CN1077166C - 含聚烯烃-聚酰胺的共轭纤维网及制法及含共轭纤维的非织造布和层压制品 - Google Patents
含聚烯烃-聚酰胺的共轭纤维网及制法及含共轭纤维的非织造布和层压制品 Download PDFInfo
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- CN1077166C CN1077166C CN96192637A CN96192637A CN1077166C CN 1077166 C CN1077166 C CN 1077166C CN 96192637 A CN96192637 A CN 96192637A CN 96192637 A CN96192637 A CN 96192637A CN 1077166 C CN1077166 C CN 1077166C
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- D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
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Abstract
本发明提供一种含聚烯烃和聚酰胺的共轭纤维,聚酰胺选自聚己内酰胺,己内酰腔和己二酰己二胺的共聚物,己内酰腔和氧化乙烯二胺的亲水共聚物,及其共混物,其中聚酰胺的数均分子量高达约16,500。本发明进一步提供了一种由这种共轭纤维做成的非织造布及生产这种非织造布的方法。
Description
有关申请的参考
本申请是1995年6月13日批准的美国专利5,424,115的延续部分。
发明背景
本发明是关于二种不同的热塑性聚合物做成的共轭纤维及制法和由这种纤维生产的非织造网及层压制品。更具体地说,本发明是关于聚烯烃和聚酰胺的共轭纤维及制法和非织造网及层压制品。
共轭纤维含至少二种沿基本上整个纤维长度分别占有不同横截面的纤维组份,这种纤维是通过同时并邻接地把能形成纤维的许多聚合物组合物熔体挤出喷丝板的纺丝孔形成的共轭丝条。通常,共轭纤维的组分组成选自具有不同收缩性的和/或化学、物理性互补优点的不同聚合物。采用具有不同收缩性的组分聚合物能典型地赋予共轭纤维卷曲性;采用具有不同优良性能的组分聚合物能赋予该纤维不同的功能性。
由于不同聚合物具有不同的熔融和加工温度以及不同的熔体流变性,通常必须或希望共轭纤维的组分聚合物成分能分别在不同温度下加工并一直保持到合并这种熔融聚合物成分形成单一的丝条之前。在许多情况下,把不同熔融聚合物合并成单一丝条时常会出现许多加工困难,如丝条的不均匀性,纺丝断头和未固化丝条在喷丝板端面弯曲等现象。这些加工困难妨碍了纤维的正常形成和并因此妨碍非织造布的成形。此外,对于采用了气动拉伸步骤的纺丝过程,如熔喷法,纺粘法纺出的纤维,如果加工条件对每种聚合物组合不是精心设计的,那末当纤维丝条从喷丝板出来后,在拉伸过程中就趋向于合并成束。这种控制加工条件例如包括确保形成丝条的组分聚合物的恰当的冷却,而且挤出的丝条在沉落到成形表面之前都是互相分开的。这些加工困难,在纺制不同聚合物成分的共轭纤维时是有不少办法可以解决的。例如:英国专利965,729公开了一种喷丝板,它的纺丝孔成角度排列,向相对于挤出的共轭纤维丝条的弯曲方向相反的方向倾斜。因为对不同聚合物的每一种组合都必须制做一种专门喷丝板,所以该专利所阐述的内容只能用于大生产过程实践。为了减少加工困难。通常将组分聚合物成分的熔体粘度大体保持在同一水平上。Uraya等人的美国专利3,536,802发明了一种方法,这种方法能分别挤出并将组分聚合物成分保持在不同的温度下一直到合并形成单一纤维丝条时为止。Uraya等人所发明的方法应用了线性热塑性聚合物一般随熔体温度增加而熔体粘度下降这一事实。但是要保证在加工过程中,每种组分聚合物的熔体要符合各自的热分布要求就需要有一种带有隔热层的笨重而又复杂的喷丝板组合件。此外,在形成单一纤维条时,不同聚合物组分的温度差异会导致挤出纤维时加工困难。例如,具有不同熔融温度的组分聚合物的固化速率往往不同,共轭纤维的未充分冷却的聚合物组分在纤维正常沉落到成形表面之前有引起纤维丝条随机粘并或成束的倾向。
含不同聚合物的各种共轭纤维中,聚烯烃和聚酰胺组成的共轭纤维是很有用的。例如,Ogata等人的美国专利3,788,940发明了一种含有一种聚烯烃和一种长碳链的聚酰胺如尼龙11、尼龙12、尼龙11/10、尼龙11/11或尼龙11/12的共轭纤维。长碳链聚酰胺的熔点和加工温度比市场上容易得到的常规尼龙如尼龙6和尼龙66的熔点和加工温度低。事实上,这种长碳链聚酰胺的熔点和加工温度和聚烯烃的熔点和加工温度不相上下。因而这种聚酰胺和聚烯烃可以容易地加工成共轭纤维。相反,比较常规的和经济的聚酰胺如尼龙6和尼龙66的熔点比聚烯烃高得多,必须在比典型的聚烯烃的加工温度范围要高的温度下进行熔融加工。况且,在技术上已经知道,一种热塑性聚合物进行熔融加工时,其加工温度范围比该聚合物熔点要高得多,以适应熔融加工设备如挤出机的典型的温度波动,避免聚合物在熔融加工设备中意外固化或冻结;同时也提供一种有恰当可加工的熔体粘度的组分熔体。通常,当组分熔体加热不够时,熔体所具有的弹性粘度或熔体弹性就会太高,致使挤出的纤维不能进行适当的拉伸,当熔体过热时,由熔体挤出的纤维就不能适当和充分冷却。因此,过热和加热不足的熔体都不可能很好地形成有用的纤维,也就是会造成纺丝断头,形成粘并和/或成束纤维。所以常规的聚酰胺和聚烯烃在不同的加工温度下进行熔融加工,通常就需要生产共轭纤维的专门加工设备。
还有一个要求就是聚酰胺和聚烯烃聚合物组分的共轭纤维可以用常规的聚烯烃加工设备进行加工,而且这种共轭纤维含有的聚合物组分不需要在不同加工温度下进行加工。
发明目的
本发明的目的在于提供一种含聚烯烃和聚酰胺的共轭纤维及制法及含有这种纤维的非织造布及层压制品。本发明概要
根据本发明提供一种含有聚烯烃和聚酰胺的共轭纤维和由此加工而成的非织造布。这里,聚酰胺选自聚己内酰胺、己内酰胺和己二酰己二胺共聚物、己内酰胺和氧化乙烯二胺亲水共聚物及其共混物。这种聚酰胺的数均分子量至多约16,500。
进一步,本发明是提供一种生产含有一种可成纤的聚烯烃和一种聚酰胺的共轭纤维和非织造布的方法。在此聚酰胺选自聚己内酰胺、己内酰胺和己二酰己二胺共聚物,己内酰胺和氧化乙烯二胺亲水共聚物及其共混物。这种聚酰胺的数均分子量高达约16,500。这种方法包括以下各步骤:熔融挤出聚烯烃、熔融挤出聚酰胺、把挤出的聚烯烃和聚酰胺喂入到喷丝板喷丝孔形成单一的纤维。这里,进入喷丝孔熔融加工的聚烯烃和聚酰胺的熔融温度在聚酰胺的熔点和约240℃之间。
附图的简单说明
图1~6,表示示范的共轭纤维横截面构型。
图7,表示按本发明生产的共轭纤维非织造布。
图8,表示用常规聚己内酰胺生产的非织造布。
图9,按本发明生产的另一种共轭纤维非织造布。
图10,表示用常规聚己内酰胺生产的另一种非织造布。
本发明的详细说明
本发明公开了含聚烯烃和聚酰胺的共轭纤维及由共轭纤维做成的非织造网。这种共轭纤维和非织造网相对于聚烯烃纤维及其非织造网使下面各种性能得到改进:强力性能,如拉伸强力和撕裂强力;耐磨性;粘接性,如粘接温度范围较宽;和功能性,如染色性和亲水性。此外,这种非织造网含有酰氨基类功能性化学基团,经过化学改性可在非织造网表面引入各种表面功能。本发明的共轭纤维的组分聚合物成分不同于以前共轭纤维制造技术中所用的短碳链聚酰胺成分,这种聚酰胺可以在熔融加工聚烯烃时典型使用的温度下进行加工,而且可以使用常规的没有隔热层的共轭纤维纺丝装置。
适合本发明的聚酰胺,又名尼龙,包括聚己内酰胺(尼龙6)、己内酰胺和己二酰己二胺共聚物(尼龙6,6/6)、己内酰胺和氧化乙烯二胺亲水共聚物及其共混物,在这些聚酰胺中,最合乎本发明需要的聚酰胺是聚己内酰胺,按本发明,合适的聚酰胺是低分子量的聚酰胺,其数均分子量约等于或小于16,500,合乎需要的约在10,000和16,200之间,较合乎需要的约在11,000和16,000之间,最合乎需要的约在11,500和15,000之间。可以相信,数均分子量为5000甚至更低的合适的低数均分子量聚酰胺也可以熔融挤出成本发明的共轭纤维。具体地说,适合本发明的聚酰胺的甲酸相对粘度约在1.8和2.15之间,更优选约1.85和2之间(按ASTMD789—66测定),其熔体流动速率约为48g/10min和100g/10min之间,更具体地说约在65g/10min和95g/10min之间(按ASTMD1238—90b条件230/2.16测定)。可选择地,共轭纤维的聚酰胺成分可含有少量的加工润滑剂以改进聚酰胺的可加工性。例如少量的硬脂酸金属盐或非金属盐,如硬脂酸钙、钠、铅、钡、镉、锌或镁盐,可以共混到聚酰胺组分中以增加其熔体流动速率和降低熔体粘度。根据需要最多可加到聚合物重量的约5%,比较合乎需要的约在0.01%和4%之间的硬脂酸盐化合物共混加入到聚合物组分中。
现已发现,适合本发明的聚酰胺可在适合于聚烯烃的常规加工温度范围内进行熔融加工而不出现曾经发生过的加工困难,如挤出的共轭丝条的弯曲和成束。合乎需要的聚酰胺熔融加工熔体温度约在聚酰胺熔点和240℃之间,更合乎需要的约在215℃到238℃之间,最合乎需要的约在225℃和235℃之间,生产纺粘共轭纤维更是如此。这里所用术语“熔体温度”是指聚合物组分熔融进入纺丝组件的温度。值得注意的是适合本发明的加工温度比聚己内酰胺常规加工温度范围低得多。但并不比聚酰胺的熔点高得多。虽然不希望受任何理论约束,但是可以相信本发明适合的聚酰胺的独特的低分子量提供了所需的熔体粘度,即使在这种低熔体加工温度范围内也是如此。相反,市场上可得到的纤维级聚己内酰胺必须在比典型的聚烯烃加工温度范围高的温度范围熔融加工,这样才能得到合适的和熔融加工聚烯烃相容的熔体流动性能。因此含有本发明的聚酰胺的共轭纤维组分的成分可以用常规的喷丝板组合件进行加工,而这种组件保持着聚烯烃典型使用的常规操作温度范围。
适合于本发明的聚烯烃包括聚乙烯,如高密度聚乙烯,中密度聚乙烯,低密度聚乙烯和线性低密度聚乙烯;聚丙烯,如等规聚丙烯和无规聚丙烯;聚丁烯,如聚(1-丁烯)和聚(2-丁烯);聚戊烯;如聚(2-戊烯)和聚(4-甲基-1-戊烯);聚醋酸乙烯酯;聚氯乙烯;聚苯乙烯和他们的共聚物,如乙烯—丙烯共聚物以及他们的共混物。在上述这些聚合物中,比较合乎需要的聚烯烃是聚丙烯、聚乙烯、聚丁烯、聚戊烯、聚醋酸乙烯酯和他们的共聚物及其共混物。最合乎本发明需要的聚烯烃是在生产非织造布时通常使用的聚烯烃,包括聚丙烯、聚乙烯、聚丙烯和聚乙烯的共聚物和它们的共混物。更具体地说,包括等规聚丙烯、等规聚丙烯和无规聚丙烯、间规聚丙烯的共混物、高密度聚乙烯、线性低密度聚乙烯和它们的共混物。此外,聚烯烃组分可进一步含有极少量的相容剂,耐磨损增强剂、卷曲诱导剂等,这类助剂的例子包括丙烯酸系聚合物,如乙烯—丙烯酸烷基酯共聚物、聚醋酸乙烯酯、乙烯醋酸乙烯酯共聚物,聚乙烯醇,乙烯—乙烯醇共聚物等。
本发明组分聚合物的成分还可包含另外一些添加剂和加工助剂,例如成核剂,着色剂、颜料、润湿剂、表面活性剂、抗静电剂、气味吸附剂、杀菌剂、润滑剂等。这些添加剂例如可以和进入熔融加工前的组分的聚合物的聚合物粒料进行干混和翻滚混和。
适合于生产共轭纤维的工艺技术是已知的。一般至少喂入两种可流动加工的组分聚合物的成分通过喷丝板的喷丝孔形成单一纤维。这种纤维沿基本上整个纤维长度分别由这些聚合物成分占有纤维的不同横截面。共轭纤维可以做成有卷曲的或有潜在卷曲性的纤维。虽然不希望受任何理论约束,但可以相信含有不同收缩性的组分聚合物组成的共轭纤维具有随后可激活的“潜在卷曲性”,当这种共轭纤维经受热处理或者机械拉伸过程时,共轭纤维组分聚合物中由于收缩的不一致性引起纤维卷曲,共同受让的Pike等人的美国专利5,382,400发明的方法非常适用于本发明的共轭纤维生产示范过程,该整个专利内容在此列出作参考。简单地说,就是制造一种卷曲的共轭纤维网,更具体地说是制造一种专利中所揭示的包括下列步骤的纺粘法纤网:将多组分聚合物熔纺成长丝;至少使多组分长丝部分冷却,以使这种长丝有潜在的可卷曲性;激活潜在卷曲性和通过施加热拉伸空气拉伸该长丝,然后将这种卷曲的拉伸的长丝沉落到成形表面形成非织造网。通常,热拉伸空气温度越高,产生的卷曲就越多。可选择地,在拉伸步骤中可以使用未加热的环境空气来抑制潜在卷曲性的激活和生产出未卷曲的共轭纤维。多组分共轭熔喷纤维和制造这种纤维的方法已公开于多篇专利中,如美国专利5,238,733、5,232,770、4,547,420、4,729,371和4,795,668。
本发明的共轭纤维可以有多种共轭构型、图1~6表示了合适的共轭纤维构型的例子,合适的共轭纤维构型包括并列型构型(图1)、偏心皮—芯型构型(图2)、同心皮—芯型构型(图3)、楔子带芯构型(星型)(图4)、楔形(桔瓣型)构型(图5)和海岛型构型(图6)。共轭纤维也可以是中空纤维。本发明的特殊分子量的聚己内酰胺可以在聚烯烃的加工温度下熔融挤出。因此其冷却分布曲线和共轭纤维聚烯烃组分的冷却分布曲线类似。此外,低分子量的聚酰胺熔融成分表现出熔体弹性或拉伸粘度降低,从而改进共轭纤维的聚酰胺和聚烯烃组分的相容性和挤出丝条的拉伸性,还可相信,即使在熔体冷却到接近或低于熔点时,也就是说,即使在熔体开始固化后,特殊分子量的聚己内酰胺熔体表现出粘弹性的改善和降低,进一步促进被挤出的共轭丝条的可拉伸性。这种聚酰胺组分可以在适合于聚烯烃的工艺设定条件下很方便地进行加工,从而减少了由于把具有不同加工温度和熔体粘度的组分聚合物加工成共轭纤维所带来的一系列困难和问题。
非织造网或非织造布可通过把共轭纤维沉落到成形表面上加工得到。典型地,纤维随机地和各向同性地沉落形成纤维均匀覆盖的非织造网。如果共轭纤维在非织造网形成时不是自粘合的,那末这种非织造网还必须被粘合加固,赋予物理完整性和强度。例如典型的熔喷纤维在沉落到成形表面时还不会完全冷却或固化,因此,当纤维沉落形成熔喷纤维网时,纤维间形成自粘接。相反,纺粘法纤维和短纤维在铺放形成非织造网时是完全或者基本上完全冷却的。因此这种非织造网需要另一个粘合加固步骤进行粘合固化。合适的粘合加固方法包括压缩粘合方法,如轧辊粘合,点粘合和花纹粘合法等;非压缩粘合法,如烘箱粘合,红外粘合和热空气穿透粘合法等。典型的压缩粘合方法采用加热和加压相结合的办法使纤维网产生粘合。如将非造网通过一个轧点,该轧点由一个加热的光面辊或带花纹的辊同一个光面砧辊形成。非压缩式粘合方法是把非织造网的温度升高到至少使形成非织造网的共轭纤维的一种组分熔化并随机粘合,在相交的纤维接触点上形成纤维自间粘合。
根据本发明的另一实例,本发明的非织造网可以层压形成复合材料。例如本发明的纺粘法共轭纤维网和熔喷纤维网可重迭铺放或按顺序铺放,然后加热或粘合剂粘合形成复合材料。这种材料既有纺粘纤维网的强度性能又有熔喷纤网的阻隔性能。Brock等人的美国专利4,041,203公开了生产这类复合材料的实例,在此提出来作为参考。
根据本发明的另一个实施方案,本发明的非织造网可以和一种常规的单组分纤维非织造网或膜层压。例如,本发明的一种共轭纤维网可以和一种聚合物膜层压,然后热点粘合形成一种高强度,象布一样的液体阻隔层压制品。这种阻隔层压制品是非常有用的。例如用作防护服材料和尿布及其他个人护理用品的外复盖材料。
如前所述,本发明的聚酰胺/聚烯烃共轭纤维非织造网表现出了诸如增加拉伸强度,改进染色性、化学功能性和吸湿性等优良性能。这种非织造网非常适合于做防护服,如医用检查服和手术服,防护复盖材料,如汽车、船只的复盖物,用可弃用品如尿布衬里等。
本发明进一步用下面实例进行说明,但这些实例并不构成对本发明的限制。
实例
实例1:
每平方码重1盎司(OSY)34g/m2的纺粘非织造网由50wt%(重量百分数)聚丙烯和50wt%聚己内酰胺并列型共轭纤维制成。所用聚丙烯是Exxon公司的PD3445,其熔体流动速率为35g/10min;所用聚己内酰胺(尼龙6)为电缆护套级401-D,甲酸相对粘度为1.97(甲酸相对粘度按ASTMD789—66测定),数均分子量约为13,800,熔体流动速率为85g/10min(按ASTMD-1238—90b条件230/2.16测定)。尼龙6树脂由Be-mis公司的分部,Custom Resins公司,Henderson,Ky,得到。聚丙烯和2wt%的二氧化钛(TiO2)浓缩物混合,(这种浓缩物含50wt%(TiO2)二氧化钛和50wt%聚丙烯)。将这种混合物喂入第一个由三个区组成的单螺杆挤出机,尼龙6和2wt%二氧化钛浓缩物混合(该浓缩物含25wt%TiO2和75wt%尼龙6),这种混合物喂入第二个由四个区组成的单螺杆挤出机。挤出的聚合物通过加热的输送管喂入双组分喷丝头纺出圆形双组分纤维。双组分喷丝板的喷丝孔直径为0.6mm,L/D为4∶1。喷丝孔的产量为0.7g/hole/minute(克/孔/分),喷丝板保持恒定温度和两种熔融组成成分也都处于这种温度。挤出机、输送管和喷丝板的加工温度设定分布情况如表1所示。从喷丝板出来双组分纤维由空气流冷却,气流速度为45SCFM/英寸喷丝板宽度,温度为65°F。冷却风在喷丝板下面5英寸处通入。被冷却的纤维在一个吸气装置里被拉伸。在Matsuki等人的美国专利3,802,817对这种吸气装置作了描述和说明。在吸气装置里由室温空气对冷却纤维进行拉伸得到2.5d纤维,然后这种经拉伸的纤维借助于抽空气流沉落到带孔的成形表面上形成非织造纤维网。
纤网喂入到由一个钢轧辊和一个钢钻辊构成的轧点对非织造纤维网进行点粘合,这种轧辊约具有每平方英寸310个凸起的方形粘合点(48点/厘米2),粘合辊加热到约143℃,轧点压力约为15.5kg/lineal cm(线性厘米)。
表1
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 216 166区域2 241 199区域3 224 221区域4 229 -区域5 230 -输送管 229 221喷丝板 232实例2(Ex2)
除了采用如表2所示不同的加工温度设定分布外,重复实例1。
表2
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 216 171区域2 241 222区域3 224 229区域4 229 -区域5 230 -输送管 229 229喷丝板 234
含有低分子量聚酰胺的实例1和2的点粘合非织造网厚度一致,纤维复盖均匀。和常规的单组分纤维的非织造纤维网类似。这种低分子量的聚酰胺可在非常低的温度下进行熔融加工,它的熔体温度接近或等于聚烯烃组分的熔体温度。对比实例1(C1)
按实例1所述步骤加工1osy(盎司/码2)聚丙烯单组分纺粘纤网。在此聚丙烯为PD3445,二台挤出机挤出的都是聚丙烯,并采用同心皮芯型纺丝组件。加工温度分布如表3所示。
对制得的非织造网进行抓样强力和撕破强力测定,抓样强力按联邦标准191A,方法5100(1978)测定。撕破强力按ASTM D117-80,方法14采用梯形撕破强力测试法测定。结果如表12所示。
表3
温度设定(℃)位置 挤出机1 挤出机2挤出机区域1 171 171区域2 199 198区域3 220 221区域4 222区域5 222输送管 230 230喷丝板 229对比实例2(C2)
按实例1所述加工步骤加工尼龙6和聚丙烯双组分共轭纤维网,在此尼龙6纺丝切片是纤维级聚酰胺,由DSM公司生产,聚丙烯是Exxon公司的PD3345,加工温度分布如表4所示,尼龙6的甲酸相对粘度为245,数均分子量约为19,700。根据聚酰胺生产厂的工艺建议和指南,采用升高的加工温度曲线。
表4
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 219 171区域2 266 199区域3 263 221区域4 263 -区域5 263 -输送管 263 221喷丝板 262
纤维级尼龙6不可能合适地纺成共轭纤维,从喷丝板出来的聚合物丝条弯曲严重。而且在拉伸过程中丝条随机地粘并和成束。这种成束纤维不可能做成有用的非织造布,所以不再加工成非织造布。对比实例3(C3)
除了升高尼龙6的熔融加工温度以降低聚合物组分的熔体粘度外。重复对比实例2,加工温度分布如表5所示。
表5
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 221 171区域2 268 199区域3 291 221区域4 288 -区域5 288 -输送管 287 221喷丝板 265
升高尼龙组分的温度可以影响聚合物的熔体粘度,但并不能解决粘并和成束问题。所以这种纤维粘并和成束了。对比实例4(C4)
除了尼龙组分的加工温度进一步提高使该组份的熔体粘度进一步降低外,重复对比实例3,按实例1所述加工步骤将该纤维加工成非织造布。加工温度分布如表6所示。
表6
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 221 171区域2 291 199区域3 303 215区域4 299 -区域5 299 -输送管 299 215喷丝板 264
同样,升高加工温度并不能解决粘并和成束现象,实际上成束问题更加严重。可以认为这种成束问题不仅是由于组分间的熔体粘度不同。而且由于熔体温度不同使尼龙组分冷却不充分造成的。如所期待的,由这类成束纤维生产出来的非织造布的纤维复盖均匀性非常差。实例3(Ex3)
除了采用同心皮芯型纺丝组件生产皮芯型共轭纤维外,重复实例1,温度分布如表7所示。
表7
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 219 171区域2 239 199区域3 242 221区域4 229 -区域5 230 -输送管 230 221喷丝板 229
图7是由该实例方法加工的点粘接非织造布照片。从图7可见,这种非织造布的纤维复盖非常均匀。对比实例5(C5)
除了用同心皮芯型纺丝组件生产皮芯型共轭纤维外,重复对比实例2,加工温度分布如表8所示。
表8
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 218 171区域2 291 199区域3 298 221区域4 299 -区域5 298 -输送管 299 221喷丝板 238
在拉伸过程中,所生产的这种共轭纤维粘并和成束,即使明显提高聚酰胺组份的加工温度,以影响该组分的熔体流动性,但是高分子量的聚酰胺仍造成纺丝困难。图8是这种非织造布的照片。照片明显地显示出粘并和成束纤维以及所形成的非织造布的纤维复盖很不均匀。实例4(Ex4)
重复实例3,加工温度分布如表9所示,加工三种由含不同聚合物组分比例的共轭纤维组成的非织造布。聚合物组分比(尼龙6和聚丙烯的重量百分比)分别为50∶50,40∶60和60∶40。
表9
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 171 171区域2 214 198区域3 239 221区域4 229 -区域5 230 -输送管 229 229喷丝板 229
三种聚合物组分比的聚合物组分都能形成均匀挤出和拉伸的共轭纤维,并做成纤维复盖均匀,厚度一致的非织造布。图9是由尼龙组分和聚丙烯组分重量百分比为50∶50的共轭纤维做成的非织造布的照片。照片显示了非织造布纤维的各向同性和铺放均匀性。
图9所示的非织造布还按照对比实例1所述方法进行了抓样强力和撕破强力测试。结果见表12。对比实例6(C6)
除了采用不同的纤维级尼龙6外,重复对比实例5,尼龙6为低分子量纤维级聚己内酰胺DSM1130,其甲酸相对粘度为2.22,数均分子量约为16,700和熔体流动速率为42g/10min。加工温度分布如表10所示。按对比实例所述方法对该非织造布进行抓样强力和撕破强力性能测试,结果见表12。
表10
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 171 171区域2 214 198区域3 241 221区域4 229 -区域5 230 -输送管 229 229喷丝板 229
在纺丝过程中可以看到纺丝断头,对比实例6挤出的纤维在拉伸过程中粘并和成束。虽然实例4和对比实例6实际上是在相同的加工条件下进行的,但只有低分子量的聚酰胺(实例4)适合于共轭纤维的纺丝。比较实例4和对比实例6可以清楚地看出低分子量的聚己内酰胺是唯一适合于和聚烯烃共轭形成共轭纤维的,并由此生产出非织造布。
图10显示了由对比实例6生产的非织造布,可以明显地看到粘并和成束纤维,如所期待的,纤维覆盖性很差,形成许多没有纤维覆盖的部分实例5(Ex5)
除了采用线性低密聚乙烯(LLDPE)代替聚丙烯外,重复实例3,线性低密聚乙烯是DOW化学公司生产的6811A级,按ASTM D1238-90b,条件230/216测定LLDPE 的熔体流动速率为43g/10min。此外,非织造布采用不同粘合花纹的粘合辊进行粘合。粘合辊的粘合点面积占整个辊总表面积的25%,粘合点的密度约为每平方英寸200个间隔规整的点(31点/cm2),加工温度分布如表11所示。按对比实例1所述方法对所加工的非织造布进行抓样强力和撕破强力性能测定。结果如表12所示。
表11
温度设定(℃)位置 尼龙6 LLDPE挤出机区域1 172 166区域2 216 194区域3 238 221区域4 231 -区域5 230 -输送管 229 229喷丝板 229
表12
拉伸强度(kg) 撕裂强度(kg)实例 MD CD MD CD实例4 15.1 11.5 3.5 3.2实例5 14.2 7.2 5.7 2.6C1 2.5 2.4 1.9 1.5C6 5.4 2.5 1.8 1.5MD=机器方向CD=横向
上述强力数据明显地显示出相对于单组分非织造网和由常规纤维级聚己内酰胺做成的共轭纤网而言本发明的共轭纤维网具有优越的强力性能如拉伸强力和撕破强力等。实例6(Ex6)
除了尼龙6用Allied Signal公司提供的Capron1676外,重复实例3。Capron1676的甲酸相对粘度为2.1,数均分子量约为16,100和熔体流动速率为49g/10min。加工温度分布如表13所示。
表13
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 171 171区域2 218 199区域3 241 229区域4 229 -区域5 229 -输送管 229 229喷丝板 231
由此生产出共轭纤维和点粘合非织造布,不过可见到少量成束纤维实例7(Ex7)
除了对聚酰胺进行改性使含有硬脂酸钠和使用6811ALLDPE代替聚丙烯外,重复实例6。硬脂酸盐粉涂在聚酰胺粒子上,硬脂酸钠的用量小于粒子重量的1wt%。此外,使用一种楔型(桔瓣型)纺丝组件和实例5的粘合花纹。与图5相似,楔型纺丝组件含有16个相同形状的楔子,两种聚合物组分相间排列占有这些楔型截面。加工温度分布如表14所示。
表14
温度设定(℃)位置 尼龙6 LLDPE挤出机区域1 240 205区域2 239 210区域3 238 229区域4 237 -区域5 237 -输送管 238 229喷丝板 239
加工成一种点粘合的非织造布。可以看到润滑剂硬脂酸钠的加入改进了聚酰胺的加工性。实例8(Ex8)
加工一种如实例7所述的共轭纤维,尼龙6/LLDPE楔型共轭纤维的热空气穿透粘合非织造布。尼龙6是由NH(新罕布什尔)州的Nyltech定做的聚己内酰胺,甲酸相对粘度为1.85,数均分子量约为12,500和熔体流动速率为94g/10min。所用的LLDPE为6811A LLDPE。按实例7所述方法生产共轭纤维并将其沉落形成未粘合的非织造网,加工温度分布如表15所示。
将未粘合的非织造网通过一装有加热空气源的热风粘合设备进行粘合。有关热风粘合设备更详细资料见上述美国专利5,382,400。加热空气速率和热空气温度分别为200feet/min(61m/min)和133℃。纤网在通气罩里停留时间约为1秒。经粘合的纤网厚度约为0.9mm和单位重量约85g/m2。
表15
温度设定(℃)位置 尼龙6 聚丙烯挤出机区域1 221 166区域2 241 203区域3 230 230区域4 228 -区域5 230 -输送管 229 230喷丝板 234
这种热风穿透粘合非织造布纤维复盖非常均匀并显示出良好的柔性和弹性。
以上述实例可见本发明的低分子量聚酰胺可出乎意料地和聚烯烃一起在典型的聚烯烃加工条件下,特别是制备聚丙烯非织造布的加工条件下熔融加工。因为通常聚酰胺的熔点和熔融加工温度比聚烯烃的高得多。
聚烯烃/聚己内酰胺共轭纤维和由此加工的非织造网与聚烯烃纤维及其非织造网相比显示出合乎需要的各种性能的组合。这些性能包括拉伸强度,撕裂强度,耐磨性,宽的粘合温度范围,可染性和亲水性等。
Claims (21)
1.一种含聚烯烃和聚酰胺的共轭纤维,其中所述聚酰胺选自聚己内酰胺,己内酰胺和己二酰己二胺的共聚物、己内酰胺和乙烯化氧二胺的亲水共聚物及其共混物,该聚酰胺的数均分子量为5000或更低至最多约16,500。
2.权利要求1所述的共轭纤维,其中所述聚酰胺为聚己内酰胺。
3.权利要求1所述的共轭纤维具有一种选自并列型,同心皮芯型,偏心皮芯型,楔型(桔瓣型),楔子带芯型(星型)和海岛型的构型。
4.权利要求3所述的共轭纤维具有一种中空构型。
5.权利要求1所述共轭纤维,在此聚酰胺的数均分子量约在10,000和16,200之间。
6.权利要求1所述共轭纤维是一种纺粘纤维。
7.权利要求1所述共轭纤维是一种熔喷纤维。
8.权利要求1所述共轭纤维,其中所述聚烯烃选自聚乙烯、聚丙烯、聚丁烯、聚戊烯、聚醋酸乙烯酯、聚氯乙烯、聚苯乙烯,及其共聚物和共混物。
9.权利要求8所述共轭纤维,其中所述聚烯烃选自高密度聚乙烯,线型低密度聚乙烯,等规聚丙烯,等规聚丙烯和无规聚丙烯的混合物、间规聚丙烯,及其共混物。
10.一种含共轭纤维的非织造布,其中所述共轭纤维由聚烯烃和选自聚己内酰胺,己内酰胺和己二酰己二胺的共聚物,己内酰胺和乙烯化氧二胺的亲水共聚物及其共混物的聚酰胺组成,聚酰胺的数均分子量最多约16,500。
11.权利要求10所述的非织造布,其中所述聚酰胺是聚己内酰胺。
12.权利要求10所述的非织造布,其中所述聚烯烃选自聚乙烯、聚丙烯、聚丁烯、聚戊烯、聚醋酸乙烯酯、聚氯乙烯、聚苯乙烯,及其共聚物和共混物。
13.权利要求10所述的非织造布,其中所述共轭纤维具有一种选自并列型,同心皮芯型,偏心皮芯型,楔型(桔瓣型),楔子带芯型(星型)和海岛型的构型。
14.权利要求10所述的非织造布,其中所述聚酰胺的数均分子量约在10,000和16,200之间。
15.权利要求10所述的非织造布,其中所述共轭纤维是纺粘纤维。
16.权利要求10所述的非织造布,其中所述共轭纤维是熔喷纤维。
17.一种层压制品,其含有含权利要求1的共轭纤维的非织造布和一种薄膜。
18.一种层压制品,其含有含权利要求1的共轭纤维的非织造布和一种附加的非织造布。。
19.一种制备含聚烯烃和聚酰胺的共轭纤维的方法,该方法包括以下步骤:
a.熔融挤出一种成纤聚烯烃;
b.熔融挤出一种选自聚己内酰胺,己内酰胺和己二酰己二胺的共聚物,己内酰胺和乙烯化氧二胺的亲水共聚物及其共混物的聚酰胺,其中聚酰胺的数均分子量最多约16,500;
c.把挤出的聚烯烃和聚酰胺喂入喷丝板的喷丝孔形成单一纤维,其中进入喷丝孔熔融加工的聚烯烃和聚酰胺的熔融温度在聚酰胺的熔点和约240℃之间。
20.权利要求19所述的方法,其中所述聚酰胺是聚己内酰胺。
21.权利要求19所述的方法,其中所述聚烯烃选自聚乙烯、聚丙烯、聚丁烯、聚戊烯、聚醋酸乙烯酯、聚氯乙烯、聚苯乙烯,及其共聚物和共混物。
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- 1996-01-19 WO PCT/US1996/000767 patent/WO1996023915A2/en active IP Right Grant
- 1996-01-19 BR BR9606851A patent/BR9606851A/pt not_active IP Right Cessation
- 1996-01-19 EP EP96903578A patent/EP0805881B1/en not_active Expired - Lifetime
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Also Published As
Publication number | Publication date |
---|---|
AU701435B2 (en) | 1999-01-28 |
ZA96620B (en) | 1996-08-15 |
KR19980701719A (ko) | 1998-06-25 |
WO1996023915A2 (en) | 1996-08-08 |
MX9705613A (es) | 1997-10-31 |
EP0805881A2 (en) | 1997-11-12 |
JP3872815B2 (ja) | 2007-01-24 |
CN1179184A (zh) | 1998-04-15 |
WO1996023915A3 (en) | 1997-02-27 |
KR100384662B1 (ko) | 2003-08-19 |
DE69621226D1 (de) | 2002-06-20 |
AR000814A1 (es) | 1997-08-06 |
DE69621226T2 (de) | 2002-08-29 |
EP0805881B1 (en) | 2002-05-15 |
JPH10513506A (ja) | 1998-12-22 |
US5534339A (en) | 1996-07-09 |
BR9606851A (pt) | 1999-06-15 |
PL321600A1 (en) | 1997-12-08 |
CA2209785A1 (en) | 1996-08-08 |
AU4761596A (en) | 1996-08-21 |
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