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WO2007041620A1 - Textile non tisse, articles comprenant des textiles non tisses et procedes de production de textiles non tisses - Google Patents

Textile non tisse, articles comprenant des textiles non tisses et procedes de production de textiles non tisses Download PDF

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Publication number
WO2007041620A1
WO2007041620A1 PCT/US2006/038747 US2006038747W WO2007041620A1 WO 2007041620 A1 WO2007041620 A1 WO 2007041620A1 US 2006038747 W US2006038747 W US 2006038747W WO 2007041620 A1 WO2007041620 A1 WO 2007041620A1
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WO
WIPO (PCT)
Prior art keywords
fiber
nonwoven
shrinkage
fabric
fibers
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/US2006/038747
Other languages
English (en)
Other versions
WO2007041620A8 (fr
Inventor
John A. Wolhar
Michael E. Kazmierczak
Carl J. Wust Jr.
Prashant Desai
Charlie B. Allen
Gregory A. Jackson
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.)
FIBERVISIONS DELAWARE Corp
Original Assignee
FIBERVISIONS DELAWARE Corp
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 FIBERVISIONS DELAWARE Corp filed Critical FIBERVISIONS DELAWARE Corp
Priority to CA002624808A priority Critical patent/CA2624808A1/fr
Priority to CN200680032495XA priority patent/CN101258029B/zh
Priority to JP2008533789A priority patent/JP2009510278A/ja
Priority to MX2008004048A priority patent/MX2008004048A/es
Priority to EP06816190.0A priority patent/EP1931512A4/fr
Priority to BRPI0616733A priority patent/BRPI0616733A2/pt
Publication of WO2007041620A1 publication Critical patent/WO2007041620A1/fr
Anticipated expiration legal-status Critical
Publication of WO2007041620A8 publication Critical patent/WO2007041620A8/fr
Ceased legal-status Critical Current

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Classifications

    • 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
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/027—Thermal properties
    • B32B7/028—Heat-shrinkability
    • 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
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • 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
    • B32B5/06—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 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • 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
    • B32B5/08—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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • 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
    • B32B5/14—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 a layer differing constitutionally or physically in different parts, e.g. denser near its faces
    • B32B5/142—Variation across the area of the layer
    • 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
    • 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
    • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
    • D04H1/06—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres by treatment to produce shrinking, swelling, crimping or curling of fibres
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers 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
    • 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
    • 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
    • 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
    • B32B2262/0276—Polyester fibres
    • 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
    • B32B2262/04—Cellulosic plastic fibres, e.g. rayon
    • 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
    • B32B2262/06—Vegetal fibres
    • 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
    • B32B2262/08—Animal fibres, e.g. hair, wool, silk
    • 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
    • B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
    • 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
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • B32B2307/736—Shrinkable
    • 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
    • B32B2432/00—Cleaning articles, e.g. mops or wipes
    • 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
    • B32B2555/00—Personal care
    • 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
    • B32B2555/00—Personal care
    • B32B2555/02—Diapers or napkins

Definitions

  • NONWOVEN FABRICS ARTICLES INCLUDING NONWOVEN FABRICS, ANU METHODS OF MAKING NONWOVEN FABRICS
  • the present disclosure relates to nonwoven fabrics in general and nonwoven fabrics that exhibit higher bulk properties.
  • Nonwoven fabrics can be produced by making a web, and then thermally bonding the fibers together.
  • staple fibers are converted into nonwoven fabrics using, for example, a carding machine, and the carded fabric is thermally bonded.
  • the thermal bonding can be achieved using various heating techniques, including heating with heated rollers, hot air, and heating through the use of ultrasonic welding.
  • Fibers can also be produced and consolidated into nonwovens in various other manners.
  • the fibers and nonwovens can be made by the spunbonding or meltblowing processes or a combination thereof.
  • consolidation processes can include needlepunching, through-air thermal bonding, ultrasonic welding and hydroentangling. Any nonwoyen a r cs, suc as conven ona erma y on e nonwoven fabrics, do not exhibit sufficient bulk or extensibility for certain end uses. Therefore, a need exists for nonwoven fabrics that exhibit sufficient bulk and extensibility.
  • embodiments of this disclosure include nonwoven fabrics, methods of making nonwoven fabrics, articles including nonwoven fabric, and the like.
  • An embodiment of a fabric includes a nonwoven fabric having at least a first fiber and a second fiber.
  • the first fiber has a first fiber shrinkage percent and the second fiber has a second fiber shrinkage percent.
  • the difference in the first fiber shrinkage percent and the second fiber shrinkage percent is at least 8%.
  • An embodiment of a fabric includes a nonwoven fabric having at least a first domain of shrinkage and a second domain of shrinkage.
  • the first domain and the second domain define differentiated domains of shrinkage.
  • the nonwoven fabric includes at least a first fiber and a first shrinking fiber.
  • An embodiment of an article includes a nonwoven fabric as described herein, where the article is selected from a cleaning wipe, a diaper, a textile stretch component, an incontinence care product, a feminine care product, and a filter.
  • An embodiment of a method of forming a nonwoven fabric includes: providing a nonwoven fabric including a first fiber and a second fiber, wherein the first fiber has a first fiber shrinkage percent and the second fiber has a second fiber shrinkage percent, wherein the difference in the first fiber shrinkage percent and the second fiber shrinkage percent is at least 8%; forming at least a first domain of shrinkage and a second domain of shrinkage, wherein the first domain and the second domain define differentiated domains of shrinkage, wherein a portion of the first fiber and a portion of the second fiber in the first domain are bonded; and heating the nonwoven fabric to an activation temperature of the second fiber, wherein the second fiber shrinks and causes the first fiber to gather to increase the thickness of the nonwoven fabric in the second domain.
  • An,,embpdjmeflt ⁇ f .ajpethod of forming a nonwoven fabric includes: providing a nonwoven fabric including a first fiber and a second fiber, wherein the first fiber has a first fiber shrinkage percent and the second fiber has a second fiber shrinkage percent, wherein the difference in the first fiber shrinkage percent and the second fiber shrinkage percent is at least 8%; and heating the nonwoven fabric to an activation temperature of the second fiber, wherein the second fiber shrinks and causes the first fiber to gather to increase the thickness of the nonwoven fabric.
  • FIGS. 1A and 1 B illustrate graphs of a shrinking fiber (FIG. 1A) and a non- shrinking fiber (FIG. 1B).
  • FIGS. 2A and 2B illustrate photomicrographs of cross sectional views of nonwoven webs of the present disclosure.
  • FIG. 2A illustrates an embodiment of a nonwoven web used for producing the bulky nonwoven fabric that has not been activated by a thermal bulking step.
  • FIG. 2B illustrates the nonwoven web that has been activated to produce the bulky nonwoven web.
  • FIG. 3 illustrates Table 1 , which describes a number of embodiments of nonwoven fabrics of the present disclosure.
  • Embodiments of the present disclosure will employ, unless otherwise indicated, techniques of textiles, chemistry, and the like, which are within the skill of the art. Such techniques are explained fully in the literature.
  • ratios, concentrations, amounts, and other numerical data may be expressed herein in a range format. It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or subranges encompassed within that range as if each numerical value and sub-range is explicitly recited.
  • a concentration range of "about 0.1% to 5%” should be interpreted to include not only the explicitly recited concentration of about 0.1 wt% to about 5 wt%, but also include individual concentrations (e.g., 1 %, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the indicated range.
  • nonwoyen a ⁇ c, s eet, or we as use erein means a textile structure of individual fibers, filaments, or threads that are directionally or randomly oriented and interact with one another by friction, and/or cohesion, and/or adhesion, as opposed to a regular pattern of mechanically inter-engaged fibers (e.g., it is not a woven or knitted fabric).
  • nonwoven fabrics and webs include, but are not limited to, carded webs, spunbond continuous filament webs, meltblown webs, air-laid webs, and wet-laid webs.
  • Suitable bonding methods include thermal bonding, chemical or solvent bonding, resin bonding, mechanical needling, hydraulic needling, stitch-bonding, combinations thereof, and the like.
  • An illustrative, nonlimiting embodiment of the present disclosure includes carded thermal bond nonwoven fabrics.
  • bonded or “bonding” are used herein to describe areas of a nonwoven fabric having inter-fiber bonding or entanglement beyond which occurs in nonwoven fabrics.
  • the term "bulk” or “loft” is used as an indication of the bulk specific volume of the nonwoven for a given areal density.
  • the terms “bulk” and “loft” are generally used interchangeably. As such, the term “bulk” is used to describe both “bulk” and “loft”.
  • Bulk specific volume can be obtained by dividing the bulk volume of a nonwoven sample by its mass. A bulky nonwoven is relatively less dense rather than compressed. Areal density is mass per unit area and is generally reported as grams per square meter (gsm). Areal density is often referred to as “basis weight” and the terms are equivalent.
  • shrink refers to the reduction in the length of the fiber as measured by thermomechanical analysis (TMA).
  • TMA thermomechanical analysis
  • a typical instrument for measuring shrinkage is the Model Q400, made by TA Instruments.
  • FIGS. 1A and 1 B illustrate graphs of a shrinking fiber and a non-shrinking fiber.
  • elasticity refers to the ability of an extensible nonwoven to return essentially to its pre-stressed state upon release of the stress. e. QTO aG r ⁇ r ⁇ f ⁇ ers o a process use o ncrease u su sequen o the formation of the nonwoven fabric.
  • embodiments of this disclosure include nonwoven fabrics, methods of making nonwoven fabrics, articles including nonwoven fabric, and the like.
  • the nonwoven fabric of the present disclosure have improved effects (e.g., increased bulk, adjustable textural feel, improved foreign particle entrapment, increased areal density, and the like) as compared to other nonwoven fabrics.
  • the nonwoven fabrics are highly extensible relative to other nonwoven fabrics.
  • the degree of extensibility is dependent on the activation temperature, fabric construction, bonding pattern, and the like. Under some conditions, a degree of elasticity may also be present which in turn, is dependent on the activation temperature, fabric construction, bonding pattern, and the like.
  • the nonwoven fabrics can be included in articles such as, but not limited to, cleaning wipes, diapers, textile stretch components, incontinence care products, feminine care products, filters, felts, and the like.
  • the nonwoven fabrics can be used in articles in the landing zones, in the acquisition/distribution layers, stretch ears, topsheet, backsheet, and the like.
  • the nonwoven fabrics can be tailored to have a pre-determined bulk, a certain softness/harshness, areal density, and the like, by selecting components of the nonwoven fabric (e.g., fibers), parameters for treating the nonwoven fabric, bonding patterns, and the like.
  • the nonwoven fabric can be designed for many applications such as, but not limited to, cleaning surfaces (e.g., soft surface or rough surface); acquiring, distributing or delivering liquids; adding comfort, filtering liquids, gases or powders; acoustic attenuation; and/or combinations thereof.
  • the nonwoven fabric includes one or more nonwoven layer(s), where the nonwoven layer(s) includes at least a first fiber and a second fiber.
  • the first fiber and the second fiber have different levels or rates of shrinkage under certain conditions (e.g., activation temperature and time to shrink the fibers, and degree of constraints against dimensional change).
  • the second fiber shrinks, and as the second fiber shrinks in size it pulls some first fibers with it to produce one or more areas of increased bulk. increase in bulk by about 20 to 500 %, about 3u to 450 %, and about 50 to 350 % relative to the bulk of the unactivated nonwoven fabric.
  • the nonwoven fabric can increase in thickness by about 30 to 650 %, about 45 to 550 %, and about 60 to 500 % relative to the thickness of the unactivated nonwoven fabric.
  • the activation conditions e.g., temperature and time or degree of constraints against dimensional change
  • the activation conditions applied to the nonwoven fabric depend, at least in part, upon the fiber composition, the amount of shrinkage desired, the textural feel (e.g., from soft to rough) of the nonwoven fabric desired, the amount of bulkiness desired, the level of extensibility and elasticity desired, and the like.
  • the activation of the fibers in nonwoven fabric is typically performed while the fibers are in a relaxed state (e.g., little or no tension in the machine direction or the cross direction relative to the force generated by the shrinking fibers).
  • the shrinkage can be controlled in the machine direction and/or the cross direction using controlled dimensional change processes such as, but not limited to, tenter frame processes, sanforizing processes, creping processes, allied processes, and combinations thereof.
  • controlled dimensional change processes such as, but not limited to, tenter frame processes, sanforizing processes, creping processes, allied processes, and combinations thereof.
  • the activation conditions, the fiber types, the number of nonwoven layers in the nonwoven fabric, and the like, are selected to produce desired effects (e.g., bulk, textural feel, and combinations thereof).
  • the shrinkage can also be controlled in the machine direction and/or the cross direction by controlling the ratio of the number of fibers oriented in the machine direction to the number of fibers oriented in the cross direction.
  • the activation temperature (e.g., of the oven or other heat source) of the second fiber is below the melting point of the polymer. Therefore, the activation conditions are dependent, at least in part, upon the type of polymeric fibers used as the second fiber.
  • the activation temperature when the second fiber is polypropylene is about 125°C to 15O 0 C for a time of about 10 seconds to 1 minute.
  • the activation temperature can be achieved by processes such as, but not limited to, heated gas, infrared heating sources, ovens, and the like. One skilled in the art can modify one or both of the temperature and time conditions to achieve the desired results.
  • the nonwoven fabric includes a pattern of differentiated domains of shrinkage.
  • the differentiated domains of shrinkage are f ⁇ De ⁇ e ow o rst oma ns an secon ⁇ domains.
  • the first domain of shrinkage is defined as the area of the nonwoven fabric that is bonded (e.g., a portion of the first fibers and the second fibers are bonded to one another), while the second domain of shrinkage is defined as the area of the nonwoven fabric that is not bonded.
  • the shrinkage of the first domain under activation conditions is very small relative to the shrinkage of the second domain under activation conditions.
  • the first fibers and the second fibers are included in both the first domains and the second domains and portions of fibers may be in both domains.
  • the first fiber and the second fiber have different rates of shrinkage under certain conditions (e.g., activation temperature and time to shrink the fibers). Exposing the nonwoven fabric to activation conditions causes the second fibers to shrink in length. As the second fibers shrink, the second fibers pull the first fibers along with them. The shrinkage of the second fibers causes the first fibers to gather in regions of the second domain, which can increase bulk of the nonwoven fabric. The increase in bulk is enhanced when the nonwoven fabric is pattern bonded so that the bonded regions prevent disentanglement of the first fibers and the second fibers.
  • a nonwoven fabric includes a single nonwoven layer including a mixture of first and second fibers.
  • the nonwoven fabric has a pattern of differentiated domains of shrinkage cause by bonding first domains of the nonwoven fabric (first bonding domain), and leaving other portions unbonded (second bonding domain).
  • the first fiber is a non-shrinking fiber (defined below) and the second fiber is a shrinking fiber.
  • the non-shrinking fiber and the shrinking fiber have different rates of shrinkage under certain activation conditions.
  • the nonwoven fabric is exposed to activation conditions that cause the shrinking fiber to shrink, while the non-shrinking fiber does not substantially shrink (as described below).
  • the shrinking fiber causes the non-shrinking fibers to gather in the second domains and increase bulk of the nonwoven fabric.
  • a nonwoven fabric in another exemplary embodiment, includes a first nonwoven layer including a first fiber, a second nonwoven layer including a second fiber, and a third nonwoven layer including the first fiber.
  • the nonwoven fabric has a pattern of differentiated domains of shrinkage caused by bonding first domains of the . nanwo.van fabric ,.(s h ⁇ ,,,b,QPdjng the first, the second, and the third nonwoven layers), and leaving other portions unbonded (second bonding domain).
  • the first fiber is a non-shrinking fiber (defined below) and the second fiber is a shrinking fiber.
  • the non-shrinking fiber and the shrinking fiber have different degrees of shrinkage under certain activation conditions.
  • the nonwoven fabric is exposed to activation conditions that cause the shrinking fiber to shrink, while the non-shrinking fiber does not substantially shrink (as described below).
  • the shrinking fiber in the second nonwoven layer causes the non-shrinking fibers in the first and third nonwoven layers to gather in the second domains and increase bulk of the nonwoven fabric.
  • the nonwoven fabric includes, but is not limited to, at least a first fiber and a second fiber.
  • the nonwoven fabric includes a first fiber, a second fiber, and a third fiber.
  • Other embodiments may include four or more fibers (e.g., a first fiber, a second fiber, ... and a "n th " fiber). Details about the fibers are described herein.
  • the nonwoven fabric can include one or more nonwoven layers (e.g., a first nonwoven layer, a second nonwoven layer, ... and a "n th " nonwoven layer).
  • Embodiments of the present disclosure can include nonwoven fabrics having 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, or more, nonwoven layers.
  • Each nonwoven layer can include, but is not limited to, a first fiber and/or a second fiber as well as additional fibers.
  • the nonwoven layers alternate between a nonwoven layer including a first fiber and a nonwoven layer including a second fiber.
  • the nonwoven layers alternate between a nonwoven layer including a non-shrinkable fiber and a nonwoven layer including a shrinkable fiber. Representative embodiments of nonwoven fabrics are described herein, while other embodiments having at least the first fiber and the second fiber that have different levels or rates of shrinkage are also included within the scope of the present disclosure.
  • the nonwoven fabric includes one nonwoven layer.
  • the nonwoven layer includes at least the first fiber and the second fiber.
  • the nonwoven layer includes the first fiber, the second fiber, and one or more additional fibers. in an emoo imen , e nonwoven a ric inc u es a irs nonwoven ayer an a second " n ⁇ nwoveri " layer.
  • the first nonwoven layer is disposed on the second nonwoven layer.
  • the first nonwoven layer is made of the first fiber and the second nonwoven layer is made of the second fiber.
  • the first nonwoven layer is made of the first fiber and the second fiber and the second nonwoven layer is made of the first fiber, the second fiber, a third fiber, or any combination thereof.
  • the nonwoven fabric includes a first nonwoven layer, a second nonwoven layer, and a third nonwoven layer.
  • the first nonwoven layer and the third nonwoven layer are made of the first fiber, while the second nonwoven layer is made of the second fiber.
  • the first nonwoven layer is made of a first fiber
  • the second nonwoven layer is made of a second fiber
  • the third nonwoven layer is made of a third fiber.
  • any of the nonwoven layers described in the previous embodiments can include combinations of the first fiber, the second fiber, the third fiber, and/or one or more other fibers.
  • the types of fibers and the combination of fibers can be selected according to the particular characteristics (e.g., bulk of the nonwoven fabric, texture of one or more surfaces of the nonwoven fabric, and the like) desired for a particular nonwoven fabric. It should be noted that conditions under which the nonwoven fabric is bonded and activated as well as the pattern of differentiated domains of shrinkage could be used to tailor the characteristics of the nonwoven fabric.
  • the nonwoven fabrics can be formed using one or more processes.
  • the nonwoven fabrics can be formed using processes such as, but not limited to, carded thermal bond, carded spun lace, carded through-air bond, wet laying, carded needlepunch, spun bond, air laying, melt blowing, and combinations thereof, each of which have the meaning typically attributed to them in the art.
  • the nonwoven fabrics are formed using carded thermal bond processes. Additional details regarding embodiments of the nonwoven fabric are described in the examples.
  • the nonwoven fabrics have a pattern of differentiated domains of shrinkage.
  • the patterns of differentiated domains of shrinkage can be ,,mgde,u5Pfl,,Kn.ow ⁇ ., ⁇ g!tteros.,,(e.g., which can be provided by any nonwoven roll maunfacturer, such as Andritz K ⁇ sters GmbH & Co. KG (Germany), and the like) or by using other patterns as well.
  • the patterns can be made using processes such as, calendar bonding with patterned rolls, patterning jets in hydroentangling, patterned needlepunching, and the like, and combinations thereof.
  • the nonwoven fabric can be post treated.
  • the post treatments include, but are not limited to, corona, plasma, soil release, flame retardant, anti-microbial, softener, and the like, and combinations thereof.
  • the first fiber can include, but is not limited to, natural fibers or naturally derived fibers (hereinafter referred to as "natural fiber"), thermoplastic polymer fibers, and thermoset and high performance polymer fibers.
  • the second fiber can include, but is not limited to, polymeric fibers (e.g., thermoplastic polymer fibers). Additional fibers (e.g., the third fiber and so on) can include, but are not limited to, natural fibers, polymeric fibers, and thermoset and high performance fibers.
  • the first fiber and the second fiber can include, but are not limited to, polymer blend fibers, bi- component fibers (e.g., a fiber comprising of two different polymers of differing chemical constitution/properties), and bi-constituent fibers (e.g., fiber composed of two or more dissimilar fibers combined before the extrusion process).
  • the first fiber and the second fiber can be made by the same process or by a different process.
  • the natural fibers can include, but are not limited to, plant fibers, vegetable fibers, and animal/insect fibers.
  • the natural fibers are derived from fibers of animal coats and silkworm cocoons, and fiber of plants seeds, leaves, stems, and the like.
  • Exemplar natural fibers include, but are not limited to, wool, cotton, silk, linen, ramie, hemp, and jute.
  • the natural fiber includes, but is not limited to, rayon, Lyocell, polylactic acid, soybean protein, and combinations thereof.
  • thermoset and high performance polymers can include, but are not limited to, carbon fibers, glass fibers, polyacrylonitrile fibers, polyvinyl alcohol fibers, polyaramid fibers, combinations thereof, and the like.
  • the polymeric fibers and thermoplastic polymer fibers can be made of copolymers, terpolymers, and higher polymers. It should be noted that the term pLIJiore monomers in e same po ymer c ain. I ne polymeric fibers and thermoplastic polymer fibers can be mono-component or multi- component. The polymer fibers and thermoplastic polymer fibers can be polymer blends.
  • the polymeric fibers and thermoplastic polymer fibers can include thermoplastic polymers such as, but not limited to, polymer blends or copolymers of each of the following: polyolefins, polyesters, polypropylene, polyethylene, polybutene, polymethylpentene, ethylene-propylene, polyamides, polyurethanes, polyvinyl acetates, ethylene vinyl acetates, polyetheresters, polyetherurethane, polyvinyl acetates, and combinations thereof.
  • thermoplastic polymers such as, but not limited to, polymer blends or copolymers of each of the following: polyolefins, polyesters, polypropylene, polyethylene, polybutene, polymethylpentene, ethylene-propylene, polyamides, polyurethanes, polyvinyl acetates, ethylene vinyl acetates, polyetheresters, polyetherurethane, polyvinyl acetates, and combinations thereof.
  • the polymeric fibers and thermoplastic polymer fibers can be made of materials such as, but not limited to, polymer blends or copolymers of each of the following: polyolefins, polyesters, polyamides, polyvinyl acetates, polyacrylonitriles, polyvinyl alcohol and ethylene acrylic acid, combinations thereof.
  • the polymeric fibers and thermoplastic polymer fibers can include spinnable polymeric materials such as polyolefins and blends comprising polyolefins (e.g., See U.S. Pat. Nos. 5,733,646, 5,888,438, 5,431 ,994, 5,318,735, 5,281 ,378, 5,882,562 and 5,985,193, the disclosures of which are incorporated by reference herein in their entireties).
  • spinnable polymeric materials such as polyolefins and blends comprising polyolefins (e.g., See U.S. Pat. Nos. 5,733,646, 5,888,438, 5,431 ,994, 5,318,735, 5,281 ,378, 5,882,562 and 5,985,193, the disclosures of which are incorporated by reference herein in their entireties).
  • the polymer is a polypropylene or a blend including a polypropylene.
  • the polypropylene can include polypropylenes that are spinnable.
  • the polypropylene can be atactic, heterotactic, syndiotactic, isotactic and stereoblock polypropylene-including partially and fully isotactic, or at least substantially fully isotactic-polypropylenes.
  • polymers include homopolymers and heteropolymers (e.g., copolymers and terpolymers), and mixtures thereof (including blends and alloys produced by mixing separate batches or forming a blend in situ).
  • the polymer can include copolymers of olefins, such as propylene, and these copolymers can contain various components.
  • polypropylene is utilized in its ordinary commercial meaning wherein the polypropylene is a substantially linear molecule.
  • a polypropylene composition includes a material that contains a broad piQj ⁇ c ⁇ ) ⁇ t ⁇ l ight , 4i ⁇ 1i!:i,b, ⁇ 1;jpQ
  • polypropylene staple fibers include polypropylene staple fibers. These fibers may also include bicomponent fibers containing various combinations of polypropylene or a combination of other polymeric materials such as polyethylene.
  • a polymeric fiber of particular interest conventionally used in producing nonwoven webs or fabrics is a high thermal bond strength spun melt fiber described in US Patent No. 5,281 ,378, incorporated herein by reference in its entirety.
  • the polypropylene can have an average molecular weight from about 3x10 5 to about 5x10 5 , a spun melt flow rate, MFR (determined according to ASTM D-1238-86 (condition L; 230/2.16), which is incorporated by reference herein in its entirety) of about 7 to about 50 dg/min, and/or a spin temperature within the range of about 220 to 315° C, about 240 to 300 0 C, and about 255-285° C.
  • MFR spun melt flow rate
  • the polypropylene can be linear or branched, such as disclosed by U.S. Pat. No. 4,626,467, which is incorporated by reference herein in its entirety, and is preferably linear.
  • the polypropylene to be made into fibers can include polypropylene compositions as taught in U.S. Pat. Nos. 5,629,080, 5,733,646 and 5,888,438 and European Patent Application No. 0 552 013, which are incorporated by reference herein in their entireties.
  • polymer blends such as disclosed in U.S. Pat. No. 5,882,562, and European Patent Application No. 0 719 879, which are incorporated by reference herein in their entireties, can also be utilized.
  • the first and the second fiber can have the same or a different size and/or cross-section.
  • the first fiber and the second fiber can have a denier of about 0.1 to 50 denier per filament.
  • the first fiber and the second fiber can be continuous or staple, with a length of about 1 mm to 250 mm.
  • the melt flow rate, MFR is dependent upon the type of polymer the fiber is made of, and, thus, the MFR can vary depending on which fibers are selected for each particular application.
  • the first polyolefin fiber and the second polyolefin fiber can have a melt flow rate (determined according to ASTM D- 1238-86 (condition L; 230/2.16), which is incorporated by reference herein in its entirety) of about 10 to 400 dg/min, but the MFR depends on the chemical composition of the fibers.
  • J 1 P 1 J 1 O ⁇ em b qdjme p.J, H t h ⁇ , f i rst fiber has a first fiber shrinkage percentage (measured using TMA) and the second fiber has a second fiber shrinkage percentage, where the difference in the first fiber shrinkage percentage and the second fiber shrinkage percentage is at least about 8%, is at least about 9%, is at least about 10%, is at least about 12%, or is at least about 15%. It should be noted that in an embodiment the first fiber might not shrink and increase in length.
  • the first fiber has a first fiber shrinkage of less than about 10%, less than about 8%, less than about 6%, less than about 3%, or less than about 1%, where each is measured at the same conditions (e.g., a temperature near the activation temperature of the fiber of interest), and may be referred to as the "non-shrinking fiber".
  • the non-shrinking fiber can include, but is not limited to, polypropylene, polyester, and combinations thereof.
  • the fiber shrinkage is less than about 10 % at about 140 0 C. It should be noted that in an embodiment the non-shrinking fiber might not shrink and increase in length.
  • the second fiber has a fiber shrinkage of greater than about 9%, greater than about 10%, greater than about 11%, greater than about 12%, greater than about 13%, and may be referred to as the "shrinking fiber".
  • the shrinking fiber can include, but is not limited to, polypropylene, polyester, polyethylene, and bicomponent fibers made therefrom.
  • the fiber shrinkage is about 9 to 40 % at 140° C.
  • the production of polymeric fibers for nonwoven materials can include the use of a mix of at least one polymer with nominal amounts of additives, such as, but not limited to, antioxidants, stabilizers, pigments, antacids, process aids and the like.
  • additives such as, but not limited to, antioxidants, stabilizers, pigments, antacids, process aids and the like.
  • the polymer or polymer blend can include various additives, such as, but not limited to, melt stabilizers, antioxidants, pigments, antacids, antistatic aids, emulsifiers, preservatives, and process aids.
  • the types, identities, and amounts of additives can be determined by those of ordinary skill in the art upon consideration of requirements of the product.
  • finishing can be applied to the fibers to maintain or render them hydrophilic or hydrophobic. Finish compositions including hydrophilic finishes or hydrfppjpbjc/pshes ⁇ ay ⁇ pelected by those of ordinary skill in the art according to the characteristics of the apparatus and the needs of the product being manufactured.
  • one or more components can be included in the polymer blend for modifying the surface properties of the fiber, such as to provide the fiber with repeat wettability, or to prevent or reduce build-up of static electricity.
  • Hydrophobic finish compositions preferably include antistatic agents.
  • Hydrophilic finishes may also include such agents.
  • Table 1 illustrates some exemplar embodiments of nonwoven fabrics A-G with combinations of fibers NS1 , NS2, NS3, NS4, NS5, S1 , and S2.
  • the examples provide a number of embodiments ranging in fabric weight, construction, fiber composition, fiber type, the number of nonwoven layers, method of fabric formation, and the like.
  • FIGS. 2A and 2B illustrate photomicrographs of cross sectional views of nonwoven fabric of A in Table 1.
  • FIG. 2A illustrates an embodiment of a nonwoven fabric used for producing the bulky nonwoven fabric that has not been activated by a thermal bulking step.
  • FIG. 2B illustrates the nonwoven web that has been activated to produce the bulky nonwoven web

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  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

Les formes de réalisation de la présente invention portent sur des textiles non tissés, des procédés de production de textiles non tissés, des articles comprenant des textiles non tissés et autres.
PCT/US2006/038747 2005-10-03 2006-10-03 Textile non tisse, articles comprenant des textiles non tisses et procedes de production de textiles non tisses Ceased WO2007041620A1 (fr)

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CA002624808A CA2624808A1 (fr) 2005-10-03 2006-10-03 Textile non tisse, articles comprenant des textiles non tisses et procedes de production de textiles non tisses
CN200680032495XA CN101258029B (zh) 2005-10-03 2006-10-03 无纺织物、包括无纺织物的物品以及制造无纺织物的方法
JP2008533789A JP2009510278A (ja) 2005-10-03 2006-10-03 不織布、不織布からなる物品、および不織布の製造法
MX2008004048A MX2008004048A (es) 2005-10-03 2006-10-03 Tela no tejida, articulos que incluyen telas no-tejidas, y metodo para producir telas no-tejidas.
EP06816190.0A EP1931512A4 (fr) 2005-10-03 2006-10-03 Textile non tisse, articles comprenant des textiles non tisses et procedes de production de textiles non tisses
BRPI0616733A BRPI0616733A2 (pt) 2005-10-03 2006-10-03 tecido não-tecido, artigos incluindo tecidos não-tecidos, e métodos de fabricação de tecidos não tecidos

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US60/723,197 2005-10-03

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WO2008140384A1 (fr) * 2007-05-16 2008-11-20 Dinair Development Ab Utilisation d'un matériau en tant que matériau de base de filtre, procédé de fabrication d'un matériau de base de filtre, matériau de base de filtre et filtre
ITMI20090381A1 (it) * 2009-03-13 2010-09-14 Losma S P A Struttura di filtro ad elevata capacita' filtrante.
WO2011073265A1 (fr) * 2009-12-17 2011-06-23 Dinair Development Ab Procédé de préparation d'un milieu filtrant de fibres à deux composants pla/pp et produits associés
US20130095288A1 (en) * 2011-10-12 2013-04-18 Hirokazu Terada Stretchable bulky nonwoven fabric and method for manufacturing the same
CN105966022A (zh) * 2016-05-04 2016-09-28 苏州宝丽洁纳米材料科技股份有限公司 一种高锁水超细柔性纤维非织造材料及制备方法
CN107215021A (zh) * 2017-06-27 2017-09-29 太仓市玛雅针织有限公司 保温性好的复合面料

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CN102407634A (zh) * 2011-08-31 2012-04-11 苏州金荣华轻纺实业有限公司 一种防水纺织品
CN103526395A (zh) * 2013-09-29 2014-01-22 吴江市凌通纺织整理有限公司 一种多功能免洗面料
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CN108909132B (zh) * 2018-06-15 2020-08-25 阿斯福特纺织（漳州）有限公司 一种耐冲洗耐水浸泡透气型化纤毯的成型工艺
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WO2008140384A1 (fr) * 2007-05-16 2008-11-20 Dinair Development Ab Utilisation d'un matériau en tant que matériau de base de filtre, procédé de fabrication d'un matériau de base de filtre, matériau de base de filtre et filtre
EP2185266A4 (fr) * 2007-05-16 2011-07-27 Dinair Dev Ab Utilisation d'un matériau en tant que matériau de base de filtre, procédé de fabrication d'un matériau de base de filtre, matériau de base de filtre et filtre
ITMI20090381A1 (it) * 2009-03-13 2010-09-14 Losma S P A Struttura di filtro ad elevata capacita' filtrante.
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US20130095288A1 (en) * 2011-10-12 2013-04-18 Hirokazu Terada Stretchable bulky nonwoven fabric and method for manufacturing the same
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CN105966022A (zh) * 2016-05-04 2016-09-28 苏州宝丽洁纳米材料科技股份有限公司 一种高锁水超细柔性纤维非织造材料及制备方法
CN107215021A (zh) * 2017-06-27 2017-09-29 太仓市玛雅针织有限公司 保温性好的复合面料

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CN101258029A (zh) 2008-09-03
CN101258029B (zh) 2011-07-06
KR20080088571A (ko) 2008-10-02
JP2009510278A (ja) 2009-03-12
EP1931512A4 (fr) 2014-01-08
BRPI0616733A2 (pt) 2016-08-23
EP1931512A1 (fr) 2008-06-18
CA2624808A1 (fr) 2007-04-12
MX2008004048A (es) 2008-10-23

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