包括：
(d)模压所述制品。
20.权利要求19的方法，其中将所述制品在两个织物层之间模压。
21.权利要求19的方法，其中所述模压包括施加热。
22.权利要求19的方法，其中所述模压包括施加压力。
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