[go: up one dir, main page]

WO1999025912A1 - Tissu lamine non tisse etirable a surface en coton - Google Patents

Tissu lamine non tisse etirable a surface en coton Download PDF

Info

Publication number
WO1999025912A1
WO1999025912A1 PCT/US1998/024781 US9824781W WO9925912A1 WO 1999025912 A1 WO1999025912 A1 WO 1999025912A1 US 9824781 W US9824781 W US 9824781W WO 9925912 A1 WO9925912 A1 WO 9925912A1
Authority
WO
WIPO (PCT)
Prior art keywords
fabric
fibers
inches
core layer
surface layer
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.)
Ceased
Application number
PCT/US1998/024781
Other languages
English (en)
Inventor
Larry C. Wadsworth
H. Charles Allen, Jr.
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.)
University of Tennessee Research Foundation
Original Assignee
University of Tennessee Research Foundation
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 University of Tennessee Research Foundation filed Critical University of Tennessee Research Foundation
Publication of WO1999025912A1 publication Critical patent/WO1999025912A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • 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
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • D04H1/425—Cellulose series
    • 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
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres

Definitions

  • This invention relates generally to a nonwoven fabric formed by laminating cotton containing surface layers to a core layer of unbonded thermoplastic filament fibers.
  • Nonwoven webs are defined as "sheet or web structures made by bonding and/or interlocking fibers, yarns or filaments by mechanical, thermal, chemical or solvent means.” These webs do not require the conversion of fibers to yarn. Nonwoven webs are also called bonded or engineered webs and are manufactured by processes other than spinning, weaving or .knitting., hence the name "nonwovens".
  • the fibers of a nonwoven web can be substantially randomly laid to form a web wherein some of the fibers are bonded by fiber to fiber fusion, or fiber entanglement, or thermal bonds as by point bonding.
  • the basic structure of all nonwovens is a web of fibers.
  • the basic element of a nonwoven can be a single type of fiber or a combination of different types of fibers. Fibers that are measured in a few centimeters or inches or fractions thereof are called staple fibers. Fibers of extreme length, generally kilometers or miles, are called filament fibers. In fibers, the length must be considerably greater than the diameter, having a ratio of at least 100: 1 and usually considerably higher. Cotton fibers may measure from less than 0.5 inches to more than 2 inches in length and have a typical length to diameter ratio of about 1400: 1. In the present application, the term "fiber” and “fibers" are intended to include both short (staple) and long (filament) fibers, unless otherwise specifically indicated by identifying the fibers as staple or filament.
  • the individual fibers may be in an organized or random arrangement.
  • Tensile, elongation and hand properties are imparted to the web or fabric by the type or types of bonding as well as fiber-to-fiber cohesion and reinforcement by its constituents.
  • Disposable nonwoven fabrics entered the medical field over four decades ago, beginning with basic paper-like face masks and proceeding through sterilization wrap and specialty drapes and gowns. These medical nonwoven fabrics have proven to be invaluable in products ranging from drape sheets to surgical gowns to adult pads and underpants by utilizing a gamut of nonwoven structures. Nonwoven fabrics now have almost complete acceptance in U.S. hospitals for applications such as surgical caps, masks and shoe covers. Because products made from nonwoven fabrics provide relatively inexpensive, lightweight and effective protection, they have made 90% - 100% penetration in operating room usage. Nonwoven fabrics have now outpaced woven fabrics in uses such as surgical gowns and drapes, where they have about a 60% - 70% share of the market. The current market for products made using nonwoven fabrics is estimated to exceed one billion dollars annually. With the majority of the medical community being convinced that disposable products made of nonwoven fabrics give the double benefits of superior barrier protection and ease of use, it is only the psychological barrier that needs to be overcome before nonwoven fabrics achieve even greater penetration in the operating room market and elsewhere.
  • Nonwoven fabrics of man-made fibers generally have the reputation of lacking many of the properties of woven natural fiber fabric, particularly hand, wicking, and liquid absorption and retention.
  • Nonwoven fabrics of man-made fibers often exl ibit undesirable chemical properties such as hydrophobicity.
  • the surface properties of nonwoven fabrics tend to be smooth, hence exhibiting a slick or oily feel and appearance.
  • Cotton by virtue of its unusual chemistry and structure, offers a set of properties including high tensile strength, exceptional absorbent, highly efficient wicking, natural resistance to electrostatic charge build-up, excellent heat resistance and good processability, all of which are important to the manufacture and perfo ⁇ nance of medical and health care products. Accordingly efforts were made to fabricate nonwoven laminates containing cotton.
  • spunbond webs are used on one side in place of a meltblown web to produce spunbond / cotton / meltblown (SCM) laminated fabrics.
  • SCM spunbond / cotton / meltblown
  • the present invention provides stretchable/elastic, nonwoven, laminated fabrics having one or more cotton containing surface layers thermally bonded to one or both sides of a thermoplastic filament fiber core layer and a method for fabricating these fabrics.
  • These fabrics can provide instantaneous elastic recoveries of 83% to 93% for 50% extension.
  • the fabrics e.xhibit a hand similar to cotton .knits, good strength, good wetting, good wicking good water retention, and minimal linting characteristics making them suitable for use in medical applications such as isolation gowns, head covers, shoe covers, bed sheets, and pillow cases. They are also suitable for sanitary consumer products such as disposable underwear, towels, wipes, and personal hygiene products.
  • the inventors have found that it is extremely difficult to produce thermally bonded laminated fabrics of cotton / spunbond (CS), cotton / meltblown (CM), cotton / spunbond / cotton (CSC) or cotton / meltblown / cotton (CMC), because the cotton fibers in unbonded or loosely bonded webs can not efficiently transfer heat to the inner spunbond or meltblown core. Instead, the cotton fibers wrap around the steel calendar rolls.
  • CS cotton / spunbond
  • CM cotton / meltblown
  • CSC cotton / spunbond / cotton
  • CMC cotton / meltblown / cotton
  • the present invention achieves a degree of extensibility and strength in a laminated fabric having cotton on one or both surfaces by laying webs containing loosely bonded cotton fibers on one or both sides of an unbonded spunbond core so that the cotton fibers can "sink" into the open spaces between the unbonded spunbond filament fibers.
  • the cotton fibers are better entrapped between the spunbond filament fibers so that thermal bonding in the calendar nip can tie the cotton fibers down and render them less likely to pull out or lint.
  • the thermally bonded fabric has much more flexibility and strength than if a pre-bonded spunbond web was utilized to prepare the thermally bonded laminate.
  • the fabrics of the present invention can also be made more elastic by consolidation, either in the MD or CD, as required by the circumstances. These fabrics when consolidated in the CD have virtually no elasticity or stretchability in the MD (heat-fixed in the MD) and when consolidated in the MD have virtually no elasticity or stretchability in the CD.
  • a key aspect of the present invention is the cotton containing surface layer.
  • the pre-bonding of the web layer must be minimal.
  • the fibers in an unbonded or loosely bonded cotton containing web will more easily intermesh with the core filament fibers during the calendaring step, so that the cotton fibers are less likely to lint or abrade away in the laminated fabric.
  • the cotton containing web layers can not be rolled up and unwound without same pre-bonding.
  • the cotton containing web layers are pre-bonded at the minimum contact area and temperature setting which will allow the web layers to be rolled and unwound, leaving most of the bonding of the cotton fibers and thermoplastic staple fibers to each other to occur during the calendaring step on the spunbond line.
  • the cotton containing surface layer may be fabricated on the spunbond line so that it does not have to be rolled and unwound, and consequently does not have to be pre-bonded.
  • the web layer should for best results contain thermoplastic fibers blended with the cotton fibers.
  • the thermoplastic fibers should preferably approximate the diameter and length of cotton fibers.
  • Webs have been made using staple polypropylene fibers having a length between about 1.0 inches and 1.5 inches with a denier of between about 1.9 and 2.2 (weight in grams per 9000 meters of fiber).
  • fibers made using other thermoplastic materials and other sizes are included within the scope of this invention.
  • Such thermoplastics are disclosed in the patents referred to in this text, and are incorporated by reference.
  • the fabrics of the invention prior to consolidation are characterized by excellent stretchability in both directions (length and width) with limited elastic recovery in both directions, for instance about up to 5 or 10% elasticity in both directions. This distinguishes the fabrics of the invention from those that are consolidated in the CD or MD.
  • Figure 1 illustrates the apparatus and process for fabricating a stretchable laminated fabric with one cotton-containing surface layer bonded to a filament fiber core layer.
  • Figure 2 illustrates a cross sectional view of a two-ply laminated fabric having a cotton containing surface layer bonded to a filament fiber core layer.
  • Figure 2A illustrates overlapping cellulosic fibers and thermoplastic staple fibers in the surface layer.
  • Figure 3 illustrates a cross sectional view of a three-ply laminated fabric having a cotton containing surface layer bonded to each side of a filament fiber core layer.
  • Figure 4 illustrates the apparatus and process for fabricating a stretchable laminated fabric in which the fiber core layer is sandwiched between two cotton-containing surface layers.
  • Figure 5 illustrates the apparatus and process for an alternate embodiment for fabricating a stretchable, laminated fabric with a cotton containing surface layer bonded to a filament fiber core layer.
  • Figure 6 illustrates the results of strike-through tests performed on sample fabrics fabricated according to the invention.
  • Figure 7 illustrates the results of abrasion tests performed on sample fabrics fabricated according to the invention.
  • the present invention relates to a stretchable laminated nonwoven fabric comprising one or more cotton containing web layers thermally bonded to one or both sides of a thermoplastic filament core layer, wherein the cotton containing web layer(s) are on the surface of the resulting laminated fabric.
  • a spunbond process for fabricating a web of filament fibers is .known in the art. See for instance: Malkey, S. R. and Wadsworth, L. C, "A Review on Spunbond Technology, Part I, International Nonwovens Bulletin. 4-14, 1992. incorporated herein in its entirety.
  • a spunbond process continuous thermoplastic polymer filament fibers are extruded onto a conveyor belt, then fed through the nip of a pair of rollers one of which is patterned (a calendar) where the fibers are thermally bonded under temperature and pressure conditions which melt and bond the thermoplastic filament fibers in the contacted areas.
  • a two-ply laminate is fabricated by thermally bonding one pre- bonded surface layer 32, consisting of cotton and thermoplastic staple fibers to a spunbond filament fiber core layer 28.
  • pre-bonded surface layer 32 consisting of cotton and thermoplastic staple fibers
  • a spunbond filament fiber core layer 28 As shown in Fig. 1, man-made thermoplastic filament fibers 16 are extruded tahrough a die 20 onto a conveyor 24 foiming an unbonded spunbond core layer 28.
  • a pre-bonded cotton containing web layer 32 is laid on the unbonded spunbond core layer 28.
  • the core layer 28 and the web layer 32 are fed tiirough the nip 36 of a set of heated pressure rollers (calendar) 40, 44.
  • the top pressure roller 40 has a pattern 48 on its surface, preferably a diamond pattern, to contact and bond a percentage of the surface area of the resulting fabric 52.
  • the lower pressure roller 44 has a smooth surface.
  • the web layer 32 can be laid either over the core layer (contacting the patterned pressure roll) or under the core layer (contacting the smooth pressure roll).
  • the laminated fabric is taken up on a roll 49.
  • the bonding area is between about 5% and 40% (16.6% in these trials) .
  • the nip pressure is set between about 100 and 800 PLI (450 PLI in these trials).
  • the patterned pressure roller is at a temperature of between about 135°C and 154°C (avg. 149°C).
  • the smooth pressure roller is at a temperature of between about 132°C and 151°C (avg. 146°C).
  • the surface speed with the calendar was 30 meters/min. but vary from 10-500 m/minutes and pressure adjusted as needed.
  • the extruded filament fibers 16 are composed of a thermoplastic polymer such as polyethylene, polyester, polyamide, or most preferably polypropylene.
  • the thermoplastic filament fibers 16 readily melt, or become soft and sticky under heat and pressure at the contact points in the nip of the thermal calendar to self bond to crossing or overlapping filament fibers 16, and also serve to stick to and bond cotton fibers 54, and especially thermoplastic staple fibers 58 from the pre- bonded surface layer 32 which is placed on one side of the core layer 28 in the first embodiment.
  • Spunbond webs are especially desirable for the core layer 28, because the filament fibers 16 are continuous in length and they are randomly laid down in the horizontal plane of the web so that one filament is bonded several times, even if there are only a few bonding points.
  • a total bonded area of between 5% and 30%, and preferably 15% is required to achieve the optimum strength for the web.
  • a staple fiber web would require a bonding area of between 40% and 50% for optimum strength since the short discontinuous staple fibers would pass through fewer bonding sites.
  • a staple fiber web with maximum strength would be much stiffer than the corresponding weight of spunbond web of maximum strength.
  • thermally bonded spunbond webs even with much less bonded area are generally much stronger than corresponding weights of optimally bonded staple fiber webs.
  • the diameter of the monocomponent spunbond filament core layer 28 is in the range between about 8 ⁇ m and 100 ⁇ m, preferably between about 10 ⁇ m and 30 ⁇ m.
  • the weight of the core layer 28 can vary depending on the intended use and desired properties of the laminate formed. A lighter spunbond core layer 28 would be less expensive and would result in a softer laminate with better drape. For applications requiring greater strength and abrasion resistance, a heavier spunbond core layer 28 may be required. A heavier spunbond core layer 28 provides more thermoplastic fiber for reinforcing the base spunbond web as well as improving the bonding of the staple fibers 58 and cotton fibers 54 to the filament fibers 16 in the core layer 28.
  • the spunbond core layer has a weight of between about 5 g/m 2 and 100 g/m 2 , and preferably between 10 g/m 2 and 50 g/m 2 .
  • a pre-bonded surface layer 32 consisting of cotton fibers 54 and thermoplastic staple fibers 58 is laid on the unbonded filament fiber core layer 28.
  • the composition and pre-bonding conditions of the surface layer 32 are critical to the properties of the resulting laminated fabric.
  • the key characteristic of the surface layer 32 is the properties imparted to it by its cotton fibers 54: hand, wicking, absorbency, and strength.
  • other cellulosic fibers could be used in place of cotton, such as viscose rayon, flax, jute, hemp, ramie and kenaf.
  • When using the preferred cotton fibers they have a diameter of between about 5-30, and preferably 8-20 ⁇ m.
  • the length may be between about 0.2 inches and 2.0 inches, and preferably between about 0.5 inches and 1.2 inches.
  • the thermoplastic staple fibers 58 may be composed of any thermoplastic fiber-foiming polymer .known in the art such as polyester, polyamide, polycarbonate, or most preferably polypropylene.
  • the thermoplastic staple fibers 58 should approximate the size of cotton fibers 54 to enhance the mixing of the cotton and the thermoplastic staple fibers.
  • the thermoplastic staple fibers have a diameter of between 1 denier and 10 denier (g/9000 m of fiber), and preferably between 1.2 denier and 4.0 denier.
  • the length of the thermoplastic staple fibers is between 0.2 inches and 4.0 inches and preferably between 1.0 inches and 1.5 inches.
  • the cotton fibers 54 and the thermoplastic staple fibers 58 are mixed in a ratio of between about 10 wt-% cotton fibers and 90 wt-% cotton fibers, and preferably between about 20 wt-% cotton fibers and 80 wt-% cotton fibers.
  • the balance of the fibers are thermoplastic staple fibers 58.
  • the cotton fibers 54 and the thermoplastic staple fibers 58 are preferably mixed using a randomizer unit 70 to orient the fibers in both the machine direction (MD) and the cross machine direction (CD) of the web.
  • a greater percentage of the fibers are oriented in the MD versus CD by a ratio of between about 2: 1 and 5:1.
  • the ratio of MD to CD would be about 10:1.
  • the web is then passed through a thermal calendar 40, 44 and bonded.
  • the bonding area, pressure and temperature are all set as low as possible while still providing sufficient strength to be rolled up and later unwound for lamination on a spunbond line.
  • Most of the bonding of the cotton / thermoplastic staple fibers to each other and to the core layer preferably occurs during thermal bonding of the laminate on a spunbond line.
  • the pre-bonded area is between 5% and 30% (21% in these trials); the bonding pressure is between 20 and 150 PLI (60 PLI in these samples); and the bonding temperature is between generally about 130°C and 150°C (140-145°C in these trials).
  • the weight of the surface layer 32 is between about 10 g/m 2 and 60 g/m 2 , and preferably between about 15 g/m 2 and 40 g/m 2 .
  • each outside layer whether 1-, 2-, or 3-ply has weight between 10 g/m 2 and 60 g/m 2 , and preferably between about 15 g/m 2 and 40 g/m 2 .
  • the second embodiment is similar to the first embodiment, except that a three-ply laminated fabric, as shown in Fig. 3, is fabricated by bonding a pre-bonded cotton containing surface layer 32 to each side of the core layer 28.
  • One surface layer 32 is laid over the core layer 28, and contacts the pattemed pressure roller.
  • a second web layer 32 is laid under the core layer 28, and contacts the smooth pressure roller. The three layers are fed into the calendar nip together.
  • the bonding area is between about 5% and 40% (16.6% in these trials).
  • the nip pressure is set between about 200 and 700 PLI (400 PLI here).
  • the patterned pressure roll is at a temperature of between about 132°C and 151°C (avg. 146°C).
  • the smooth pressure roll is at a temperature of between about 129°C and 149°C (avg. 143°C).
  • the speed can vaiy from 10 to 500 meter s/min.
  • the third embodiment is similar to the second or third embodiment except that the surface layer(s) 32 are not pre-bonded. Instead the surface layer(s) 32 are formed on the spunbond line, as shown in Fig. 5, by feeding cotton fibers 54 and thermoplastic staple fibers 58 through a blender 70, then into an in-line carding unit 74, then into a randomizer 75, and onto a conveyor belt.
  • the cotton / thermoplastic staple fiber web layer(s) 32 are laid on one or both sides of a core layer 28 formed by extruding thermoplastic filament fibers 16 onto a conveyor belt.
  • the unbonded web layer(s) 32 and the unbonded core layer 28 are fed into the nip of a thermal calendar where they are simultaneously self bonded and bonded to each other.
  • the laminated fabric is taken up on a roll 59.
  • the laminated fabrics fabricated according to the first, second and third embodiments have notable flexibility and extendible adequate for many applications. However even greater flexibility and extensibility can be achieved by further processing the fabric using a heat-stretch or consolidation process. Heat is applied to the fabric while it is being drafted in the machine direction for cross-machine direction consolidation. After cooling the cross-machine direction consolidated fabric exhibits improved stretch and recovery characteristics in the cross machine direction. The fabric can also be consolidated in the machine direction by stretching in the cross-machine direction under heat and then allowing to cool or cooling.
  • the fabric can be consolidated using a draw ratio (wind speed/unwind speed) of between about 1.3 and 2.0 to draw the fabric in the machine direction. Consolidation can be performed in an oven at temperatures of between about 283°F (139°C) and 306°F (152°C). Instantaneous elastic recovery at 50% extension in the cross-machine direction for cross-machine direction consolidated fabric is between about 83% and 93%.
  • thermoplastic fiber-forming polymers are not intended to be limiting the invention, and are only illustrative.
  • One skilled in the art can readily use different thermoplastic fiber-forming polymers and make other changes as may be desirable.
  • Sample fabrics were fabricated in accordance with the present invention. Their compositions and weights are shown in Table 1. As indicated, samples 1, 2, 3, 6 and 7 were prepared using surface layers 32 of TCPP1 which is a carded web consisting of 60 weight-% cotton / 40 weight-% polypropylene staple fibers pre-bonded at about 21% of their surface area. The web has a weight of about 0.7 oz yd 2 .
  • Sample 1 is a two-ply laminated fabric in which a TCPP1 surface layer 32 was bonded to a core layer 28 consisting of a spunbond filament web with a weight of 0.5 oz/yd 2 (SB 1 ).
  • Samples 6 and 7 are three-ply laminated fabrics with a TCPP1 surface layer 32 bonded on each side of a core layer 28.
  • Sample 6 has a SB1 core layer 28
  • sample 7 has a core layer 28 consisting of a spunbond filament web with a weight of 1.0 oz/yd 2 (SB2).
  • SEM photographs of sample 6 show a clearly defined thermal bond, although there is not as much melting and fusing as in sample 1.
  • SEM photographs of sample 7 do not show a well defined bond on either side of the thermal bond area.
  • polypropylene spunbond core layers as light as 0.5 oz/yd 2 would not generally be recommended for three-ply laminates unless the polypropylene staple fiber or other thermoplastic binder fiber content is increased from 40% to between 60% and 80%. However, depending on the end-use, the 0.5 oz/yd 2 spunbond core could be preferable for two-ply fabrics.
  • the fabric samples 1, 2, 3, 4, 5, 6 and 7 were consolidated in the cross-machine direction under the conditions indicated in table 2.
  • the actual weights and thickness of the samples after consolidation are listed, as are the instantaneous and time dependant elastic recoveries.
  • the absorbency properties of the laminated fabric samples were determined using ISO 9073- 8: 1995 "Textiles -Test method for nonwovens, Part 8: Determination of liquid strike-through time (simulated urine)".
  • This test was designed to determine the time required for simulated urine solution to penetrate through a disposable diaper over stock fabric and into an absorbent pad beneath the fabric.
  • the side of the fabric that would be against the body is placed face up on the standard filter paper blotter and the amount of time for 5 ml. of simulated urine solution to penetrate through to the filter paper is electronically determined.
  • both the core side and the cotton containing web side were tested since the particular end use would determine which side is against the body.
  • the test with the cotton containing web side down against the filter paper is arbitrarily designated cotton side.
  • cotton side With diaper cover stock, it is desirable to have a strike- through time as short as possible. However, in the present invention, it is hoped that the cotton component will increase the absorbancy or water holding capacity of the laminates. Thus, the longer the strike-through time, the greater the aqueous holding capacity of the laminates.
  • the absorbency data is shown in Fig. 6. Sample 1 had very high strike-through times as determined with the cotton side against the filter paper, both before and after consolidation. Testing with the core layer against the filter paper also resulted in high strike-through times.
  • the specimens were conditioned for 24 hours and tested at 65 +/- 2 % relative humidity and 20 +/- 2 °C (according to ASTM D 1776-85).
  • a small hole (approximately 5 mm in diameter) was made in the center of the specimen to fit over the turntable clamping screw.
  • the abrading wheel was lowered onto the specimen and the tester was turned on. During the abrasion test, the vacuum device on the abrader was operated to suction away abraded particles. The test was stopped after the turntable had rotated 20 cycles with the abrading wheel on the specimen.
  • the specimen was removed and the percentage of peeled-off surface area that was subjected to the abrasion was visually estimated.
  • abrasion test results are shown in Fig. 7.
  • the heavier core layer also corresponds to lower abrasion.
  • Sample 2 and sample 3 have the same composition. The only difference between them is that the cotton containing web in sample 2 was under the core layer, contacting the smooth calendar roller, and the cotton containing web in sample 3 was over the core layer, contacting the diamond patterned calendar roller.
  • the raised diamond pattern served to better compress the cotton containing web into the spunbond polypropylene core at the raised diamond areas.
  • sample 3 only lost about 40% of the cotton containing surface compared to 90% for sample 2.
  • the embodiments described herein have monocomponent thermoplastic filament fibers in the core layer and monocomponent staple fibers in the web layer(s).
  • bicomponent filament fibers and/or staple fibers with a lower melting point component could also be used in the core layer and web layer(s) respectively, replacing between 10% and 100% of the monocomponent thermoplastic fibers.
  • the bicomponent fibers could be a core / sheath (i.e.
  • the bicomponent may be a side-by-side arrangement of the same compositions as the core / sheath fibers. Other bicomponent arrangements are also possible.
  • thermal calendar bonding process to bond the surface layer(s) to the core layer.
  • other thermal bonding processes such as hot-through-air bonding or ultra-sonic bonding may be used.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

La présente invention concerne un tissu laminé non tissé étirable comportant une ou plusieurs couches de surface contenant du coton thermosoudé à l'une des faces ou aux deux faces d'une couche centrale en filaments thermoplastiques et un procédé de fabrication de ce tissu. Après avoir été soumis à un processus d'étirement thermique, ces tissus peuvent présenter des retours élastiques instantanés de 83 à 93 % pour une extension de 50 %. En outre, le tissu de la présente invention présente un toucher de tricot en coton, une bonne résistance, une bonne capacité de mouillage et d'imbibition par capillarité, une bonne capacité de rétention de l'eau, des caractéristiques de peluchage minimales et il peut être utilisé pour des applications médicales. L'invention se rapporte également à des tissus laminés non tissés capables d'un retour élastique instantané.
PCT/US1998/024781 1997-11-18 1998-11-18 Tissu lamine non tisse etirable a surface en coton Ceased WO1999025912A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US6617997P 1997-11-18 1997-11-18
US60/066,179 1997-11-18

Publications (1)

Publication Number Publication Date
WO1999025912A1 true WO1999025912A1 (fr) 1999-05-27

Family

ID=22067771

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1998/024781 Ceased WO1999025912A1 (fr) 1997-11-18 1998-11-18 Tissu lamine non tisse etirable a surface en coton

Country Status (1)

Country Link
WO (1) WO1999025912A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015101852A1 (fr) * 2013-12-31 2015-07-09 Kimberly-Clark Worldwide, Inc. Procédés de fabrication de stratifiés élastiques étirables
US9358759B2 (en) 2013-12-19 2016-06-07 Kimberly-Clark Worldwide, Inc. Multilayered elastic laminates with enhanced strength and elasticity and methods of making thereof
US9428638B2 (en) 2013-12-19 2016-08-30 Kimberly-Clark Worldwide, Inc. Strong polyolefin-based thermoplastic elastomeric films and methods of making
US9802392B2 (en) 2014-03-31 2017-10-31 Kimberly-Clark Worldwide, Inc. Microtextured multilayered elastic laminates with enhanced strength and elasticity and methods of making thereof

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3837995A (en) * 1972-04-24 1974-09-24 Kimberly Clark Co Autogenously bonded composite web
US4287251A (en) * 1978-06-16 1981-09-01 King Mary K Disposable absorbent nonwoven structure
EP0060687A2 (fr) * 1981-03-12 1982-09-22 JOHNSON & JOHNSON MEDICAL, INC. Procédé de fabrication d'électrets fibreux
US4885202A (en) * 1987-11-24 1989-12-05 Kimberly-Clark Corporation Tissue laminate
US4904523A (en) * 1987-01-06 1990-02-27 Pellon Company Polyester heat bonded product
US5683794A (en) * 1992-02-26 1997-11-04 The University Of Tennessee Research Center Fibrous web having cellulosic fibers

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3837995A (en) * 1972-04-24 1974-09-24 Kimberly Clark Co Autogenously bonded composite web
US4287251A (en) * 1978-06-16 1981-09-01 King Mary K Disposable absorbent nonwoven structure
EP0060687A2 (fr) * 1981-03-12 1982-09-22 JOHNSON & JOHNSON MEDICAL, INC. Procédé de fabrication d'électrets fibreux
US4904523A (en) * 1987-01-06 1990-02-27 Pellon Company Polyester heat bonded product
US4885202A (en) * 1987-11-24 1989-12-05 Kimberly-Clark Corporation Tissue laminate
US5683794A (en) * 1992-02-26 1997-11-04 The University Of Tennessee Research Center Fibrous web having cellulosic fibers

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9358759B2 (en) 2013-12-19 2016-06-07 Kimberly-Clark Worldwide, Inc. Multilayered elastic laminates with enhanced strength and elasticity and methods of making thereof
US9428638B2 (en) 2013-12-19 2016-08-30 Kimberly-Clark Worldwide, Inc. Strong polyolefin-based thermoplastic elastomeric films and methods of making
WO2015101852A1 (fr) * 2013-12-31 2015-07-09 Kimberly-Clark Worldwide, Inc. Procédés de fabrication de stratifiés élastiques étirables
US10213990B2 (en) 2013-12-31 2019-02-26 Kimberly-Clark Worldwide, Inc. Methods to make stretchable elastic laminates
US9802392B2 (en) 2014-03-31 2017-10-31 Kimberly-Clark Worldwide, Inc. Microtextured multilayered elastic laminates with enhanced strength and elasticity and methods of making thereof

Similar Documents

Publication Publication Date Title
US5494736A (en) High elongation thermally bonded carded nonwoven fabrics
EP0715571B1 (fr) Nouveau voile composite
EP0896645B1 (fr) Structures textiles spunlaced durables
US4761322A (en) Laminated fibrous web comprising differentially bonded layers, and method and apparatus for making the same
KR100761571B1 (ko) 터프트 형성된 섬유질 웨브
JP4068171B2 (ja) 積層不織布およびその製造方法
KR100803015B1 (ko) 타래가 형성된 라미네이트 웨브
KR101019805B1 (ko) 터프트화된 섬유질 웨브
KR101913447B1 (ko) 현재 권축성 복합 단섬유와 그 제조 방법, 섬유 집합물 및 위생 물품
JPH0226973A (ja) 水圧撚り不織弾性ウエブ及び該ウエブを形成する方法
EP1325183A2 (fr) Non-tisse souple resistant a l'abrasion
KR20150042786A (ko) 부직포, 흡수성 물품용 시트, 및 이를 사용한 흡수성 물품
EP0171807A2 (fr) Etoffe non-tissée entremêlée contenant des fibres thermoplastiques en surface et son procédé de fabrication
WO1991014414A1 (fr) Materiau non tisse pour feuille superieure de couche et procede de fabrication
JP5884733B2 (ja) 積層不織布とその製品
JPWO2018225512A1 (ja) 不織布
WO2021066663A1 (fr) Article d'hygiène
JPH08509432A (ja) 新規な複合ウエブ
US20030129908A1 (en) Stretchable, cotton-surfaced, nonwoven, laminated fabric
US20030176136A1 (en) Biodegradable cotton composites
WO1999025912A1 (fr) Tissu lamine non tisse etirable a surface en coton
JP3124017B2 (ja) 熱接着性繊維および不織布
JPH09105060A (ja) 積層不織布およびその製法
JPH06128855A (ja) 三層構造不織布及びその製造方法
JP2023019810A (ja) 吸収性物品用不織布及びこれを備える吸収性物品

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): CA US

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE

WWE Wipo information: entry into national phase

Ref document number: 09341393

Country of ref document: US

121 Ep: the epo has been informed by wipo that ep was designated in this application
DFPE Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101)
122 Ep: pct application non-entry in european phase
NENP Non-entry into the national phase

Ref country code: CA