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CN110945173A - 具有改善的可堆叠性和可储存性的大体积熔喷无纺布 - Google Patents

具有改善的可堆叠性和可储存性的大体积熔喷无纺布 Download PDF

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Publication number
CN110945173A
CN110945173A CN201880044693.0A CN201880044693A CN110945173A CN 110945173 A CN110945173 A CN 110945173A CN 201880044693 A CN201880044693 A CN 201880044693A CN 110945173 A CN110945173 A CN 110945173A
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CN
China
Prior art keywords
nonwoven
meltblown nonwoven
melt
woven fabric
meltblown
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Pending
Application number
CN201880044693.0A
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English (en)
Inventor
阿克塞尔·尼克尔
诺贝特·佐丁
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Individual
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Individual
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Publication of CN110945173A publication Critical patent/CN110945173A/zh
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Abstract

本发明涉及面结构形式的熔喷无纺布，其单位面积重量为100至600g/m2且密度为5至50kg/m3，其中所述熔喷无纺布(10)具有至少一个在其至少一个表面上和/或至少部分地在熔喷无纺布(10)的厚度方向上延伸的间隔物(12)，所述间隔物布置为使得当对所述熔喷无纺布的表面施加的压力为50 Pa时，所述熔喷无纺布(10)具有小于10％的压缩率。

Description

具有改善的可堆叠性和可储存性的大体积熔喷无纺布
本发明涉及具有改善的可堆叠性和可储存性的大体积熔喷无纺布。本发明进一步涉及用于制造这种熔喷无纺布的方法。
毡和无纺布通常使用已知的机械或气体动力学方法由短纤维和/或连续长丝制造。一种已知的气体动力学方法是如例如在US 3,755,527中所描述的根据埃克森(Exxon)原理的熔喷法。在该方法中，低粘度聚合物通过位于喷嘴尖端的毛细管挤出。对形成的聚合物液滴然后从两侧施以被称为鼓风的具有高温和速度的空气流，由于该空气流而将聚合物液滴以细长丝形式拉出以产生聚合物自由射流。通过以锐角相继撞击到聚合物液滴上的空气流，此外在聚合物自由射流中在此时存在的自由射流中诱发振荡过程，该振荡过程导致使聚合物束加速超过鼓风速度的高频过程。由此，聚合物束被额外地拉伸，以使得在将长丝铺设在载体上之后和在冷却之后所获得的长丝可以具有一位数的微米范围或甚至更小的直径和细度。由此制造的熔喷无纺布或熔喷无纺布用于不同应用，如例如卫生领域中的屏障功能。对于这些应用，将长丝作为平坦二维无纺布铺设在载体上。
另一种已知的熔喷方法由Biax Fiberfilm Corp.公司开发并且例如描述在US 4,380,570中。
对于某些无纺布应用，如例如将其用作声阻尼材料，该无纺布必须是大体积的，即具有大的内部空腔体积。这种大体积三维熔喷无纺布可以通过将形成的长丝铺设在两个抽吸筒(Saugtrommel)或双筒之间来制造，这如例如描述在DE 17 85 712 C3和US 4,375,446中。这些大体积熔喷无纺布特别可以用作声阻尼材料，但是也可以用于其它应用，如例如用作吸油剂。但是，这些大体积熔喷无纺布的缺点在于它们是高延展的并且具有弛豫差的特征，这在压力载荷后导致体积的损失。由此，这些大体积熔喷无纺布在没有不希望的变形的情况下只能非常受限地堆叠。因此，它们必须复杂地储存，以避免由于例如堆叠所致的不希望的变形。
因此，本发明的目的是提供大体积熔喷无纺布，其易于堆叠而不由此引起不希望的变形，并且此外保持其厚度特定性的声学性能，例如声吸收程度。
根据本发明，该目的通过面(flächig)结构形式的大体积熔喷无纺布得以实现，其单位面积重量为100至600g/m2且密度为5至50kg/m3，其中所述熔喷无纺布10具有至少一个在其至少一个表面上和/或至少部分地在该熔喷无纺布10的厚度方向上延伸的间隔物12，该间隔物布置为使得当对所述熔喷无纺布的表面施加的压力为50 Pa时，所述熔喷无纺布具有小于10％的压缩率。
通过使所述大体积熔喷无纺布，即单位面积重量为100至600g/m2且密度为5至50kg/m3的熔喷无纺布具有至少一个且优选多个至少部分地在该熔喷无纺布的厚度方向上延伸间隔物，且所述间隔物布置为使得当对该熔喷无纺布的表面施加的压力为50Pa时所述熔喷无纺布具有小于10％的压缩率，各层的大体积无纺布可以容易地彼此重叠地堆叠而不由此引起该无纺布的不可接受的变形和特别是压缩，这是因为所述各层各自通过其间隔物接触并被这些间隔物彼此间隔开，以使得上面的层不因其重量而压缩下面的层，或者至少不以显著程度压缩。由此实现了大体积熔喷无纺布的可容易储存性。此外，通过防止显著压缩，使得该大体积熔喷无纺布保持其厚度特异性的声学性能，如声吸收程度。
在本专利申请的意义上，吸收是指声波的声吸收，或者换句话说是指“压力波的能量的耗散”。为了在较低频率下也实现该功能，所述材料根据物理定律必须具有一定的厚度和大体积。
在本专利申请的意义上，间隔物是指具有足够刚度的尺寸稳定结构，以使得在无纺布部件堆叠时通常发生的压力载荷下这些部件的厚度没有显著变化。
在本发明的意义上，熔喷无纺布是指使用已知的熔喷方法之一制造的无纺布。例如在US 4,118,531、US 4,375,446、US 4,380,570和DE 17 85 712 C3中描述了制造这类熔喷无纺布的方法。
此外，在本发明的意义上，面结构是指其厚度明显小于由其长度和宽度定义的面积的三维结构，特别是其中厚度为由其长度和宽度定义的面积的最多20％的三维结构。
根据本发明，通过在熔喷无纺布上施加相应的压力(在前述情况下为50Pa)来测量熔喷无纺布的压缩率。在施加压力之前和之后，测量所述熔喷无纺布的厚度。施加压力之前的无纺布厚度与施加压力之后的无纺布厚度之间的差值除以施加压力之前的无纺布厚度乘以100得到以百分率表示的熔喷无纺布的压缩率。无纺布的厚度是任选由间隔物界定的无纺布顶面与任选由间隔物界定的无纺布底面之间的距离。在此，施加压力之前的无纺布厚度和施加压力之后的无纺布厚度的测量优选根据DIN EN ISO 9073-2, 方法B和C或根据SAE J1355, 2007年1月版本中所述的方法来进行，其中在该方法中为了测量施加压力之后的无纺布厚度而施加相当于50Pa的相应测试压力。
对此替代地也可以通过如下方式容易地测定压缩率：将熔喷无纺布铺设在重量例如为20g/m2(相当于0.2 Pa)的两个平坦的泡沫聚苯乙烯板之间，并在不施加压力的情况下测量施加压力之前的无纺布厚度，其作为这些板的朝向无纺布的两个表面之间的距离。在此应注意的是，两个板与支承面是平面平行的。然后例如通过在这些板上施加相应的重量，在这些板上作用相应压力(在前述情况下为50 Pa)。当然，对此代替泡沫聚苯乙烯板，也可使用其它板，其中此时必须考虑上板的重量，以使得此时施加相应的重量，从而由该板的重量和所施加的重量而产生的压力相当于50Pa。对此替代地，也可以通过夹紧装置对这些板施以压力，以使得压力相当于50Pa。然后，测定在施加压力之后的无纺布的厚度，其作为两个板的与该无纺布相邻的两个边缘的距离。
优选地，当对该熔喷无纺布的表面上施加75Pa的压力时，所述熔喷无纺布具有小于10％的压缩率。特别优选地，当对该熔喷无纺布的表面施加的压力为100Pa，更优选125Pa，还更优选150Pa，特别优选175Pa，非常特别优选200Pa，最优选250Pa时，所述熔喷无纺布具有小于10％的压缩率。
换句话说，当对该熔喷无纺布的表面上施加50Pa的压力时，所述熔喷无纺布的压缩率小于10％，优选小于5％，更优选小于2.5％，特别优选小于1％，非常特别优选小于0.5％，最优选为0％。
在本发明构思的一个扩展方案中设置的是，当对该熔喷无纺布的表面上施加200Pa的压力时，所述熔喷无纺布的压缩率小于10％，优选小于5％，更优选小于2.5％，特别优选小于1％，非常特别优选小于0.5％，最优选为0％。
关于布置至少一个间隔物，本发明不受限制。例如，当本发明的熔喷无纺布具有至少一个和优选多个间隔物且所述间隔物i)布置在无纺布的顶面和/或底面上，和/或ii)至少部分地穿过无纺布延伸和任选地突出超过无纺布的顶面和/或底面时，实现良好的结果。
根据本发明的第一特别优选实施方案，所述至少一个间隔物由压缩无纺布组成。优选地，所述至少一个间隔物是通过施加机械压力而形成的凹陷，其中该凹陷的侧面和底面由压缩无纺布界定。优选地，由压缩无纺布界定的凹陷的底面在厚度方向上观察时以所述熔喷无纺布的厚度的0％至高达10％位于所述熔喷无纺布的底面下方，或者其突出超过该无纺布的底面。在该实施方案中，将由压缩无纺布制成的间隔物引入到所述无纺布中，所述间隔物可以容易地通过施加具有要引入的凹陷形状的压模并将该压模压入所述无纺布中来形成。与非压缩无纺布相比，由于压缩无纺布的机械稳定性远远高得多，因此这些间隔物可以在没有变形的情况下吸收位于其上的无纺布层的压力并由此实现所述熔喷无纺布的可堆叠性。
例如，所述凹陷可以具有长方体形或圆柱形的横截面形状。
在该实施方案中，如果所述凹陷的宽度为无纺布厚度的0.1倍至5倍，特别优选0.25倍至2倍，非常特别优选0.3倍至0.7倍，特别地获得良好的结果。在无纺布厚度优选为10至30mm的情况下，所述凹陷的宽度最优选为5至10mm。凹陷的宽度是指凹陷在横截面中的最长尺寸，即在所述凹陷的圆柱形横截面形状的情况下为直径。
为了得到良好的可堆叠性而没有变形风险，在本发明构思的扩展方案中建议，在熔喷无纺布中设置多个至少基本上均匀地布置在熔喷无纺布的表面上的间隔物，所述间隔物呈在其侧面和底面由压缩无纺布界定的凹陷的形式。优选地，这些凹陷在无纺布平面上观察时的彼此距离为50至500mm，优选100至300mm，特别优选150至250mm。前述距离是每个间隔物与每个另外相邻的间隔物在无纺布平面的每个方向上的距离。因此在足够高的可堆叠性和同时尽可能少的间隔物数量之间实现了良好的折衷。
根据本发明的替代前述实施方案、但同样优选的第二特别优选实施方案，所述至少一个在熔喷无纺布的厚度方向上布置的间隔物是由不同于该无纺布的其它材料形成的元件。
优选地，不同于所述无纺布的材料是尺寸稳定材料，如例如选自金属、塑料、陶瓷、木材、玻璃以及上述材料中的两种或更多种的任意组合的材料。
特别优选地，不同于所述无纺布的材料由相关或相容的原材料组成，以使得包括间隔物在内的无纺布的材料再循环成为可能。
在此，在该实施方案中，所述至少一个间隔物可以施加在所述无纺布的顶面和/或底面上并且优选通过胶粘剂、通过连接元件、通过热焊接或通过机械压制来固定。
对此替代地，所述至少一个间隔物可以穿过先前以不加压的方式引入到该无纺布中的缺口延伸，并且在厚度方向上观察时至少具有所述熔喷无纺布的厚度的90％至100％的尺寸或突出超过所述无纺布的顶面和/或底面。
特别是在所述至少一个间隔物具有圆柱形、长方体形或蘑菇形的形状的情况下，得到可容易制造性。
为了得到良好的可堆叠性而没有变形风险，在本发明构思的扩展方案中建议，在熔喷无纺布中设置多个至少基本上均匀地布置在熔喷无纺布的表面上的间隔物。优选地，这些间隔物在无纺布平面上观察时的彼此距离为50至500mm，优选100至300mm，特别优选150至250mm。
根据本发明的替代前述实施方案、但同样优选的第三特别优选实施方案，将局部附加无纺布施加到该无纺布上作为间隔物，以使得在熔喷无纺布的所述一个/多个区域中的总厚度大于该无纺布的其余部分的厚度。
在此，所述附加无纺布可以通过胶粘剂、热焊接或机械压制而固定在所述无纺布上。
在本发明构思的扩展方案中建议，将所述附加无纺布施加到所述无纺布的边缘区域的至少一部分上作为间隔物，以使得在该边缘区域中的总厚度大于该无纺布的其余部分的厚度。
例如，这可以容易地通过如下方式实现：将附加无纺布通过折叠熔喷无纺布而施加到该熔喷无纺布的边缘区域的至少一部分上，任选地压缩并优选通过胶粘剂、热焊接或机械压制而固定在该熔喷无纺布的边缘区域上。
根据本发明，所述大体积熔喷无纺布的单位面积重量为30至600g/m2，特别优选100至600g/m2。特别是如果所述大体积熔喷无纺布的单位面积重量为100至400g/m2，优选150至400g/m2，特别优选200至400g/m2，非常特别优选250至350g/m2，如例如300g/m2，在所获得的声学性能方面获得良好的结果。
此外，根据本发明，所述大体积熔喷无纺布的密度为5至50kg/m3。特别是如果所述大体积熔喷无纺布的密度为7至40 kg/m3，优选8至25 kg/m3，特别优选10至20 kg/m3，如例如15 kg/m3，在所获得的声学性能方面获得良好的结果。
所述熔喷无纺布的厚度优选为6至50mm，特别优选8至40mm，非常特别优选10至30mm，最优选15至25mm，特别是例如15或例如20mm。
关于长丝的化学性质，本发明的熔喷无纺布不受特别限制。原则上，熔喷无纺布的长丝可以由具有适合于挤出的熔点和在熔融状态下对于熔喷方法而言足够低粘度的各种聚合物，如例如由聚烯烃、聚酰胺、聚酯、聚苯硫醚、聚四氟乙烯或聚醚醚酮组成。由选自聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚丙烯和聚乙烯的聚合物组成的长丝被证明是特别合适的。根据本发明的熔喷无纺布的长丝非常特别优选由全同立构聚丙烯组成。
所述熔喷无纺布可以使用各个已知的熔喷方法来制造，如例如使用在US 4,118,531、US 4,375,446、US 4,380,570或DE 17 85 712 C3中描述的方法。原则上，无纺布通过如下方式在熔喷方法中制造：对通过喷嘴挤出的聚合物熔体从外侧施以流动空气并使其被拉伸，然后将由此形成的长丝铺设在载体上并冷却。在形成大体积熔喷无纺布的情况下，所述载体优选为双抽吸筒。
总体上，本发明使得能够制造可堆叠而不会变形并因此易于储存的熔喷无纺布。
下面，本发明参考阐释性、但不限制其的附图来描述。
在此：
图1示出了根据现有技术的没有间隔物的熔喷无纺布的示意图。
图2示出了根据图1的熔喷无纺布的示意图，其由于施加的机械压力而不可逆地变形。
图3示出了根据本发明的第一实施例的具有在熔喷无纺布的厚度方向上布置的间隔物的熔喷无纺布的示意图。
图4 示出了根据本发明的第二实施例的具有在熔喷无纺布的厚度方向上布置的间隔物的熔喷无纺布的示意图。
图5示出了根据本发明的第三实施例的具有在熔喷无纺布的厚度方向上布置的间隔物的熔喷无纺布的示意图。
图1示出了根据现有技术的没有间隔物的熔喷无纺布10的示意图，其根据DE 1785 712 C3中描述的方法制造。可看出熔喷无纺布10内的C形结构，其由于DE 17 85 712中描述的制造方法中的长丝帘幕的高频往复振荡而产生。
如果对根据现有技术的熔喷无纺布10施以压力，该压力例如由于将熔喷无纺布10与多层熔喷无纺布10堆叠而产生，则所述熔喷无纺布10被不可逆地压缩并保持变形，如图2所示。
为了提高熔喷无纺布10的抗压力载荷性和因此可堆叠性，根据本发明建议，在所述熔喷无纺布10中设置至少一个和优选多个间隔物12。图3中所示的间隔物12是通过施加机械压力而形成的凹陷14，其侧面和底面由压缩无纺布16界定，其中由压缩无纺布16界定的凹陷14的底面在厚度方向上观察时突出超过无纺布10的底面距离L。与非压缩无纺布10相比，由于压缩无纺布16的机械稳定性远远高得多，因此这些间隔物12可以在没有变形的情况下吸收位于其上的无纺布层的压力并由此实现所述熔喷无纺布10的可堆叠性。
在图4所示的实施方案中，在所述熔喷无纺布10的厚度方向上布置的间隔物12由不同于无纺布的其它材料制成，即是由塑料形成的蘑菇形元件12。在此，间隔物穿过先前以不加压的方式引入到无纺布10中的缺口18延伸，并且在该实施例中在厚度方向上观察时突出超过无纺布10底面距离L。
在图5所示的实施方案中，在熔喷无纺布10的左边缘和右边缘处将附加无纺布20作为间隔物施加在熔喷无纺布10上，以使得在熔喷无纺布10的这些区域中的总厚度大于所述无纺布的其余部分的厚度。在此，附加无纺布20在两个边缘处通过折叠熔喷无纺布10来施加、压缩和通过胶粘剂来固定。
通过在熔喷无纺布10中设置间隔物12，该间隔物在熔喷无纺布10的表面的至少一个上和/或至少部分地在熔喷无纺布10的厚度方向上延伸并且布置为使得当对该熔喷无纺布的表面施加的压力为50Pa时所述熔喷无纺布10具有小于10％的压缩率，各层熔喷无纺布10可以容易地彼此重叠地堆叠而不由此引起所述熔喷无纺布10的不可接受的变形和特别是压缩，这是因为所述各层各自通过其间隔物12接触并且被这些间隔物彼此间隔开，以使得上面的层不因其重量而压缩下面的层。由此实现了所述熔喷无纺布10的可容易储存性。
下面，本发明参考阐释性、但不限制本发明的实施例来描述。
实施例1
由具有平均5μm的长丝细度的全同立构聚丙烯长丝制造单位面积重量为300g/m2且厚度为15mm的熔喷无纺布。如先前结合所述实施方案所描述地，将具有图4所示形状且由最大抗压力载荷性大于2kg的聚苯乙烯制成的间隔物引入该熔喷无纺布中，并且更确切地说使得网格尺寸，即各个间隔物的距离为20cmx 20cm。
将66层的所述无纺布彼此堆叠，以使得总堆叠高度为约1米。因此，对于最下层而言的压力载荷为20 kg/m2，相当于约200 Pa，因此对于每平方米25个间隔物的每个而言的压力载荷为800g。由于每个间隔物在该压力下是尺寸稳定的，所以无法确定最下层的厚度变化。因此，最下层的熔喷无纺布在对其表面施加的200Pa的压力下的压缩率为0％。
附图标记列表：
10 熔喷无纺布
12 间隔物
14 凹陷
16 压缩无纺布
18 缺口
20 附加无纺布
L 由压缩无纺布界定的凹陷底面在厚度方向上观察时突出超过无纺布底面的距离。

Claims (15)

1.面结构形式的熔喷无纺布(10)，其单位面积重量为100至600g/m2且密度为5至50kg/m3，其中所述熔喷无纺布(10)具有至少一个在其至少一个表面上和/或至少部分地在熔喷无纺布(10)的厚度方向上延伸的间隔物(12)，所述间隔物布置为使得当对所述熔喷无纺布的表面施加的压力为50 Pa时，所述熔喷无纺布(10)具有小于10％的压缩率。
2.根据权利要求1所述的熔喷无纺布，其特征在于：当对其表面施加的压力为75Pa，优选100Pa，更优选125Pa，还更优选150Pa，特别优选175Pa，非常特别优选200Pa，最优选250Pa时，所述熔喷无纺布(10)具有小于10％的压缩率。
3.根据权利要求1或2所述的熔喷无纺布，其特征在于：所述至少一个间隔物(12)由压缩无纺布组成，其优选为在所述熔喷无纺布(10)中通过施加机械压力形成的凹陷(14)，其中凹陷(14)的侧面和底面由压缩无纺布(16)界定，其中由压缩无纺布(16)界定的凹陷(14)的底面优选在厚度方向上观察时以所述熔喷无纺布(10)的厚度的0％至高达10％位于熔喷无纺布(10)的底面下方或突出超过熔喷无纺布(10)的底面。
4.根据权利要求2或3所述的熔喷无纺布，其特征在于：所述凹陷(14)的宽度为所述无纺布(10)厚度的0.1倍至5倍，优选0.25倍至2倍，特别优选0.3倍至0.7倍。
5.根据权利要求3或4所述的熔喷无纺布，其特征在于：其具有多个凹陷(14)，所述凹陷在无纺布平面上观察时的彼此距离为50至500mm，优选100至300mm，特别优选150至250mm。
6.根据前述权利要求中至少一项所述的熔喷无纺布，其特征在于：所述至少一个间隔物(12)是由不同于无纺布的其它材料形成的元件，其中所述元件优选由选自如下的材料制成：金属、塑料、陶瓷、木材、玻璃以及上述材料中的两种或更多种的任意组合，并且所述元件特别优选由在化学方面与所述无纺布相关或相容的原材料组成，以使得包括间隔物在内的无纺布的材料再循环成为可能。
7.根据权利要求6所述的熔喷无纺布，其特征在于：所述至少一个间隔物(12)施加到所述无纺布(10)的顶面和/或底面上并且优选通过胶粘剂、通过连接元件、通过热焊接或通过机械压制来固定。
8.根据权利要求6或7所述的熔喷无纺布，其特征在于：所述至少一个间隔物(12)穿过先前以不加压的方式引入到所述无纺布(10)中的缺口(18)延伸，并且在厚度方向上观察时至少具有所述熔喷无纺布(10)的厚度的90％至100％的尺寸或突出超过所述无纺布(10)的顶面和/或底面，其中所述至少一个间隔物(12)优选具有圆柱形、长方体形或蘑菇形的形状。
9.根据权利要求6至8中任一项所述的熔喷无纺布，其特征在于：其具有多个间隔物(12)，所述间隔物在无纺布平面上观察时的彼此距离为50至500mm，优选100至300mm，特别优选150至250mm。
10.根据前述权利要求中至少一项所述的熔喷无纺布，其特征在于：将作为间隔物(12)局部附加的无纺布(20)施加到无纺布(10)上，以使得在该一个/多个区域中的总厚度大于无纺布(10)的其余部分的厚度，所述局部附加的无纺布(20)优选在无纺布(10)上通过胶粘剂、热焊接或机械压制来固定。
11.根据权利要求10所述的熔喷无纺布，其特征在于：将所述附加的无纺布(20)作为间隔物(12)施加到所述无纺布(10)的边缘区域的至少一部分上，以使得在该边缘区域中的总厚度大于所述无纺布(10)的其余部分的厚度。
12.根据权利要求11所述的熔喷无纺布，其特征在于：将所述附加的无纺布(20)通过折叠所述熔喷无纺布(10)而施加到所述熔喷无纺布(10)的边缘区域的至少一部分上，并通过胶粘剂、热焊接或机械压制而固定在所述熔喷无纺布(10)的边缘区域上。
13.根据前述权利要求中至少一项所述的熔喷无纺布，其特征在于：所述熔喷无纺布(10)的单位面积重量为100至400g/m2，优选150至400g/m2，特别优选200至400g/m2，非常特别优选250至350g/m2。
14.根据前述权利要求中至少一项所述的熔喷无纺布，其特征在于：所述熔喷无纺布(10)是大体积熔喷无纺布(10)，其具有7至40 kg/m3，优选8至25 kg/m3，特别优选10至20kg/m3的密度。
15.根据前述权利要求中至少一项所述的熔喷无纺布，其特征在于：所述熔喷无纺布(15)的厚度为6至50mm，优选8至40mm，特别优选10至30mm，最优选15到25mm。
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