WO1999006207A1 - Textile non tisse, souple, fabrique par extrusion de matiere fondue - Google Patents

Textile non tisse, souple, fabrique par extrusion de matiere fondue Download PDF

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Publication number
WO1999006207A1
WO1999006207A1 PCT/US1998/015601 US9815601W WO9906207A1 WO 1999006207 A1 WO1999006207 A1 WO 1999006207A1 US 9815601 W US9815601 W US 9815601W WO 9906207 A1 WO9906207 A1 WO 9906207A1
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WO
WIPO (PCT)
Prior art keywords
softness
melt
fabric
spunbond
enhancing agent
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1998/015601
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English (en)
Inventor
Rahul Dharmadhikary
Karen Chu
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.)
International Paper Co
Fitesa Simpsonville Inc
Original Assignee
International Paper Co
BBA Nonwovens Simpsonville Inc
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Publication date
Application filed by International Paper Co, BBA Nonwovens Simpsonville Inc filed Critical International Paper Co
Priority to CA002298600A priority Critical patent/CA2298600A1/fr
Publication of WO1999006207A1 publication Critical patent/WO1999006207A1/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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • 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
    • 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
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding 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
    • D04H1/42—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
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • 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
    • D04H1/56—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 in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • 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
    • D04H3/007—Addition polymers
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres

Definitions

  • the invention relates to nonwoven fabric suitable for use as a component in a disposable diaper.
  • the invention relates to nonwoven fabric comprising one or more layers of melt-extruded fibers.
  • Nonwoven webs and laminates thereof have application in a variety of disposable products, including wipers, garments, medical drapes and absorbent articles such as diapers.
  • One class of such nonwoven web laminates is commonly referred to as spunbonded/meltblown/ spunbonded (SMS) laminates.
  • SMS laminates generally consist of nonwoven outer layers of spunbonded polyolefins and an interior layer of meltblown poly- olefins.
  • nonwoven web refers to a web that has a structure of individual fibers or filaments which are interlaid, but not in an identifiable repeating pattern.
  • spunbonded fibers refers to fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinnerette. Cooling air is fed to a guenching chamber wherein the filaments are cooled. The cooling air is then sucked through a nozzle, which accelerates the flow of air. The friction between the flowing air and the filaments creates a force which draws the filaments, i.e., attenuates the filaments to a smaller diameter. The drawn filaments are then passed through a diffusor and deposited on a conveyor belt to form a nonwoven web.
  • a conventional spinbonding technique is disclosed in U.S. Patent No. 4,340,563 to Appel .
  • meltblown fibers refers to fibers which are formed by extruding molten thermoplastic material as threads or filaments through a plurality of fine, usually circular capillaries of a die.
  • a high-velocity, usually heated gas (e.g., air) stream attenuates the filaments of molten thermoplastic material to reduce their diameter.
  • the meltblown fibers are carried by the high-velocity heated gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers.
  • a conventional meltblowing technique is disclosed in U.S. Patent No. 4,707,398 to Boggs.
  • meltblown fibers differ from spunbonded fibers in that the extruded polymer strands have much finer diameters. These fine diameter filaments are easily dispersed by the forced hot air stream before being deposited on the collecting surface. In addition, the meltblown fibers are substantially cooled by the air so that they do not significantly bond together. Bonding of the web to retain integrity and strength occurs as a separate downstream operation.
  • SMS fabrics lack the softness and feel of carded fabrics.
  • the key problem is the presence of the central meltblown layer, which causes the SMS structure to become stiff/harsh upon calendaring.
  • the softness of the SMS composite can be improved by reducing the meltblown content, i.e., by reducing the basis weight of the meltblown layer, a need exists to further increase the softness of the SMS composite. Further, there is a need to improve the softness of spunbond nonwoven fabric.
  • the present invention is a nonwoven fabric comprising one or more layers of melt-extruded fibers and having improved softness.
  • the softness of the fabric is improved by the addition of a softness-enhancing agent to a polyolefin melt prior to extrusion.
  • the softness-enhancing agent in accordance with one preferred embodiment is titanium dioxide (Ti0 2 ) . If Ti ⁇ 2 is the only softness-enhancing agent in the polyolefin melt, then the percentage loading of Ti0 2 is preferably 1-10% to achieve a desired enhanced softness.
  • the Ti0 2 is preferably rutile or anitase grade.
  • the softness-enhancing agent in accordance with another preferred embodiment is an additive having an active ingredient which is an oligomeric ester.
  • the percentage loading of this additive in the polyolefin melt is preferably 0.2-10% to achieve a desired enhanced softness.
  • the oligomeric ester preferably belongs to the class which increases the hydrophilicity of the polyolefin fibers. Alternatively, the oligomeric ester may belong to the class which increases the hydropho- bicity of the polyolefin fibers.
  • both Ti0 2 and the oligomeric ester agent are added to the polyolefin melt prior to extrusion.
  • the Ti0 2 loading can be reduced to 0.2-4%.
  • the invention can be applied in the manufacture of a spunbond fabric, a spunbond/meltblown laminate, a spunbond/spunbond laminate, an SMS laminate or any other composite formed from spunbond and/or meltblown layers.
  • the softness-enhancing agents are added only to the spunbond melts.
  • the softness-enhanc- ing agents can also be added to the meltblown melt.
  • Ti0 2 alone in accordance with the invention results in a fabric having increased softness and increased opacity.
  • the addition of both Ti0 2 and hydrophilic oligomeric ester agent in accordance with the invention produces a fabric having increased softness, increased opacity, decreased coefficient of friction, and increased hydrophilicity.
  • the addition of both Ti0 2 and hydrophobic oligomeric ester agent in accordance with the invention produces a fabric having increased softness, increased opacity, decreased coefficient of friction, and increased hydrophobicity.
  • FIG. 1 is a schematic diagram showing the construction of a conventional spunbonded/meltblown/spunbonded fiber laminate.
  • FIG. 2 is a schematic diagram showing the essential components of a system for continuously producing non- woven web material having enhanced softness in accordance with the present invention.
  • the present invention can be incorporated in a nonwoven composite material 2 of the type shown in FIG. 1.
  • This nonwoven composite 2 comprises a meltblown fabric layer 4 of thermoplastic polymeric microfibers sandwiched between two spunbonded fabric layers 6 and 8 each made of thermoplastic polymer filaments.
  • only the spunbonded layers contain the softness-enhancing agents of the present invention.
  • the softness-enhancing agents can also be added to the meltblown polymer.
  • the meltblown fabric layer 4 can be prepared by extruding a fiber-forming thermoplastic polymer resin in molten form through a plurality of fine, usually circular capillaries of a die.
  • a high-velocity, usually heated gas (e.g., air) stream attenuates the filaments of molten thermoplastic material to reduce their diameter.
  • the meltblown fibers are carried by the high-velocity heated gas stream and are deposited on a collecting surface to form a nonwoven web of randomly dispersed meltblown fibers.
  • the thermoplastic polymeric microfibers of meltblown fabric layer 4 are polypropyl- ene. Polymers other than polypropylene, such as nylon, polyethylene, polyester, and copolymers and blends thereof, may also be used.
  • Each of the spunbonded fabric layers 6 and 8 may be produced by continuously extruding a thermoplastic polymer through a plurality of fine, usually circular capillaries of a spinnerette. Pressurized cooling air is fed to a quenching chamber wherein the filaments are cooled. The cooling air is then accelerated through a nozzle by a positive air pressure. The friction between the flowing air and the filaments creates a force which draws the filaments, i.e., attenuates the filaments to a smaller diameter. The filaments are drawn to achieve molecular orientation and tenacity. The continuous filaments are then deposited in a substantially random manner to form a web of substantially continuous and randomly arranged, molecularly oriented filaments.
  • the preferred thermoplastic polymer used to make spunbonded fabric layers 6 and 8 is polypropylene, although nylon, polyethylene, polyester, and copolymers and blends thereof can be used.
  • the meltblown (MB) fabric layer 4 is sandwiched between two spunbonded (SB) fabric layers 6 and 8. All three of these fabric layers are then bonded together by the application of heat and pressure to form the SMS fabric laminate 2.
  • FIG. 2 shows a production line 10 for producing an SMS fabric laminate 2 in accordance with the present invention.
  • This production line can be operated at a speed in the range of 250 to 600 m/min, preferably about 375 m/min.
  • the equipment of production line 10 consists of an endless foraminous forming belt 12 wrapped around rollers 14 and 16. The belt 12 is driven in the direction shown by the arrows.
  • the production line 10 includes a forming machine which has three stations: spunbond station 18, meltblown station 20 and spunbond station 22. First, the spunbond station 18 lays down a web 8 of spunbonded fibers 28 onto the carrier belt 12. Then the meltblown station 20 lays down a web 4 of meltblown fibers 26 onto the spunbonded web 8. Lastly, the spunbond station 22 lays down a web 6 of spunbonded fibers 30 onto the meltblown web 4.
  • each of the component fabric layers may be formed separately, rolled, and later converted to the SMS fabric laminate offline.
  • the spunbond stations 18 and 22 are conventional extruders with spinnerettes which form continuous filaments of a polymer and deposit those filaments onto the forming belt 12 in a random interlaced fashion. Each spunbond station may include one or more spinnerette heads depending on the speed of the process and the particular polymer being used. Forming spunbonded material is a conventional process well known in the art.
  • the meltblown station 20 consists of a die 24 which is used to form microfibers 26. As the thermoplastic polymer exits the die 24, the polymer threads are attenuated and spread by high-pressure fluid, usually air, to form microfibers 26. The microfibers 26 are randomly deposited on top of the spunbond layer 8 and form a meltblown layer 4.
  • the construction and operation of the meltblown station 20 for forming microfibers 26 are well known in the art.
  • the basis weight of the meltblown fabric layer can be in the range of 0.5 to 15.0 gsm, while the total basis weight of the spunbonded fabric layers can be in the range of 5.0 to 50.0 gsm.
  • the meltblown fibers have an average diameter of 1-10 ⁇ m, preferably 3-5 ⁇
  • the spunbonded fibers have an average diameter of 10-30 ⁇ m, preferably 12-20 ⁇ m.
  • the SMS fabric laminate in accordance with the preferred embodiment has a mean pore size in the range of 15-50 ⁇ m, preferably about 30-40 ⁇ m.
  • the molten polypropylene used to make the meltblown fibers has a molecular weight distribution in the range of about 1.8-5.0, preferably 3.6, and a melt flow rate in the range of about 400-3000 grams/10 minutes, preferably about 1000 grams/10 minutes, whereas the molten polypropylene used to make the spunbonded fibers has a molecular weight distribution in the range of about 1.8- 5.0, preferably 2.5-2.7, and a melt flow rate in the range of about 10-100 grams/10 minutes, preferably about 35 grams/10 minutes.
  • the SMS fabric laminate web 2 (see FIG. 2) is then fed through bonding rolls 32 and 34.
  • the surfaces of the bonding rolls 32 and 34 are provided with a pattern of raised lands which apply heat and pressure to thermally spot bond the three layers together.
  • the bonding rolls are heated to a temperature which causes the meltblown polymer to soften.
  • the composite material is compressed and heated by the bonding rolls in accordance with the pattern on the rolls to create a pattern of discrete bonding areas.
  • Such discrete area or spot bonding is well known in the art and can be carried out by means of heated rolls or by ultrasonic bonding.
  • the bond pattern is selected to provide desired fabric strength characteristics.
  • the pattern bonding area is not limited in accordance with the present invention, although pattern bonding areas in the range of 5-25%, preferably
  • the laminate can be ultrasonically spot bonded or bonded by hot melt/glue adhesive lamination.
  • a spunbonded/spunbonded (SS) fabric laminate is formed by operating only spunbond stations 18 and 22, i.e., meltblown station 20 is turned off.
  • the softness-enhancing agents of the present invention can be added to either or both spun beams.
  • the bonding rolls 32 and 34 must be heated to a temperature which causes the spunbonded polymer to soften.
  • the SS fabric laminate will have the same tensile strength and elongation as an SMS fabric laminate having the same spunbonded layers since the meltblown layer does not contribute to these physical properties.
  • a monolayer of spunbond fabric having enhanced softness can be fabricated.
  • both the meltblown station 20 and the second spunbond station 22 are turned off, and the softness- enhancing agent is added to the polymer being fed to the operating spunbond station.
  • Ti0 2 is compounded with a base resin to form a masterbatch. This masterbatch is then mixed at a low percentage with the primary resin being fed to one or more stations.
  • the primary and base resins may be different or the same.
  • a hydrophilic additive is compounded with a base resin to form a masterbatch, which is then mixed at a low percentage with the primary resin being fed to one or more stations.
  • the masterbatch can be formed by compounding both Ti0 2 and hydrophilic additive with a base resin and then mixing the masterbatch with the main resin before feeding the polymer melt to the extruder.
  • the preferred base and primary resins are polyolefins.
  • the primary resin is preferably polypropylene
  • the base resin is preferably either polyethylene or polypropylene.
  • a masterbatch consisting of 70% Ti0 2 and 30% polyethylene (PE) was compounded with molten polypropylene (PP) to produce spunbond fabric samples having a basis weight of 25 gsm. The letdown was 4%, giving a melt composition of 2.8% Ti0 2 , 1.2% polyethylene and 96% polypropylene.
  • the fabric softness and opacity as evaluated subjectively, were considerably higher than those for a 100% polypropylene spunbond control sample (i.e., 0% Ti0 2 ) .
  • the processing conditions during this trial were similar for the con- trol samples and the Ti0 2 /PE masterbatch samples. The fabric uniformity was also comparable.
  • a second trial run was made to evaluate the influence of Ti0 2 in an SMS configuration.
  • a masterbatch consisting of 70% Ti0 2 and 30% polyethylene (PE) was compounded with molten polypropylene (PP) only in the spunbond melts.
  • the meltblown layer was formed from polypropylene without Ti0 2 or polyethylene. SMS composites having a meltblown layer of varying basis weight were produced, as set forth in the following table: TABLE 1
  • SMS composite having a total basis weight of 15.5 gsm with a 2.5-gsm meltblown layer was produced using a masterbatch consisting of 70% Ti0 2 and 30% polypropylene at letdowns of 2% and 4%, i.e., the spunbond melt compositions were, respectively, 1.4% Ti0 2 /98.6% polypropylene (2% letdown) and 2.8% Ti0 2 /97.2% polypropylene (4% letdown) .
  • the spunbond melt compositions were, respectively, 1.4% Ti0 2 /98.6% polypropylene (2% letdown) and 2.8% Ti0 2 /97.2% polypropylene (4% letdown) .
  • fabric uniform- ity was poorer compared to SMS control samples made with
  • melt-extruded fabric In order to study the influence of polyethylene alone on the softness of polypropylene melt-extruded fabric, a masterbatch consisting of 50% polypropylene and 50% polyethylene was compounded with molten polypropylene at 6% letdown for the spunbond melts, i.e., the spunbond melt composition was 3.0% polyethylene/97% polypropylene. Again the meltblown melt consisted of polypropylene without Ti02 or polyethylene. These melts were used to produce SMS composites having a total basis weight of 15.5 gsm with meltblown basis weights of 2.5 and 1.0 gsm, respectively. No significant improvement in softness was observed compared to the polypropylene control samples.
  • a masterbatch consisting of 50% Ti0 2 and 50% polyethylene was compounded with polypropylene to produce spunbond fabric samples having a basis weight of 20 gsm. Letdowns of 6%, 4% and 2% were used, giving melt compositions of 3.0% TiO 2 /3.0% poly- ethylene/94% polypropylene, 2.0% TiO 2 /2.0% polyethy- lene/96% polypropylene, and 1.0% TiO 2 /1.0% polyethylene/ 98% polypropylene, respectively.
  • spunbond fabric was fabricated from a masterbatch consisting of 50% Ti0 2 and 50% polypropylene compounded with polypro- pylene at letdowns of 6%, 4% and 2%.
  • the melt compositions were 3.0% Ti0 2 /97% polypropylene, 2.0% Ti0 2 /98% polypropylene, and 1.0% Ti0 2 /99% polypropylene, respectively. Again significant improvements in softness and opacity were observed.
  • the Ti0 2 loading can be in the range of 1-10%, with about 2% being preferred. Either rutile or anitase types of Ti0 2 can be used.
  • masterbatches consisting of Ti0 2 compounded with either polyethylene or polypropylene provide enhanced softness when added to a polypropylene spunbond melt. Initial observations indicated that the polyethylene-based masterbatch provided better softness than that provided by the polypropylene-based masterbatch.
  • the softness of an SMS composite can be enhanced by adding Ti0 2 to one of the spunbond layers, but not to the other spunbond layer and not to the meltblown layer.
  • the softness of an SS composite can be enhanced by adding Ti0 2 to one but not the other spunbond layer.
  • the softness of spunbond, SMS or other melt-extruded fabrics can be enhanced using a melt additive which migrates to the surface during fiber formation.
  • an oligomeric ester additive was used to enhance the softness of a polypropylene spunbond fabric. This additive increased the softness at the level of 0.5% or more. The melt additive was durable since it did not wash away after the first insult.
  • a trial run was made in which a masterbatch consisting of 25% hydrophilic oligomeric ester additive and 75% polypropylene, with a final melt flow rate of approximately 60 grams/10 minutes (PPM 11186 from Techmar PM, Collinso Dominguez , California), was compounded with polypropylene to produce spunbond fabric samples having a basis weight of about 24 gsm. Two levels of letdown were utilized: 2% and 10%, giving a final concentration of hydrophilic oligomeric ester additive in the spunbond melt of 0.5% and 2.5%, respectively. The throughput of the spunbond station was 0.35 gm/hr/min; the spunbond fabric was spot bonded with the top and bottom bonding rolls having temperatures of 272°F and 269°F, respectively.
  • the resulting spunbond fabrics had improved softness compared to the control samples made from polypro- pylene without hydrophilic oligomeric ester additive and the softness improved with increasing levels of additive.
  • the physical properties of the samples incorporating hydrophilic oligomeric ester additive are listed in Table 2: TABLE 2
  • both Ti0 2 and hydrophilic additive can be added to the masterbatch to further enhance the softness of a melt-extruded, e.g., spunbond, fabric.
  • the throughput of the spunbond station was 0.30 gm/hr/min; the spunbond fabric was spot bonded with the top and bottom bonding rolls both having a temperature of 272 °F.
  • the throughput for the second trial was 0.30 gm/hr/ min as compared to 0.35 gm/hr/min for the first trial.
  • the softness and opacity were considerably better compared to the previous trial run due to the addition of Ti0 2 .
  • the physical properties of the spunbond fabric incorporating both hydrophilic oligomeric ester additive and Ti0 2 are listed in Table 3 : TABLE 3
  • the coefficient of friction was measured in accor- dance with ASTM Standard D 1894-75, "Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting," American Society for Testing and Materials, Part 35 (1977), pp. 575-580.
  • the samples with 1.2% hydrophilic oligomeric ester additive had a coefficient of friction of 0.33 and the samples with 2.2% hydrophilic oligomeric ester additive had a coefficient of friction of 0.3, indicating a significant improvement in softness.
  • the preferred levels for the hydrophilic oligomeric ester additive and the Ti0 2 are 0.2-10% and 0.2-4%, respectively.
  • different levels of hydrophilic oligomeric ester additive can be incorporated in the melt and spun beams to improve the strikethrough and rewet properties.
  • hydrophilic agents can be applied topically to further enhance hydrophilicity.
  • SMS composites having basis weights of 13 and 11.5 gsy were fabricated using a masterbatch consisting of 25% hydrophilic additive and 75% polypropylene (11186 from Techmar PM) at letdown rates of 3% and 5% in both spunbond beams, yielding final concentrations of 0.75% and 1.25%, respectively.
  • the hydrophilic additive was not used in the meltblown beam.
  • a white masterbatch of 50% Ti0 2 and 50% polypropylene was used in conjunction with hydrophilic additive at a letdown rate of 0.33%, yielding a final concentration of 0.17%, respectively.
  • Ti0 2 was not used in the meltblown beam.
  • Samples containing Ti0 2 but not the hydrophilic additive were also produced at basis weights of 13 and 11.5 gsy.
  • the physical properties of the 13-gsy SMS fabric containing Ti0 2 with and without the hydrophilic additive are listed in Table 7.
  • hydrophobicity of the SMS composites with the oligomeric ester matched that of SMS composites having no oligomeric ester.
  • the level of hydrophilic oligomeric ester additive can be increased in order to achieve hydrophilic properties.
  • hydrophilic agents can be used to treat the fabrics topically to further enhance hydrophilicity.

Landscapes

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

Abstract

Cette invention se rapporte à un textile non tissé (2) comportant une ou plusieurs couches de fibres (4, 6, 8) obtenues par extrusion de matière fondue et présentant une souplesse accrue. On accroît la souplesse de ce textile (2) en ajoutant un agent assouplissant à une polyoléfine fondue avant l'extrusion. Ledit agent assouplissant est du dioxyde de titane (TiO2) ou un additif comportant un ingrédient actif qui est un ester oligomère, ou les deux. Si le dioxyde de titane est le seul agent assouplissant dans la polyoléfine fondue, alors le pourcentage de charge du dioxyde de titane est de préférence compris entre 1 et 10 % pour obtenir la souplesse accrue souhaitée. Le dioxyde de titane est de préférence du rutile ou de l'anatase. Le pourcentage de charge de l'additif ester oligomère dans la polyoléfine fondue est de préférence compris entre 0,2 et 10 % pour obtenir une souplesse accrue souhaitée. Il est possible d'ajouter l'agent assouplissant au cours de la fabrication d'un textile filé-lié, d'un stratifié comportant des couches filées-liées et des couches obtenues par fusion-soufflage, d'un stratifié ne comportant que des couches filées-liées, d'un stratifié SMS ou de tout autre composite constitué de couches filées-liées et/ou obtenues par fusion-soufflage.
PCT/US1998/015601 1997-07-29 1998-07-28 Textile non tisse, souple, fabrique par extrusion de matiere fondue Ceased WO1999006207A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002298600A CA2298600A1 (fr) 1997-07-29 1998-07-28 Textile non tisse, souple, fabrique par extrusion de matiere fondue

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US5408197P 1997-07-29 1997-07-29
US60/054,081 1997-07-29

Publications (1)

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WO1999006207A1 true WO1999006207A1 (fr) 1999-02-11

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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004061171A3 (fr) * 2002-12-17 2004-10-21 Kimberly Clark Co Procede de fabrication de fibres, non-tisses, films poreux et mousses comportant des additifs de traitement cutane
WO2005025854A1 (fr) * 2003-09-08 2005-03-24 Kimberly-Clark Worldwide, Inc. Lamelle textile non-tisse reduisant la migration des particules et couche-culotte comportant un tel lamelle
EP1327713A4 (fr) * 2000-09-18 2006-11-22 Idemitsu Unitech Co Ltd Non-tisse multicouche et ses utilisations
KR100696218B1 (ko) * 1999-08-27 2007-03-21 유니챰 가부시키가이샤 흡수성 물품
US20120100772A1 (en) * 2009-06-25 2012-04-26 Fibertex A/S High barrier nonwoven
WO2014011837A1 (fr) * 2012-07-13 2014-01-16 The Procter & Gamble Company Laminés étirables pour articles absorbants et procédés de fabrication associés
US20140259579A1 (en) * 2013-03-15 2014-09-18 The Procter & Gamble Company Methods for forming absorbent articles with nonwoven substrates
US9205006B2 (en) 2013-03-15 2015-12-08 The Procter & Gamble Company Absorbent articles with nonwoven substrates having fibrils
JP2016089278A (ja) * 2014-10-30 2016-05-23 セーレン株式会社 防護服用素材および防護服
US10512289B2 (en) 2016-05-04 2019-12-24 O&M Halyard, Inc. Disposable surgical gown
CN110699860A (zh) * 2019-11-18 2020-01-17 江苏盛纺纳米材料科技股份有限公司 一种绵柔爽滑非织造布及其制备方法和应用
US11090407B2 (en) 2017-03-09 2021-08-17 The Procter & Gamble Company Thermoplastic polymeric materials with heat activatable compositions
US11110013B2 (en) 2014-09-10 2021-09-07 The Procter & Gamble Company Nonwoven webs with hydrophobic and hydrophilic layers
US11129919B2 (en) 2016-03-09 2021-09-28 The Procter & Gamble Company Absorbent article with activatable material
US11528947B2 (en) 2018-08-24 2022-12-20 O&M Halyard, Inc. Personal protection and ventilation system
US11528954B2 (en) 2018-08-24 2022-12-20 O&M Halyard, Inc. Personal protection and ventilation system
US11583013B2 (en) 2016-07-29 2023-02-21 O&M Halyard, Inc. Collar for a disposable surgical gown
WO2023071094A1 (fr) * 2021-10-28 2023-05-04 国桥实业(深圳)有限公司 Couette et procédé de fabrication pour celle-ci
CN120366971A (zh) * 2025-06-25 2025-07-25 山东华业无纺布有限公司 一种柔软sms无纺布及其制备方法

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US5705249A (en) * 1995-01-26 1998-01-06 Uni-Charm Corporation Liquid-permeable composite nonwoven fabric for use in body fluids absorptive articles

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US3770562A (en) * 1971-09-09 1973-11-06 Kendall & Co Composite nonwoven fabrics
US4753834A (en) * 1985-10-07 1988-06-28 Kimberly-Clark Corporation Nonwoven web with improved softness
US5705249A (en) * 1995-01-26 1998-01-06 Uni-Charm Corporation Liquid-permeable composite nonwoven fabric for use in body fluids absorptive articles

Cited By (27)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100696218B1 (ko) * 1999-08-27 2007-03-21 유니챰 가부시키가이샤 흡수성 물품
EP1078621B2 (fr) † 1999-08-27 2011-11-30 Uni-Charm Corporation Article absorbant
EP1327713A4 (fr) * 2000-09-18 2006-11-22 Idemitsu Unitech Co Ltd Non-tisse multicouche et ses utilisations
WO2004061171A3 (fr) * 2002-12-17 2004-10-21 Kimberly Clark Co Procede de fabrication de fibres, non-tisses, films poreux et mousses comportant des additifs de traitement cutane
WO2005025854A1 (fr) * 2003-09-08 2005-03-24 Kimberly-Clark Worldwide, Inc. Lamelle textile non-tisse reduisant la migration des particules et couche-culotte comportant un tel lamelle
US20120100772A1 (en) * 2009-06-25 2012-04-26 Fibertex A/S High barrier nonwoven
CN104428131A (zh) * 2012-07-13 2015-03-18 宝洁公司 用于吸收制品的可拉伸层压体及其制备方法
WO2014011837A1 (fr) * 2012-07-13 2014-01-16 The Procter & Gamble Company Laminés étirables pour articles absorbants et procédés de fabrication associés
US9974700B2 (en) 2013-03-15 2018-05-22 The Procter & Gamble Company Absorbent articles with nonwoven substrates having fibrils
US9504610B2 (en) * 2013-03-15 2016-11-29 The Procter & Gamble Company Methods for forming absorbent articles with nonwoven substrates
US20140259579A1 (en) * 2013-03-15 2014-09-18 The Procter & Gamble Company Methods for forming absorbent articles with nonwoven substrates
US10016319B2 (en) 2013-03-15 2018-07-10 The Procter & Gamble Company Absorbent articles with nonwoven substrates having fibrils
US10993855B2 (en) 2013-03-15 2021-05-04 The Procter & Gamble Company Absorbent articles with nonwoven substrates having fibrils
US9205006B2 (en) 2013-03-15 2015-12-08 The Procter & Gamble Company Absorbent articles with nonwoven substrates having fibrils
US11839531B2 (en) 2014-09-10 2023-12-12 The Procter And Gamble Company Nonwoven webs with hydrophobic and hydrophilic layers
US11110013B2 (en) 2014-09-10 2021-09-07 The Procter & Gamble Company Nonwoven webs with hydrophobic and hydrophilic layers
JP2016089278A (ja) * 2014-10-30 2016-05-23 セーレン株式会社 防護服用素材および防護服
US11129919B2 (en) 2016-03-09 2021-09-28 The Procter & Gamble Company Absorbent article with activatable material
US11576449B2 (en) 2016-05-04 2023-02-14 O&M Halyard, Inc. Disposable surgical gown
US10512289B2 (en) 2016-05-04 2019-12-24 O&M Halyard, Inc. Disposable surgical gown
US11583013B2 (en) 2016-07-29 2023-02-21 O&M Halyard, Inc. Collar for a disposable surgical gown
US11090407B2 (en) 2017-03-09 2021-08-17 The Procter & Gamble Company Thermoplastic polymeric materials with heat activatable compositions
US11528954B2 (en) 2018-08-24 2022-12-20 O&M Halyard, Inc. Personal protection and ventilation system
US11528947B2 (en) 2018-08-24 2022-12-20 O&M Halyard, Inc. Personal protection and ventilation system
CN110699860A (zh) * 2019-11-18 2020-01-17 江苏盛纺纳米材料科技股份有限公司 一种绵柔爽滑非织造布及其制备方法和应用
WO2023071094A1 (fr) * 2021-10-28 2023-05-04 国桥实业(深圳)有限公司 Couette et procédé de fabrication pour celle-ci
CN120366971A (zh) * 2025-06-25 2025-07-25 山东华业无纺布有限公司 一种柔软sms无纺布及其制备方法

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