CN119507067A - Polyolefin composition, method for preparing nonwoven fabric, and nonwoven fabric - Google Patents
Polyolefin composition, method for preparing nonwoven fabric, and nonwoven fabric Download PDFInfo
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- CN119507067A CN119507067A CN202411748564.3A CN202411748564A CN119507067A CN 119507067 A CN119507067 A CN 119507067A CN 202411748564 A CN202411748564 A CN 202411748564A CN 119507067 A CN119507067 A CN 119507067A
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
- D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/10—Other agents for modifying properties
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/10—Other agents for modifying properties
- D01F1/106—Radiation shielding agents, e.g. absorbing, reflecting agents
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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
- D04H1/42—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
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
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- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Processes Of Treating Macromolecular Substances (AREA)
Abstract
本公开涉及一种聚烯烃组合物、使用该聚烯烃组合物制备非织造织物的方法和包含该聚烯烃组合物的非织造织物或由所述方法得到的非织造织物。本公开的聚烯烃组合物具有优异的机械性能、较窄的分子量分布、良好的可纺性，特别是在纺丝过程中滴落少，由其得到的织物表面缺陷少且织物性能优异。本公开的制备非织造织物的方法采用较低的温度和较低的牵伸风压箱的压力，使得纺丝过程滴落少且减少了织物缺陷。
The present disclosure relates to a polyolefin composition, a method for preparing a nonwoven fabric using the polyolefin composition, and a nonwoven fabric comprising the polyolefin composition or a nonwoven fabric obtained by the method. The polyolefin composition disclosed in the present disclosure has excellent mechanical properties, a narrow molecular weight distribution, and good spinnability, especially less dripping during the spinning process, and the fabric obtained therefrom has fewer surface defects and excellent fabric properties. The method for preparing a nonwoven fabric disclosed in the present disclosure adopts a lower temperature and a lower pressure of a drafting air pressure box, so that the spinning process has less dripping and reduces fabric defects.
Description
Technical Field
The present disclosure relates to a polyolefin composition, a method of preparing a nonwoven fabric using the polyolefin composition, and a nonwoven fabric comprising the polyolefin composition or a nonwoven fabric obtained by the method.
Background
In the nonwoven industry, there are many bi-component recycling diaper auxiliary materials that are either discarded or sold to third party processors for recycling at an unfavorable price.
It is counted that in the nonwoven spunbond industry, about 15% of the recovered adjunct is produced during the manufacturing process. However, only up to 10% of the recovered auxiliary material is returned to the extruder to reduce waste. However, for recycled bicomponent material adjuncts, nonwoven processors have to sell these adjuncts to third party processors at the detrimental price of scrap in order to achieve closed loop recycling economy and attempt to recycle these adjuncts back onto the production line.
There is thus a need to develop a viable solution to achieve a cyclic economy of closed loop and a material that has good properties and is suitable for the spinning industry.
Disclosure of Invention
One aspect of the present disclosure relates to a polyolefin composition, wherein the components forming the polyolefin composition comprise:
(i) A first polypropylene;
(ii) A compound masterbatch comprising, based on the total weight of the compound masterbatch:
4-35% by weight of a propylene-based elastomer,
65-96% By weight of a bicomponent material of polypropylene and polyethylene, and
0-5% By weight of an antioxidant,
And
Wherein the amount of the polypropylene and polyethylene bicomponent material is 2 to 8.4 wt%, such as 5 to 8.4 wt%, based on the total weight of the polyolefin composition.
In one aspect, the present disclosure relates to a method of making a nonwoven fabric using the polyolefin composition of the present disclosure, wherein the method is performed using an apparatus comprising an extruder, a die, a spinneret, a draft wind box, a web, calender rolls, and a winder, wherein the temperature of the extruder zone immediately adjacent to the die and the die is 190-215 ℃, e.g., 195-205 ℃, and the pressure of the draft wind box is 2450-2600Pa, e.g., 2500-2580Pa.
In one aspect, the present disclosure relates to a nonwoven fabric comprising the polyolefin composition of the present disclosure or a nonwoven fabric resulting from the process of the present disclosure.
The polyolefin composition disclosed by the disclosure has excellent mechanical properties, relatively narrow molecular weight distribution, good spinnability, particularly small dripping in a spinning process, and the fabric obtained by the polyolefin composition has few surface defects and excellent fabric performance. The method of making nonwoven fabrics of the present disclosure employs lower temperatures and lower draft wind box pressures, resulting in less dripping during spinning and reduced fabric defects.
Drawings
Fig. 1 (a), (b) and (c) show atomic force microscope pictures of compound masterbatches 1, 2 and 3, respectively.
Detailed Description
Polyolefin composition
One aspect of the present disclosure relates to a polyolefin composition, wherein the components forming the polyolefin composition comprise:
(i) A first polypropylene;
(ii) A compound masterbatch comprising, based on the total weight of the compound masterbatch:
4-35% by weight of a propylene-based elastomer,
65-96% By weight of a bicomponent material of polypropylene and polyethylene, and
0-5% By weight of an antioxidant,
And
Wherein the amount of the polypropylene and polyethylene bicomponent material is 2 to 8.4 wt%, such as 5 to 8.4 wt%, based on the total weight of the polyolefin composition.
In forming the components of the polyolefin composition, the compound masterbatch may be present in an amount of 3 to 30 wt% (e.g., 5 wt%, 6 wt%, 8 wt%, 10 wt%, 12 wt%, 15 wt%, 20 wt%, or 25 wt%), such as 5 to 20 wt%, based on the total weight of the polyolefin composition.
In one embodiment, the compound masterbatch has a molecular weight distribution (Mw/Mn) of 3-3.45 (e.g., 3.1, 3.2, 3.3, or 3.4), or has a molecular weight distribution of 3.1-3.3.
In one embodiment, the compound masterbatch has a melt flow rate of 20-45g/10min (e.g., 25g/10min, 30g/10min, 35g/10min, 38g/10min, 40g/10min, 42g/10min, or 44g/10 min), such as 25-45g/10min or 25-40g/10min, as determined according to ASTM D1238 under a load of 2.16kg at 230 ℃.
According to the present disclosure, the compound masterbatch comprises 4-35 wt% (e.g., 6 wt%, 8 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 or 32 wt%) of the propylene-based elastomer, e.g., 6-35 wt%, such as 10-32 wt%, or 20-32 wt%, or 25-30 wt%, of the propylene-based elastomer, based on the total weight of the compound masterbatch. According to the present disclosure, propylene-based elastomers may improve spinnability of the polyolefin composition at higher amounts in the compound masterbatch, e.g. above 25 wt%, such as 30 wt%, significantly reducing surface defects of the resulting fabric.
The propylene-based elastomer comprises units derived from propylene and units derived from one or more C 2 or C 4-C12 alpha-olefins. In the propylene-based elastomer, the amount of units derived from propylene may be at least 60 wt%, or at least 75 wt%, or at least 80 wt%. In one embodiment, the propylene-based elastomer comprises at least 60 wt% or at least 75 wt%, or at least 80 wt% units derived from propylene and 3 to 25 wt% (e.g., 5 wt%, 8 wt%, 10 wt%, 12 wt%, 15 wt%, 18 wt%, or 20 wt%) units derived from one or more C 2 or C 4-C12 α -olefins. For example, the alpha-olefin may have 2 to 8 carbon atoms. The alpha-olefin may be selected from 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene or 1-octene.
The units derived from one or more C 2 or C 4-C12 alpha-olefins may consist essentially of units derived from ethylene, for example at least 95 wt% or at least 98 wt% of the units derived from one or more C 2 or C 4-C12 alpha-olefins are units derived from ethylene. In one embodiment, the units derived from one or more C 2 or C 4-C12 α -olefins consist of units derived from ethylene.
In one embodiment, the propylene-based elastomer has a melt flow rate of from 12 to 30g/10min (e.g., 14g/10min, 15g/10min, 18g/10min, 20g/10min, 22g/10min, 25g/10min, or 28g/10 min), such as from 15 to 25g/10min, as determined according to ASTM D1238 under a load of 2.16kg at 230 ℃.
In one embodiment, the propylene-based elastomer has a density of 0.84 to 0.92g/cm 3 (e.g., 0.88g/cm 3 or 0.90g/cm 3).
In one embodiment, the propylene-based elastomer is a semi-crystalline propylene-ethylene copolymer prepared by a metallocene catalyst. For example, the propylene-based elastomer has a crystallinity of 1% to 40% (e.g., 2%, 5%, 10%, 15%, 20%, 25%, 30%, or 35%), or has a crystallinity of 2% to 30%.
According to the present disclosure, the compound masterbatch comprises 65-96 wt% (e.g., 66 wt%, 67 wt%, 68 wt%, 69 wt%, 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 92 wt%, or 94 wt%) of a two-component material of polypropylene and polyethylene, e.g., 69-92 wt%, or 67-78 wt%, 68-78 wt%, or 69-78 wt%, or 80-92 wt% of a two-component material of polypropylene and polyethylene, based on the total weight of the compound masterbatch.
The weight ratio of polypropylene to polyethylene in the bicomponent material of polypropylene and polyethylene may be 10:1-1:5 (e.g. 9:1, 8:1, 7:1, 6:1, 5:1, 4:1, 3:1, 2:1, 1:1, 1:2, 1:3 or 1:4), such as 8:1-1:1 or 5:1-2:1.
The weight average molecular weight (Mw) of the bicomponent materials of polypropylene and polyethylene may be 7-20 ten thousand g/mol (e.g. 8-15 ten thousand g/mol, 9-10-12-15-or 18-thousand g/mol). The bicomponent materials of polypropylene and polyethylene may have a number average molecular weight (Mn) of 2.5 to 8 thousand g/mol (e.g., 2.8, 3, 3.5, 4, 5, 6 or 7 thousand g/mol), for example 3 to 6 thousand g/mol. The polypropylene and polyethylene bicomponent materials may have a molecular weight distribution (Mw/Mn) of 2.2 to 4 (e.g., 2.5, 2.8, 3, 3.2, 3.5, or 3.8), for example, 2.5 to 3.5.
According to the present disclosure, the bicomponent material of polypropylene and polyethylene may be recycled material (e.g. material recovered from hygiene articles) or scrap, such as scrap in industrial production. The two-component material may first undergo a densification process, such as by forming a popcorn material through a densification process, and then be used to prepare a compound masterbatch.
According to the present disclosure, the amount of the polypropylene and polyethylene bicomponent material is 2-8.4 wt% (e.g., 2.5 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, or 8.2 wt%) such as 5-8.4 wt%, based on the total weight of the polyolefin composition.
According to the present disclosure, the compound masterbatch comprises 0-5 wt% (e.g., 0.01 wt%, 0.02 wt%, 0.05 wt%, 0.08 wt%, 0.1 wt%, 0.2 wt%, 0.5 wt%, 0.8 wt%, 1 wt%, 2 wt%, 3 wt%, or 4 wt%) of an antioxidant, e.g., 0.05-5 wt%, such as 0.1-2 wt%, or 0.1-1 wt%, or 0.1-0.8 wt% of an antioxidant, based on the total weight of the compound masterbatch. Antioxidants include, for example, hindered phenols, hindered amines, phosphates and phosphites.
According to the present disclosure, the components forming the polyolefin composition may further comprise an additional propylene-based elastomer (iii), i.e. a propylene-based elastomer other than the propylene-based elastomer in the compound masterbatch. The amount of the additional propylene-based elastomer (iii) may be from 1 to 15 wt% (e.g., 2 wt%, 3 wt%, 5 wt%, 8 wt%, 10 wt%, 12 wt%, or 14 wt%), such as from 5 to 10 wt% of the additional propylene-based elastomer (iii), based on the total weight of the polyolefin composition. According to the present disclosure, the additional propylene-based elastomer (iii) (e.g., when used in an amount of 5 wt% or more) helps to improve spinnability of the polyolefin composition and reduce surface defects of the resulting fabric. The specific details of the additional propylene-based elastomer (iii) are as described above for the propylene-based elastomer in the masterbatch.
According to the present disclosure, the amount of the first polypropylene may be 60-95 wt% (e.g., 65 wt%, 68 wt%, 70 wt%, 72 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 92 wt%, or 94 wt%) such as 70-92 wt% or 70-85 wt% or 72-85 wt%, based on the total weight of the polyolefin composition.
The first polypropylene has a melt flow rate of 1 to 500g/10min (e.g., 2g/10min、5g/10min、10g/10min、15g/10min、20g/10min、30g/10min、40g/10min、50g/10min、80g/10min、100g/10min、150g/10min、200g/10min、250g/10min、300g/10min、350g/10min、400g/10min or 450g/10 min), such as 5 to 200g/10min or 10 to 100g/10min or 15 to 50g/10min, as measured according to ASTM D1238 under a load of 2.16kg at 230 ℃.
The polypropylene may be predominantly crystalline, e.g. having a melting point of 110-170 ℃ (e.g. 110 ℃, 115 ℃, 130 ℃, 140 ℃, 150 ℃ or 160 ℃), or 115-160 ℃ or 130-150 ℃.
The term "crystalline" as used herein is characterized by those polymers having a high degree of intermolecular and intramolecular order. The polypropylene has a heat of fusion of at least 60J/g, or at least 70J/g, or at least 80J/g, as determined by DSC analysis. The heat of fusion depends on the composition of the polypropylene.
The polypropylene may have a weight average molecular weight (Mw) of 40,000 to 1,000,000 g/mole, or 50,000 to 500,000 g/mole, or 80,000 to 400,000 g/mole. The number average molecular weight (Mn) may be 20,000 to 70,000 g/mole, or 30,000 to 60,000 g/mole, or 40,000 to 55,000 g/mole. The molecular weight distribution (Mw/Mn) may be from 1.5 to 5.5 or from 2 to 5 or from 2.5 to 4.5.
There is no particular limitation on the method of preparing the polypropylene of the present disclosure. For example, the polymer may be a propylene homopolymer obtained by homopolymerization of propylene in a single-stage or multistage reactor. The polymerization process includes a high pressure, slurry, gas, bulk or solution phase or combinations thereof using conventional Ziegler-Natta catalysts or single-site metallocene catalyst systems or combinations thereof, including bimetallic supported catalyst systems. The polymerization may be carried out by continuous or batch processes and may include the use of chain transfer agents, scavengers, or other additives deemed suitable. Most preferably, however, a Ziegler-Natta catalyst is used to form the polypropylene homopolymer.
According to the present disclosure, the first polypropylene is a propylene homopolymer.
In one embodiment, the components forming the polyolefin composition further comprise 0.1 to 5 wt% (e.g., 0.2 wt%, 0.4 wt%, 0.5 wt%, 0.8 wt%, 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, 4 wt%, or 4.5 wt%) of a slip masterbatch, such as 0.2 to 2 wt%, based on the total weight of the polyolefin composition. In one embodiment, the slip masterbatch is an erucamide based slip masterbatch.
In one embodiment, the components forming the polyolefin composition comprise:
(i) 60 to 95 weight percent of a first polypropylene based on the total weight of the polyolefin composition;
(ii) 3-30 wt% of a compound masterbatch based on the total weight of the polyolefin composition, the compound masterbatch comprising, based on the total weight of the compound masterbatch:
4-35% by weight of a propylene-based elastomer,
65-96% By weight of a bicomponent material of polypropylene and polyethylene, and
0-5% By weight of an antioxidant,
And
(Iii) 0 to 15 weight percent of an additional propylene-based elastomer based on the total weight of the polyolefin composition, (iv) 0 to 5 weight percent of a slip masterbatch based on the total weight of the polyolefin composition;
wherein the amount of the polypropylene and polyethylene bicomponent material is 2 to 8.4 wt%, such as 5 to 8.4 wt%, based on the total weight of the polyolefin composition.
In one embodiment, the components forming the polyolefin composition comprise:
(i) From 70 to 92 weight percent of a first polypropylene based on the total weight of the polyolefin composition;
(ii) From 5 to 20 weight percent, based on the total weight of the polyolefin composition, of a compound masterbatch comprising, based on the total weight of the compound masterbatch:
10 to 32% by weight of a propylene-based elastomer,
65-90% By weight of a bicomponent material of polypropylene and polyethylene, and
0-5% By weight of an antioxidant,
And
(Iii) 1 to 15 weight percent of an additional propylene-based elastomer based on the total weight of the polyolefin composition, (iv) 0.1 to 5 weight percent of a slip masterbatch based on the total weight of the polyolefin composition;
wherein the amount of the polypropylene and polyethylene bicomponent material is 2 to 8.4 wt%, such as 5 to 8.4 wt%, based on the total weight of the polyolefin composition.
In one embodiment, the components forming the polyolefin composition comprise:
(i) From 70 to 92 weight percent of a first polypropylene based on the total weight of the polyolefin composition;
(ii) From 5 to 20 weight percent, based on the total weight of the polyolefin composition, of a compound masterbatch comprising, based on the total weight of the compound masterbatch:
20 to 32% by weight of a propylene-based elastomer,
65-80% By weight of a bicomponent material of polypropylene and polyethylene, and
0.05-2 Wt% of an antioxidant, and
(Iii) 5 to 15 weight percent of an additional propylene-based elastomer based on the total weight of the polyolefin composition, (iv) 0.1 to 5 weight percent of a slip masterbatch based on the total weight of the polyolefin composition;
wherein the amount of the polypropylene and polyethylene bicomponent material is 2 to 8.4 wt%, such as 5 to 8.4 wt%, based on the total weight of the polyolefin composition.
In one aspect, the present disclosure relates to a polyolefin composition, wherein the components forming the polyolefin composition comprise:
(i) 70 to 85 weight percent of a first polypropylene based on the total weight of the polyolefin composition;
(ii) From 5 to 20 weight percent of a compound masterbatch based on the total weight of the polyolefin composition, the compound masterbatch comprising, based on the total weight of the compound masterbatch:
20 to 32% by weight of a propylene-based elastomer,
67-78 Wt% of a polypropylene and polyethylene bi-component material, wherein the polypropylene and polyethylene bi-component material has a weight ratio of polypropylene to polyethylene of 5:1-2:1, and
0.1-2 Wt% of an antioxidant;
The melt flow rate of the compound masterbatch is 20-45g/10min, such as 25-40g/10min, as measured according to ASTM D1238 at 230 ℃ under a load of 2.16 kg;
The compound masterbatch has a molecular weight distribution of 3 to 3.45;
(iii) From 5 to 10 weight percent of an additional propylene-based elastomer based on the total weight of the polyolefin composition;
(iv) 0.2 to 2 weight percent of a smooth masterbatch based on the total weight of the polyolefin composition;
wherein the amount of the polypropylene and polyethylene bicomponent material is 5 to 8.4 wt% based on the total weight of the polyolefin composition, and
The propylene-based elastomer has a melt flow rate of 15-25g/10min, as measured according to ASTM D1238 under a load of 2.16kg at 230 ℃.
Method for producing a nonwoven fabric and nonwoven fabric
One aspect of the present disclosure relates to a method of making a nonwoven fabric using the polyolefin composition of the present disclosure, wherein the method is performed using an apparatus comprising an extruder, a die, a spinneret, a drawing wind box, a web, calender rolls, and a winder, wherein the temperature of the extruder zone immediately adjacent to the die and the die is 190-215 ℃ (e.g., 192 ℃, 195 ℃, 198 ℃, 200 ℃, 202 ℃, 205 ℃, 208 ℃, 210 ℃, and 212 ℃) such as 195-205 ℃, and the pressure of the drawing wind box is 2450-2600Pa (e.g., 2480Pa, 2500Pa, 2520Pa, 2550Pa, or 2580 Pa), such as 2500-2580Pa.
In the process of the present disclosure, continuous filaments are formed from the polyolefin composition and formed into a web, which is then thermally bonded by (heated) calender rolls to form a nonwoven fabric.
The temperature of the other zones of the extruder may be 10-40 ℃, e.g. 20-35 ℃, higher than the die temperature.
The temperature of the calender rolls is typically 120-160 ℃, for example 130-150 ℃.
Those skilled in the art will appreciate that in the process of the present disclosure, the polyolefin composition is passed sequentially through an extruder, a die, a spinneret, a draw box, a web, calender rolls, and a winder.
One aspect of the present disclosure relates to a nonwoven fabric comprising the polyolefin composition of the present disclosure or a nonwoven fabric resulting from the process of the present disclosure.
The nonwoven fabric of the present disclosure may have 1,2,3, or 4 of the following properties:
The nonwoven fabric of the present disclosure may have a machine direction maximum tensile strength of 20 to 30N (e.g., 21N, 22N, 23N, 24N, 25N, 26N, or 28N), for example 20 to 25N;
The nonwoven fabric of the present disclosure may have an elongation corresponding to the maximum strength in the machine direction of 50-70% (e.g., 51%, 52%, 55%, 58%, 60%, 62%, 65%, or 68%), for example 52-68%;
the nonwoven fabric of the present disclosure may have a cross-machine direction maximum tensile strength of 10 to 20N (e.g., 11N, 12N, 13N, 14N, 15N, 16N, or 18N), for example 10 to 15N;
the nonwoven fabrics of the present disclosure may have an elongation corresponding to a maximum tenacity in the cross direction of 40-70% (e.g., 41%, 42%, 45%, 48%, 50%, 55%, 60%, 65%, or 68%), for example 42-65%, or 48-65%.
The tensile test, i.e., the test of the maximum tensile strength and elongation corresponding to the maximum strength, may be performed according to Edana test method WSP 110.4 (05), "Standard test method for nonwoven breaking force and elongation (banding)", option B.
The present invention can be more readily understood by those skilled in the art from the following embodiments:
1. a polyolefin composition, wherein the components forming the polyolefin composition comprise:
(i) A first polypropylene;
(ii) A compound masterbatch comprising, based on the total weight of the compound masterbatch:
4-35% by weight of a propylene-based elastomer,
65-96% By weight of a bicomponent material of polypropylene and polyethylene, and
0-5% By weight of an antioxidant,
And
Wherein the amount of the polypropylene and polyethylene bicomponent material is 2 to 8.4 wt%, such as 5 to 8.4 wt%, based on the total weight of the polyolefin composition.
2. The polyolefin composition according to embodiment 1 wherein the amount of the compound masterbatch is 3 to 30 wt%, such as 5 to 20 wt%, based on the total weight of the polyolefin composition, and/or the melt flow rate of the compound masterbatch is 20 to 45g/10min, such as 25 to 40g/10min, as determined according to ASTM D1238 at a load of 2.16kg, 230 ℃.
3. The polyolefin composition according to embodiment 1 or 2 wherein the amount of the two-component material of polypropylene and polyethylene in the compound masterbatch is 69 to 92 wt% or 67 to 78 wt%, based on the total weight of the compound masterbatch.
4. The polyolefin composition according to any of embodiments 1-3 wherein the amount of propylene-based elastomer in the compound masterbatch is 6-35 wt%, such as 10-32 wt% or 20-32 wt%, based on the total weight of the compound masterbatch.
5. The polyolefin composition according to any of embodiments 1-4 wherein the amount of antioxidant in the compound masterbatch is 0.05-5 wt%, such as 0.1-2 wt%, based on the total weight of the compound masterbatch.
6. The polyolefin composition according to any of embodiments 1-5 wherein the components forming the polyolefin composition further comprise from 1 to 15 weight percent, such as from 5 to 10 weight percent, of an additional propylene-based elastomer (iii), based on the total weight of the polyolefin composition.
7. The polyolefin composition according to any of embodiments 1-6 wherein the propylene-based elastomer comprises units derived from propylene and units derived from one or more C 2 or C 4-C12 α -olefins, e.g. the propylene-based elastomer comprises at least 60 wt% or at least 75 wt% of units derived from propylene and 3 to 25 wt% of units derived from one or more C 2 or C 4-C12 α -olefins, and/or the propylene-based elastomer has an MFR of 12 to 30g/10min, such as 15 to 25g/10min, as determined according to ASTM D1238 at a load of 2.16kg, 230 ℃.
8. The polyolefin composition according to embodiment 7 wherein in the propylene-based elastomer the units derived from one or more C 2 or C 4-C12 α -olefins consist essentially of ethylene.
9. The polyolefin composition according to any of embodiments 1-8 wherein the weight ratio of polypropylene to polyethylene in the bicomponent material of polypropylene and polyethylene is 10:1-1:5, such as 8:1-1:1 or 5:1-2:1.
10. The polyolefin composition according to any of embodiments 1-9 wherein the amount of the first polypropylene is 60 to 95 wt%, such as 70 to 92 wt% or 70 to 85 wt%, based on the total weight of the polyolefin composition, and/or the first polypropylene has a melt flow rate of 1 to 500g/10min, such as 5 to 200g/10min or 10 to 100g/10min, as measured according to ASTM D1238 under a load of 2.16kg, 230 ℃.
11. The polyolefin composition according to any of embodiments 1-10 wherein the components forming the polyolefin composition further comprise 0.1-5 wt%, such as 0.2-2 wt%, of a smooth masterbatch (iv), based on the total weight of the polyolefin composition.
12. The polyolefin composition according to any of embodiments 1-11 wherein the weight average molecular weight of the bicomponent material of polypropylene and polyethylene is 7-20 ten thousand g/mol or 8-15 ten thousand g/mol.
13. A polyolefin composition, wherein the components forming the polyolefin composition comprise:
(i) 70 to 85 weight percent of a first polypropylene based on the total weight of the polyolefin composition;
(ii) From 5 to 20 weight percent of a compound masterbatch based on the total weight of the polyolefin composition, the compound masterbatch comprising, based on the total weight of the compound masterbatch:
20 to 32% by weight of a propylene-based elastomer,
67-78 Wt% of a polypropylene and polyethylene bi-component material, wherein the polypropylene and polyethylene bi-component material has a weight ratio of polypropylene to polyethylene of 5:1-2:1, and
0.1-2 Wt% of an antioxidant;
The melt flow rate of the compound masterbatch is 20-45g/10min, such as 25-40g/10min, as measured according to ASTM D1238 at 230 ℃ under a load of 2.16 kg;
The compound masterbatch has a molecular weight distribution of 3 to 3.45;
(iii) From 5 to 10 weight percent of an additional propylene-based elastomer based on the total weight of the polyolefin composition;
(iv) 0.2 to 2 weight percent of a smooth masterbatch based on the total weight of the polyolefin composition;
wherein the amount of the polypropylene and polyethylene bicomponent material is 5 to 8.4 wt% based on the total weight of the polyolefin composition, and
The propylene-based elastomer has a melt flow rate of 15-25g/10min, as measured according to ASTM D1238 under a load of 2.16kg at 230 ℃.
14. A method of making a nonwoven fabric using the polyolefin composition according to any of embodiments 1-13, wherein the method is performed using an apparatus comprising an extruder, a die, a spinneret, a drawing wind box, a web, calender rolls, and a winder, wherein the temperature of the extruder zone immediately adjacent to the die and the die is 190-215 ℃, e.g., 195-205 ℃, and the pressure of the drawing wind box is 2450-2600Pa, e.g., 2500-2580Pa.
15. A nonwoven fabric comprising the polyolefin composition according to any of embodiments 1-14 or a nonwoven fabric obtained from the process according to embodiment 14.
Examples
The following examples serve to illustrate, but not limit, the invention. The amounts of each material in the examples are based on weight unless otherwise indicated.
Raw materials
PP3155E5 ExxonMobil TM PP3155E5 propylene homopolymer, having 36g/10min MFR (ASTM D1238,2.16kg,230 ℃), commercially available from ExxonMobil;
Vistamaxx TM BF: propylene-based elastomer, a semi-crystalline propylene-ethylene copolymer prepared by a metallocene catalyst having an ethylene content of 15wt%, having an MFR of 20g/10min (ASTM D1238,2.16kg,230 ℃) and a density of 0.863g/cm 3, commercially available from ExxonMobil (hereinafter 7020 BF);
The bicomponent PP/PE (70/30) is a scrap of a bicomponent material of polypropylene and polyethylene having a propylene/ethylene weight ratio of 70/30, a weight average molecular weight (Mw) of 109,284 g/mol, a number average molecular weight of 37,4819 g/mol, a molecular weight distribution (Mw/Mn) of 2.93, from Fitesa Simpsonville;
Antioxidant: 168, phosphite antioxidants, available from BASF;
and the smooth master batch is erucamide-based smooth master batch.
Method of
Atomic Force Microscopy (AFM) each sample was frozen microtomed to form a smooth surface at-125 ℃ prior to scanning and purged under N 2 in a desiccator prior to AFM imaging. Imaging was performed on an Icon AFM according to EM-120. The scan dimensions included 85 μm and 45 μm on the body regions of the two regions. The TESPA tip is used for scanning, and the monitored data channels are height and phase;
Melt Flow Rate (MFR) measured according to ASTM D1238 at a load of 2.16kg and at 230 ℃;
Molecular weight distribution as measured by GPC;
differential Scanning Calorimetry (DSC) based on ASTM D-3418;
average fiber size (average fiber width) measured using a Calzeiss Axio Scope A1 microscope, wherein 10 fiber sizes were measured at 10 random locations on the fabric sample and averaged, the results are shown in Table 5;
Tensile test according to Edana test method WSP 110.4 (05), "Standard test method for nonwoven breaking force and elongation (banding method)", option B: edana ERT20.2-89: "50mm banding tensile test specimen", wherein five nonwoven bands 50mm wide and about 250mm long were prepared in the Machine Direction (MD) and Cross Direction (CD), respectively, for each fabric sample. The samples were conditioned in a constant temperature laboratory at 23 ± 2 ℃ and 50% ± 10% relative humidity for at least 40 hours. The nonwoven fabric strips were tested on a Zwick material tester Z010TN at a test speed of 100mm/min and the results were averaged.
EXAMPLE 1 preparation of compound masterbatch
The two-component PP/PE material is crushed and then densified for subsequent preparation of the compound masterbatch. In particular, the bi-component PP/PE material is cut into small pieces by a high speed rotor in a long cylindrical device and compacted into a popcorn shape during which the material does not melt or undergo any heat treatment, but some heat is generated due to the shearing action, so that the surface of the material reaches a temperature of 60-70 ℃. After densification, the cooled popcorn material is collected from the apparatus for later preparation of the compound masterbatch.
The compound masterbatch was prepared using a twin screw extruder with an L/D of 44:1, a co-rotating twin screw extruder, and a maximum throughput of 500kg/h. The temperature profile of the twin-screw extruder was such that the temperature in zones 1 to 10 was 190-205 ℃. The densified bicomponent PP/PE material was fed to the main feeder, the antioxidant and 7020BF were mixed and fed through the side feeder. Compound masterbatches 1,2 and 3 were prepared from the components and amounts shown in table 1. The MFR, molecular weight distribution and Differential Scanning Calorimetry (DSC) results of the compound masterbatch are also shown in table 1.
TABLE 1
As can be seen from table 1, the molecular weight distribution of compound masterbatch 3 with 7020BF added was reduced by 7% compared to compound masterbatch 1, which is advantageous for better processability during the nonwoven fiber spinning process.
Atomic force microscopy pictures of compound masterbatches 1,2 and 3 are shown in fig. 1 (a), (b) and (c), respectively, wherein compound masterbatch 1 shows larger polymer domains. Compound masterbatches 2 and 3 exhibited finer dispersion of regularly sized polymer domains, so 7020BF may improve the phase dispersion of the two-component PP/PE material. The improved phase dispersion helps to improve the spinning stability of the nonwoven fibers and the overall mechanical properties of the nonwoven fabric.
Example 2 preparation of nonwoven fabric samples 1-7 and spinning Process therein
Nonwoven fabric samples 1-7 were prepared using the compound masterbatch prepared in example 1 and the other components shown in table 2. The components shown in table 2 were processed on a single-end spunbond line from macroco, which included, in order, an extruder, a die, a spinneret, a draft wind box, a web, calender rolls and a winder, wherein continuous filaments were formed and a web was formed using a spunbond process, and then thermally bonded by heated calender rolls to produce a spunbond fabric of 15 grams per square meter basis weight. Table 3 below shows the processing parameters for this experiment. Table 4 shows a comparison of processing parameters of the conventional process with those of the present disclosure, and other processing parameters of the conventional process are the same as the present disclosure. The average fiber widths and tensile properties of fabric samples 1-7 are shown in table 5.
Similar to the preparation of fabric samples 2-4, the preparation of spunbond fabrics was also performed using 9% of compound masterbatch 1 instead of compound masterbatch 2, respectively, however, the filaments were often interrupted during spinning, and the resulting fabric samples were severe in defects and failed to be successfully prepared by the spunbond process.
TABLE 2 preparation of the components of fabric samples 1-7 and weight percent thereof
| PP3155E5 | Compound masterbatch 2 | Compound masterbatch 3 | 7020BF | Smooth master batch | |
| Fabric sample 1 | 99% | - | - | - | 1% |
| Fabric sample 2 | 90% | 9% | - | - | 1% |
| Fabric sample 3 | 85% | 9% | - | 5% | 1% |
| Fabric sample 4 | 80% | 9% | - | 10% | 1% |
| Fabric sample 5 | 87% | - | 12% | - | 1% |
| Fabric sample 6 | 82% | - | 12% | 5% | 1% |
| Fabric sample 7 | 77% | - | 12% | 10% | 1% |
As shown in table 2, for the fabric samples with the addition of 9% of compound masterbatch 2 or 12% of compound masterbatch 3, the amounts corresponding to the two component PP/PE in the fabric samples were 8.08 wt% and 8.38 wt%, respectively.
Applicants have also attempted to prepare fabric samples containing more than 8.4% bicomponent PP/PE, however severe dripping occurred during spinning.
During the spinning process, it was observed that the addition of 5% 7020BF to the preparation of fabric samples 3 and 6 resulted in improved spinnability compared to the preparation of fabric samples 2 and 5, respectively, with fewer drips, the spinnability of fabric sample 4 with the addition of 10%7020BF being similar to fabric sample 3, and the spinnability of fabric sample 7 with the addition of 10%7020BF being similar to fabric sample 6. In the spinning process for preparing fabric samples 5, 6 and 7, a significantly improved spinnability was observed due to the use of compound masterbatch 3, and the surface of the resulting fabric samples had few defects, compared to the preparation process for fabric samples 2, 3 and 4, respectively.
TABLE 3 processing parameters for preparing fabric samples
| Processing parameters | Processing condition setting |
| Total flow (kg/h) | 150 |
| Extruder temperature zone 1 (°c) | 200 |
| Extruder temperature zone 2 (°c) | 215 |
| Extruder temperature zone 3 (°c) | 230 |
| Extruder temperature zone 4 (°c) | 230 |
| Extruder temperature zone 5 (°c) | 200 |
| Die temperature (°c) | 200 |
| Draft wind pressure (Pa) | 2570 |
| Embossing calender roll temperature (°c) | 145 |
| Smooth calender roll temperature (°c) | 143 |
TABLE 4 comparison of processing parameters of conventional methods with processing parameters of the present disclosure
| Conventional method | Processing parameters of the present disclosure | |
| Extruder temperature zone 5 (°c) | 230°C | Reduced by 30 DEG C |
| Die temperature (°c) | 230°C | Reduced by 30 DEG C |
| Draft wind pressure (Pa) | 2800Pa | Reduce by 8% |
When spinning was performed using the processing parameters of the conventional method shown in table 4 (other parameters of the conventional method are the same as the present disclosure), a yarn breakage phenomenon was observed seriously during spinning, and the resulting fabric sample was more defective. In the process of the present disclosure, the use of lower melt temperatures and die temperatures and appropriate reduction of draft wind pressure results in a fabric with significantly reduced defects and less dripping during spinning compared to conventional processes.
Table 5:
As can be seen from table 5, fabric samples 2-6 containing different amounts of propylene-based elastomer 7020BF provided better tensile properties in both the machine and cross directions than fabric sample 1 without any propylene-based elastomer 7020 BF.
The propylene-based elastomer 7020BF contributes to achieving a cyclic economical closed loop of the two-component PP/PE material. The propylene-based elastomer 7020BF improves the quality and performance of the compound masterbatch. In the spunbond spinning process, the propylene-based elastomer 7020BF contributes to improved spinning stability and fabric properties.
While the invention has been described in terms of preferred embodiments, the invention is not so limited. Any person skilled in the art should not depart from the spirit and scope of the present invention and should therefore fall within the scope of the invention as defined by the appended claims.
Claims (15)
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