CN1942616B - 包含用作阻碍物的纳米纤维的制品 - Google Patents

包含用作阻碍物的纳米纤维的制品 Download PDF

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Publication number
CN1942616B
CN1942616B CN2005800115061A CN200580011506A CN1942616B CN 1942616 B CN1942616 B CN 1942616B CN 2005800115061 A CN2005800115061 A CN 2005800115061A CN 200580011506 A CN200580011506 A CN 200580011506A CN 1942616 B CN1942616 B CN 1942616B
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China
Prior art keywords
nonwoven web
nanofiber
fiber
goods
cleaning piece
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CN1942616A (zh
Inventor
O·E·A·伊泽勒
R·查博拉
徐晗
S·K·莫雷
E·B·邦德
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Procter and Gamble Ltd
Procter and Gamble Co
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Procter and Gamble Ltd
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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
    • D04H13/00—Other non-woven fabrics
    • D04H13/02—Production of non-woven fabrics by partial defibrillation of oriented thermoplastics films
    • 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
    • D04H1/43838—Ultrafine fibres, e.g. microfibres
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15203—Properties of the article, e.g. stiffness or absorbency
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/45—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
    • A61F13/49—Absorbent articles specially adapted to be worn around the waist, e.g. diapers
    • A61F13/494—Absorbent articles specially adapted to be worn around the waist, e.g. diapers characterised by edge leakage prevention means
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/51121—Topsheet, i.e. the permeable cover or layer facing the skin characterised by the material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A61F13/51401—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by the material
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
    • A61F13/514—Backsheet, i.e. the impermeable cover or layer furthest from the skin
    • A61F13/51456—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties
    • A61F13/51458—Backsheet, i.e. the impermeable cover or layer furthest from the skin characterised by its properties being air-pervious or breathable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • 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
    • B32B5/22—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y40/00—Manufacture or treatment of nanostructures
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/42—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments
    • D01D5/423—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments by fibrillation of films or filaments
    • 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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/728—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by electro-spinning
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F2013/15284—Properties of the article, e.g. stiffness or absorbency characterized by quantifiable properties
    • A61F2013/15406—Basis weight
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    • A61F2013/15284—Properties of the article, e.g. stiffness or absorbency characterized by quantifiable properties
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    • Y10T442/2213—Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant
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    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]

Abstract

本发明涉及包括纳米纤维的制品。优选的制品包括尿布、训练裤、成人失禁衬垫、诸如女性护理衬垫和短裤护垫之类的经期用品、卫生棉塞、个人清洁制品、个人护理制品以及包括婴儿擦拭物、面部擦拭物、身体擦拭物和女性擦拭物在内的个人护理擦拭物。纳米纤维网可被用作阻碍物、擦拭物、吸收材料和其它用途。直径小于1微米的纳米纤维必须大量包括在非织造纤维网的至少一个纳米纤维层内。非织造纤维网可具有的水压头与基重比率大于约1kPa/gsm(10mbar/gsm)。纳米纤维可由熔膜原纤化方法进行生产。

Description

包含用作阻碍物的纳米纤维的制品
相关申请的交叉参考
本申请要求2004年4月19日提交的美国临时申请60/563,346的优先权。
发明领域
本发明涉及由纳米纤维制成的制品及该制品的阻碍性能。
发明背景
对由包含纳米纤维的非织造材料生产的制品的需求一直在持续增加。通常认为纳米纤维的直径小于约1000纳米或一微米。纳米纤维网因其表面积高、孔径低和其它特性而受到欢迎。可用多种方法和多种材料来制造纳米纤维，通常也称为微纤维或超细纤维。虽然已经采用了数种方法，但是每种方法均有缺点，并且生产高性价比纳米纤维仍存在着困难。
生产纳米纤维的方法包括通过熔体原纤化所描述的一类方法。熔体原纤化方法的非限制性实施例包括熔喷法、熔体纤维破裂法和熔膜原纤化法。不用熔体生产纳米纤维的方法为薄膜原纤化法、静电纺纱法和溶液纺丝法。生产纳米纤维的其它方法包括以海岛型、分割饼型或其它构型纺丝较大直径的双组分纤维，其中纤维随后被进一步加工以便形成纳米纤维。
熔体原纤化是制造纤维的一般类别，定义为其中一种或多种聚合物被熔融并挤压成多种可能的构型(例如复合挤压成型的均相或双组分薄膜或长丝)，然后被原纤化或纤维化成长丝。
熔喷法是生产纤维的常用方法。典型的纤维直径在2至8微米范围内。熔喷法可被用来制造直径较小的纤维但对工艺来说需要大量变化。通常，需要重新设计的喷丝头和喷丝板。这些方法的实施例包括Fabbricante等人的美国专利5,679,379和6,114,017，和Nyssen等人的美国专利5,260,003和5,114,631。这些方法利用较高的压力、温度和速度来获得小的纤维直径。
熔体纤维破裂法是的矿物纤维制造方法的衍生并已应用于聚合物纤维制造中。矿物熔体纤维破裂法的实施例包括Walz等人的美国专利4,001,357以及Muschelknautz等人的美国专利4,337,074和4,533,376。这种方法的关键是利用音速和超音速空气(气体)速度将熔融长丝破裂成多个细旦纤维。典型的纤维直径在小于1微米至约6微米的范围内。将聚合物熔体破裂成细旦纤维的方法的实施例包括Nyssen等人的美国专利5,075,161；Gerking的欧洲专利1 192 301 B1和0 724029 B1以及欧洲专利申请1 358 369 A2；Sodemann等人的WO04/020722。这些方法利用拉瓦尔喷嘴将气流速度加速至音速和/或超音速范围。当聚合物熔体被暴露到这么高的气速下时，将破裂成多个细旦纤维。通过利用所需的工艺条件及喷丝板和喷丝头几何形状将这些方法设定为生产理想的纤维尺寸。
熔膜原纤化法是生产纤维的另一种方法。由熔体产生熔膜，然后用流体由熔膜制成纳米纤维。该方法的两个实施例包括转让给University ofAkron的Torobin的美国专利6,315,806、5,183,670和4,536,361以及Reneker的美国专利6,382,526、6,520,425和6,695,992。
薄膜原纤化法是生产纳米纤维的另一种方法，尽管不是为用于非织造纤维网中的聚合物纳米纤维的生产而设计。转让给3M的Perez等人的美国专利6,110,588描述了给高度取向、高度结晶、熔融加工的凝固聚合物薄膜表面赋予流体能量以形成纳米纤维的方法。薄膜和纤维用于高强度应用场合，例如聚合物的增强纤维或如混凝土这类浇注建筑材料。
静电纺丝法是生产纳米纤维的一种常用方法。在该方法中，将一种聚合物溶解在一种溶剂中并放入一个隔室中，隔室在一端密封，在另一端颈缩部分具有一个小开口。然后靠近隔室的开口端在聚合物溶液和收集器之间施加高电压。这种方法的生产速度很慢并且纤维典型地以小批量进行生产。生产纳米纤维的另一种纺丝技术是利用溶剂的溶液纺丝或闪蒸纺丝。
生产纳米纤维的两步法也为人所熟知。第一步骤是以海岛型、分割饼型或其它构型纺丝较大直径的多组分纤维。较大直径的多组分纤维然后进行分裂或所述海被溶解以便在第二步骤中产生纳米纤维。例如，转让给Chisso的Nishio等人的美国专利5,290,626和转让给Kimberly-Clark的Pike等人的美国专利5,935,883分别描述了海岛型和分割饼型方法。这些方法涉及两个连续的步骤：制造纤维和分割纤维。
要生产具有商业竞争力的包含纳米纤维的一次性制品，必须控制纳米纤维的成本。设备、工艺、加工助剂以及聚合物成本均可被控制。因此，生产成本低的纳米纤维是本发明的一个目标。
也期望为多种用途和有益效果制成包含纳米纤维的产品。除了其它用途之外，用途包括执行品例如尿布、擦拭物和吸收材料。
发明概述
本发明涉及包含适于作为阻碍物的纳米纤维网的制品。所述制品可包括卫生、医用、工业、过滤和土工织物制品。卫生制品的非限制性实施例包括尿布、训练裤、成人失禁衬垫、诸如女性护理衬垫和短裤护垫之类的经期用品、卫生棉塞、个人清洁制品、个人护理制品和包括婴儿擦拭物、面部擦拭物、身体擦拭物和女性擦拭物在内的个人护理擦拭物。除了用作阻碍物之外，纳米纤维网还可用作擦拭物、吸收材料以及其它用途。纳米纤维网尤其可用作尿布内的液体阻碍物如外覆盖件、腿箍或阻碍层。也可将其用作用于降低液体梯度的擦拭物、材料的控制递送和其它用途。
直径小于1微米的纳米纤维可包括大量的纤维，优选大于制品所包含的一层纤维网中纤维的50％。对于较低的纤维网基重，纳米纤维可提供高的阻碍性和良好的透气率。
迄今为止，生产一种由常用的聚合物例如聚丙烯和聚乙烯制成的低基重的均匀纳米纤维网非常具有挑战性。静电纺纱是一种制造纳米纤维的常用方法，但不适于诸如聚丙烯和聚乙烯之类的聚烯烃。聚苯乙烯可被用于静电纺纱中，然而太脆并会形成珠球。另外，对于高速生产或对于纤网其它层的在线加工而言，静电纺纱并不是一种合适的方法。已经利用了制造纳米纤维的其它方法，然而还不足以控制来制造低基重的均匀纤维网。需要均匀纤维网，因为任何类型的孔洞或不均匀性均会产生不受欢迎的障碍。因此，对生产包含大量纳米纤维的均匀的低基重纤维网存在着很大的期望。
优选生产的非织造纤维网包含至少一个具有大量(优选大于50％)的直径小于一微米的纤维的层。也优选非织造纤维网的水压头与纳米纤维层基重比率大于约1kPa/gsm(10mbar/gsm)，优选大于约1.5kPa/gsm(15mbar/gsm)，更优选大于约2kPa/gsm(20mbar/gsm)，甚至更优选大于约3kPa/gsm(30mbar/gsm)。也可期望非织造纤维网的透气率大于约1m/min，优选大于约15m/min，更优选大于约30m/min，并且最优选大于约75m/min。水压头与透气率的乘积优选为至少约75kPa*m/min(750mbar*m/min)，更优选大于约100kPa*m/min(1000mbar*m/min)，甚至更优选大于约200kPa*m/min(2000mbarm/min)，并且最优选大于300kPa*m/min(3000mbar*m/min)。水压头与透气率的乘积除以基重典型地大于约50kPa*m/min/gsm(500mbar*m/min/gsm)，优选大于约75kPa*m/min/gsm(750mbar*m/min/gsm)，并且最优选大于约100kPa*m/min/gsm(1000mbar*m/min/gsm)。
阻碍性能可通过静水压头来测量，通常称为水压头测量。水压头可大于1kPa(10mbar)，并且典型地为约1.5至15kPa(15至约150mbar)。在纤维网的纳米纤维层内的大量纤维的平均纤维直径可小于一微米，优选约0.1微米至1微米，更优选约0.3微米至约0.9微米。纳米纤维层的基重可小于约25gsm，通常约0.1至约15gsm，优选小于10gsm或5gsm。取决于非织造纤维网的用途，纳米纤维层可具有的基重在约0.5至约3gsm或约0.5至约1.5gsm的范围内。将阻碍定义为对液体、固体和/或其混合物的阻碍。对于具体实施，通过用涂层进一步改性纤维和/或纤维网的表面可将阻碍设计用于某些表面张力液体或其它特殊用途，该涂层设计用来提供这种阻碍。例如，非织造纤维网可为涂敷表面以改进对低表面张力流体的阻碍性能。
本发明纤维网在使用期间也可提供一种物质的控制传输。一个实施例是擦拭物内洗剂的传输。可将擦拭物设计成通过采用纳米纤维选择性地控制阻碍性能。这样可实现定时以及区域传输。也可实现某些物质在包含多种物质的擦拭物内的传输。例如，可根据需要对亲水和疏水液体进行分配。控制传输也可为光线，因为不同区域的纤维网可容许不同数量的光线穿过纤维网。
纤维网均匀性可通过几种方法进行测定。均匀性测量的实施例包括孔径、基重、透气率和/或不透明性的低变异系数。均匀性也可意味着没有纤维束或结索或可见的孔洞或其它此类缺陷。均匀性也可通过纤维网的水压头或其它液体阻挡测量进行评价。阻挡得分越高通常表示纤维网更均匀。
孔径可通过本领域技术人员已知的方法进行确定。纳米纤维层的平均孔径优选小于约15微米，更优选小于约10微米，并且最优选小于约5微米。均匀纤维网的理想变异系数可小于20％，优选小于约15％，并且更优选约10％或更小。没有成束可通过在纤维网的测定面积上计数纤维索或束的数量进行测定。没有孔洞也可通过在纤维网的测定面积上计数直径超过某一阈值的洞的数目进行测定。可利用扫描电子显微镜或其它放大部件。例如，如果洞为肉眼所见或者直径大于100微米，则可利用灯箱对它们进行计数。
希望形成多层纤维网。纳米纤维层可与一个、两个或多个层相结合。纺粘-纳米纤维-纺粘纤维网是一个实施例。整体复合纤维网的基重在约5gsm至约100的范围内，并且通常在约10至约50gsm的范围内。
当今许多产品利用包含熔喷纤维的阻碍纤维网。熔喷纤维的平均直径为约2至8微米。熔喷纤维网将典型具有的水压头与基重比率为约0.3至0.5kPa/gsm(3至5mbar/gsm)。熔喷纤维网的基重通常为约2至约20gsm。取决于纤维网的形成方法，透气率典型地为约0.1至100m/min。
纳米纤维层可通过产生均匀纳米纤维层的任何方法来生产。纳米纤维优选由熔体原纤化方法生产，更优选由为熔膜原纤化方法生产。熔体原纤化方法通常包括以下步骤：提供聚合物熔体、利用中心流体流形成中空聚合物膜管和利用这种和/或其它流体流由所述中空管制成多根纳米纤维。可设计装置以在孔口处形成薄膜中空管，正压流体由此吹过薄膜中心，使其经受拉伸和骤冷过程，一旦局部粘度达到由材料特性所限定的临界状态，该过程使得薄膜粘度增加并原纤化。原纤化和凝固可发生在纤维和流体离开喷丝头之前。可设计装置使得中空聚合物膜管可具有熔融削弱区以有助于促使原纤化。制备纳米纤维的可供选择的设备是狭槽或狭缝类型的喷丝头设计，其生产出薄的相对平面薄膜(而不是中空膜管)，该薄膜产生纳米纤维。
附图概述
虽然本说明书通过指出并清楚地要求保护本发明的权利要求书作出结论，但应该相信通过下述说明书随附的附图可更好地理解本发明。
图1是示出不同纤维尺寸的水压头/基重比率的图表。
图2是示出不同纤维尺寸的水压头x透气率/基重的图表。
发明详述
本发明涉及由纳米纤维制成的制品。纳米纤维由一种或多种热塑性聚合物制成。适于本发明的热塑性聚合物的非限制性实施例包括聚烯烃、聚酯、聚酰胺、聚苯乙烯、聚氨酯、包括热塑性淀粉、PHA、PLA、淀粉组合物在内的可生物降解的聚合物以及它们的组合。均聚物、共聚物、和它们的共混物均包含于本说明书内。最优选的聚合物为诸如聚丙烯和聚乙烯、尼龙和聚对苯二甲  乙二醇酯之类的聚烯烃。
合适的热塑性聚合物包括适于熔体纺丝法的任何聚合物。聚合物的流变学性质必须使得聚合物可被熔融挤出。聚合物的熔融温度通常为约25℃至400℃。本发明的聚合物可具有小于每分钟约400分克的熔融流动速率。当聚合物存在于喷丝板中时进行该测量。采用ASTM方法D-1238测定熔融流动速率。优选地，熔融流动速率可小于每分钟约300分克，更优选小于每分钟约200分克，并且最优选小于每分钟约100分克。熔融流动速率的最优选范围为每分钟约1分克至每分钟约100分克。一般而言，熔融流动速率越低则越优选。因此，可利用熔融流动速率小于每分钟约40分克的聚合物。
纤维可为单组分纤维或诸如双组分纤维的多组分纤维。纤维可具有皮芯型或并列型或其它合适的几何构型。在纤维制成之后，在形成纤维网之前可对纤维进行处理或涂层。此外，在纤维网制成之后，可对纤维网进行处理。任选地，可将添加剂掺进聚合物树脂中，并且这些添加剂在纤维形成之后迁移至表面。迁移至表面的添加剂可能需要利用外部能量例如热量进行固化，或者表面上的添加剂可能需要与另一种组分进行化学反应，或者固化可能需要在另一种组分存在的情况下进行催化，使得可采用掺有添加剂的树脂在制造纤维的时候或在纤维制成之后将附加组分添加到加工过程中。适当的处理包括亲水或疏水处理。疏水处理剂的一个实施例为聚二甲基硅氧烷。具体的处理取决于使用的纤维网、聚合物种类和其它因素。所需的处理为本领域的技术人员所熟悉。
任选地，所述聚合物可包含另外的材料以提供纤维的其它性能。除了别的以外，这些材料还可改变所得纤维的物理属性例如弹性、强度、热或化学稳定性、外观、吸收性、气味吸收性、表面性质和印刷适性。可添加合适的亲水熔体添加剂。任选材料的存在量可为总聚合物混料的最多50％。
制备本发明纳米纤维的方法优选为熔体原纤化方法或更优选地为熔膜原纤化方法。通常，这种方法涉及提供聚合物熔体；利用中心流体流形成聚合物膜；然后使用流体由所述聚合物膜形成多根纳米纤维。合适的方法详述于如授予Torobin的美国专利4,536,361以及授予Reneker的美国专利6,382,526、5,520,425和6,695,992中。薄膜可为中空管、较平坦的结构或其它合适结构。
如4,536,361中进一步所述，聚合物被加热直到其成为液体并易于流动。熔融聚合物的温度可以为约0℃至约400℃，优选约10℃至约300℃，并且更优选约20℃至约220℃。聚合物的温度取决于聚合物或聚合物混料的熔点。聚合物的温度可超过其熔点不到约50℃，优选超过其熔点不到25℃，更优选超过其熔点不到15℃，以及刚好处在其熔点或其熔化范围内或之上。熔点或熔化范围用ISO 3146方法进行测量。熔融聚合物具有的粘度典型地将为约1Pa-s至约1000Pa-s，典型地为约2至约200Pa-s，并且更常见为约4至约100Pa-s。这些粘度在剪切速率在每秒约100至约100,000的范围内给出。熔融聚合物处在约大气压力或略高的压力下。
在一种方法中，通过在薄膜上并随后在管的内表面上吹气并施加压力，成纤流体可穿过聚合物流体膜以形成中空聚合物管。在6,695,992内详述的另一种方法中，成纤流体将由狭缝或狭槽类的喷丝板设计形成薄膜片。成纤流体可处在接近于熔融聚合物温度的温度下。成纤流体的非限制性实施例为诸如氮气之类的气体，更优选为空气。成纤流体温度可比熔融聚合物的温度高，以有助于聚合物的流动以及中空管或平面薄膜的成型。可供选择地，成纤流体温度可处在熔融聚合物温度之下，以有助于纳米纤维的成型和凝固。成纤流体温度超过聚合物熔点不到约50℃，优选超过聚合物熔点不到25℃，更优选超过聚合物熔点不到15℃，或刚好处于聚合物熔点或之上。成纤流体温度也可处在加工温度之下，低至15℃。成纤流体的压力足以吹制纳米纤维并在其被挤出喷丝孔时略微高于熔融聚合物的压力。
成纤流体将通常具有低于34.5Mpa(5000psi)的压力。成纤流体压力将优选小于6.9Mpa(1000psi)，更优选小于约690kPa(100psi)，并且最优选为约100至约550kPa(约15至约80psi)。
聚合物产量将主要取决于所用的具体聚合物，喷丝头样式以及聚合物的温度和压力。聚合物产量将超过每分钟每喷丝孔约1克。聚合物产量可优选大于每分钟每喷丝孔约5克，并且更优选大于每分钟每喷丝孔约10克。将有可能一次运行几个喷丝孔，这将增加总的生产量。产量连同压力、温度和速度一起在喷丝孔出口处进行测量。描述产量的另一种方法是使用术语挤压润湿长度。聚合物产量将超过每厘米挤压润湿长度约0.3克。挤压润湿长度定义为产生纳米纤维之前熔融薄膜的线性距离。例如，如果表明本发明是利用离散喷丝头且喷丝头孔口直径为1厘米，则该喷丝头的质量产出速率为1克/分钟，总速率为每厘米每分钟0.318克。聚合物产量将优选超过每厘米每分钟约3克，更优选大于每厘米每分钟约6克，并且最优选大于每厘米每分钟10克。
输送流体或其它流体可被用来产生脉动或波动压力场以有助于形成多根纳米纤维。输送流体可通过一个横向喷口来提供，定位横向喷口用来引导输送流体在薄膜和纳米纤维形成区域上和周围流动。输送流体的速度可为每秒约1至约100米，并且优选为每秒约3至约50米。输送流体的温度与上述成纤流体相同，但其典型地为与薄膜刚好形成时的熔融聚合物大约相同的温度。也可利用空气帘或其它辅助空气流来影响纳米纤维从两个或多个喷丝头的喷射图案。空气流或空气帘可有助于保护邻近喷丝头之间的喷射形成或者可有助于压缩喷射图案。空气帘或空气流可改进纤维网的均匀性。
可任选采用另一种流体流，骤冷或加热流体。可定位此第三种流体流以将流体引导进纳米纤维来冷却或加热纤维。如果流体被用作骤冷流体，则其温度为约-20℃至约100℃，优选为约10℃至40℃。如果流体被用作加热流体，则其温度为约40℃至400℃，并且典型地为约100℃至约250℃。任何流体流均有助于聚合物熔体的纤维化并因此可通常被称作成纤流体。任何流体流可包含用于改变所制备纤维的表面、化学、物理或力学性质的处理剂或添加剂。
喷丝孔或喷丝头至收集器的距离(通常称为喷丝板至收集器距离(DCD))可进行优化。优化可有助于生产更均匀的纤维网。DCD的减少有助于降低纤维成捆或成束的数量。这种较小的距离使纤维来不及缠结、彼此缠绕或成捆。可期望在纤维网利用不只一个的DCD、在生产期间改变DCD、或用不同的DCD产生不同的束。最理想的是通过改变DCD形成均匀性不同的纤维网。
其它由聚合物熔体制备纳米纤维方法的非限制性实施例包括熔体纤维破裂法、高级熔喷法、由多组分纤维的纤维分裂法和固体成膜法。利用将聚合物熔体破裂成细旦纤维的熔体纤维破裂法的实施例包括Nyssen等人的美国专利5,075,161；Gerking的欧洲专利1 192 301 B1和0 724029 B1以及欧洲专利申请1 358 369 A2；Sodemann等人的WO04/020722。这些方法利用拉瓦尔喷嘴将气流速度加速至音速和/或超音速范围。当聚合物熔体被暴露到这么高的气速下时，将破裂成多个细旦纤维。
Nyssen等人在美国专利5,075,161中公开了将聚苯硫醚熔体破裂成细旦长丝的方法。在该方法中，恰好在纺丝喷嘴之后放置拉瓦尔喷嘴。通过将聚合物熔体流挤压至气体介质中使其拉长并冷却至低于熔体温度，从而可生产具有平均纤维直径小于约6微米(优选约0.2微米至6微米)聚合物纤维，气体介质基本平行于聚合物熔体流流动并获得音速或超音速的速度。这种同时变形和冷却产生了有限长度的无定形的细旦或超细旦纤维。高速纤维爆裂使纤维的表面氧化达到最小。Sodemann等人的WO04/020722公开了通过利用音速及超音速的流体速度由热塑性聚合物的纤维破裂生产长丝纺粘非织造材料的类似方法。在所述方法中，拉瓦尔喷嘴放置在纺丝喷嘴之下。纺丝速度、熔体温度和拉瓦尔喷嘴的位置被近似设定以实现细旦长丝在它们的表面仅局部热氧化。已公开由这种方法生产的纤维具有小于1微米的直径，并在离散点相互连接。Gerking在欧洲专利申请1 192 301 B1和1 358 369 A2中所公开的方法和设备也利用拉瓦尔喷嘴将气体加速至音速及超音速的速度，从而可利用该气体将聚合物熔体破裂成多个细旦长丝。
熔膜原纤化方法在纤维的制备方式以及生产细旦长丝的起始熔体几何形状上与熔体纤维破裂法不同。熔膜原纤化法开始于薄膜，在一些情况下开始于中空熔膜管，其通过中心空气喷射变细，然后原纤化成多根纳米纤维。相反，熔体破裂法的起始熔体几何形状为长丝熔体。当在拉瓦尔喷嘴中暴露于音速和超音速气速时，其破裂成多根纳米纤维。由这些方法制成的纤维网可在均匀性上不同，这是由于纤维与纤维间的分隔以及纤维束构成的不同。
可采用各种方法和方法的组合来制造本发明的纤维网。优选的方法是生产均匀纳米纤维层的方法。熔体纤维破裂法可与熔膜原纤化法结合，其中在单条线上有两个单独的束。可将熔体纤维破裂法的各方面合并到熔膜原纤化法中。例如，可生产不同强度和直径的纤维以提供所需的性质组合。可供选择地，通过利用一个细长的中空管来形成纤维，可将熔体薄膜原纤化的各方面包括在其它熔体原纤化方法中以增加生产率。例如，可改进熔膜原纤化方法以包括一个拉瓦尔喷嘴帮助拉伸纤维。拉伸可有助于进一步拉细并增加纤维的强度。这对高Tg聚合物如聚酯尤其优选，其中应力诱导结晶。
本发明的纳米纤维用于制备适于制品中阻碍性能的非织造纤维网。纤维网的定义是整体的非织造材料复合物。纤维网可具有一层或几层，这些层通过热点粘合或其它技术被加固以获得强度、完整性及某些美观性质。一个层是在一个单独的纤维网铺展或成型步骤中产生的纤维网或纤维网的一部分。本发明的纤维网将包含一个或多个具有大量直径小于一微米的纳米纤维的层。大量的定义是至少约25％。大量纤维可为层中纤维总数的至少约35％、至少约50％或超过约75％。纤维网可具有超过约90％或约100％的直径小于约一微米的纤维。纤维网的纤维直径采用扫描电子显微镜进行测量。根据视觉分析的需要，放大倍数为大于约500倍以及最多约10,000倍。要确定是否大量纤维具有小于一微米的直径，必须测量至少约100根纤维，优选更多根纤维。测量必须在遍布整个层的不同区域进行。采样必须足够，满足统计意义上的显著性。
纳米纤维层内剩余的较大纤维(最多75％)的纤维可具有处在任何范围内的直径。典型地，较大的纤维直径将刚好在一微米之上至约10微米。
纳米纤维层内大量纤维的纤维直径优选小于约900纳米，并且更优选为约100纳米至约900纳米。纤维直径的其它优选范围为小于约700纳米和约300至约900纳米。优选的直径取决于纤维网的用途。期望有大量纤维的直径小于约一微米并且有大量纤维的直径大于约一微米。较大的纤维可捕集和固定纳米纤维。这可帮助减少纳米纤维的团聚或成束量并防止纳米纤维被逸出的气流吹走。
本发明纤维网中的纳米纤维层可包含一种以上的聚合物。不同的聚合物或共混聚合物可被用于不同孔口，在纤维网中产生具有不同纤维直径和不同聚合物混料的纤维层。
理想的是生产具有不同纤维直径的单层非织造材料。可供选择地，希望生产每层具有不同纤维直径的多层的非织造纤维网。可改进熔体薄膜原纤化方法生产小直径和大直径纤维以制造各种纤维网。较小直径纤维被认为是具有大量的直径小于一微米的纤维。较大直径纤维包括从熔喷范围(典型为3至5微米)至纺粘(典型为10微米左右)或1微米以上的任何纤维直径范围的纤维。例如，可生产平均纤维直径小于一微米的一个层和平均纤维直径5微米左右的另一个层。可在采用传统的纺粘-熔喷-纺粘(SMS)纤维网中使用这类结构。在同一条生产线上用同样的设备可生产具有不同纤维直径的纤维网。这是一种低成本的方法，因为可使用同样的设备和部件。运行成本和设备成本均可得到控制。同样，如果需要，可使用同样的聚合物产生不同的纤维直径。
本发明制品将包含上述非织造纤维网。纤维网可构成整个制品例如擦拭物，或者纤维网可包括制品的一个组分，例如尿布。卫生制品是优选的制品。卫生制品包括尿布、训练裤、成人失禁衬垫、诸如女性护理衬垫和短裤护垫之类的经期用品、卫生棉塞、个人清洁制品、个人护理制品以及包括婴儿擦拭物、面部擦拭物、身体擦拭物和女性擦拭物在内的个人护理擦拭物。个人护理制品包括诸如伤口敷料、活性成分递送包裹物或贴剂和用于身体尤其是皮肤的其它基质之类的制品。也需要用于个人或工业用途的一次性内衣或衣服及防护服。擦拭物的其它用途可为用于吸收或控制喷溅物的清洁居室擦拭物或净化擦拭物以及其它工业擦拭物。
在尿布中，纤维网可被用作阻碍层如芯上阻碍或外  盖件。纤维网也可被用作具有高静水压头的高阻碍箍，实现舒适性和贴合性所希望的裆部又  又窄的尿布的低泄漏事故率。利用纳米纤维的典型纤维网是这样的纤维网，其中纳米纤维层与至少一个纺粘层结合并利用热点粘合、水刺缠绕或其它合适且适于最终用途的技术加固。可有一个或两个纺粘层围绕纳米纤维层。
在尿布或其它一次性吸收制品中，可将含有纳米纤维的非织造纤维网用作阻碍层。阻碍层可设置在吸收芯和包含衣服的外层之间。吸收芯为制品主要起到诸如捕集、输送、分配和存储体液之类的流体处理性能作用的部件。吸收芯典型地位于液体可透过的身体侧内层和蒸汽可透过的、液体不可透过的外  盖件之间。外层也称作底片或外  盖件，其位于一次性制品的外侧。在尿布的情况下，外层接触使用者的衣服或衣物。阻碍层可供选择地或也被设置在吸收芯和内层之间。内层也称作顶片，其位于紧贴使用者皮肤的一侧上。内层可接触使用者的皮肤或可接触与使用者的皮肤接触的单独的顶片。阻碍层可为吸收材料。阻碍层最优选在对流的空气流和吸收阻挡性之间具有平衡。对流的空气流动性有效地降低吸收制品和穿着者的皮肤间的空间的相对湿度。液体吸收性和液体阻碍性的组合保护制品免除透湿问题并在吸收制品处在碰撞和/或持续压力下时尤其有益。阻碍层的进一步描述和有益效果可见于WO 01/97731中。
纤维网可被用于擦拭物中以改进洗剂处理性并降低液体梯度。纤维网也可提供物质的控制输送。输送的物质可为液体、洗剂、活性物质或其它材料。由于纳米纤维的高表面积，纤维网可被用作擦拭物或女性护理产品护垫、尿布、训练裤或成人失禁用品的芯的吸收材料。纤维网可增强流体的分配性和/或保持性。此外，用于吸收性用途的纤维网可用附加的颗粒或用于增加吸附性的吸收性纤维或天然纤维制造，或者纤维网的某些层可具有不同的性能。
纳米纤维也可被用于希望具有不透明性的制品中。因小纤维直径和均匀性，或可将颜料添加到聚合物熔体或纤维网中，可产生附加的不透明性。还已发现纤维网具有低的起绒性。这可能是由于较长的纤维或纤维网内纤维的缠绕。
将受益于纳米纤维网的其它产品包括过滤器。过滤器可用于工业、个人或家用，并且可用于过滤空气、液体或小颗粒。工业用途可包括汽车、炉子、水及其它类型的过滤器。一种个人过滤器包括过滤面具如手术口罩。含有纳米纤维层的纤维网的其它医疗用途包括外科手术衣、伤口敷料和医疗防渗层。纤维网也可用作噪音和热的绝缘体，以用于户外装置、衣服和可用作导电纤维。
测试方法
透气率
通过在恒定的压力和温度下测量其中标准体积的空气通过测试样本的时间来确定透气率。该测试尤其适于对气体具有较高渗透性的材料，例如非织造材料、开孔薄膜等。采用TexTest FX3300型仪器。(以TextestAG购自Switzerland(www.textest.ch)，或者购自Advanced TestingInstruments，Spartanburg SC，USA)。测试方法符合ASTM D737。测试在约22±2℃和约50％相对湿度的实验室环境下进行。测试压力为125帕斯卡以及测试面积为38cm2。在本测试中，仪器在整个样本上产生一个恒定压差，使空气吹过样本。空气流过样本的速率以ft3/ft2/min(常称为cfm或ft/min)或m/min测量。对于每个样本，应该取三个重复值，并且记录下平均结果。
静水压(水压)或排斥性测试
本测试测定的性质是对材料的液体阻碍性能(或液体不可渗透性)的量度。具体地讲，本测试测量材料在达到水渗透的控制含量时将承受的静水压。采用TexTest Hydrostatic Head Tester FX3000(购自AdvancedTesting Instruments，Corp.，Spartanburg，SC，或者以Textest AG购自Switzerland(www.textest.ch))。测试方法符合EDANA 120.2-02及INDA 80.6。对于该测试，将压力施加到限定的样本部分上并逐渐加压直至水渗过样本。测试在约22±2℃的温度和约50％的相对湿度的实验室环境下进行。将样本夹在柱夹顶端，采用合适的垫圈材料(O形环类型)以防止测试期间侧漏。水与样本接触面积等于水柱的横截面积，其等于28cm2。将水以0.3kPa/min(3mbar/min)的速度抽进水柱。因此，样本在一个表面上承受稳定增加的水压。当在样本另一个表面上的三个位置出现水渗透时，记录发生第三个渗透处的压力。如果水直接渗透样本(即，样本没有提供阻力)，则记录零读数。对每种材料测试三个样本，并记录平均结果。
基重或克重
基重可依照法定方法ASTM D 756、ISO 536和EDANA ERT-40.3-90测量。基重的定义为每单位面积的质量，优选单位为克每平方米(通常称为gsm而非g/m2)。所需的仪器为一把剪刀或一个用于样本切割的模压切割器和一个精密的称重装置(天平)。将样本切割到每层总面积100cm2，准确度和精密度为±0.5％。天平需要具有0.001g的灵敏度、可读、标定过并精确到施加载荷的0.25％范围内。样本被置于23摄氏度(±2℃)和约50％的相对湿度下2小时达到平衡。在一个分析天平上称出样本总面积为1000cm2＝0.1m2的10层切割样本的重量，精确到0.001g，并记录下重量。(对于比1mm厚的样本而言，称出仅1层的重量是优选的，但如果这样做应当注明)。通过将重量除以样本面积(所测试的所有层)计算基重，给出单位为gsm的基重。将所有的数据记录下来进行统计分析。
纤维直径(和旦)
纤维直径可采用扫描电子显微镜(SEM)和图象分析软件进行测定。选择500至10,000的放大倍数使得纤维(或长丝)被适当放大以便测量。图象分析软件对SEM图像中的纤维直径自动取样是可能的，但也可采用更加人工的程序。一般而言，寻找随机选取的纤维的边缘，然后横越宽度(在那点处垂直于纤维方向)至纤维的另一个边缘进行测量。带刻度的和标定过的图象分析工具提供标度以得到例如以米或mm或微米(μm)为单位的实际读数。因此，沿着SEM内的纤维网样本随机选择一些纤维或长丝。典型地，来自纤维网的一些样本被切割并用这种方式进行测试。总共进行至少约100次这样的测量并将所有的数据记录下来进行统计分析。如果结果要以旦为单位进行记录，那么需要进行下面的计算。以旦为单位的直径＝横截面积*密度*9000m*1000g/kg。横截面积是π*直径2/4。密度例如对于PP，可取为910kg/m3。若想结果为分特(dtex)，则采用10,000m来代替9000m。
实施例
已利用一些技术制备样本并用所述方法进行评价。样本为一个或多个纳米纤维层与邻近较大直径纤维层的挤出聚丙烯的复合物。此外，采用热点粘合方法对所有复合物进行加固或粘合。基重和纤维直径以平均数据给出。
样本类型 复合物 大直径纤维层 纳米纤维层
1  SMS，SM 直径12至20微米；基重5至20gsm每S层 直径0.7至4微米；基重2至20gsm。
2  SN 直径12至20微米，基重10至15gsm 直径0.5至0.9，基重0.5至22gsm。
3  纺粘-静电纺纱复合物(“静电纺纱”) 直径15至20微米，基重10至15gsm 直径0.1至0.3微米，基重2和3gsm。(2个样本)
在每一种样本类型中，以所列出的不同基重(依照线速度)制备多个样本，然后依照所述方法测试纤维尺寸、静水压头和透气率。“静电纺纱”样本的静水压头通过基于拉普拉斯方程的全面计算机模拟进行预测。采用聚丙烯的表面能。其它纤维网特征例如纤维尺寸、基重和厚度由平均纤维直径为0.1至0.3微米的静电纺纱尼龙-6获得。为给出复合物内纳米纤维层的效力，可用静水压头结果除以纳米纤维层的基重。给出样本之一作为样本类型1的比较实施例，如通过本领域的技术人员所已知的进行制备的SMS是一种复合物，S/M/S层的基重为13.5/3/13.5gsm，S层直径约18微米，并且M层直径约2微米。上述图表示出了几种样本以及纳米纤维层的基重和纳米纤维层的直径。
图1为图示水压头/基重对纤维直径尺寸的图表。如所能看出的，纳米纤维层内纤维的直径越细，用基重规一化时的静水压头结果越高。
在图2中，实施例中样本被评价为透气率(透气率方法)与液体阻碍性(采用静水压头方法)的联合乘积。图表图示了水压头x透气率/基重对纤维直径尺寸。重要的观察是在某一纤维直径范围内可达到最优值。产生该直径纤维的方法可以并不关键，但最终直径是重要的。
显示具有相似趋势的样本可采用其它技术制备，例如包含来自其它熔体原纤化方法的纤维网的复合物，例如采用海岛型。
为获得最佳的高液体阻碍性与透气率乘积，纳米纤维层内纤维的优选直径介于0.1和约1微米之间，最优选介于0.3和0.7微米之间。可供选择地，可利用各自的孔径描述该范围。
不受理论的约束，据信对于阻碍及透气性能存在最佳纤维尺寸。对于较大孔径，表面张力支配阻碍性能。对于中等孔径，表面张力和阻力均会影响阻碍性能。对于非常小的孔径(对于纳米纤维)，阻力支配阻碍性能。随着孔径增加，对液体阻碍的增加程度大于对空气阻碍的增加程度，这是由于液体阻力增加速率比空气阻力增加速率快。因此，最佳纤维直径尺寸可存在于透气率不显著减少而液体阻碍性能很高处。本文所用阻力是指摩擦阻力。
所有引用文献的相关部分均引入本文以供参考，任何文献的引用不可解释为是对其作为本发明的现有技术的认可。
尽管已用具体实施方案来说明和描述了本发明，但对于本领域的技术人员显而易见的是，在不背离本发明的精神和保护范围的情况下可作出许多其它的变化和修改。因此，有意识地在附加的权利要求书中包括属于本发明范围内的所有这些变化和修改。

Claims (20)

1.一种包括至少一个纳米纤维层的非织造纤维网，所述纳米纤维层具有至少50％的直径为300-900纳米的纳米纤维，所述纳米纤维层的基重小于25gsm以及平均孔径小于15微米，其中所述非织造纤维网具有水压头和透气率，其中水压头和透气率的乘积除以基重为大于500mbar*m/min/gsm。
2.如权利要求1所述的非织造纤维网，其中水压头和透气率的乘积除以基重为大于750mbar*m/min/gsm。
3.如权利要求1所述的非织造纤维网，其中所述纳米纤维层具有0.5gsm至3gsm的基重。
4.如权利要求1所述的非织造纤维网，其中所述纳米纤维层具有3gsm至15gsm的基重。
5.一种包括至少一个纳米纤维层的非织造纤维网，所述纳米纤维层具有至少50％的直径为300-900纳米的纳米纤维，所述纳米显微的基重小于25gsm以及平均孔径小于15微米，其中所述非织造纤维网具有的水压头为至少10mbar，并且透气率为至少15米每分钟，其中水压头和透气率的乘积除以基重为至少500mbar*m/min/gsm。
6.如权利要求5所述的非织造纤维网，其中所述非织造纤维网具有至少20mbar/gsm的水压头与纳米层基重比和至少75米每分钟的透气率。
7.如权利要求5所述的非织造纤维网，其中所述非织造纤维网的基重为0.5gsm至15gsm。
8.如权利要求5所述的非织造纤维网，其中水压头与透气率的乘积为至少750mbar*m/min。
9.一种包括如权利要求1所述的非织造纤维网的制品。
10.如权利要求9所述的制品，其中所述制品选自尿布、训练裤、成人失禁衬垫、经期用品、卫生棉塞、个人清洁制品、个人护理制品、个人护理擦拭物，以及它们的组合。
11.如权利要求10所述的制品，其中所述经期用品包括女性护理衬垫和短裤护垫。
12.如权利要求10所述的制品，其中所述个人护理擦拭物包括婴儿擦拭物、面部擦拭物、身体擦拭物和女性擦拭物。
13.如权利要求10所述的制品，其中所述非织造纤维网为阻碍层。
14.如权利要求13所述的制品，其中所述阻碍层设置在吸收芯和接触衣服的外层之间，或设置在吸收芯和接触使用者皮肤的内层之间。
15.如权利要求13所述的制品，其中所述非织造纤维网被表面涂敷以改进阻碍性能。
16.如权利要求5所述的制品，其中所述制品选自尿布、训练裤、成人失禁衬垫、经期用品、卫生棉塞、个人清洁制品、个人护理制品、个人护理擦拭物，以及它们的组合。
17.如权利要求16所述的制品，其中所述经期用品包括妇女护理衬垫和短裤护垫。
18.如权利要求16所述的制品，其中所述个人护理擦拭物包括婴儿擦拭物、面部擦拭物、身体擦拭物和女性擦拭物。
19.如权利要求16所述的制品，其中所述非织造纤维网为阻碍层。
20.如权利要求19所述的制品，其中所述阻碍层设置在吸收芯和接触衣服的外层之间，或设置在吸收芯和接触使用者皮肤的内层之间。
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JP2007533873A (ja) 2007-11-22
ZA200608860B (en) 2008-06-25
ES2361843T3 (es) 2011-06-22
AU2005236053A1 (en) 2005-11-03
US20060014460A1 (en) 2006-01-19
KR20070006912A (ko) 2007-01-11
EP1738006B1 (en) 2011-03-02
AU2005236053B2 (en) 2009-06-25
WO2005103354A1 (en) 2005-11-03
KR100843520B1 (ko) 2008-07-03
PL1738006T3 (pl) 2011-07-29
CA2561081C (en) 2009-10-20
CA2561081A1 (en) 2005-11-03
DE602005026640D1 (de) 2011-04-14
EP1738006A1 (en) 2007-01-03
US9464369B2 (en) 2016-10-11
CN1942616A (zh) 2007-04-04
US20160369439A1 (en) 2016-12-22
MXPA06011347A (es) 2006-12-15
BRPI0509999A (pt) 2007-10-16
ATE500366T1 (de) 2011-03-15
IL178704A0 (en) 2007-02-11

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