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CN1041227C - 一种复合材料、它的用途及其制备方法 - Google Patents

一种复合材料、它的用途及其制备方法 Download PDF

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CN1041227C
CN1041227C CN94190213A CN94190213A CN1041227C CN 1041227 C CN1041227 C CN 1041227C CN 94190213 A CN94190213 A CN 94190213A CN 94190213 A CN94190213 A CN 94190213A CN 1041227 C CN1041227 C CN 1041227C
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film
thermoplastic
fiber
fibers
micropore
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CN1107279A (zh
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B·比兹尔
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Guial SA
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Guial SA
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • 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
    • D04H1/56—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 in association with fibre formation, e.g. immediately following extrusion of staple fibres
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  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Nonwoven Fabrics (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

本发明公开了一种复合材料及其制备方法，该复合材料由热塑性薄膜(2)和纤维(3)组成，薄膜(2)在其一个面上有多个火山口状微孔(4)、另一光滑面被纤维覆盖，纤维(3)绝大部分是热塑性的。本发明的复合材料特别可用作吸湿性卫生制品如尿布、月经带的透气薄膜。

Description

一种复合材料、它的用途及其制备方法
本发明涉及一种含有薄膜和纤维的复合面纤维材料，其中薄膜被互相粘结并粘结于该薄膜上的纤维覆盖；还涉及所述材料用作可透气膜的用途，该膜优透是(但不绝对是)不可透过液体的，特别是用于卫生制品如可处理尿布和月经带；还涉及特别设计用于制备所述复合面纤维材料的方法。
在尿布中，通常是将吸湿性软垫(wad)置于不透过液体的薄膜上，薄膜用于载附所述软垫使其可以适当放置和包住使用者，同时又可阻止尿液透过。当把尿布置于使用者的适当位置并且吸湿性软垫被尿液弄湿时，尿液经常渗透软垫，并与使用者的皮肤接触，因而引起皮疹、甚至过敏症。为改善上述情况，已建议使用不透过液体、但可透过空气和水蒸汽的薄膜载附吸湿性软垫。这样，薄膜阻止了尿液的透过，但能使该制品的内外之间发生气体交换，从而使吸湿性软垫中的尿液以水蒸汽的形式逐渐消失。
这样的一种不透过液体、可透过空气和水蒸汽的薄膜通常由商品名为Goretex的微孔材料制备。这种材料的成本非常高。另外，本申请人认为，它的感觉不是很舒服。
对于月经带，是用薄膜缠绕吸湿性软垫，该膜必须能使血液流进去，但不能使其返流回来。为此，已建议使用具有火山口状穿孔的多孔膜，火山口状穿孔的凸起在与吸湿性软垫接触的面上。同样，这种材料的感觉也不舒服。
本申请的目的是提供一种克服了上述薄膜缺点的复合面材料。这种材料的特征在于它由多孔热塑性薄膜和绝大多数为热塑性纤维的纤维组成，薄膜的一个面具有许多火山口状微孔、另一面是光滑的并被上述纤维覆盖，这些纤维以基本连续的方式互相粘结并粘结于薄膜上。
纤维粘结于薄膜上时必须不能产生EP 0 403187中所述的破碎点，因为这样会使火山口状微孔变形并会使纤维层不均匀。应当注意到，在EP 0 403 187中纤维层是粘结于具有火山口状微孔的薄膜面上，而不是象本发明这样，粘结于光滑面上。
纤维优选互相粘结并粘结于薄膜上，甚至粘结于所述火山口壁上。
由于这些微孔的存在，使得可透过空气和水蒸汽，这样能在所述材料的界面发生气体交换。适当地选择这些微孔的尺寸、数量和形状，以确保热塑性薄膜不能透过液体、或者只能在一个方向透过液体。热塑性薄膜上的纤维使本发明材料的感觉如同纤维，比较舒服。
纤维覆盖热塑性薄膜的光滑面、即相当于火山口状微孔内壁的面。在下列优选实施方案中，火山口状微孔的“内壁”和“外壁”的涵义将更清楚。
本发明的复合面材料优选的微孔密度为10-100个/cm2，微孔的大小为0.1-1.5mm。
借助于纤维原料的热塑性将纤维互相粘结并粘结于薄膜上。因此需要绝大多数的纤维为热塑性纤维，使本发明复合材料在薄膜和纤维之间有充分的粘结。
多孔热塑性薄膜还可在其另一面上、即在具有火山口状微孔的面上覆盖热塑性纤维，这些纤维以基本连续的方式互相粘结并粘结于薄膜上。这样两个面的感觉都如同纤维一样舒服。
制备热塑性纤维和薄膜的原料优选是一样的，例如用聚乙烯。但是，薄膜还可以由其它材料制成，例如聚酰胺或聚丙烯、或聚乙烯与乙烯-乙酸乙烯酯共聚物(EVA)的混合物。热塑性纤维可由聚丙烯制成。
这一变异方法中，可以在粘合剂的存在下，同时借助于纤维和薄膜的组成原料的热塑性，将纤维互相粘结并将其粘结于薄膜上。在这种情况下，可以使用熔点差别很大的原料。
粘合剂的用量必须较低，以避免损害复合材料的柔软性。纤维的用量为2g/m2-20g/m2时，粘合剂用量为0.2g/m2-5g/m2。
本发明复合面纤维材料可很好地用作制备吸湿性卫生制品、特别是可处理尿布和月经带的透气薄膜。经特别可用作载附或包覆吸湿性软垫的透气薄膜。
本发明还提供了制备上述复合面纤维材料的第一种方法，它包括下列步骤：
a)在非强制性地可预涂布有粘合剂的热塑性薄膜上分散一层绝大多数是热塑性纤维的纤维，
b)将上述得到的组合件置于具有微孔的表面上，和
c)将所述组合件加热到接近构成纤维和薄膜的热塑性材料软化点的温度，同时通过微孔吸气，使覆盖在所述微孔上的薄膜穿孔。
加热薄膜/纤维组合件可以使对应于微孔的区域的薄膜软化，同时又使纤维之间以及纤维和薄膜之间在它们的接触处以基本连续的方式粘结。特别地发现，在通过微孔吸入空气作用下穿孔薄膜时形成的火山口状穿孔的火山口壁是纤维和薄膜之间粘结较好的区域。
可用任意适宜方法在热塑性薄膜表面上分散一层纤维，特别是使用短纤维技术喷洒纤维、或者使用纺粘技术，或者试用喷熔法。
在优选变异方法中，制备方法是一连续方法，放置薄膜/纤维组合件的表面是内部装有吸气系统的转筒的圆筒表面。
特别可用位于转筒表面上方的辐射板，在转筒装有吸气系统区域加热薄膜/纤维组合件。
也可以用另一种方法制备本发明复合面纤维材料，其中，在一个面上具有多个火山口状微孔的热塑性薄膜上、至少在其另一光滑面上分散覆盖一层热塑性纤维，分散过程中纤维的温度足够高，使其冷却后能自然粘结于薄膜的所述表面上。
在这种情况下，薄膜上均匀地覆盖一层纤维，纤维之间以及纤维与薄膜之间仅由于原料的热塑性而点粘结，粘结只发生在薄膜没有火山口的表面上。
为了保证纤维之间以及纤维与薄膜表面之间真正粘结，上述方法的一个变异方法还包括在多孔热塑性薄膜的光滑面上涂布在所述温度下稳定的粘合剂。粘合剂同样地优选是热塑性聚合物，适于用喷熔法涂布。
本发明还提供制备上述本发明复合面材料的第三种方法，它包括：
a)在绝大多数是热塑性纤维的纤维层组成的无纺织物上挤塑一热塑性薄膜；
b)将上述得到的组合件置于具有微孔的表面上；和
c)将所述组合件加热到接近构成纤维和薄膜的热塑性材料软化点的温度，同时通过微孔吸气，使覆盖在所述微孔上的薄膜穿孔。
与上述第一种方法相比，第三种方法的第一步中使用无纺织物代替热塑性薄膜作为载体。在这种情况下，不再需要用粘合剂涂布，因为在挤出过程中直接将薄膜涂布于非纺织物上，就可使纤维与薄膜牢固粘结。
通过描述附图中所示的多孔聚乙烯薄膜/纤维复合材料的两个实施方案，将更好地说明本发明，其中：
图1是一种复合材料的示意剖示图；
图2A、2B、2C和2D是在火山口区域不同纤维构型的示意剖示图；
图3和4是制备所述复合材料的两种设备的示意图；和
图5是另一种复合材料的示意剖示图。
本发明复合材料1由热塑性薄膜2和覆盖在该薄膜一个面上的纤维3组成，纤维3的绝大部分是热塑性纤维。复合材料1具有许多基本为火山口状的穿孔，这可从图1中清楚地看到。
纤维3互相粘结，并且至少在薄膜的光滑区域24与薄膜粘结，区域24痊于火山口4的背面，相当于除火山口4内壁5的平面区域。纤维3之间以及纤维3与薄膜2之间以基本连续的方式粘结，即没有纤维被压碎或火山口被变形的地点。
另外，纤维3也可以在火山口4的壁5上互相粘结并粘结于薄膜2上。
更具体地说，图2A、2B、2C和2D是在火山口4上的纤维3可采取的四种构型的示意图。
在第一种构型中(图2A)，纤维3a位于火山口4的壁5上，使火山口具有开口6。
在第二种构型中(图2B)，纤维3b覆盖了火山口的壁5，并且至少一些纤维从一个壁5a贯穿到另一个壁56，从而至少在火山口的区域7(火山口的顶部区域)遮住了开口6。
在第三种构型中(图2C)，纤维3a如同在第一种构型中的那样覆盖火山口4的壁5。但是，还有其它纤维3c在与非穿孔区域的其它纤维基本上同一个平面上延伸经过火山口4。
在第四种构型中(图2D)，只有沿光滑区域24的其它纤维的平面延伸经过火山口4的纤维3d。
本发明的一种复合材料中火山口处的纤维可采取上述四种构型中的一种或多种构型，实际上，根据制备方法它们还可采取其它构型。例如，可如图2a所示的火山口4没有被纤维遮盖，并且在火山口的内壁也没有纤维。
制备复合材料的条件决定了火山口处的纤维主要为哪种构型，这将在下面更清楚地说明。
图3是制备图1和2所示的复合材料的第一种设备29的简单示意图。
设备29包括用于输入塑料薄膜2、如聚乙烯膜的装置。这些装置包括由驱动装置(未示出)驱动的转轴8和转轴8上的一卷薄膜2组成的辊9。
在薄膜2经过的途径上，设备29包括用于喷洒纤维3的装置10，所述装置10位于传送器11的上方，在向所述薄膜2的上表面喷洒一层纤维3的过程中，传送器11用于支撑薄膜2。
设备29还包括一个可绕轴13转动的转筒12，它用传统方法驱动(未示出)。转筒12的圆周面上有许多微孔14。
转筒12是一中空圆柱体，内部有吸气室15。吸气室15基本上为气密性的，由静止的内壁16和转筒12的区段17界定。已知的吸气装置(未示出)、如风扇与所述吸气室15连通。
设备29还包括一个呈圆弧状的辐射板18，它位于覆盖吸气室15的转筒12的区段17的上方。
最后，设备29包括用于卷起复合材料1的收集装置19。
设备29按如下所述操作。热塑性薄膜2被置于传送器11上。喷洒装置10在薄膜2的上平面喷洒一层连续和均匀的纤维3，这些纤维只是被放在薄膜2上，并设有与薄膜粘结。在被收集装置19卷起之前，由薄膜2和一层纤维3组成的组合件被传送到转筒12上，并被压在覆盖吸气室15的区段17上。当转筒12的转轴13转动时，薄膜/纤维组合件转过转筒12，在此过程中用辐射板18将其加热、同时借助于吸气室15对其吸气。
加热是为了将薄膜/纤维组合件的温度升至接近于组成薄膜2和纤维3的热塑性原料的软化温度。
由于转筒12上具有微孔14，吸气不仅能使薄膜2压在转筒12的表面上，而且还能对所述薄膜/纤维组合件穿孔。由于热塑性薄膜2的温度非常接近于它的软化点，吸力使覆盖在微孔14上的薄膜变形，这种变形(一种起泡)直至起泡破裂，因而呈火山口型穿孔。因此，薄膜2只是在吸气机械力下被穿孔。
形成火山口4的同时，位于薄膜2的表面上的纤维3同样被软化、并在薄膜2变形时或多或少地陷入火山口中。纤维3的陷入程度取决于各种操作条件，特别是加热温度、纤维3压在薄膜2上的压力、纤维3的长度、纤维混合物中非热塑性纤维的量、纤维3与薄膜2的软化温度差等。这样在薄膜起泡时，或多或少的纤维将粘结于每一起泡的内壁上，因此，起泡破裂时，形成了内壁5覆盖有所述纤维的火山口4。图2A、2B、2C和2D示出了火山口处纤维的不同构型。
可优选在喷洒纤维装置10的上游、在  热塑性薄膜2的路径上设置一喷洒粘合剂装置25，在薄膜2的上表面沉积少量、均匀的粘合剂。该装置25可以是喷熔型装置，注射呈热塑性粘合剂树脂形式的粘合剂26。
粘合剂的用量必须足以改进纤维之间以及纤维与薄膜之间的粘合力，但其用量又不能损害本发明复合材料的柔软性。其用量也与沉积在薄膜2上的纤维3的用量有关，纤维的用量为2g/m2-20g/m2时，粘合剂的用量优选为0.2g/m2-5g/m2。
在另一实施例方案中，本发明复合材料可在图4所示的另一设备上制备。为简化起见，在设备29和30中，相同的元件使用相同的符号表示。
轴8上有一辊31，其上缠有一卷无纺织物32，无纺织物32上具有一层纤维，其中的绝大部分是热塑性纤维。
在无纺织物32的路径上，设备30包括用于挤出热塑性薄膜34的装置33。挤出机装置33位于传送器11的上方，在所述无纺织物32的上表面上挤出薄膜34时，传送器11用于支撑无纺织物32。
设备30包括如在设备29中所述的装有吸气装置的穿孔转筒12和辐射板18。但是，转筒12的装配方式必须使热塑性薄膜34与覆盖吸气室15的转筒12的区段17接触，因此，其装配方式与设备29中的相反。
设备30按如下所述操作。无纺织物32被置于传送机11上。装置33挤出热塑性薄膜34，并在它完全冷却前立即粘附于无纺织物32的上表面上。这样可保证无纺织物32的纤维与薄膜34之间有一定程度的粘结。
其它步骤与描述设备29时的相同。
在使用设备30时，由于热塑性薄膜被挤出在一层已经固化的纤维上，该复合材料经过转筒后，无纺织物在覆盖火山口区域纤维一般不仅不与火山口的内壁的薄膜粘结，而且还互相分开，在火山口处形成孔。
当然也可以用除上述方法以外的方法制备本发明复合材料，例如采用针刺工艺。但是采用上述方法可以通过调节操作条件得到基于同一原理的不同产品，可选择的范围要比用针刺工艺的广。
也可以在已经穿孔的薄膜上分散纤维。在这种情况下，必须将纤维分散在没有火山口的薄膜表面上，使纤维在操作温度下互相粘结并粘结于薄膜的光滑区域24上。这可如下操作：在薄膜连续移动时将纤维直接挤出在薄膜上，在高于构成纤维的热塑性原料的熔点的温度下，将纤维粘附于薄膜上。所得复合材料将主要为图2D所示构型。
在上述方法中，也优选用粘合剂预涂布待分散纤维的薄膜面。例如，粘合剂可以是热塑性粘合剂树脂，它在纤维与薄膜接触的温度下反应。
在上述示例中，只在相当于火山口4的内壁5的薄膜表面分散纤维层。本发明并不限于此。图5示出了本发明复合材料的另一示例，其中，在相当于火山口23的外壁22的薄膜21表面21a上有第一纤维面20，在相当于火山口23的内壁23的薄膜21表面21b上有另一纤维面27。可首先用图3所示设备、随后将纤维直接纺粘于复合材料的另一面上，制备上述复合材料。
本发明复合材料可有利地用于制备可处理吸湿性卫生制品。对于吸湿性尿布，它被用作吸湿性软垫的支撑层，火山口优选指向制品的内部。这样，该支撑层不透过液体，可以阻止尿液通过，但是由于穿孔的存在，它可透过气体，使制口的内外之间可进行空气和水蒸汽的交换。
对于月经带，它用作缠绕吸湿性软垫的膜，薄膜的火山口指向吸湿性软垫。穿孔的形状和大小使本发明的复合材料只能使液体流向吸湿性软垫，而不能反向流动。在两种应用中，纤维的存在使本发明材料具有更宜人的感觉，与常规使用的塑料膜的感觉差别很大。
穿孔的尺寸和密度决定于意欲的用途。在用于卫生制品的具体示例中，在厚度约为80微米的薄膜中，穿孔的密度约为50个火山口/cm2，开口面积比率为25％(火山口的顶部与薄膜总面积的比率)。薄膜的重量优选为30g/m2-40g/m2。
热塑性薄膜具有一定的天然弹性比较有利。在这种情况下，优选薄膜在拉伸态时与纤维粘结。复合材料制成后，薄膜恢复到起始的未拉伸状态，纤维层因此变得更稠密。复合材料重新被拉伸时，纤维也不会断裂。
构成无纺织物的纤维例如可以是如聚丙烯或聚乙烯的聚合物，它们或者是不同聚合物的混合物，或者是合成纤维与天然或人造纤维的混合物，如胶丝纤维。双组份纤维还可包括一种溶液，用于形成纤维垫。
本发明不受上述非排它性示例的限制。特别地，热塑性薄膜可由聚乙烯、聚丙烯、EVA、聚丙烯制成，或它们的混合物共挤出或复合层制成。

Claims (18)

1.一种由热塑性薄膜(2)和薄膜(2)上覆盖的纤维组成的复合面材料，纤维中的绝大部分是热塑性的、并且互相粘结并与薄膜粘结，所述薄膜在其一个面上具有许多火山口状微孔(4)，该材料的特征在于，所述薄膜具有一个光滑的面并且所述纤维以基本连续的方式在薄膜的光滑面与薄膜粘结。
2.根据权利要求1的材料，其特征在于，纤维(3)互相粘结，并与薄膜粘结，甚至在火山口(4)的内壁(5)上与薄膜粘结。
3.根据权利要求1或2的材料，其特征在于，它包括密度为10个/cm2-100个/cm2的穿孔，所述穿孔的大小为0.1mm-1.5mm。
4.根据权利要求1的材料，其特征在于，热塑性薄膜(21)具有火山口状微孔(23)的另一面(21a)也被纤维(20)覆盖，所述纤维的绝大部分是热塑性的，并且互相粘结并与薄膜粘结。
5.权利要求1-4中任一要求的复合面材料在制备吸湿性卫生制品、特别是尿布和月经带时作为透气薄膜的应用。
6.一种制备权利要求1的复合面纤维材料的方法，其特征在于包括下列步骤，
a)在热塑性薄膜(2)上分散一层纤维(3)，纤维(3)中的绝大部分是热塑性的；
b)将上述得到的组合件置于具有微孔(14)的表面(12)上；和
c)将所述的组合件加热到接近构成纤维(3)和薄膜(2)的热塑性材料的软化点的温度，同时通过微孔(14)吸气，使覆盖在所述微孔上的薄膜穿孔。
7.根据权利要求6的方法，其特征在于，它包括在薄膜(2)待分散纤维(3)的面上预涂布粘合剂的步骤。
8.根据权利要求7的方法，其特征在于，所述粘合剂是一种热塑性粘合剂树脂，它在纤维与薄膜接触的温度下反应。
9.根据权利要求8的方法，其特征在于，采用喷熔方法、以0.2g/m2-5g/m2粘合剂的速度进行预涂布。
10.根据权利要求6的方法，其特征在于，它包括将纤维分散在所述薄膜上时拉伸该热塑性薄膜。
11.根据权利要求6的方法，其特征在于，放置薄膜/纤维组合件的表面是内部装配有吸气系统的转筒(12)的圆周面。
12.一种制备权利要求1的复合面纤维材料的方法，其特征在于它包括下列步骤：在一个面上具有多个火山口状微孔的穿孔热塑性薄膜上分散一层热塑性纤维，至少在薄膜的另一光滑面上分散所述纤维，分散过程中纤维的温度应足够高，使其冷却后能自然粘结于薄膜表面上。
13.根据权利要求12的方法，其特征在于，它包括在薄膜(2)待分散纤维(3)的面上预涂布粘合剂的步骤。
14.根据权利要求13的方法，其特征在于，所述粘合剂是一种热塑性粘合剂树脂，它在纤维与薄膜接触的温度下反应。
15.根据权利要求14的方法，其特征在于，采用喷熔方法、以0.2g/m2-5g/m2粘合剂的速度进行预涂布。
16.根据权利要求12的方法，其特征在于，它包括将纤维分散在所述薄膜上时拉伸该热塑性薄膜。
17.一种制备权利要求1的复合面纤维材料的方法，其特征在于包括下列步骤，
a)在由一层纤维组成的无纺织物上挤出热塑性薄膜，所述纤维的绝大部分是热塑性的；
b)将上述得到的组合件置于具有微孔(14)的表面(12)上；和
c)将所述组合件加热到接近构成纤维(3)和薄膜(2)的热塑性材料的软化点的温度，同时通过微孔(14)吸气，使覆盖在所述微孔上的薄膜穿孔。
18.根据权利要求17的方法，其特征在于，放置薄膜/纤维组合件的表面是内部装配有吸气系统的转筒(12)的圆周面。
CN94190213A 1993-04-19 1994-04-11 一种复合材料、它的用途及其制备方法 Revoked CN1041227C (zh)

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FR9304791A FR2704244B1 (fr) 1993-04-19 1993-04-19 Materiau plan composite comportant un film et des fibres thermoplastiques, utilisation et procede de fabrication.
FR9305605A FR2704179B1 (fr) 1993-04-19 1993-05-05 Materiau plan composite comportant un film perfore et des fibres thermoplastiques, utilisation et procede de fabrication.
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