EP1448361A2 - Etoffe nappee gaufree a structure tridimensionnelle - Google Patents

Etoffe nappee gaufree a structure tridimensionnelle

Info

Publication number
EP1448361A2
EP1448361A2 EP02790397A EP02790397A EP1448361A2 EP 1448361 A2 EP1448361 A2 EP 1448361A2 EP 02790397 A EP02790397 A EP 02790397A EP 02790397 A EP02790397 A EP 02790397A EP 1448361 A2 EP1448361 A2 EP 1448361A2
Authority
EP
European Patent Office
Prior art keywords
elevations
nonwoven
depressions
binder
flat structure
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.)
Granted
Application number
EP02790397A
Other languages
German (de)
English (en)
Other versions
EP1448361B1 (fr
Inventor
William A. Casey
Claudio Julian Balbin 2561 SUAREZ
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.)
Carl Freudenberg KG
Original Assignee
Carl Freudenberg KG
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
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Application filed by Carl Freudenberg KG filed Critical Carl Freudenberg KG
Publication of EP1448361A2 publication Critical patent/EP1448361A2/fr
Application granted granted Critical
Publication of EP1448361B1 publication Critical patent/EP1448361B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/07—Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
    • 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
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • 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
    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • 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
    • D04H3/12—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 filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/0733—Pattern
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • B31F2201/0723—Characteristics of the rollers
    • B31F2201/0738—Cross sectional profile of the embossments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0784—Auxiliary operations
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1007—Running or continuous length work
    • Y10T156/1023—Surface deformation only [e.g., embossing]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24612—Composite web or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495—Thickness [relative or absolute]

Definitions

  • the invention relates to an embossed, open-pore nonwoven fabric with a three-dimensional structure, a method for its production and a device used in the process.
  • the nonwoven fabric consists of regularly alternating areas with deep-drawn, weight-thinned 3D surveys and non-deep-drawn, flat and unchanged zones.
  • the invention also relates to a special embossing process and the roll geometry required for this, in order to impart the special 3D embossing structure to the nonwoven fabric after passing through the press nip of two interlocking positive and negative rolls.
  • the absorbent core of children's diapers, incontinence and feminine hygiene products is on the wearing side today, i.e. the body-facing side is covered by at least two layers.
  • a receiving and distribution layer made of nonwoven or reticulated foam, which, as the name already expresses, absorbs the body fluid (urine, thin stool or menses) quickly and as evenly as possible the underlying core, usually made of pulp and superabsorbent powder.
  • AVS receiving and distribution layer
  • nonwovens bonded thermally in hot air flow dryers or nonwovens bonded with polymer dispersions made of crimped, relatively coarse-titer fibers are known.
  • the fibers have a titer of more than 3.3 dtex and exist preferably on polyester (polyethylene terephthalate) and / or polyolefins, bicomponent fibers with side-by-side or core / jacket structure being used for the purpose of fiber bonding in the through-flow furnace and one of the two fiber components melting significantly more deeply than the other component.
  • Such nonwovens have a relatively high volume (thickness) in relation to their low weight immediately after they have been manufactured. However, it is known that this initial thickness is already significantly reduced when the goods are rolled up under the usual stresses and the pressing conditions in the packaging make a further contribution to the reduction in thickness.
  • DE 197 25 749 A1 describes an embossing process for producing a structured, voluminous nonwoven.
  • a pre-consolidated spunbonded nonwoven whose continuous filaments have only been stretched 50 to 70% of the maximum possible stretch is subjected to a special post-processing. This consists of a passage of the spunbonded nonwoven fabric between a positive roller with a knob surface and a negative roller with lamellar webs transverse to the machine direction, the lamellas engaging in the alleys kept clear of the knob.
  • EP-B 0.809.991 and EP-A 0.810.078 describe a fluid distribution material with improved fluid properties.
  • a plastically deformable web is deformed into a nonwoven fabric with an SD structure by passing through a pair of negative / positive rollers.
  • the embossed material and process for this purpose are those which are described in EP-B 0.499.942.
  • such a structure similar to corrugated cardboard has the disadvantage that it does not withstand permanent pressure stresses.
  • nonwovens are produced in an intermediate stage with elevations and depressions in that the fabric passes through two heated gear rollers.
  • the ribs are not compression stable due to the fact that you lack a non-stabilizing flat surface that is glued to one side of the elevations or stiffeners. Rather, the patent applications mentioned relate to pulling out the corrugations as far as possible or in part in order to thereby produce soft and slightly elastic products transverse to the corrugation.
  • Disposable absorbent articles with a faeces management layer are known from EP-A 0.976.375, EP-A 0.976.374 and EP-A 0.976.373, the latter consisting of a corrugated nonwoven fabric which is placed on a flat nonwoven fabric carrier (EP-A 0.976. 375) is glued on. Instead of the nonwoven backing, thick polymer filaments (EP-A 0.976.374) or nets (EP-A 0.976.37) can also be used.
  • Such corrugated and stabilized nonwoven laminates have proven to be suitable AVS for faecal management and improved urine management.
  • the manufacture of such SD laminate structures is very complex and requires two components and in some cases an additional glue.
  • the object of the present invention to remedy the disadvantages of the prior art described above and to show an embossed nonwoven which, without the need for an additional stabilizing layer after a previous compression, returns better to its original shape than the previously known designs and which therefore better suited for the absorption of liquids of different compositions or the transport of liquids in a suction layer.
  • the invention is also based on the object of specifying a method for producing a nonwoven fabric and a device suitable for carrying out the method.
  • the diaper manufacturer is to be offered an embossing device as an additive for a diaper production line, which allows him to convert an unembossed, two-dimensional nonwoven fabric in-line with the diaper production into the shape of an embossed, three-dimensional nonwoven fabric with improved liquid absorption and distribution function and in a diaper or to place a wound dressing.
  • the nonwoven fabric should also be able to be produced independently of the diaper production and should largely have the same properties after an intermediate storage in the rolled-up state.
  • the three-dimensionally embossed nonwoven consists of fibers and / or filaments 3 and zones 5, 7 oriented mainly in the machine direction 2, with regularly alternating elevations 4a, 8a and depressions 4b, 8b, which are characterized by continuous areas 6, which are unembossed in the machine direction 2, from one another are separated, which make up a share of 5% to 50% based on the total area of the nonwoven fabric 1 and in which the elevations 4a, 8a and depressions 4b, 8b form depressions or elevations, viewed from the opposite side, the elevations limited areas give the nonwoven fabric 1 an apparent thickness in the range of 0.5 mm to 5.5 mm. Further advantageous refinements are set out in the subclaims.
  • the invention describes a nonwoven fabric made of staple fibers, in which partial surface areas in the machine running direction have alternating elevations and depressions (peaks / valleys) and each row of elevations is interrupted by a non-deformed linear area.
  • the non-deformed linear regions are arranged in the 3-dimensionally deformed nonwoven fabric symmetrically to asymmetrically to the ridges and valleys of the respectively adjacent regions.
  • the regions deformed into heights and valleys extend symmetrically along the non-deformed linear region.
  • the row of the next deforming areas transverse to the machine direction are arranged in the machine direction in such a way that they are each in a gap with the adjacent shaft row.
  • the corrugations extend exactly in the machine direction.
  • the method according to the invention for producing a nonwoven fabric is carried out in such a way that fibers and / or filaments 3 are laid down in a machine-oriented manner mainly in the machine direction 2 to form a pile, and are formed into a three-dimensional nonwoven fabric by treatment with embossing rollers at temperatures from 65 ° C. to 160 ° C. become.
  • the staple fibers of the 2-dimensional nonwoven for 3D embossing are used in
  • the fibrous web can additionally along this
  • Preferred direction have been reoriented by an upsetting device.
  • the staple fibers of the staple fiber pile deposited in the machine direction are crimped in two and / or three dimensions.
  • the fibers consist of such fiber polymers, which result in a high restoring force against mechanical forces.
  • Polyethylene terephthalate fibers with a titer of 3.3 to 30 dtex, but preferably 6.7 to 18 dtex, have proven particularly suitable. Fiber 'different titers may be blended with each other.
  • the staple fiber webs are bound either adhesively by using aqueous polymer dispersions by known processes, by thermal fiber / fiber bonding in a forced air oven or by application of heat and pressure in a pair of calenders.
  • aqueous polymer dispersions by known processes, by thermal fiber / fiber bonding in a forced air oven or by application of heat and pressure in a pair of calenders.
  • bicomponent fibers are added to the homophilic fibers as binding fibers.
  • the nonwoven fabric presented for embossing contains a hydrophilic, well-wetting surface-active agent (surfactant) that has either already been applied in or on the fiber by the fiber manufacturer and / or has been subsequently applied to the nonwoven fabric and / or by the polymer dispersion preparation used in the Nonwoven has been registered.
  • the surfactant can have a different degree of adhesion to the fibers and thus be washable or semi-permanent up to being completely permanent against contact with body fluids.
  • an aqueous polymer dispersion based on a butadiene copolymer e.g. Styrene-butadiene or acrylonitrile-butadiene copolymer used.
  • the binder is preferably free of crosslinking components and remains in the nonwoven in a thermoplastic deformable state after application.
  • the Shore A hardness of the binder film cast from the dispersion is in the range from approximately 70-100, preferably 75-95.
  • the cross section of the staple fibers can have different shapes, such as round, oval, trilobal, square, rectangular.
  • the fiber polymer can be distributed in the same density over the entire fiber cross section. However, the fiber can also be hollow on the inside, the cavity being able to make up 10-30% of the total volume of the fiber. All crimped one-component synthetic fibers are suitable for the embossing process according to the invention, which do not shrink or even melt under the embossing conditions.
  • the crimped synthetic fibers can also be blended with undrawn, uncrimped fibers, but with a proportion ⁇ 50%.
  • the base material to be deformed into a 3D structure preferably contains polyester fibers if the nonwoven is bonded with an aqueous dispersion.
  • the fiber: binder ratio is approximately 20:80 to 40:60.
  • the binder can have been applied using known application methods, such as foam impregnation, one-sided slapping or wet-on-wet printing.
  • the binder can be evenly distributed over the cross-section of the nonwoven or have a binder application quantity gradient from one side to the other side.
  • the drying temperatures and residence times in the dryer must be selected so that the polymer is completely filmed. This can be seen from the transparency (of the unpigmented binder) of the binder points.
  • the staple fiber pile of the precursor can consist of one or up to three layers.
  • the three layers preferably have an increasing average titer from one layer to the next adjacent layer.
  • the multi-layer nonwoven fabric with the coarsest (higher titer) pile side facing the underside of the covering nonwoven fabric is positioned in the diaper as an AVS.
  • the binder-rich side is in contact with the absorbent core or the hydro-melt meltblown nonwoven or tissue paper (English gore wrap) enveloping it.
  • the device according to the invention for carrying out the method consists of at least two embossing rollers 21, 22 which are in engagement with one another in such a way that a nonwoven fabric 20 is guided and shaped between them, the embossing rollers 21, 22 consisting of gear wheels 11 which are separated by spacers 12 are arranged on a shaft 13.
  • Figure 1 the top view of a three-dimensionally shaped nonwoven according to the invention
  • Figure 2 the cross section of a three-dimensionally shaped nonwoven according to the invention along the section line 9 - 9
  • Figure 3 the cross section of a three-dimensionally shaped nonwoven according to the invention along the section line 27-27
  • the 3D embossed nonwoven fabric 1 is shown in the top view in Fig. 1.
  • 2 indicates the machine direction.
  • the nonwoven fabric consists of the fibers 3 oriented in the machine direction 2, which are bound to one another by known methods.
  • the nonwoven fabric 1 has two continuously repeating zones 5, 7 and the area 6, the zones 5 and 7 being 3D embossed and the area 6 positioned between zones 5 and 7 remaining in the unembossed state.
  • the elevations 4a of the zones 5 alternate with depressions (valley depressions) 4b.
  • the elevations 8a and depressions 8b are arranged within the zones 7 such that they are, for example, at a gap with respect to the elevations 4a and depressions 4b of the zones 5.
  • the nonwoven fabric 1 thus consists of two surfaces, the elevations forming one surface and the depressions forming the other surface.
  • Fig. 2 shows a section along the line AA and the view from this section in the cross-machine direction 2.
  • the wavy 3D structure which is shown by stringing together the arcuate elevations 4a and depressions 4b.
  • the unembossed areas 6 extend behind these corrugations in the foreground in the machine direction 2.
  • Behind the areas 6 there extends a second wavy line, which is characterized by the elevations 8a and valleys 8b ' . 8a and 8b each stand on the gap to 4a and 4b.
  • Fig. 3 the sectional view along the line B - B (ie across the machine direction 2) is shown as the foreground and the view in the machine direction 2 as the background (dashed lines).
  • the weight per unit area of the non-deep-drawn areas 6 is significantly higher than the weight of the adjacent zones 5 and 7.
  • the weight per unit area of the 3D-embossed zones 5 and 7 is reduced by the factor resulting from the division of the distance 28 from the circumference of position 29 Digit 30 results.
  • the 3D-embossed zones have a weight of 24 along their surfaces g / m 2 , which corresponds to a significant thinning of the material within the embossed zones by 60% fiber mass.
  • the higher basis weight in zones 6 in connection with the undamaged fiber bonds causes the advantageous property of the nonwoven that, overall, without the need for an additional stabilizing layer, it returns better to its original shape after a previous compression than all previously known designs with the result that the nonwoven is more suitable for absorbing liquids of different compositions or for transporting the liquids into a suction layer.
  • An embossing roller 21 is shown in Fig. 4.
  • a shaft 13 which is provided with a clamping wedge 14, a toothed wheel washer 11, then an unserrated spacer washer 12 with a smaller diameter are placed alternately.
  • the diameter of the disc 12 corresponds to the diameter of the gear disc 11 at its lowest points 17 (the valleys).
  • Fig. 5 shows a cross section of such an embossing roller 21.
  • the teeth 15 of the front toothed wheel disk 11 have the elevations 16 and depressions 17.
  • an embossing unit consists of at least two intermeshing embossing rollers 21 and 22. At least one of the two can be heated. A heat source 26 can also be attached to heat the roller surface. In the region 23, the non-embossed nonwoven web 20 passes the interlocking teeth of the two embossing rollers 21 and 22 and is deformed, favored by heat, to form a 3D-embossed nonwoven with the new surface structure.
  • the take-off roller 24 has a rough surface 25, which favors the further transport of the flat goods.
  • the embossing device can be used in a max. Width up to approx. 220 cm can be operated. In a narrower embodiment in roller widths between approximately 55 to 125, preferably between 65 and 90 cm, it can be integrated in diaper machines. This is a special embodiment of the method, which has the advantage of delivering flat roll goods, cut into slices and avoiding the logistical problem of storing the tapes in boxes (fastooning) or cost-intensive, cross-shaped winding (spooling).
  • the method according to the invention with the special design of an embossing in the diaper machine has the further advantage that the non-embossed nonwoven fabric with fluid absorption and distribution function can be compressed more than one that is not subjected to 3D embossing.
  • a non-embossed roll product is always fraught with the problem that a greater thickness compression takes place in the roll core near the sleeve than in the outside area, which does not completely equalize even after being placed in the diaper.
  • a master roll with a 3 inch core as the inside diameter, wrapped with binder-bound absorbent and distribution nonwoven on an outside diameter of 114 cm results in approx. 2,500 to 3,000 running meters per roll.
  • the winding hardness could largely solve the compression problem in the winding core, it is associated with the cost disadvantage of having fewer running meters on the roll.
  • the method according to the present invention or the resulting embossed, voluminous finished material permits a significantly stronger compression of the unembossed semi-material with the advantage of eliminating the compression problem mentioned on the winding core and the logistical advantage of significantly more running meters (running meters) length on the winding to get.
  • the non-embossed nonwoven in the weight range from 30 to 100 g / m 2 , preferably 40 to 80 g / m 2 has a thickness, measured at 0.5 kPA load, of 0.20 to 1.50 mm, preferably 0.35 to 1, 20 mm on.
  • the thickness of the embossed nonwoven measured over the areas conceived by the elevations is in the range from approximately 0.50 to approximately 5.50 mm, preferably approximately 0.900 to approximately 4.50 mm.
  • Zones 5 and 7 with gear embossing is in the range from approximately 3.0 to approximately 20 mm, preferably 6 to 12 mm.
  • Zones 5 and 7 can each have the same width or else different widths. They are preferably of the same width.
  • the area 6 is generally ⁇ half the sum of the width of the zone 5 and zone 7 and is preferably only about 5% to about 25% of this sum. If, for example, a width of 7.0 mm is selected for zones 5 and 7, the width of the areas 6 is only 0.7 mm to 3.5 mm.
  • the areas 6 may have different widths, but may have a total area share of max. Do not exceed 50% and are preferably in the range from about 10 to about 33% based on the total area of the embossed nonwoven. However, 3D optics with regions 6 of equal width are particularly preferred.
  • hydrophilic binder On the underside of the 3D-embossed nonwoven fabric that can be used as AVS, hydrophilic (or designed to be absorbent by adding wetting agents) binder may have been subsequently applied.
  • This side is understood to be the underside, the surface of which is delimited by the unembossed areas 6 and the depressions 4b and 8b becomes.
  • Such a one-sided binder application can be advantageous for the purpose of further 3D structure stabilization and can promote the transport of the fluid in the direction of the absorbent core through increased hydrophilicity.
  • a pile of crimped polyester staple fibers with a titer of 6.7 dtex and a cutting length of 51 mm is laid down in the machine direction.
  • the pile weight is 45 g / m 2 .
  • the pile is wetted with water in order to facilitate the subsequent printing on one side with binder.
  • An aqueous polymer dispersion based on carboxylated copolymer styrene-butadiene is used as the binder.
  • the Shore A hardness of the film produced from this binder is approximately 90 to 95.
  • the 50% dispersion is added with wetting agent, some pigment and dilution water, so that a "water-thin" 40% mixture results.
  • This mixture is applied to one side of the fiber web with the aid of an anilox roller, the depressions of which are filled with this mixture.
  • some of the binder migrates in the direction of the binder-free side. This creates a concentration gradient of the binder from one side of the nonwoven to the other. After drying, the goods remain on the dryer until a complete filming of the binding points has taken place.
  • the application amount of this relatively hard carboxylated styrene-butadiene latex is 15 g / m 2 . This results in a fiber: binder ratio of 75:25.
  • This semi-finished material was then subjected to the embossing according to the invention, an embossing device according to FIGS. 4 to 6 being used.
  • Fig. 7 shows an enlarged cross section of a gear wheel.
  • n the inner radius of the gear
  • r a the outer radius of the Gear.
  • the height h of the teeth is calculated from the difference between r a and n.
  • the extent u a and uj can be calculated by multiplying the number of teeth z on the gear by the pitch tj and t a :
  • Example 1 the ratio of d a : dj is 2.88: 1.0.
  • the width of the spacer 12 (see Fig. 4) is 0.20 mm and the width of the gearwheels is 0.75 mm, which results in a portion of the non-embossed area 6 of approximately 20% of the total area of the nonwoven fabric.
  • the 60 g / m 2 heavy nonwoven fabric 20 is passed through the nip of the two intermeshing embossing rollers 21 and 22 at a speed of 10 m / min (600 m / h).
  • the outside temperature of the gear roller 11 made of steel SAE 1045 is 125 ° C.
  • the gear roller 22 made of polyamide is unheated and heats up slightly when running. On Falling of the temperature on the steel roller is ensured by the additional heat source 26.
  • the take-off roller 24 is cooled. The goods are then rolled up with the lowest possible tension.
  • Example 2 The procedure is as in Example 1, but with the difference that the pile weight has been reduced to 31 g / m 2 .
  • the proportion of binder was 12 g / m 2 , which corresponds to a fiber: binder ratio of approximately 73:27.
  • the 3D embossing was carried out in accordance with Example 1.
  • the 60 g / m 2 binder-bonded nonwoven fabric produced in Example 1 is subjected to embossing according to the prior art.
  • a pair of rollers has been produced in which no spacer disks 12 have been placed on the cone between the gear disks and in which the gear disks all have the same position, ie have not been rotated to a gap.
  • the tooth depth is the same as in example 1.
  • Example 1 The binder-bound, 60 g / m 2 heavy nonwoven semi-material produced in Example 1 was embossed under the conditions of Example 1.
  • Strike through time was measured after the 1st, 2nd and 3rd fluid exposure and the rewet after the 3rd fluid exposure.
  • Tab. 1 shows the results of Examples 1 and 2 of the non-embossed and embossed binder-bonded nonwoven as arithmetic mean values from 3 individual measurements.
  • Tab. 1 Liquid Strike Through and Rewet measured directly on the test piece (outside the diaper) according to the EDANA method with the Lister test arrangement
  • Table 2 shows that the nonwoven fabric according to the invention, incorporated into a diaper, has significantly better properties than AVS.
  • the test specimen was exposed to 7.2 kPa at 45 ° C for 72 hours. The area to be charged has been marked. The sample was then removed from the oven and relieved for 2 minutes. Then the thickness measured with a pressure of 0.5 kPa and a pressure area of 25 cm 2 . After a discharge time of 2 hours and 24 hours, the thickness was measured again.
  • Table 3 Thickness measurement after thermal storage (creep resistance KB) and after different stress-free recovery times
  • the initial thickness of the reference sample with conventional embossing (corrugation) shows a significantly lower thickness than example 1, 3D-embossed according to the inventive method, even after a load of 0.5 kPa.
  • FG is the basis weight of the nonwoven in g / m 2 and d is the thickness in mm.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Nonwoven Fabrics (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Woven Fabrics (AREA)

Abstract

La présente invention concerne une étoffe nappée gaufrée tridimensionnelle qui est composée principalement de fibres et/ou filaments (3) dont l'orientation correspond à la direction (2) de la machine, et présente des zones (5, 7) comprenant des parties en saillie (4a, 8a) et des parties creuses (4b, 8b) alternées de façon régulière qui sont séparées par des zones (6) non gaufrées, continues dans la direction (2) de la machine, la proportion de celles-ci valant de 5 à 50 % vis-à-vis de la surface totale de l'étoffe nappée (1). Selon l'invention, les parties en saillie (4a, 8a) et les parties creuses (4b, 8b) forment de l'autre côté respectivement des parties creuses et des parties en saillie, et les surfaces (10a, 10b) limitées par les parties en saillie confèrent à l'étoffe nappée (1) une épaisseur apparente de 0,5 mm à 5,5 mm.
EP02790397A 2001-11-21 2002-11-18 Etoffe nappee gaufree a structure tridimensionnelle Expired - Lifetime EP1448361B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AR0105436 2001-11-21
ARP010105436A AR031489A1 (es) 2001-11-21 2001-11-21 Tela no tejida, aparato para gofrar la misma y rodillo para usar en dicho aparato
PCT/EP2002/012903 WO2003043806A2 (fr) 2001-11-21 2002-11-18 Etoffe nappee gaufree a structure tridimensionnelle

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EP1448361A2 true EP1448361A2 (fr) 2004-08-25
EP1448361B1 EP1448361B1 (fr) 2006-08-02

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MX (1) MXPA04004846A (fr)
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AU2002366221A8 (en) 2003-06-10
KR100592617B1 (ko) 2006-06-26
RU2266823C2 (ru) 2005-12-27
AR031489A1 (es) 2003-09-24
CA2468027A1 (fr) 2003-05-30
CN1310746C (zh) 2007-04-18
KR20050044583A (ko) 2005-05-12
DE50207743D1 (de) 2006-09-14
WO2003043806A2 (fr) 2003-05-30
CN1589199A (zh) 2005-03-02
MXPA04004846A (es) 2004-07-30
RU2004119034A (ru) 2005-03-10
WO2003043806A3 (fr) 2003-09-18
CA2468027C (fr) 2007-09-18
US7678442B2 (en) 2010-03-16
JP4210598B2 (ja) 2009-01-21
BR0106472A (pt) 2004-03-09
ATE334813T1 (de) 2006-08-15
JP2005509758A (ja) 2005-04-14
EP1448361B1 (fr) 2006-08-02
US20050008825A1 (en) 2005-01-13
AU2002366221A1 (en) 2003-06-10

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