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CN114161783A - 一种热复合速渗导流材料及其应用 - Google Patents

一种热复合速渗导流材料及其应用 Download PDF

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Publication number
CN114161783A
CN114161783A CN202111284000.5A CN202111284000A CN114161783A CN 114161783 A CN114161783 A CN 114161783A CN 202111284000 A CN202111284000 A CN 202111284000A CN 114161783 A CN114161783 A CN 114161783A
Authority
CN
China
Prior art keywords
composite
flow guide
layer
fiber
rapid infiltration
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202111284000.5A
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English (en)
Inventor
任继春
王娟
冯勋旺
屈义俭
马克·纽曼
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fitesa China Airlaid Co Ltd
Original Assignee
Fitesa China Airlaid Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fitesa China Airlaid Co Ltd filed Critical Fitesa China Airlaid Co Ltd
Priority to CN202111284000.5A priority Critical patent/CN114161783A/zh
Publication of CN114161783A publication Critical patent/CN114161783A/zh
Pending legal-status Critical Current

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Abstract

本发明提供了一种在线热复合速渗导流材料及其应用，包括相互液体连通的速渗导流层和无尘纸层；速渗导流层的材料为多孔性非织造材料，占复合速渗导流材料总质量的8‑85％；无尘纸层包括至少一层纤维层，纤维层的材料为纤维素纤维和双组分复合纤维，无尘纸层的质量占复合导流材料无尘纸总质量的15‑92％；纤维层中纤维素纤维的质量占该层纤维层总质量的5‑95％，双组份复合纤维的质量占该层纤维层总质量的5‑95％；当纤维层的层数为两层或两层以上时，相邻纤维层之间液体连通。本发明所述的复合速渗导流材料制得的卫生巾产品蓬松柔软、回弹性好、生产成本低、整体性能好、结构简单新颖，不仅具有快速液体导流、速渗、扩散、临时贮存液体，还具有优良抗返渗性能。

Description

一种热复合速渗导流材料及其应用
本申请为分案申请，原申请的申请号为201710284171.5，申请日为2017.4.26，专利名称为一种在线热复合速渗导流材料。
技术领域
本发明涉及一种蓬松柔软、回弹性好、生产成本低、整体性能好、结构简单新颖的在线热复合速渗导流材料，具有快速液体导流、速渗、扩散、临时贮存液体，并具有优良抗返渗性能的复合导流材料，包括该复合速渗导流材料的结构、生产工艺和应用。
背景技术
无尘纸(亦称为膨化芯材)是以几毫米长的木浆纤维为主要原料，通过气流成网及不同固结方法生产出来的。这种技术可生产出各种不同厚度、不同柔软度、不同吸湿性的材料，其产品主要用于纸尿裤、妇女卫生用品、成人失禁用品等一次性用即弃卫生用品。
卫生巾的结构由外至内大致可概括为四层：面层、导流层、吸收层、底层、外包装。其中速渗(Z方向导流)、快速吸收、大量吸收及防返渗是卫生巾的关键要求。传统的导流层的材料用的是吸湿性差的多孔性非织造布材料(如热风无纺布)，其Z向导流快速，但对液体横向(X方向和Y方向)的导流扩散性非常差，而且试验研究发现，对于用于导流作用的传统多孔性非织造布材料，液体在被导流的过程中，易被吸附在非织造布材料的孔隙中，这些被孔隙吸附的液体会导致返渗值高，影响表面干爽性能。之后，因无尘纸具有良好吸液性和扩散性，故将无尘纸材料用作一次性卫生用品的导流层，其较传统的导流材料提高了对液体扩散性。
公开号CN103409941B公开了一种100％可降解的导流材料，该导流材料中均使用的是可降解材料，且底衬层为可完全降解的絮纸(卫生纸)材料，在应用到卫生巾时，该絮纸层是和卫生巾中的吸收层相接触(联接)的，主要起到联通和将上层中的液体快速扩散开的作用。该技术方案的有益效果是绿色环保，但在实际应用中因PLA纤维的昂贵价格限制了其广泛应用。另外，絮纸(卫生纸)材料在使用中遇水后强度会大大被破坏，使其在结构中失去整体性。
公开号CN103006391B公开了一种复合无尘纸，该复合无尘纸是集导流层和吸收层于一体的复合材料，该复合无尘纸结构新颖，同时具有快速液体导流、吸收、保持性能和防返渗的性能。但因该复合无尘纸中加入了高分子吸水材料，为了保证底衬层和与其相邻层的粘合强度，需要同时加入粉状或颗粒状的粘结材料，并在生产工艺过程中需要较大的压力，虽然增加了粘结效果，但会影响材料的蓬松性、反弹性能和导流效果，也增加了原料成本；另一缺点是粉状粘结材料增加了生产过程的控制复杂性，成型过程中会因真空作用有微量的粉状粘结材料透过底衬材料(当真空度波动较大时，亦有粉状粘结材料透过的现象)，影响非织造材料的孔隙，进而影响整个产品的质量。另外在卫生巾生产使用时，该导流复合无尘纸的尺寸需要与卫生巾的面层面积一样大小，而一般的卫生巾吸收层芯体面积是小于面层的，所以使用该复合无尘纸会导致部分原料的浪费。
发明内容
本发明的目的是克服现有技术的缺陷，提供一种在线热复合速渗导流材料，该复合速渗导流材料由具有快速渗入导流作用的多孔性非织造布材料和起到吸收作用及扩散作用的纤维素纤维、复合纤维及其它起到粘结作用的材料通过一定的特殊结构设计在气流成网工艺中完成。
该复合速渗导流材料应用于卫生巾等卫生用品结构中的导流层，是一种高性能的简单高效的新型导流材料，应用该复合速渗导流材料制得的卫生巾产品蓬松柔软、回弹性好、生产成本低、整体性能好、结构简单新颖，不仅具有快速液体导流、速渗、扩散、临时贮存液体，还具有优良抗返渗性能。为达到很好的液体导流、扩散、适当层间结合强度和蓬松柔软等性能的要求，各层的结构、材料选择及工艺控制是非常关键的。其设计原理与常规现有技术的不同，参见附图1-4所示。
为达到上述目的，本发明的技术方案是这样实现的：
一种在线热复合速渗导流材料，包括相互液体连通的速渗导流层和无尘纸层；
所述的速渗导流层的材料为多孔性非织造材料，占复合速渗导流材料总质量的8-85％；
所述的无尘纸层包括至少一层纤维层，所述纤维层的材料为纤维素纤维和双组分复合纤维，所述无尘纸层的质量占复合速渗导流材料总质量的15-92％；所述纤维层中纤维素纤维的质量占该层纤维层总质量的5-95％，双组份复合纤维的质量占该层纤维层总质量的5-95％；当纤维层的层数为两层或两层以上时，相邻纤维层之间液体连通。
本发明的复合速渗导流材料整体设计为速渗导流层和无尘纸层两层，根据目前市场的需求及特点，纤维层的层数可设计为一层、两层或三层，可以通过改变设计层数及各层的材料种类及配比，得到不同结构及性能的一次性热复合材料。
进一步的，所述无尘纸层的外表面压制有纵向的等间距或非等间距的条纹，所述条纹的宽度为1-10mm。
优选地，所述条纹的宽度为2-5mm。
进一步的，所述多孔性非织造材料为梳理成型的热风无纺布、梳理成型的化学粘合无纺布、打孔无纺布或水刺无纺布。
进一步的，所述纤维素纤维为经过处理或未经过处理的绒毛浆、针叶木浆、阔叶木浆、草浆、化学浆、化学机械浆、热机浆的纤维中一种或两种以上的混合物,其长度为2-5mm，且具有多种形态。
进一步的，所述双组分复合纤维为聚丙烯一聚乙烯共聚物、聚对苯二甲酸二乙酯一聚乙烯共聚物、聚对苯二甲酸二乙酯一聚丙烯共聚物中一种或两种以上的混合物，所述双组分复合纤维的长度为2.5-10mm，纤度为1.0-17分特，具有多种截面结构。
进一步的，所述无尘纸层的外表面喷涂有乳胶，质量占复合速渗导流材料总质量的0-20％。
当喷涂乳胶时，不仅在生产中起到除尘，更有助于材料很好的复合，并起到产品的表面整饰作用；亦可以不喷涂乳胶，但得到的复合速渗导流材料中粉尘会比喷涂乳胶的材料略高一些，当有应用场合对粉尘要求不是特别严格的情况下，可以不用喷涂乳胶，所得到的复合速渗导流材料相对更柔软些；当然，当不喷涂乳胶时，亦可以适当增加无尘纸中最外层纤维层中复合纤维的比例，亦可以起到提高降低粉尘的作用。
进一步的，所述乳胶为醋酸乙烯酯一乙烯型乳液、丙烯酸酯类乳液、苯乙烯一丁二烯类乳液、苯乙烯丁二烯一丙烯酸类乳液或聚乙烯醇中一种或两种以上的混合物。
该复合速渗导流材料的定量为25－400g/m2，厚度为0.4-8mm，抗张强度不小于10N/inch，液体渗透速度不大于3秒，液体保持能力大于7g/g蒸馏水；该复合速渗导流材料的另一特点是蓬松柔软，材料密度一般小于0.15g/cc(克每立方厘米)，且材料有很好的回弹性，成品经三个月老化后放置后，回弹能力可以达到10％以上。
本发明的另一个目的是提供一种该在线热复合速渗导流材料的制备工艺，该复合速渗导流材料是采用气流成网制造工艺在成型过程中一次性连续生产完成的，具体包括以下步骤：
1)将速渗导流层的材料用开卷机展开形成速渗导流层并输送到成型区；
2)将步骤(1)得到的速渗导流层传递到第一成型区，将纤维素纤维和双组份复合纤维输送至第一成型头中均匀混合形成混合物，通过气流成型及真空抽吸作用，使该混合物经过第一成型头而均匀地铺落在速渗导流层上，形成第一层纤维层，得到具有两层的复合层；
3)当复合速渗导流材料中的无尘纸层为两层或两层以上的纤维层时，所述制备工艺还包括如下步骤：将步骤(2)得到的具有一层纤维层的复合层传递到下一成型区中，将纤维素纤维和复合纤维输送至下一成型区内的成型头中均匀混合形成混合物，通过气流成型和真空抽吸作用，使该混合物铺落到上一层纤维层表面，并根据纤维层的层数依次重复该步骤，得到复合层；
4)将上一步得到的复合层输送到第一加热烘箱中进行加热，烘干固化，其中，所述第一加热烘箱设定的温度小于150℃；
复合层中的双组份复合纤维受热后，表层材料溶化并将周围材料粘结在一起，使材料有了一定的复合强度；本发明经过多次试验，为达到良好的材料蓬松和柔软性能，需要对该过程的温度进行严格控制，一般不宜高于150℃。
5)将经过步骤(4)处理的复合层输送至喷胶工序，对复合层中最外层纤维层的外表面喷涂乳胶；
为保证材料的柔软性能，乳液的浓度不宜过高，一般在20％以下为宜；
6)将经过步骤(5)喷胶工序的复合层输送到第二加热烘箱中进行再次加热，烘干固化形成复合速渗导流材料产品，其中，所述第二加热烘箱设定的温度小于150℃；
7)将复合速渗导流材料产品冷却后进行卷绕成卷；
8)将成卷的复合速渗导流材料产品切成所要求的不同宽度的产品。
进一步的，为取得较好的层间结合效果，在第一个成型头、第二个成型头之间以及最后一个成型头之后安装有预压辊，分别对上一步得到复合层进行预压。该步骤会影响产品的厚度。
进一步的，在步骤(3)之前还包括使用沟纹辊对复合层中无尘纸层的外表面进行的条纹压花处理，所述沟纹辊的沟纹间隙为1-10mm，优选为2-5mm。同时需控制一定的压力和温度。
进一步的，所述步骤(6)之前还包括如下步骤：将步骤(5)得到的复合速渗导流材料产品输送到第三加热烘箱中进行再次加热，烘干固化，其中，所述第三加热烘箱设定的温度小于150℃；
该步骤可使复合层中的双组份复合纤维中的表层材料进一步熔化，加强复合强度，同时可以将所喷涂的乳胶进行烘干固化，亦起到加强材料复合强度的作用。根据本公司设备工艺特点，还设计有第三加热烘箱，可以根据复合材料的设计及应用需求，选择性的使用该组烘箱；如前所述，本发明经过多次试验，为达到良好的材料蓬松和柔软性能，需要对该过程的温度进行严格控制，一般不宜高于150℃；
本发明还涉及一次性卫生用品，所述一次性卫生用品中的导流层为权利要求1-7所述的在线热复合速渗导流材料，所述的一次性卫生用品包括妇女卫生用品、成人失禁用品和纸尿裤、食品垫(如鱼垫、肉垫等)、宠物垫。
将本发明作为卫生巾的导流层，多孔性非织造材料起到速渗(Z向快速导流)，在卫生巾使用的结构中该柔软的多孔性非织造材料是和表面层相联，起速渗导流作用(不同于公开号CN103409941B技术方案中的絮纸层，该絮纸层在卫生巾结构中是吸收层相联，起到联接吸收层和扩散层的作用)；与之在线复合气流成网的无尘纸层兼有Z向导流及X，Y方向导流扩散作用，还具有暂时贮存液体功能；
本发明的另一创新点是制备工艺中，通过适宜的成型控制工艺，如纤维配比及真空度和气流速度等，使无尘纸中的纤维素纤维相嵌入到多孔性的非织造布材料中，在多孔性非织造材料内的Z方向形成立体网状“森林”状结构，该结构可以将残留在多孔性非织造材料孔隙中的液体快速引流到无尘纸层中，并将液体扩散开来，这也是为什么本发明的复合速渗导流材料具有更好的抗返渗效果及表面干爽的原因之一。(注，热风无纺布用的纤维是亲水的，但纤维本身不吸水，少量液体会残留在热风无纺布的微孔中，导致返渗不好，表面不干爽)。用本发明的新材料所生产的一次性卫生产品柔软有弹性，干爽舒适。
相对于现有技术，本发明所述的在线热复合速渗导流材料具有以下优势：
(1)本发明所述的复合速渗导流材料选用速渗和导流性好的无纺布，采用一定的结构及工艺设计将无纺布很好地与多层无尘纸层一次性热复合在一起，不易分层以满足后续加工的要求。
(2)本发明所述的复合速渗导流材料蓬松柔软、整体密度低，同时，速渗导流层采用的梳理成型的热风无纺布、梳理成型的化学粘合无纺布、打孔无纺布或水刺无纺布等材料具有多孔性，且孔隙较无尘纸层的孔隙大很多，这样就使本发明的复合速渗导流材料内部形成一定密度梯度，这一特点赋予本发明的产品有快速导流、扩散及良好的应用体感。
(3)本发明所述的复合速渗导流材料的速渗导流层是具有多孔结构，孔隙大、密度小，能瞬间将液体导流到与之复合的无尘纸结构中；所在线一次性复合的无尘纸结构相对于速渗导流层，结构致密、孔隙小、密度大，且无尘纸层结构中含有纤维素纤维，极易吸液，所以该复合速渗导流材料在兼顾快速导流液体的同时，无尘纸层还能够快速扩散液体，并短时间内贮存液体，将液体快速扩散和传递到下一层(一般是卫生巾结构设计的吸收层)的作用。
(4)本发明所述的复合速渗导流材料回弹性好、结构新颖，经加工成品后，同现有无尘纸导流材料进行老化试验对比，本发明产品的三个月老化后厚度的回弹性能达到15-20％以上，对比产品的回弹性能在10％以下，优于对比产品的回弹性能。这一优点可以赋予终端产品良好的柔软蓬松体验感，并且因厚度大的材料，一般导流速度快，所以本发明产品的这一优点是赋予复合速渗导流材料和终端产品优良的导流效果。
(5)本发明所述的复合速渗导流材料具有很好的抗返渗性能，所生产的卫生巾等应用产品表面干爽，进一步提升了使用者的使用舒适性。
(6)本发明所述的复合速渗导流材料的制备工艺将纤维层中两种纤维分布均匀、层间接合完整，将卫生巾结构中不同材料所起到的导流、扩散、吸收和防返渗一次性完成。
(7)本发明所述的复合速渗导流材料具有不同孔隙密度梯度，当进行液体吸收时，相对于没有密度梯度的导流材料，该产品的表面液体吸收点(Stain Size)面积小，因新颖特殊的梯度设计，所吸收液体在通过速渗导流层后能迅速扩散开来，这种效果使产品在液体吸收时达到了表面液体点面积小，与之相通的无尘纸层中液体吸收面积大，这样赋予终端产品(如卫生巾)较小的表面视觉效果，这也是本发明产品返渗性能好的原因之一。
(8)本发明所述的复合速渗导流材料相对于本公司已公开的技术，结构更加简单，在导流和速渗方面更优，抗返渗效果更好，且因不使用粉状粘结剂和高分子树脂，产品更加柔软蓬松，节约了原料，降低了生产成本及提高了品质。
附图说明
图1为传统的多孔性导流材料导流扩散效果剖面示意图；
图2为传统的多孔性导流材料导流扩散效果俯视示意图；
图3为用无尘纸作导流层导流扩散效果剖面示意图；
图4为用无尘纸作导流层导流扩散效果俯视示意图；
图5为本发明作导流层导流扩散效果剖面示意图；
图6为本发明作导流层导流扩散效果俯视示意图；
图7为本发明压制有条纹的复合速渗导流材料导流扩散效果纵向剖面示意图；
图8为本发明压制有条纹的复合速渗导流材料导流扩散效果横向剖面示意图；
图9为本发明压制有条纹的复合速渗导流材料导流扩散效果俯视示意图；
图10为本发明复合速渗导流材料的结构示意图；
图11为本发明复合速渗导流材料的制备工艺示意图。
其中：a1为速渗导流层，a2为第一层纤维层，a3为第二层纤维层，a4为第三层纤维层。
具体实施方式
除有定义外，以下实施例中所用的技术术语具有与本发明所属领域技术人员普遍理解的相同含义。以下实施例中所用的试验试剂，如无特殊说明，均为常规生化试剂；所述实验方法，如无特殊说明，均为常规方法。
下面结合实施例及附图来详细说明本发明。
本发明的复合速渗导流材料的测试方法如下：
1.厚度(EDANA 30.5-99)
厚度:在两个测量板间,在一定压力(0.5kPa)下测出的距离,单位为mm。
测试仪器:数显式厚度测试仪。
按照不同产品的要求进行取样、切样,测试的试样尺寸的边缘与仪器上盘边缘不小于5mm；要求在恒温恒湿(23士2℃；相对湿度50％士5％)的条件下,平衡试样至少4小时以上。如果为在线实时检测可以不做平衡,但在进行测量的同时应记录下当时的温度与湿度,以供参考比较。
厚度回弹性的测试：
从老化的产品中取样后，不用平衡4小时，在30分钟内完成第一次测试，厚度为T1；将样品放置4小时后，重新测试厚度，厚度值为T2，回弹性能用(T2-T1)/T1值的百分比表示。
2.定量(EDANA 40.3-90)
定量:单位面积的质量即为试样的定量(克重),单位为g/m2。
测定仪器:电子天平(精确到0.001克),天平外设有屏风防止气流和其他干扰因素对天平的影响。
试样要求在恒温恒湿(23士2℃；相对湿度50％士5％)的条件下,平衡试样至少4小时以上。如果为在线实时检测,可以不做平衡,但在进行测量的同时应记录下当时的温度与湿度,以供参考比较。
将测定试样放在天平上,当天平的读数稳定后,记录重量,以克表示。
定量(GSM)＝＝A/B
其中:GSM一试样的定量(克重)；
A一试样的重量；
B一试样的面积。
3.抗张强度及断裂伸长率(EDANA 20.2-89)
抗张强度:规定尺寸的试样受到恒速拉伸至断裂时所需的张力。当样品被拉断时的长度与样品原来长度的百分比即为断裂伸长率，用％表示。
测定仪器:Zwick2.5强力测试仪
将试样切成200mm x 25.4mm的大小,要求在恒温恒湿(23士2℃；相对湿度50士5％)的条件下,平衡试样至少4小时以上,如果为在线实时检测,可以不做平衡,但在进行测量的同时应记下当时的温度与湿度,以供参考比较。
按照如下测试参数设定测试程序:
最大测量限度:100N
测试速度:254mm/min
夹距:51mm
夹压:5bar
4.液体渗透速度(EDANA 150.5-02)
液体渗透速度：当5m1的0.9％氯化钠溶液渗透试样时,通过电路导电性记录液体的通过时间,单位为秒。
测定仪器：Lister液体渗透仪
5.液体吸收(EDANA 10.4-02)
液体吸收能力：将试样在液体中浸泡10分钟一定时间后,总重量增加的百分比即为试样的吸收能力。
液体保持能力：将试样在液体中浸泡10分钟后,再在容器中放置2分钟,然后将重量为1976g的砝码小心地放置在试样之上，重量增加的百分比即为试样的保水能力
6.抗返渗性能(参考标准：EDANA 150.5-02，ERT 154.0-02)
取待测样品，将
Figure BDA0003332149850000091
的圆筒放在待测样品的中心位置，取15ml盐水加入该圆筒内，同时计时，5min后，迅速将已知质量的滤纸若干层(以最上层滤纸无吸液为止)放到试样表面，同时将1.2kg标准压块压在滤纸上，重新开始计时，加压1min时将标准压块移去，用天平称量试样表面滤纸的质量，其增加的重量即为返渗值。该值越小，表示抗返渗性能越好。
7.液体的吸液高度(参考标准：EDANA 10.4-02)
液体吸液高度：垂直悬挂的试样一端浸泡在液体中5分钟后，液体沿着试样上升的高度,即为试样的吸液高度。
试样尺寸：试样尺寸:30mm*200mm
试样要求在恒温恒湿(23±2℃；相对湿度50±5％)的条件下，平衡至少4小时以上。
将测试支架放入塑料容器内，使两把尺子竖直固定在架子上，加入0.9％NaCl溶液或蒸馏水(根据客户要求)，将液面调至支架上两把尺子的刻度为15mm处。在溶液中加入适量蓝色染色剂搅匀，以方便读数。把尺子旋出液面，并且把表面的水擦净，将准备好的样品用鱼尾夹固定在尺子上，注意样品下端与尺子的零点对齐。将尺子旋入液面，同时开始计时.伸入液体中的尺子一端稍向后倾斜，使尺子与样品保持一定缝隙。五分钟后定时器响起的同时将两把尺子旋出液面并读数(看液体沿样品上升高度，读最高点的值，若样品边上个别点太高将这个值舍去，读其它最高点的值)。测试结果为实际读数减去15mm，即为吸液高度数值。
实施例1
本实施例的复合速渗导流材料的总定量约为50g/m2，设计为两层结构，厚度约为1.0mm，其具体原料及结构如下：纤维素纤维采用的是Weyerhauser NB416，纤维长约2-5mm。双组分复合纤维由芯层和皮层组成，芯层为聚丙烯(PET)，皮层为聚乙烯(PE)，纤维长度大约为3-10mm，纤度约为1.5-3.0分特。无纺布采用20gsm热风无纺布，本实施例中在纤维层的外表面上喷涂乳液，来自Wacker公司的Vinnapas 192产品。
该复合速渗导流材料结构包括两层，其中速渗导流层的定量约占产品总定量的40.00％，纤维层的定量约占产品总定量的58％，乳胶约占产品总定量的2.00％。各组分在各层中的分布如下列表1中所示，表中的比例是按各材料在该层的质量百分比表示的。
表1
Figure BDA0003332149850000101
该无尘纸采用M&J公司的水平筛网式成型技术设备上实现的。
先将热风无纺布等速渗导流层材料用退卷机1输送到成型区等后续工序过程，成型区由一无端的网带连续输送速渗导流层材料，待运行稳定后，将纤维素纤维和双组份复合纤维送入到第一个水平筛网式成型头2中均匀混合，通过气流成型及真空抽吸作用，使该混合物经过第一成型头而均匀地铺落在速渗导流层材料上，在第一成型头和第二成型头间设计了预压辊3可以选择性的对初期复合层进行一定的预压；
本实施例中，没有使用第三成型头4和5。将上述形成的复合层通过热压辊6以进一步稳定结构，被输送到第一个加热烘箱8中进行加热；复合层经加热烘箱8后，转向，被输送到第二喷胶区10，对纤维层的外表面面进行喷涂约为总量2％的乳胶，然后送往第二个加热烘箱11及可选择的第三个加热烘箱12中继续加热，烘干固化而形成复合速渗导流材料产品；
复合速渗导流材料产品冷却后由卷纸机13进行卷绕成卷；
按需求，用分切机分切成所要求的不同宽度的产品。
将本实施例的复合速渗导流材料产品进行各种性能的检测，其结果如表7中所示。
实施例2
本实施例的复合速渗导流材料的总定量约为85g/m2，设计为三层结构，厚度约为1.75mm，其具体原料及结构如下：纤维素纤维采用的是Weyerhauser NB416，纤维长约2-5mm。双组分复合纤维由芯层和皮层组成，芯层为聚丙烯(PET)，皮层为聚乙烯(PE)，纤维长度大约为3-6mm，纤度约为1.7-3.0分特。无纺布采用35gsm热风无纺布，本实施例中在第三层上喷涂乳胶，来自Wacker公司的Vinnapas 192产品。
该复合速渗导流材料结构包括三层，速渗导流层的定量约占产品总定量的41.20％，第一层纤维层的定量约占产品总定量的26.34％，第二层纤维层的定量约占产品总定量的30.46％，乳胶约占产品总定量的2.00％。各组分在各层中的分布如下列表2中所示，表中的比例是按各材料在该层的质量百分比表示的。
表2
Figure BDA0003332149850000111
该无尘纸采用M&J公司的水平筛网式成型技术设备上实现的。
先将热风无纺布等速渗导流层材料用退卷机1输送到成型区等后续工序过程，成型区由一无端的网带连续输送速渗导流层材料，待运行稳定后，将纤维素纤维和双组份复合纤维送入到第一个水平筛网式成型头2中均匀混合，通过气流成型及真空抽吸作用，使该混合物经过第一成型头而均匀地铺落在速渗导流层材料上，在第一成型头和第二成型头间设计了预压辊3可以选择性的对初期复合层进行一定的预压；
接着将该复合层传递到第二个成型区，将双组份复合纤维和纤维素纤维由第二个水平筛网式成型头4中均匀混合，通过气流成型和真空抽吸铺落到速渗导流层和第一层纤维层上；
本实施例中，没有使用第三成型头5。将上述形成的复合层通过热压辊6以进一步稳定结构，被输送到第一个加热烘箱8中进行加热；复合层经加热烘箱8后，转向，被输送到第二喷胶区10，对第二层纤维层的外表面进行喷涂约为总量2％的乳胶，然后送往第二个加热烘箱11及可选择的第三个加热烘箱12中继续加热，烘干固化而形成复合速渗导流材料产品；
复合速渗导流材料产品冷却后由卷纸机13进行卷绕成卷；
按需求，用分切机分切成所要求的不同宽度的产品。
将本实施例的无尘纸产品进行各种性能的检测，其结果如表7中所示。
实施例3
本实施例的复合速渗导流材料的总定量约为140g/m2，设计为四层结构，厚度约为3.10mm，其具体原料及结构如下：纤维素纤维采用的是WeyerhauserNB405和NB416，纤维长约2-5mm。双组分复合纤维由芯层和皮层组成，芯层为聚丙烯(PET)，皮层为聚乙烯(PE)，纤维长度大约为3-6mm，纤度约为1.7-3.0分特。无纺布采用55gsm热风无纺布，本实施例中在第三层纤维层的外表面上喷涂乳胶，来自Wacker公司的Vinnapas 192产品。
该复合速渗导流材料结构包括四层,速渗导流层的定量约占产品总定量的39.29％，第一层纤维层的定量约占产品总定量的16.07％，第二层纤维层的定量约占产品总定量的21.43％,第三层纤维层的定量约占产品总定量的21.43％，乳胶约占产品总定量的1.79％。各组分在各层中的分布如下列表3中所示，表中的比例是按各材料在该层的质量百分比表示的。其中，第一层的纤维素纤维设计使用经处理的木桨NB05，该木桨能提供更柔软和蓬松的效果，并使第一层纤维层和第二、三层纤维层形成密度梯度。
表3
Figure BDA0003332149850000131
该无尘纸采用M&J公司的水平筛网式成型技术设备上实现的。
先将热风无纺布等速渗导流层材料用退卷机1输送到成型区等后续工序过程，成型区由一无端的网带连续输送速渗导流层材料，待运行稳定后，将纤维素纤维和双组份复合纤维送入到第一个水平筛网式成型头2中均匀混合，通过气流成型及真空抽吸作用，使该混合物经过第一成型头而均匀地铺落在速渗导流层材料上，在第一成型头和第二成型头间设计了预压辊3可以选择性的对初期复合层进行一定的预压；
接着将该复合层传递到第二个成型区，将复合纤维和纤维素纤维由第二个水平筛网式成型头4中均匀混合，通过气流成型和真空抽吸铺落到速渗导流层和第一层纤维层上；经过第二成型区后，该复合层传递到第三个成型区，将双组份复合纤维和纤维素纤维由第三个水平筛网式成型头5中均匀混合，通过气流成型和真空抽吸铺落到前三层上；
将上述形成的复合层通过热压辊6以进一步稳定结构，被输送到第一个加热烘箱8中进行加热；复合层经加热烘箱8后，转向，被输送到第二喷胶区10，对第三层纤维层的外表面进行喷涂约为总量2％的乳胶，然后送往第二个加热烘箱11及可选择的第三个加热烘箱12中继续加热，烘干固化而形成复合速渗导流材料产品；
复合速渗导流材料产品冷却后由卷纸机13进行卷绕成卷；
按需求，用分切机分切成所要求的不同宽度的产品。
将本实施例的无尘纸产品进行各种性能的检测，其结果如表7中所示。
实施例4
本实施例与实施例3的不同之处在于，还包括了对本发明复合速渗导流材料进行条纹压花处理的工艺步骤，在通过热压辊6以进一步稳定结构后，被输送到第一个加热烘箱8中进行加热前，设计了一对压花辊7，可对复合层进行条纹压花处理，沟纹宽度为3mm，等间隔，间隔为3mm，其中只对接触无尘纸的沟纹辊进行升温，优选的控制温度在不高于120℃，压力根据条纹深浅进行调整，一般不大于60Nmm，可以根据最终产品要求对温度及压力进行适当的调整。复合速渗导流材料经过压花后再通过后续加工工艺，可以得到有条纹的产品。
按需求，用分切机分切成所要求的不同宽度的产品。
将本实施例3和实施例4的复合速渗导流材料产品进行各种性能的检测，其结果如表7中所示。
对比例1
本实施例的导流材料的总定量约为80g/m2，厚度约为1.3mm，其具体原料如下：卫生纸(絮纸)选用金红叶公司生产的，如NKA130系列，或由Havix公司生产的17gsm产品，纤维素纤维选取Weyerhauser_NB416或International Paper Super soft M或GeorgiaPacific 4821，4822，4823或其混合物，纤维长约2-5mm；PLA/PLA复合纤维纤度为2.2dtex/6mm，纤维皮层约为130℃，芯层约为160℃。
该导流材料结构包括四层，第一层的定量约占产品总定量的16％，第二层的定量约占产品总定量的23％，第三层的定量约占产品总定量的29％，第四层定量约占产品总定量的32％。并在工艺过程中在材料的两面喷涂总定量10％的水。各组分在各层中的分布如下列表4中所示。
表4
Figure BDA0003332149850000141
对比例2
本实施例的导流材料的总定量约为150g/m2，厚度约为1.3mm，其具体原料如下：卫生纸(絮纸)选用金红叶公司生产的，如NKA130系列，或由Havix公司生产的17gsm产品，纤维素纤维选取Weyerhauser NB416或International Paper Supersoft M或GeorgiaPacific4821，4822，4823或其混合物，纤维长约2-5mm；PLA/PLA复合纤维纤度为2.2dtex/6mm，纤维皮层约为130℃，芯层约为160℃。
该导流材料结构包括四层，第一层的定量约占产品总定量的11％，第二层的定量约占产品总定量的25％，第三层的定量约占产品总定量的31％，第四层定量约占产品总定量的33％。并在工艺过程中在材料的两面喷涂总定量10％的水。各组分在各层中的分布如下列表5中所示。
表5
Figure BDA0003332149850000151
对比例3
本实施例的无尘纸的总定量约为175g/m2，厚度约为1.45mm，其具体原料及结构如下：纤维素纤维采用的是Weyerhauser NB416，纤维长约2-5mm。双组分复合纤维由芯层和皮层组成，芯层为聚丙烯(PP)，皮层为聚乙烯(PE)，纤维长度大约为3-6mm，纤度约为1.7-3.0分特。无纺布采用22gsm聚丙烯纺粘无纺布，高分子吸水树脂来自于Sandia-930，或来自Stockhausen，Sumitomo，Shokubai等厂家，本实施例中在第四层上喷涂乳液，来自Wacker公司的Vinnapas 192产品。
该复合速渗导流材料结构包括四层，第一层的定量约占产品总定量的12.6％，第二层的定量约占产品总定量的27.4％，第三层的定量约占产品总定量的30％，第四层定量约占产品总定量的28％，并在第四表面喷涂约总量2％的乳液。各组分在各层中的分布如下列表6中所示。
表6 各组分在各层中的分布
Figure BDA0003332149850000152
Figure BDA0003332149850000161
对比例1-3的制备工艺与实施例1-3的制备工艺相同。
将实施例1-4得到的本发明的产品与对比例1-3得到的无尘纸以及传统热风导流材料、常规的的无尘纸材料进行各种性能的检测，测试结果见下表：
表7
Figure BDA0003332149850000162
Figure BDA0003332149850000171
注：盲测方法，随机找了20个人，用自己的感觉评价材料的柔软性，蓬松性及在测试完返渗性能后的材料表面干爽性，★越多，越柔软蓬松，表面越干爽。
由表7的数据可以看出，本发明复合速渗导流材料有更优性能，尤其是返渗性能更好，表面更加干爽。同时有条纹的本发明产品具有更强的扩散能力，如吸液高度(纵向，也就是条纹的方向)增加一倍以上，这也是产生液体扩散纵横比远大于1的主要原因，使用本发明作为卫生用品的导流层，可以充分利用导流层下面吸收层的有效面积，减少原料投入，降低生产成本。
另外，由上表对比可以看出，本发明产品更加蓬松(密度低)和干爽性有了很大的提高，且材料有很好的回弹性，是一种优质导流速渗材料。本发明产品即使压上条纹之后，依然比现有技术中的导流材料要蓬松(密度低)，返渗和干爽性也非常好，较以往技术有了很大的提高，且材料有很好的回弹性，是一种优质导流速渗材料。
综上所述，本发明复合材料兼具了对比材料的综合优点：具有较好的吸液高度(有条纹的)，扩散性能好，返渗性能及回弹性能也非常优异，表面干爽，且具有弹性柔软蓬松的优点。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

1.一种在线热复合速渗导流材料，其特征在于：
所述复合速渗导流材料包括相互液体连通的速渗导流层和无尘纸层；
所述的速渗导流层的材料为多孔性非织造材料，占复合速渗导流材料总质量的8-85％；
所述的无尘纸层包括至少一层纤维层，所述纤维层的材料为纤维素纤维和双组分复合纤维，所述无尘纸层的质量占复合速渗导流材料总质量的15-92％；所述纤维层中纤维素纤维的质量占该层纤维层总质量的5-95％，双组份复合纤维的质量占该层纤维层总质量的5-95％；当纤维层的层数为两层或两层以上时，相邻纤维层之间液体连通；所述无尘纸层的外表面压制有纵向的等间距或非等间距的条纹；
所述复合速渗导流材料的制备工艺包括如下步骤：
1)将速渗导流层的材料用开卷机展开形成速渗导流层并输送到成型区；
2)将步骤(1)得到的速渗导流层传递到成型区，将纤维素纤维和双组份复合纤维输送至成型头中均匀混合形成混合物，通过气流成型及真空抽吸作用，使该混合物经过第一成型头而均匀地铺落在速渗导流层上，形成第一层纤维层，得到具有两层的复合层；
3)当复合速渗导流材料中的无尘纸层为两层或两层以上的纤维层时，所述制备工艺还包括如下步骤：将步骤(2)得到的具有一层纤维层的复合层传递到下一成型区中，将纤维素纤维和复合纤维输送至下一成型区内的成型头中均匀混合形成混合物，通过气流成型和真空抽吸作用，使该混合物铺落到上一层纤维层表面，并根据纤维层的层数依次重复该步骤，得到复合层；
4)将上一步得到的复合层输送到第一加热烘箱中进行加热，烘干固化，其中，所述第一加热烘箱设定的温度小于150℃；
5)将经过步骤(4)处理的复合层输送至喷胶工序，对复合层中最外层纤维层的外表面喷涂乳胶；
为保证材料的柔软性能，乳液的浓度不宜过高，一般在20％以下为宜；
6)将经过步骤(5)喷胶工序的复合层输送到第二加热烘箱中进行再次加热，烘干固化形成复合速渗导流材料产品，其中，所述第二加热烘箱设定的温度小于150℃；
7)将复合速渗导流材料产品冷却后进行卷绕成卷；
8)将成卷的复合速渗导流材料产品切成所要求的不同宽度的产品。
2.根据权利要求1所述的在线热复合速渗导流材料，其特征在于：
所述条纹的宽度为1-10mm；优选地，所述条纹的宽度为2-5mm。
3.根据权利要求1所述的在线热复合速渗导流材料，其特征在于：
所述多孔性非织造材料为梳理成型的热风无纺布、梳理成型的化学粘合无纺布、打孔无纺布或水刺无纺布。
4.根据权利要求1所述的在线热复合速渗导流材料，其特征在于：
所述纤维素纤维为经过处理或未经过处理的绒毛浆、针叶木浆、阔叶木浆、草浆、化学浆、化学机械浆、热机浆的纤维中一种或两种以上的混合物,其长度为2-5mm，且具有多种形态；
所述双组分复合纤维为聚丙烯一聚乙烯共聚物、聚对苯二甲酸二乙酯一聚乙烯共聚物、聚对苯二甲酸二乙酯一聚丙烯共聚物中一种或两种以上的混合物，所述双组分复合纤维的长度为2.5-10mm，纤度为1.0-17分特，具有多种截面结构。
5.根据权利要求1所述的在线热复合速渗导流材料，其特征在于：
所述无尘纸层的外表面喷涂有乳胶，所述乳胶的质量占复合速渗导流材料总质量的0-20％。
6.根据权利要求5所述的在线热复合速渗导流材料，其特征在于：
所述乳胶为醋酸乙烯酯一乙烯型乳液、丙烯酸酯类乳液、苯乙烯一丁二烯类乳液、苯乙烯丁二烯一丙烯酸类乳液或聚乙烯醇中一种或两种以上的混合物。
7.根据权利要求1所述的在线热复合速渗导流材料的导流材料，其特征在于：
在第一个成型头、第二个成型头之间以及最后一个成型头之后安装有预压辊，分别对上一步得到复合层进行预压。
8.根据权利要求1所述的在线热复合速渗导流材料，其特征在于：
在步骤(3)之前还包括使用沟纹辊对复合层中无尘纸层的外表面进行的条纹压花处理，所述沟纹辊的沟纹间隙为1-10mm，优选为2-5mm。
9.根据权利要求1所述的在线热复合速渗导流材料，其特征在于：
所述步骤(6)之前还包括如下步骤：将步骤(5)得到的复合速渗导流材料产品输送到第三加热烘箱中进行再次加热，烘干固化，其中，所述第三加热烘箱设定的温度小于150℃。
10.一种一次性卫生用品，其特征在于：
所述一次性卫生用品中的导流层为权利要求1-7任一所述的在线热复合速渗导流材料，所述的一次性卫生用品包括妇女卫生用品、成人失禁用品和纸尿裤、食品垫、宠物垫。
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