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WO2007035525A2 - Procédé de production de substrat de fibre naturelle renforcé par un non-tissé synthétique - Google Patents

Procédé de production de substrat de fibre naturelle renforcé par un non-tissé synthétique Download PDF

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Publication number
WO2007035525A2
WO2007035525A2 PCT/US2006/036097 US2006036097W WO2007035525A2 WO 2007035525 A2 WO2007035525 A2 WO 2007035525A2 US 2006036097 W US2006036097 W US 2006036097W WO 2007035525 A2 WO2007035525 A2 WO 2007035525A2
Authority
WO
WIPO (PCT)
Prior art keywords
substrate
paper
woven
paper pulp
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/US2006/036097
Other languages
English (en)
Other versions
WO2007035525A3 (fr
Inventor
James Al Shearer
Philip Forshee
Paul Cronin
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.)
Authentix Inc
Original Assignee
Authentix Inc
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 Authentix Inc filed Critical Authentix Inc
Publication of WO2007035525A2 publication Critical patent/WO2007035525A2/fr
Publication of WO2007035525A3 publication Critical patent/WO2007035525A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • D21H27/32—Multi-ply with materials applied between the sheets
    • D21H27/34—Continuous materials, e.g. filaments, sheets, nets
    • 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
    • D04H1/407—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 containing absorbing substances, e.g. activated carbon
    • 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
    • D04H1/42—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
    • D04H1/4374—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 using different kinds of webs, e.g. by layering 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay

Definitions

  • TECHNICALFBELD This invention relates to manufacture of flexible substrates, and more particularly to the manufacture of paper products.
  • Reinforced paper substrates are important in several applications, including the manufacture of bank notes. Because bank notes experience significant wear and tear, there is a desire to reinforce such substrates to be more resistant. Currently, attempts have been made to produce such a substrate. Two main methods include gluing and incorporating loose fibers.
  • the gluing method essentially brings a paper/non-woven/paper "sandwich” together either by adhesives or by utilizing a non-woven that is made up of bi- component fibers, whereas the sheath of the fibers are comprised of a low melt polymer that can be heated to melt and adhere the two individual paper substrates together.
  • United States Patent Application Serial No. 11/266,475 discloses a process which takes a synthetic web roll, two cotton/paper rolls where the three separate rolls are evenly fed together through a series of heated rolls or a heated press which melts the sheath material and essentially glues the three separate substrates together.
  • Embodiments of the present invention produce an improved substrate, comprising a core of non-woven synthetic materials encapsulated by regular paper.
  • the encapsulation occurs during the wet paper pulp stage. This encapsulation provided the same look and feel as normal paper substrates, but many increased strengths also.
  • Alternative embodiments of the present invention produce normal substrate but with non-woven synthetic inclusions. These inclusions may be used as security devices that are incorporated into the substrate of a security paper. They may have some visual effect such as iridescence, fluorescence, etc. The incorporation of the inclusions into the paper may also occur during the wet paper pulp stage. This incorporation allows the otherwise standard paper new and interesting features such as tactile feel, novel optical features and even other, more covert security features.
  • embodiments of the present invention produce a natural or synthetic fiber (or combination of both) substrate that is stronger and lasts longer, while exhibiting similar printing characteristics as typical paper substrates. Such substrates are useful in many markets, including the currency market.
  • a synthetic cross-linked component such as a non- woven
  • a natural fiber matrix augments an ability to incorporate more advanced security features to thwart counterfeiting efforts, both foreign and domestic. It also enables the inclusion of anti-bacterial components to sustain cleanliness, if so desired.
  • Embodiments of the present invention further solve delaminating problems as • the synthetic substrate and natural fibers essentially become a single substrate that looks and feels like a normal paper/cotton substrate, but possessing strength properties associated with the polymer core of the substrate. This strength enhancement produces a stronger substrate product that exhibits superior longevity.
  • Synthetic non-wovens of embodiments of the present invention have a capability of being printed or modified (such as die cut) prior to being incorporated into a natural fiber slurry. This enables a clear and recognizable overt security feature to be incorporated within a natural substrate, which cannot be duplicated. Further, other typical security features may be deployed within the fibers of the non-woven, which may not be able to be implemented into the paper itself.
  • FIG. IA illustrates a synthetic substrate
  • FIG. IB illustrates entangling of fibers in the substrate
  • FIG. 1C illustrates the entangled substrate "sandwiched" between encapsulating paper slurry
  • FIG. ID illustrates the product of FIG. 1C after being rolled
  • FIG. 2A illustrates a headbox
  • FIG. 2B illustrates a split headbox
  • FIG. 3 illustrates a cut-away view of an embodiment of the present invention
  • FIG. 4 illustrates an alternative embodiment of the present invention
  • FIG. 5 illustrates a process in accordance with an embodiment of the present invention.
  • Embodiments of the present invention use a melt blown or spun-bond synthetic web being fed at some point into a slurry flow of a typical paper manufacturing method, possibly within a "headbox” or between a “split headbox.”
  • the substrate material may thus be a "nonwoven,” which as the name implies, are fibers formed and bonded together without interweaving them.
  • the individual fibers may be structured fibers or multi-component fibers.
  • the fibers may have an inner core made of one material (nylon) with an outer sheath made from another (polylactic acid or PLA). Virtually any polymer may be used, which may depend upon the application and how the material is to be used and what characteristics of the material are to be achieved.
  • Utilizing multi-component technology allows one to be able to have fibers that are made from a high viscosity polymer (nylon) for strength and a low viscosity polymer (PLA) that may be used for adhesion or for softness.
  • nylon high viscosity polymer
  • PLA low viscosity polymer
  • By varying the ratio of the high and low viscosity polymers allows one to dictate how much strength and how soft the fibers are. Also, considerations for the specific gravity of the polymer may be a factor.
  • Other polymers that may be used are polyester, polypropylene, co-polyester, and polyethylene.
  • tertiary materials such as our phosphors or fluorescent materials, may be added into the core with the surrounding sheath protecting them from the external environment. These can give long life. Additives or sheath/core configurations may be added as the application needs; nylon may be used where the need is a long lasting component, or PLA where the need is of thermosoftening materials.
  • FIG. IA illustrates a porous non- woven synthetic substrate 101.
  • synthetic web material (or substrate) 101 may be exposed to sonication in the presence of some amount of paper slurry (step 501 in FIG. 5). This forces some of the paper slurry into the open pores of the substrate 101, mechanically entangling fibers 102 of the paper slurry within the synthetic web 101. This increases the bonding between the encapsulating paper 103 and the internal non- woven materials 101.
  • step 502 the synthetic web and fiber substrate 120 is evenly distributed or fed into a headbox 203 in such a way that the paper slurry 204 can migrate underneath and above the synthetic substrate 120, as in a typical paper making process. As illustrated in FIG. 1C, this allows the natural fibers 103 to become entangled with the synthetic fibers of the non- woven substrate 101, as well as the web-entrained paper fibers 102, which may be located or placed in the top, middle or bottom of the final natural/synthetic product 104. As the paper making process progresses, in step 503, the water is removed from the slurry by vacuum boxes and rollers 207 located downstream.
  • FIG. 2B This vacuum process draws the natural fibers into the synthetic web and causes even further entanglement as shown in FIG. ID.
  • a "split" headbox 209, 210 method may also be used as illustrated in FIG. 2B in a manner similar to FIG. 2A.
  • Single and split headboxes for making paper are well known in the art.
  • FIG. 3 illustrates a substrate 104 manufactured in accordance with an embodiment of the present invention.
  • the substrate 104 is shown in a cut-away view where the natural paper 103 is cut away to show the non-woven synthetic core 101, 120 inbetween.
  • the incorporation of large pieces of the non- woven material 403 into the substrate 401 can occur, where these large inclusions may support many security features. These inclusions may be loose from each other, or only connected in a very tenuous manner in the form of a daisy-chain.
  • the embedded inclusions403, may be formed of the same non-woven materials as used in the substratelOl. There are various methods of forming them from the substrates. They include:
  • the synthetic web may be produced as a bi-component spun-bond web in which the sheath is comprised of a specific ratio of a lower melt temperature polymer such as PLA (polylactide), PVA (Poly(vinyl acetate)), or EVA (Ethylene vinyl acetate).
  • PLA polylactide
  • PVA Poly(vinyl acetate)
  • EVA Ethylene vinyl acetate

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Paper (AREA)

Abstract

Selon cette invention, un substrat (101) d’une âme de matériau synthétique non tissé est enveloppé par du papier ordinaire (103). Le substrat (101) est un matériau non tissé poreux imprégné de fibres de pâte à papier (102). L’enveloppage a lieu au cours d’une phase de pâte à papier humide. Lors de l’enveloppage, les fibres (102) se lient aux couches de papier enveloppantes (103). Ceci produit un substrat de fibre naturelle ou synthétique (ou mixte) qui s’avère plus résistant et durable tout en présentant des caractéristiques d’impression similaires à celles des substrats de papier classiques.
PCT/US2006/036097 2005-09-16 2006-09-15 Procédé de production de substrat de fibre naturelle renforcé par un non-tissé synthétique Ceased WO2007035525A2 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US71791305P 2005-09-16 2005-09-16
US60/717,913 2005-09-16
US81930906P 2006-07-07 2006-07-07
US60/819,309 2006-07-07
US81957506P 2006-07-10 2006-07-10
US60/819,575 2006-07-10

Publications (2)

Publication Number Publication Date
WO2007035525A2 true WO2007035525A2 (fr) 2007-03-29
WO2007035525A3 WO2007035525A3 (fr) 2007-05-18

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PCT/US2006/036097 Ceased WO2007035525A2 (fr) 2005-09-16 2006-09-15 Procédé de production de substrat de fibre naturelle renforcé par un non-tissé synthétique

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2227354A2 (fr) * 2007-11-26 2010-09-15 Arjowiggins Arches Procede de fabrication d'un support pour produit abrasif applique renforce et produit obtenu
WO2011137526A1 (fr) * 2010-05-07 2011-11-10 Emballages Stuart Inc. Stratifié et structure de carton résistants à la déchirure

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4652015A (en) * 1985-12-05 1987-03-24 Crane Company Security paper for currency and banknotes
US5137600A (en) * 1990-11-01 1992-08-11 Kimberley-Clark Corporation Hydraulically needled nonwoven pulp fiber web
US6177370B1 (en) * 1998-09-29 2001-01-23 Kimberly-Clark Worldwide, Inc. Fabric

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2227354A2 (fr) * 2007-11-26 2010-09-15 Arjowiggins Arches Procede de fabrication d'un support pour produit abrasif applique renforce et produit obtenu
CN101873911A (zh) * 2007-11-26 2010-10-27 亚宙维金斯阿尔什 用于加强的实用研磨产品的基底的制造方法及由此获得的产品
WO2011137526A1 (fr) * 2010-05-07 2011-11-10 Emballages Stuart Inc. Stratifié et structure de carton résistants à la déchirure
US8685505B2 (en) 2010-05-07 2014-04-01 Emballages Stuart Inc. Tear-resistant paperboard laminate and structure

Also Published As

Publication number Publication date
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