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WO2016018341A1 - Non-tissés souples et résistants de faible coût - Google Patents

Non-tissés souples et résistants de faible coût Download PDF

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Publication number
WO2016018341A1
WO2016018341A1 PCT/US2014/049051 US2014049051W WO2016018341A1 WO 2016018341 A1 WO2016018341 A1 WO 2016018341A1 US 2014049051 W US2014049051 W US 2014049051W WO 2016018341 A1 WO2016018341 A1 WO 2016018341A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
spunbond
spunbond layer
basis weight
laminate web
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/US2014/049051
Other languages
English (en)
Inventor
Francis Paul Abuto
Michael John Faulks
Virginia Lee DAY
Ray Anthony STERLING
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.)
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Original Assignee
Kimberly Clark Worldwide Inc
Kimberly Clark 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 Kimberly Clark Worldwide Inc, Kimberly Clark Corp filed Critical Kimberly Clark Worldwide Inc
Priority to PCT/US2014/049051 priority Critical patent/WO2016018341A1/fr
Publication of WO2016018341A1 publication Critical patent/WO2016018341A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • 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
    • 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
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/263—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer having non-uniform thickness
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • 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
    • B32B5/04—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 layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
    • 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
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • 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
    • D04H3/14—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 yarns or filaments produced by welding
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—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
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • 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
    • B32B2307/728—Hydrophilic
    • 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
    • B32B2307/73—Hydrophobic
    • 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

  • This invention relates to nonwoven laminated fabric-like material made of predominantly synthetic fibers.
  • Bonded carded webs or webs formed from polyethylene or bicomponent fibers of both polyethylene and polypropylene (bicomponent PP/PE) are soft nonwovens but are high cost and not affordable for many disposable absorbent article applications.
  • Prior art describes various laminates of two or more materials. None of these teach forming a low basis weight spunbond and re-threading it though the meltspun formation and bonding process a second time to achieve a soft nonwoven material.
  • Polypropylene spunbond is relatively lower cost compared to bonded carded webs, polyethylene, or bicomponent nonwovens. Described herein is a new process to make an improved spunbond material that is softer, yet stronger, using lower cost polypropylene.
  • the disclosure provides for a method for producing a laminate web having a basis weight, the method including forming a first spunbond layer comprising about half of the basis weight of the laminate web, bonding the first spunbond layer, winding the first spunbond layer into a roll, and unwinding the roll.
  • the method also includes forming a second layer comprising the remainder of the basis weight of the laminate web on top of the first spunbond layer to form a laminate web and bonding the laminate web.
  • the disclosure provides for a method for producing a laminate web having a basis weight, the method including forming a first spunbond layer comprising about half of the basis weight of the laminate web, bonding the first spunbond layer, forming a second spunbond layer comprising the remainder of the basis weight of the laminate web on top of the first spunbond layer to form a laminate web, and bonding the laminate web.
  • the disclosure provides a method for producing a laminate web having a basis weight, the method including forming a first spunbond layer comprising about half of the basis weight of the laminate web, bonding the first spunbond layer, winding the first spunbond layer into a roll, and unwinding the roll.
  • the method also includes forming a second layer comprising the remainder of the basis weight of the laminate web on top of the first spunbond layer to form a laminate web, wherein the second layer is spunbond, meltblown, coform, or film and is heat bondable to the first spunbond layer; incorporating a benefit agent between the first and second layers; and bonding the laminate web.
  • the nonwoven laminate has sufficient strength for many desired applications and can be further treated with elements for additional applications. Additional elements can include but are not limited to odor control components, softening agents, hydrophilic, superhydrophilic, hydrophobic, and superhydrophobic treatments.
  • the nonwoven laminate can incorporate dissimilar second layer substrates that include but are not limited to meltblown, coform, and films that are compatibly heat bondable to the first layer.
  • the nonwoven laminate can also include stretchable, extensible, or elastic properties and can be created with desired ripples, rugosities, or textures.
  • Figure 1 is a diagram illustrating apparatus for producing a base layer of spunbond material in accordance with the invention
  • Figure 2 is a diagram illustrating apparatus for producing a laminate material using the base layer of Fig. 1 in accordance with the invention
  • Figure 3 is a partial cross section to an enlarged scale of the laminate material of Fig. 2 in accordance with the invention
  • Figure 4 is a partial cross section to an enlarged scale of the base layer of Fig. 1 in accordance with the invention.
  • the present disclosure is generally directed towards a nonwoven material having improved softness and strength for use in a variety of products including absorbent articles.
  • a nonwoven material having improved softness and strength for use in a variety of products including absorbent articles.
  • Each example is provided by way of explanation and is not meant as a limitation.
  • features illustrated or described as part of one aspect or figure can be used on another aspect or figure to yield yet another aspect. It is intended that the present disclosure include such modifications and variations.
  • absorbent article refers herein to an article that can be placed against or in proximity to the body (i.e. , contiguous with the body) of the wearer to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body.
  • absorbent articles as described herein, are intended to be discarded after a limited period of use instead of being laundered or otherwise restored for reuse.
  • bonded refers herein to the joining, adhering, connecting, attaching, or the like, of two elements. Two elements will be considered bonded together when they are joined, adhered, connected, attached, or the like, directly to one another or indirectly to one another, such as when each is directly bonded to intermediate elements. The bonding of one element to another can occur via continuous or intermittent bonds.
  • carded web refers herein to a web containing natural or synthetic staple length fibers typically having fiber lengths less than about 100 mm. Bales of staple fibers can undergo an opening process to separate the fibers that are then sent to a carding process that separates and combs the fibers to align them in the machine direction after which the fibers are deposited onto a moving wire for further processing. Such webs are usually subjected to some type of bonding process such as thermal bonding using heat and/or pressure. In addition to or in lieu thereof, the fibers can be subject to adhesive processes to bind the fibers together such as by the use of powder adhesives.
  • the carded web can be subjected to fluid entangling, such as hydroentangling, to further intertwine the fibers and thereby improve the integrity of the carded web.
  • Carded webs due to the fiber alignment in the machine direction, once bonded, will typically have more machine direction strength than cross machine direction strength.
  • a carded web so bonded becomes a bonded carded web or BCW.
  • film refers herein to a thermoplastic film made using an extrusion and/or forming process, such as a cast film or blown film extrusion process.
  • the term includes apertured films, slit films, and other porous films that constitute liquid transfer films, as well as films that do not transfer fluids, such as, but not limited to, barrier films, filled films, breathable films, and oriented films.
  • grams refers herein to grams per square meter.
  • hydrophilic refers herein to fibers or the surfaces of fibers that are wetted by aqueous liquids in contact with the fibers.
  • the degree of wetting of the materials can, in turn, be described in terms of the contact angles and the surface tensions of the liquids and materials involved.
  • Equipment and techniques suitable for measuring the wettability of particular fiber materials or blends of fiber materials can be provided by Cahn SFA-222 Surface Force Analyzer System, or a substantially equivalent system. When measured with this system, fibers having contact angles less than 90 are designated “wettable” or hydrophilic, and fibers having contact angles greater than 90 are designated “nonwettable” or hydrophobic.
  • meltblown refers herein to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity heated gas (e.g., air) streams that attenuate the filaments of molten thermoplastic material to reduce their diameter, which can be a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers.
  • heated gas e.g., air
  • a “meltspun” fiber refers generically to a fiber that is formed from a molten polymer by a fiber-forming extrusion process, for example, such as fibers that are made by the meltblown and spunbond processes.
  • nonwoven refers herein to materials and webs of material that are formed without the aid of a textile weaving or knitting process.
  • the materials and webs of materials can have a structure of individual fibers, filaments, or threads (collectively referred to as "fibers") that can be interlaid, but not in an identifiable manner as in a knitted fabric.
  • Nonwoven materials or webs can be formed from many processes such as, but not limited to, meltblowing processes, spunbonding processes, carded web processes, etc.
  • pliable refers herein to materials that are compliant and that will readily conform to the general shape and contours of the wearer's body.
  • spunbond refers herein to small diameter fibers that are formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinnerette having a circular or other configuration, with the diameter of the extruded filaments then being rapidly reduced by a conventional process such as, for example, eductive drawing, and processes that are described in U.S. Patent No. 4,340,563 to Appel et al., U.S. Patent No. 3,692,618 to Dorschner et al., U.S. Patent No. 3,802,817 to Matsuki et al., U.S. Patent Nos. 3,338,992 and 3,341 ,394 to Kinney, U.S. Patent No.
  • Spunbond fibers are generally continuous and often have average deniers larger than about 0.3, and in an aspect, between about 0.6, 5, and 10 and about 15, 20, and 40. Spunbond fibers are generally not tacky when they are deposited on a collecting surface.
  • the term "thermoplastic" refers herein to a material that softens and that can be shaped when exposed to heat and that substantially returns to a non-softened condition when cooled.
  • Absorbent and other articles can be made from a material that includes a layer of substantially continuous polymeric filaments formed by a spunbonded process into a web, the thermoplastic polymer being extruded through a spinnerette or the like to form discrete filaments which are, thereafter, drawn and deposited in a substantially random manner on a carrier belt or the like to form a web.
  • a material that includes a layer of substantially continuous polymeric filaments formed by a spunbonded process into a web, the thermoplastic polymer being extruded through a spinnerette or the like to form discrete filaments which are, thereafter, drawn and deposited in a substantially random manner on a carrier belt or the like to form a web.
  • Such web material is a "spunbonded" web material.
  • the web possesses integrity due to the entanglement of the individual fibers in the web as well as some degree of thermal or self-bonding between the fibers.
  • the polymers used to prepare the spunbonded webs can be a wide variety of thermoplastic polymers of either the same or different type.
  • Polypropylene is a particularly useful polymer for this purpose.
  • the filaments in the spunbonded web layer can for example have a diameter of between 15 to 25 microns.
  • the material can have a basis weight of less than about 7 gsm to greater than about 40 gsm.
  • spunbonded fabric may be the conventional spunbond material made in accordance with the teachings of U.S. Pat. No. 3,692,618, it is preferred that the spunbonded layers be made by a process as taught in U.S. Pat. No. 4,340,563.
  • Spunbond webs are typically formed in one step wherein continuous meltspun fibers from one or more banks are deposited onto a moving porous forming surface then consolidated in a nip between a pair of bonding rolls.
  • the current practice for producing a 20 gsm spunbond web involves laying down 20 gsm of meltspun fibers from one or more banks onto the forming surface, feeding the web through bond rolls nip, and winding up the material in one pass.
  • a smaller portion of the basis weight such as approximately half of the web (e.g., 10 gsm) is first formed, bonded, and wound in a roll.
  • the 10 gsm roll is then unwound and a second 10 gsm layer is formed on top of it.
  • the two-layer web has a soft, drapable, and cotton-like handfeel that approaches the softness of high cost BCW or bicomponent webs.
  • the present multi-layer material is thus softer in hand and has improved formation than an equivalent weight spunbond material produced in one pass, which is the current industry practice.
  • the spunbond web is bonded between a pair of bonding rolls. In a two-layer structure, when that spunbond web is subsequently fed back into the second layer forming process, it is bonded a second time.
  • a laminate nonwoven material including two webs of spunbonded fibers will hereafter be referred to as nonwoven laminate material of the type described.
  • the material is preferably a laminate of two spunbonded layers but may be a laminate of a single spunbonded layer and another layer such as a melt-blown layer.
  • the laminate can be impregnated with a thermal stabilizing agent before hot calendering on at least one side.
  • Fig. 3 illustrates an example of a laminate material in accordance with the invention from which it will be seen that the material is composed of two layers 16, 18 of spunbonded material.
  • the material can be treated by impregnating it with a fluorocarbon.
  • the outer surface of each of the spunbonded layers can be hot calendered.
  • the laminate material has been subjected to embossing as illustrated at 19 of Fig. 3.
  • embossments are in the form of small bond areas normally arranged in a pattern (e.g., a rectangular or diagonal pattern).
  • the calendering can be carried out by a single pass between a steel roller and a backing roller.
  • the roller may be a ' NIPCCT type variable crown roller to ensure uniform pressure across the width especially when the material is wide (i.e., having a width of 1 to 2 meters).
  • a calender system can also be used to simultaneously calender both sides of a fabric.
  • a spinneret 20 is fed with an appropriate polymer from a hopper 22 through inlet pipes 24 and with optional suitable pigments/additives from the second hopper 26.
  • the fine polymer filaments 28 produced by the spinneret 20 pass through a high velocity air drawing system generally illustrated at 30 and the resultant filaments 32 are fed on to a moving forming screen 34, a vacuum being supplied beneath the screen so that the hot filaments form a tangled bonded web on the forming screen.
  • the spunbonded layer 36 of spunbonded polymer is moved along by the movement of the forming screen 34 that rotates in the direction of the arrows x.
  • the spunbonded layer 36 is fed between two bonding rollers 42, one of which is provided with projections in a pattern so as to produce a pattern of depressed bond areas (e.g., that shown at 19 in Fig. 4), over the whole surface of the spunbonded layer 36.
  • the spunbonded layer 36 is then optionally fed into a bath 44 of a fluorocarbon and lithium nitrate mixture that saturates the laminate. On leaving the bath, the spunbonded layer 36 is optionally passed between two squeeze rollers 46 to remove excess liquid.
  • the impregnated spunbonded layer 36 is then dried by passing it over a series of heated rollers, drums, or the like within a standard drying unit generally indicated at 48 and the dried web is then passed between two calendered rollers 50/52, the top roller 50 being a heated steel roller and the bottom roller 52 being a backing roller.
  • the spunbonded layer(s) can be calendered on either one side which is suitable, for example, for garments (with the calendered side on the outside) or the two outer sides to make it suitable for use in other applications such as wipes.
  • Such calendering is preferably carried out by passing the material through a nip of a smooth heated roller and a non-heated roller.
  • a smooth heated roller is of steel and the backing roller is made for example of plastic, cotton, or paper.
  • the roller is heated to a temperature substantially the same as the melting point of the polymer of the fibers in the layer to be calendered (e.g., 167° C (333° F) for polypropylene).
  • the nip is set so as to give a light pressure (e.g., 40 kg per cm) and the material is passed through the nip sufficiently quickly so that in effect the surface is given a "shock heat” treatment which acts to produce additional fiber to fiber bonds in the spunbond layer in contact with the heated roller between the primary pattern bonds already produced by the bonding rollers.
  • a light pressure e.g. 40 kg per cm
  • Either one or both spunbond sides of the material may be smooth calendered.
  • both sides are calendered the material could be used for other applications for example wipes.
  • the wiping surfaces would have low lint for critical wiping applications.
  • Such a fabric calendered on both sides could also usefully be used in a variety of other applications demanding good surface durability, examples of which could include protective bedding fabrics, for mattresses and pillows, robot cover fabrics, and agricultural fabrics, for example, a substrate fabric for a thermal screen in a greenhouse.
  • the spunbonded layer 36 is then wound on a rewind roller 54.
  • the spunbonded layer 36 can be produced by one apparatus and the spunbonded layer 36 can then be treated by passing it through a bath, drying it, and then calendering on a second separate apparatus.
  • a spinneret 120 is fed with an appropriate polymer from a hopper 122 through inlet pipes 124 and with optional suitable pigments/additives from the second hopper 126.
  • the fine polymer filaments 128 produced by the spinneret 120 pass through a high velocity air drawing system generally illustrated at 130 and the resultant filaments 132 are fed on to a moving forming screen 134, a vacuum being supplied beneath the screen so that the hot filaments form a tangled bonded web on the forming screen.
  • the layer 36 of spunbonded polymer and the laminate material 140 are moved along by the movement of the forming screen 134 that rotates in the direction of the arrows x.
  • the laminate material 140 is fed between two bonding rollers 142, one of which is provided with projections in a pattern so as to produce a pattern of depressed bond areas (e.g., that shown at 19 in Fig. 3), over the whole surface of the laminate material.
  • the laminate material 140 is then optionally fed into a bath 144 of a fluorocarbon and lithium nitrate mixture that saturates the laminate. On leaving the bath, the laminate material 140 is optionally passed between two squeeze rollers 146 to remove excess liquid.
  • the impregnated laminate material 140 is then dried by passing it over a series of heated rollers, drums or the like within a standard drying unit generally indicated at 148 and the dried web is then passed between two calendered rollers 150, 152, the top roller 150 being a heated steel roller and the bottom roller 152 being a backing roller.
  • the upper surface of the laminate material 140 is thus calendered to produce the desired effect described hereinbefore and to create a laminate material 140 in accordance with the invention.
  • the laminate material 140 is then wound on a rewind roller 154.
  • the extra time that would typically be needed to run the material twice through the process can be mitigated by running the machine at twice the speed to produce half the basis weight (e.g., 10 gsm for a 20 gsm final product), compared to the typical speed used to produce a 20 gsm product using the standard industry one-pass spunbond process.
  • half the basis weight e.g. 10 gsm for a 20 gsm final product
  • the first and second layers 16, 18 of the laminate material 140 need not be equal in basis weight.
  • Each layer 16, 18 and the laminate material 140 itself can be of any suitable basis weight.
  • benefit agents such as odor control actives, softening agents, hydrophilic, superhydrophilic, hydrophobic, and superhydrophobic treatments, and the like can be incorporated within, on, or between the layers 16, 18 by spraying, soaking, or any other suitable method.
  • the number of layers in the laminate material 140 can be two as described above or can be greater than two to increase bulk and achieve other benefits.
  • three 8 gsm layers rather than two 12 gsm layers can be processed to produce an integrated, soft 24 gsm laminate material 140.
  • one or more of the layers 16, 18 need not be spunbond, but can be meltblown, coform, film, or any other suitable materials that are heat bondable to each other.
  • One or more of the layers 16, 18 can be stretchable, extensible, or elastic as is known in the art. Similarly, the degree of bonding can be adjusted; for example, low bonding can accommodate extensibility. Different bond pattern designs with different arrangements and/or varying bond percent areas can be used for aesthetic and other reasons.
  • the rate at which one or more of the layers 16, 18 is fed into the bond roll nip can be adjusted to be different.
  • one layer can be fed faster or slower than the other layer(s) to create ripples, rugosity, or texture for aesthetics and other benefits.
  • one or more layers can have different colors for aesthetics, indication, or any other suitable reason.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne un procédé de production d'une bande stratifiée présentant une masse surfacique de base et comprenant la formation d'une première couche filée-liée d'environ la moitié de la masse surfacique de base de la bande stratifiée, la liaison de la première couche filée-liée, l'enroulement de la première couche filée-liée en un rouleau, et le déroulement du rouleau. Le procédé comprend également la formation d'une seconde couche du reste de la masse surfacique de base de la bande stratifiée sur le dessus de la première couche filée-liée afin de former une bande stratifiée et la liaison de la bande stratifiée.
PCT/US2014/049051 2014-07-31 2014-07-31 Non-tissés souples et résistants de faible coût Ceased WO2016018341A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2014/049051 WO2016018341A1 (fr) 2014-07-31 2014-07-31 Non-tissés souples et résistants de faible coût

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2014/049051 WO2016018341A1 (fr) 2014-07-31 2014-07-31 Non-tissés souples et résistants de faible coût

Publications (1)

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WO2016018341A1 true WO2016018341A1 (fr) 2016-02-04

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10354556B2 (en) 2015-02-19 2019-07-16 Applied Medical Resources Corporation Simulated tissue structures and methods
US10490105B2 (en) 2015-07-22 2019-11-26 Applied Medical Resources Corporation Appendectomy model

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003027374A1 (fr) * 2001-09-26 2003-04-03 E.I. Du Pont De Nemours And Company Procede permettant de produire un tissu non-tisse file-lie a partir de filaments a composants multiples
US20040102123A1 (en) * 2002-11-21 2004-05-27 Bowen Uyles Woodrow High strength uniformity nonwoven laminate and process therefor
US20040127128A1 (en) * 2002-12-31 2004-07-01 Kimberly-Clark Worldwide, Inc. Elastomeric materials
US20070026753A1 (en) * 1998-10-01 2007-02-01 Neely J R Differential basis weight nonwoven webs
KR20080060829A (ko) * 2006-12-27 2008-07-02 (주)크린앤사이언스 내연기관 유입공기 정화용 필터 소재 및 그의 제조 방법
US20120234333A1 (en) * 2011-03-16 2012-09-20 Jenkins Shawn E Medical Fabric With Asymmetrical Layers

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070026753A1 (en) * 1998-10-01 2007-02-01 Neely J R Differential basis weight nonwoven webs
WO2003027374A1 (fr) * 2001-09-26 2003-04-03 E.I. Du Pont De Nemours And Company Procede permettant de produire un tissu non-tisse file-lie a partir de filaments a composants multiples
US20040102123A1 (en) * 2002-11-21 2004-05-27 Bowen Uyles Woodrow High strength uniformity nonwoven laminate and process therefor
US20040127128A1 (en) * 2002-12-31 2004-07-01 Kimberly-Clark Worldwide, Inc. Elastomeric materials
KR20080060829A (ko) * 2006-12-27 2008-07-02 (주)크린앤사이언스 내연기관 유입공기 정화용 필터 소재 및 그의 제조 방법
US20120234333A1 (en) * 2011-03-16 2012-09-20 Jenkins Shawn E Medical Fabric With Asymmetrical Layers

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10354556B2 (en) 2015-02-19 2019-07-16 Applied Medical Resources Corporation Simulated tissue structures and methods
US10490105B2 (en) 2015-07-22 2019-11-26 Applied Medical Resources Corporation Appendectomy model

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