WO2015143352A1 - Procédé permettant d'influencer l'énergie de surface d'une étoffe non tissée - Google Patents

Procédé permettant d'influencer l'énergie de surface d'une étoffe non tissée Download PDF

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Publication number
WO2015143352A1
WO2015143352A1 PCT/US2015/021798 US2015021798W WO2015143352A1 WO 2015143352 A1 WO2015143352 A1 WO 2015143352A1 US 2015021798 W US2015021798 W US 2015021798W WO 2015143352 A1 WO2015143352 A1 WO 2015143352A1
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WIPO (PCT)
Prior art keywords
surface energy
woven fabric
fibers
energy modifier
polyolefin
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English (en)
Inventor
Charles Omotayo KEROBO
Emmanuel ATTIOGBE
Anping Wang
Colleen Rocafort
John Andrew RANDOLPH
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BASF SE
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BASF SE
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    • 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
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • 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

Definitions

  • the present disclosure generally relates to a method of influencing the surface energy of a non-woven fabric and the non-woven fabric itself. More specifically, the non-woven fabric includes a plurality of fibers that includes a polyolefin and a surface energy modifier that increases or decreases the surface energy (e.g. the hydro-philicity/phobicity) of the fibers.
  • a surface energy modifier that increases or decreases the surface energy (e.g. the hydro-philicity/phobicity) of the fibers.
  • Non-woven fabrics have become one of the fast growing industries in the textile world and are typically processed by web forming and web consolidation, which differ from the processing of conventional textile fabrics.
  • polypropylene (PP) fibers have grown to be one of the dominant materials in the non-woven fabric industry. It is estimated that over 90% of all melt-blown non-woven fabrics are made from polypropylene because of low cost, ease of processing, favorable chemical and physical properties, such as lack of heat shrinkage, impact strength, tensile strength, and an ability to be drawn into very fine fibers.
  • polypropylene is a typical hydrophobic polymer which causes the non-woven fabrics made therefrom to have poor hydrophilicity, which limits their use in some applications.
  • the polypropylene is not hydrophobic enough which also limits application usefulness. More specifically, due to the ordered structure and the lack of polar functionalities in polypropylene, interactions with polar materials are very poor; particularly in areas where absorption and wettability are required or in areas where super-hydrophobicity is required.
  • migratory additives i.e., materials that exhibit controlled migration to the surface of nonwoven fabrics.
  • These migratory additives are typically recognized as low cost materials that can generate desirable surface properties without altering the bulk properties of the non-woven fabrics. Nevertheless, over time, the migratory additives migrate entirely, or almost entirely, out of the non-woven fabrics thereby reducing their useful lifetime. Accordingly, there remain opportunities for improvement.
  • the present disclosure provides a method of influencing the surface energy of a non- woven fabric that includes a plurality of fibers.
  • the method includes the steps of providing a polyolefin that includes a matrix structure and providing a surface energy modifier.
  • the surface energy modifier is chosen from alcohol alkoxylates, alcohol block alkoxylates, polyoxyalkylene block polymers, copolymers of maleic acid and acrylic acid, copolymers of polycarboxylate and polyethylene, polyethylene wax copolymers, and combinations thereof.
  • the method also includes the step of combining the polyolefin and the surface energy modifier to disperse the surface energy modifier throughout the matrix structure to form a mixture.
  • the method subsequently includes the step of forming the plurality of fibers and the non-woven fabric from the mixture.
  • This disclosure also provides a non-woven fabric having increased hydrophobicity and including the plurality of fibers.
  • each of the plurality of fibers includes the polyolefin and the surface energy modifier.
  • the surface energy modifier is chosen from copolymers of maleic acid and acrylic acid, copolymers of polycarboxylate and polyethylene, and combinations thereof.
  • this non-woven fabric exhibits a water contact angle of greater than 90 degrees when evaluated using ASTM D7490-13.
  • the disclosure further provides a non-woven fabric having increased hydrophilicity and including the plurality of fibers.
  • each of the plurality of fibers also includes the polyolefin and the surface energy modifier.
  • the surface energy modifier is chosen from alcohol alkoxylates, alcohol block alkoxylates, polyoxyalkylene block polymers, and combinations thereof.
  • this non-woven fabric exhibits a water contact angle of less than 90 degrees when evaluated using ASTM D7490-13.
  • Figure 1 is a bar graph of water absorptive capacity of various examples
  • Figure 2 is a bar graph of strike through times of various examples
  • Figure 3A is a table of various water contact angle measurements of various examples; and [0013] Figure 3B is a line graph of contact angles of various examples as set forth in Figure 3A.
  • non-woven fabric describes a sheet, layer or web that includes the plurality of fibers, e.g. a structure of individual fibers, filaments, or threads that are positioned in a substantially random manner to form a planar material, as opposed to a knitted or woven fabric, as is understood in the art.
  • Non- limiting examples non-woven fabrics include meltblown webs, spunbond webs, carded webs, air-laid webs, wet-laid webs, and spunlaced webs.
  • the non-woven fabric is further defined as a textile and is neither woven nor knit.
  • the non-woven fabric may be manufactured by putting individual fibers together in the form of a sheet or web, and then binding them either mechanically, with an adhesive, or thermally by melting a binder onto the textile.
  • Non-woven textiles may include staple non-woven textiles and spunlaid non- woven textiles. Staple non-woven textiles are typically made by spinning fibers that are spread in a uniform web and then bonded by using either resin or heat.
  • Non-woven fabrics or textiles may also include films and fibrillates and can be formed using serration or vacuum-forming to form patterned holes.
  • the non-woven fabric is further defined as a spunlaid non-woven fabric.
  • Spunlaid non-woven fabrics/textile are typically made in one continuous process by spinning fibers directly disposed into a web. The spunlaid process can be combined with a meltblowing process to form a SMS (spun-melt-spun) non-woven textile.
  • the spunlaid non-woven fabric is a multi-layer composite fabric including a layer of meltblown fibers bonded between two layers of spunbond fibers (e.g., a spunbond- meltblown-spunbond (SMS)).
  • SMS nonwoven fabric can include multiple layers of spunbond or meltblown fibers, such as an SMMS (spunbond-meltblown-meltblown- spunbond), SMSS (spunbond-meltblown-spunbond-spunbond), or the like.
  • the non-woven fabric is defined as a sheet or web structure bonded together by entangling fibers or filaments mechanically, thermally or chemically.
  • the non-woven fabric is a flat or tufted porous sheet that is made directly from separate fibers. Typically, non-woven fibers are not made by weaving or knitting and do not require converting the fibers to yarn.
  • the non-woven fabric is described as an engineered fabric that may be described as a limited life, single-use fabric or a durable fabric. The non-woven fabric may be absorbent, repellant to liquid, resilient to tearing, flame retardant, washable, insulating, etc.
  • the non-woven fabric may be itself, or may be used to form, any article of the art.
  • the article may be or include wipes, diapers, water or air filters, membranes, or packaging.
  • the article may be further defined as clothing or apparel.
  • the non-woven fabric may be itself or may be used to form one or more of surgical gowns, masks, and apparel, medical packaging, gasoline, oil and air filters, food grade filters, pharmaceutical filters, mineral processing filters, liquid cartridge and bag filters, vacuum bags, allergen membranes, laminates, geotextiles, carpet backing, laminates, backing for embroidery, insulation, pillows, cushions, mattress cores, and upholstery padding, envelopes, tarps, tenting and transportation wrapping, (disposable), weather resistant house wrap, and the like.
  • non-woven fabric further includes the plurality of fibers.
  • fiber(s) may be substituted below for either “the plurality of fibers", “each of the plurality of fibers", or both.
  • the fibers may be in monofilament form, collated fibrillated form, ribbon form, or any core-sheath, core-shell, mono component, or bi-component form or any other form known in the art.
  • each of the plurality of fibers may have a basis weight 10 to 80 grams per square meter (gsm) or 10 to 60 gsm or 10 to 55 gsm, or 10 to 55 gsm or 10 to 45 gsm and 0.5 to 35 denier.
  • each of the plurality of fibers may have a denier of from 0.5 to 35, from 1 to 20, from 1 to 5, from 1 to 10, from 1 to 4, of from 1.5 to 3 denier, of from 1.5 to 2.5 denier, of from 1.5 to 2 denier, of from 1.6 to 2 denier.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges are hereby expressly contemplated.
  • spunbond fibers have an average basis weight of greater than 10 gsm.
  • Spunbond webs can be formed by laying spunbond fibers randomly on a collecting surface, and subsequently bonding the fibers, such as by thermal bonding, hydroentanglement, or the like.
  • meltblown fibers have an average basis weight of less than about 10 gsm.
  • Meltblown webs can be formed by laying meltblown fibers randomly on a collecting surface, and bonding, such as by thermal bonding, hydroentanglement, or the like.
  • the spunbond fibers and meltblown fibers can be substantially continuous fibers but are not limited thereto. For example, staple fibers or carded fibers may be used instead or in conjunction with substantially continuous fibers.
  • the non- woven fabric typically includes approximately 100% by weight of the plurality of fibers but may include from 90 to 99, or from 95 to 99, % by weight of the plurality of fibers.
  • the method includes the steps of providing a polyolefin that includes a matrix structure and providing a surface energy modifier.
  • the method also includes the step of combining the polyolefin and the surface energy modifier to disperse the surface energy modifier throughout the matrix structure to form a mixture.
  • the method includes the step of forming the plurality of fibers and the non-woven fabric from the mixture.
  • the polyolefin is not particularly limited. Suitable non-limiting polyolefins include polymers and copolymers formed from the polymerization of ethylene or propylene monomers. Mixtures of pure polyolefins with copolymers are also suitable in various embodiments.
  • the polyolefin may alternatively be combined with other synthetic or natural polymers, for example cellulose, polylactic acid or hemp.
  • the polyolefin is, includes, consists essentially of, or consists of, one or more of, poly (ethylenes), such as HDPE (high-density polyethylene), LDPE (low-density polyethylene), VLDPE (very-low-density polyethylene), LLDPE (linear low-density polyethylene), MDPE (medium-density polyethylene), UHMPE (ultra high molecular polyethylene), VPE (crosslinked polyethylene), HPPE (high-pressure polyethylene); poly(propylenes), such as isotactic polypropylene; syndiotactic polypropylene; metallocene- catalyzed polypropylene, high-impact polypropylene, random copolymers based on ethylene and propylene, block copolymers based on ethylene and propylene; EPM (poly[ethylene-co- propylene]); EPDM (poly[ethylene-co-propylene-co-unconjugated diene
  • the polyolefin is chosen from polyethylene, polypropylene, polymethylpentene, polybutene-1, and combinations thereof.
  • the polypropylene may be isotactic, syndiotactic, or atactic.
  • generic chemical structures of atactic, isotactic, and syndiotactic polypropylene are shown below:
  • n may be any integer.
  • a non-limiting example of a suitable polypropylene is commercially available from LyondellBasel Industries of Houston, TX, under the trade name of MetoceneTM, such as MetoceneTM MF650W.
  • Each of the plurality of fibers typically includes at least 90 parts by weight of the polyolefin based on 100 parts by weight of each of the plurality of fibers.
  • the polyolefin may be used in a lesser weight percent.
  • each of the plurality of fibers may include at least 92 parts by weight, at least 94 parts by weight, at least 96 parts by weight, at least 97 parts by weight, at least 98 parts by weight, or at least 99 parts by weight of the polyolefin, each based on 100 parts by weight of each of the plurality of fibers.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges are hereby expressly contemplated.
  • the polyolefin includes a matrix structure.
  • the matrix structure is formed from the monomers that are polymerized to form the polyolefin.
  • the matrix structure is typically formed from a series of oligomer and/or polymer chains that are entwined or intermingled to form the polyolefin as a whole.
  • the matrix structure is typically porous at a micro-level but may appear solid at a macro-level.
  • the surface energy modifier is dispersed in the matrix structure.
  • the surface energy modifier is dispersed homogenously throughout the matrix structure, e.g. evenly or consistently or uniformly throughout the matrix structure.
  • the surface energy modifier is dispersed heterogeneously throughout the matrix structure, e.g. unevenly, randomly, or non-uniformly throughout the matrix structure.
  • the surface energy modifier may be dispersed homogeneously in one or more portions of the matrix structure and heterogeneously in one or more other portions of the matrix structure.
  • the surface energy modifier may be bonded to the matrix structure, e.g. by covalent bonds.
  • the surface energy modifier may be subject to one or more intermolecular forces with the matrix structure, e.g. hydrogen bonding or van der Waals forces.
  • the surface energy modifier may be present in the polyolefin, each fiber itself, and/or non-woven fabric in an amount of from 0.1 to 5, 0.2 to 4.9, 0.3 to 4.8, 0.4 to 4.7, 0.5 to 4.6, 0.6 to 4.5, 0.7 to 4.4, 0.8 to 4.3, 0.9 to 4.2, 1 to 4.1, 1.1 to 4, 1.2 to 3.9, 1.3 to 3.8, 1.4 to 3.7, 1.5 to 3.6, 1.6 to 3.5, 1.7 to 3.4, 1.8 to 3.3, 1.9 to 3.2, 2 to 3.1, 2.1 to 3, 2.2 to 2.9, 2.3 to 2.8, 2.4 to 2.7, or 2.5 to 2.6, weight percent based on a total weight of the polyolefin, fibers, and/or non-woven fabric.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges are hereby expressly contemplated.
  • the particular surface energy modifier may be chosen based on a desire to increase or decrease the surface energy (e.g. the hydrophilicity or hydrophobicity) of the polyolefin, fibers, and/or non-woven fabric.
  • the surface energy modifier is chosen from alcohol alkoxylates, alcohol block alkoxylates, polyoxyalkylene block polymers, copolymers of maleic acid and acrylic acid, copolymers of polycarboxylate and polyethylene, polyethylene wax copolymers, and combinations thereof.
  • the surface energy modifier is selected to decrease the surface energy, i.e. increase the hydrophobicity and decrease the hydrophilicity, of the polyolefin, fibers, and/or the non-woven fabric.
  • the decreased surface energy and/or hydrophobicity can be quantified, for example, by water contact angle, which is described in greater detail below.
  • the surface energy modifier is chosen from copolymers of maleic acid and acrylic acid, copolymers of polycarboxylate and polyethylene, polyethylene wax copolymers, and combinations thereof.
  • the surface energy modifier is a copolymer of maleic acid and acrylic acid.
  • This copolymer is not particularly limited relative to weight average molecular weight or order of maleic acid and acrylic acid blocks.
  • the copolymer may be any type of copolymer, e.g. a random copolymer, a block copolymer, etc.
  • this copolymer may be sodium salt of maleic acid/acrylic copolymer, under the trade name of Sokalan® CP 5 or Sokalan® CP9 by BASF Corporation, Florham Park, New Jersey.
  • the surface energy modifier is a copolymer of polycarboxylate and polyethylene.
  • the copolymer is anionically modified.
  • anionically modified typically describes that the copolymer may be sodium salt of modified polycarboxylate under the trade name of Sokalan® CP42 by BASF Corporation, Florham Park, New Park, New Jersey.
  • this copolymer includes a weight percent of a homopolymer, such as a (poly)carboxylate, of from 0.5 to 15, 1 to 10, 2 to 7, 2 to 6, 2 to 5% with the balance stabilizing additives and polypropylene.
  • a homopolymer such as a (poly)carboxylate
  • the classes of polycarboxylates are sold by BASF Corporation as Sokalan® acrylic acid homopolymers.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges are hereby expressly contemplated.
  • the surface modifier is a polyethylene wax copolymer.
  • the surface modifier may be a polyethylene wax of an ethylene copolymer having two or more acid groups.
  • the surface modifier has an acid number of 160 to 180 mg KOH/g and/or a Melt Flow Index of 6 to 12 g/ 10 min.
  • the polyethylene wax copolymer may be a copolymer of polycarboxylate and polyethylene wax having a melting point of from 100 to 250, from 150 to 200, from 160 to 190,°C.
  • Increasin2 the Surface Enerev of the Polyolefin, Fibers, and/or Non- Woven Fabric:
  • the surface energy modifier is selected to increase the surface energy, i.e. increase the hydrophilicity and decrease the hydrophobicity, of the polyolefin, fibers, and/or the non-woven fabric.
  • the increased surface tension and/or hydrophobicity can be quantified, for example, by water contact angle, which is described in greater detail below.
  • the surface energy modifier is chosen from alcohol alkoxylates, alcohol block alkoxylates, polyoxyalkylene block polymers, and combinations thereof.
  • the surface energy modifier is an alcohol alkoxylate.
  • the alcohol alkoxylate is not particularly limited and may be an alcohol alkoxylate with an alcohol moiety having the formula:
  • R is Cs to C 18 , such as Cs , C 10, Cn , C 12, Ci 3> C 14, Cis , C 16, C 17 , or C 18 branched or straight chain alkyl group
  • m is 0 to 14, such as 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14
  • n is 0 to 14, such as 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14, o is 0 to 14, such as 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, or 14,
  • p is 0 to 14, such as 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14, and
  • R' is -CH 3 , -CH 2 CH 3 , and mixtures thereof
  • R" is -CH 3 , -CH 2 CH 3 , and mixture thereof
  • R'" is -OH, -CH 3 , -0-C 3 -Cis hydroxyalkyl group and mixtures thereof.
  • the alcohol alkoxylate may alternatively be an alcohol alkoxylate with one or more alcohol moieties alkoxylate and have the formula:
  • R is Cs to C 18 , such as Cs , C 10, Cn , Ci 2> Ci 3> C 14, Cis , C 16, Cn, or C 18 branched or straight chain alkyl group, x is 0 to 14, such as 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, or 14, y 3 to 14, such as 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, or 14, z is 0 to 20, such as 0, 1 , 2, 3, 4, 5, 6,
  • the alcohol alkoxylate may alternatively be an alcohol alkoxylate having one or more oxyethylate moieties having the formula:
  • R(OCH 2 CH 2 ) ⁇ OH wherein R is C 10 to C 13 such as C 10 , Cn, C 12 , or C 13 branched or straight chain alkyl group, and x is 4 to 10, such as 4, 5, 6, 7, 8, 9, or 10.
  • R is C 10 to C 13 such as C 10 , Cn, C 12 , or C 13 branched or straight chain alkyl group, and x is 4 to 10, such as 4, 5, 6, 7, 8, 9, or 10.
  • the alcohol alkoxylate is typically nonionic, but may be cationic, anionic, amphoteric or zwitterionic.
  • the alcohol alkoxylate may have a degree of ethoxylation of from 1 to 100.
  • the alcohol alkoxylate may have a degree of ethoxylation of from 20 to 100, of from 40 to 100, of from 60 to 100, or of from 70 to 90.
  • the alcohol alkoxylate has an average weight average molecular weight of from 500 to 10,000 g/mol.
  • the alcohol alkoxylate has an average weight average molecular weight of from 1 ,000 to 10,000 g/mol, of from 2,000 to 4,500 g/mol, of from 2,500 to 4,000 g/mol, or of from 3,000 to 4,000 g/mol.
  • a non-limiting example of a suitable alcohol alkoxylate is commercially available from BASF Corporation of Florham Park, NJ.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
  • the surface energy modifier is an alcohol block alkoxylate.
  • the alcohol block alkoxylate is not particularly limited and may be an alcohol block/heteric alkoxylate.
  • the surface energy modifier is a polyoxyalkylene block polymer.
  • the polyoxyalkylene block polymer is further defined as a copolymer of ethylene oxide and propylene oxide represented by the following chemical structure:
  • a is from 12 to 141, 12 to 101, 12 to 80, 12 to 64, 64 to 141, 64 to 101, 64 to 80, 80 to 141, 80 to 101 , or 101 to 141
  • b is from 20 to 56, 20 to 44, 20 to 37, 20 to 27, 27 to 56, 27 to 44, 27 to 37, 37 to 56, 37 to 44, or 44 to 56.
  • the polyoxyalkylene block polymer has a weight average weight average molecular weight of from 1000 to 2400, from 7600 to 9600, from 6800 to 8900, from 12700 to 17400, or from 9800 to 14600, g/mol.
  • the polyoxyalkylene block polymer has a weight % of oxyethylene of 45 to 50, 80 to 85, or 70 to 75, + 1 , 2, 3, 4, or 5, weight percent.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
  • the surface energy modifier is a polyoxyethylene/polyoxypropylene block/heteric copolymer (EO/PO block/heteric copolymer).
  • EO/PO block/heteric copolymer may be any block or heteric/block polyoxyalkylene polymer for example having the formula:
  • Y is the nucleus of an active hydrogen containing organic compound having a functionality of x from 1 to 6, such as 1, 2, 3, 4, 5, or 6 and (i) 2 to 6 carbon atoms, such as 2, 3, 4, 5, or 6 carbon atoms and 2 to 3 reactive hydrogen atoms or (ii) 6 to 18 carbon atoms, such as 6, 7, 8, 9 ,10, 11, 12, 13, 14, 15, or 16, 17, or 18 carbon atoms and 1 to 3 reactive hydrogen atoms, such as 1, 2, or 3 reactive hydrogen atoms.
  • A is typically a lower alkylene oxide selected from the group consisting of propylene oxide, butylene oxide, tetrahydrofuran or mixtures thereof.
  • Up to 25 percent by weight, up to 20 percent by weight, up to 15 percent by weight, up to 10 percent by weight, or up to 5 percent by weight of A may be reacted directly with the active hydrogen containing organic compound in admixture with ethylene oxide, 75 percent by weight or more, 80 percent by weight or more, 85 percent by weight or more, 90 percent by weight or more, or 95 percent by weight or more of A may be subsequently reached to produce the polymer.
  • m may be 0 to 110, such as 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41 , 42, 43, 44, 45, 46, 47, 48 ,49, 50, 51 , 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71 , 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91 , 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, or 110.
  • N may be 0 to 26, such as 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22, 23, 24, 25, or 26.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
  • the EO/PO block/heteric copolymer may also be a block or heteric/block polyoxyalkylene polymer having the formula:
  • Y is the nucleus of an active hydrogen containing organic compound having a functionality of x from 1 to 6, such as 1, 2, 3, 4, 5, or 6 and (i) 2 to 6 carbon atoms, such as 2, 3, 4, 5, or 6 carbon atoms and 2 to 3 reactive hydrogen atoms or (ii) 6 to 18 carbon atoms, such as 6, 7, 8, 9 ,10, 11, 12, 13, 14, 15, or 16, 17, or 18 carbon atoms and 1 to 3 reactive hydrogen atoms, such as 1, 2, or 3 reactive hydrogen atoms.
  • A is typically a lower alkylene oxide selected from the group consisting of propylene oxide, butylene oxide, tetrahydrofuran or mixtures thereof.
  • Up to 25 percent by weight, up to 20 percent by weight, up to 15 percent by weight, up to 10 percent by weight, or up to 5 percent by weight of A may be reacted directly with the active hydrogen containing organic compound in admixture with ethylene oxide, 75 percent by weight or more, 80 percent by weight or more, 85 percent by weight or more, 90 percent by weight or more, or 95 percent by weight or more of A may be subsequently reached to produce the polymer.
  • m may be 0 to 110, such as 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41 , 42, 43, 44, 45, 46, 47, 48 ,49, 50, 51 , 52, 53, 54, 55, 56 ,57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71 , 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91 , 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, or 110.
  • N may be 0 to 26, such as 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, or 26.
  • O may be 0 to 26, such as 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22, 23, 24, 25, or 26.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
  • the EO/PO block/heteric copolymer may alternatively be a block or heteric/block polyoxyalkylene polymer having the formula:
  • Y is the nucleus of an active hydrogen containing organic compound having a functionality of x from 1 to 6, such as 1 , 2, 3, 4, 5, or 6, and (i) 2 to 6 carbon atoms, such as 2, 3, 4, 5, or 6 carbon atoms and 2 to 3 reactive hydrogen atoms or (ii) 6 to 18 carbon atoms, such as 6, 7, 8, 9 ,10, 11, 12, 13, 14, 15, or 16, 17, or 18 carbon atoms and 1 to 3 reactive hydrogen atoms, such as 1, 2, or 3 reactive hydrogen atoms.
  • A is typically a lower alkylene oxide selected from the group consisting of propylene oxide, butylene oxide, tetrahydrofuran or mixtures thereof.
  • Up to 25 percent by weight, up to 20 percent by weight, up to 15 percent by weight, up to 10 percent by weight, or up to 5 percent by weight of A may be reacted directly with the active hydrogen containing organic compound in admixture with ethylene oxide, 75 percent by weight or more, 80 percent by weight or more, 85 percent by weight or more, 90 percent by weight or more, or 95 percent by weight or more of A may be subsequently reached to produce the polymer.
  • m may be 0 to 110, such as 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41 , 42, 43, 44, 45, 46, 47, 48 ,49, 50, 51 , 52, 53, 54, 55, 56 ,57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71 , 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91 , 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, or 110.
  • N may be 0 to 26, such as 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, or 26.
  • O may be 0 to 26, such as 0, 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22, 23, 24, 25, or 26.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
  • the EO/PO block/heteric copolymer is typically nonionic, but may be cationic, anionic, amphoteric or zwitterionic.
  • the EO/PO block/heteric copolymer may terminate in a primary hydroxyl group, but may be different.
  • the EO/PO block/heteric copolymer is formed from repeating units polyethylene oxide and polypropylene oxide. The polyethylene oxide contributes to the degree of ethoxylation of the EO/PO block/heteric copolymer.
  • the EO/PO block/heteric copolymer has an average weight average molecular weight of from 5,000 to 15,000 g/mol.
  • the EO/PO block/heteric copolymer may have an average weight average molecular weight of from 5,500 to 14,000 g/mol, of from 6,000 to 13,500 g/mol, of from 6,500 to 13,000 g/mol, or of from 7,000 to 13,000 g/mol.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
  • the non-woven fabric typically exhibits a water contact angle of greater than 90° or less than 90°.
  • water contact angle measurements can be used to quantify surface tension, i.e., hydrophilicity/hydrophobicity.
  • the surface energy modifier may lower the interfacial tension between water and the polyolefin, fibers, and/or non-woven fabric thereby increasing the surface energy and the hydrophilicity of the polyolefin, fibers, and/or non-woven fabric and permitting the water to "wet" the polyolefin, fibers, and/or non-woven fabric.
  • wetting describes the ability of a liquid to maintain contact with a solid resulting from intermolecular interactions when the liquid and solid are combined.
  • This "wetting" of the polyolefin, fibers, and/or non-woven fabric may be evaluated by determining the contact angle that water exhibits with a molded sheet and/or with the polyolefin, fibers, and/or non-woven fabric.
  • a lower contact angle generally indicates that the polyolefin, fibers, and/or non-woven fabric has increased hydrophilicity.
  • Water typically exhibits a contact angle with polypropylene (without the surface energy modifier) of about 90° according to modified ASTM D7490-13.
  • the polyolefin, fibers, and/or non-woven fabric may exhibit a water contact angle of less than or equal to 85°, 80°, 75°, 70°, 65°, 60°, 55°, 50°, 45°, or 40°, each according to modified ASTM D7490-13.
  • the alcohol alkoxylates, alcohol block alkoxylates, and polyoxyalkylene block polymers each independently allow the polyolefin, fibers, and/or non-woven fabric to exhibit a water contact angle of less than 90°, according to modified ASTM D7490-13.
  • these surface energy modifiers may be described as allowing the polyolefin, fibers, and/or non-woven fabric to exhibit a water contact angle that is less than a reference contact angle measured using the same polyolefin, fibers, and/or non- woven fabric without the surface energy modifier, according to modified ASTM D7490-13.
  • the surface energy modifier may increase the interfacial tension between water and the polyolefin, fibers, and/or non-woven fabric thereby decreasing the surface energy and increasing the hydrophobicity of the polyolefin, fibers, and/or non-woven fabric and reducing the ability of water to "wet" the polyolefin, fibers, and/or non-woven fabric, as described above.
  • a higher contact angle generally indicates that the polyolefin, fibers, and/or non-woven fabric has increased hydrophobicity.
  • the polyolefin, fibers, and/or non-woven fabric may exhibit a water contact angle of greater than or equal to 90 °, 95°, 100°, 105°, 110°, 115°, 120°, 125°, 130°, 135°, or 140°, each according to modified ASTM D7490-13.
  • the copolymers of maleic acid and acrylic acid and copolymers of polycarboxylate and polyethylene each independently allow the polyolefin, fibers, and/or non-woven fabric to exhibit a water contact angle of greater than 90°, according to modified ASTM D7490-13.
  • these surface energy modifiers may be described as allowing the polyolefin, fibers, and/or non-woven fabric to exhibit a water contact angle that is greater than a reference contact angle measured using the same polyolefin, fibers, and/or non- woven fabric without the surface energy modifier, according to modified ASTM D7490-13.
  • the plurality of non-woven fibers may also have a water absorptive capacity of from 50 to 100%, or from 100 to 150%, or from 150% 200%, from 200 to 250%, or from 250 to 300%, as determined using ISO 9073-6:2000(E)
  • the plurality of non-woven fibers may have a strike through time of from 1 to 14 sec, 1 to 2 sec, from 2 to 3 sec, from 3 to 5 sec, 5 to 10 sec, from 10 to 14 sec, as determined using ED ANA 150.5 - 02.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges are hereby expressly contemplated.
  • the polyolefin, fibers, and/or non- woven fabric may also include one or more additives.
  • additives are dyes, pigments, lubricants, sizing agents, delustrants, antistats, bleaches, flame retardants, biocides, antifungals, or antibacterials, and combinations thereof.
  • a biocidal, antifungal, or antibacterial additive may be added to the polyolefin, fibers, and/or non-woven fabric.
  • a suitable non- limiting example of a biocidal additive is a silver- zinc glass composition, e.g. Irgaguard ® B7000, commercially available from BASF Corporation.
  • the additive is present in the polyolefin, fibers, and/or non-woven fabric in an amount of from 0.1 to 3, 0.2 to 2.9, 0.3 to 2.8, 0.4 to 2.7, 0.5 to 2.6, 0.6 to 2.5, 0.7 to 2.4, 0.8 to 2.3, 0.9 to 2.2, 1 to 2.1 , 1.1 to 2, 1.2 to 1.9, 1.3 to 1.8, 1.4 to 1.7, or 1.5 to 1.6, weight percent, based on a total weight of the polyolefin, fibers, and/or non-woven fabric.
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges are hereby expressly contemplated.
  • polyolefin, fibers, and/or non-woven fabric may also include one or more softness additives.
  • the one or more softness additives are typically utilized to impart softness to non-woven fabrics and improve skin compatibility.
  • the softness additive is chosen from Polyquaternium 37 with Propylene Glycol Dicaprylate and PPG- 1 Trideceth - 6; or Polyquaternium 37 with Dicaprylyl Carbonate and Lauryl Glucoside.
  • the softness additive has the formula MDaD' b M wherein M is (R 1 )(CH 3 ) 2 Si0 1/2 , D is (CH 3 ) 2 Si0 1/2 , D' is (CH 3 )Si0 1/2 (CH 2 CH 2 CH 2 0(R 2 )H), R 1 is CH 3 , or OH, OCH 3 , or OCH 2 CH 3 , or -CH 2 CH 2 CH 2 0(EO) n (PO) m -H and R 2 is (EO) n , (PO) n , [(EO/A) m (A) n H] x , [(A) 0 (EO) m (A) n H] x , or [(A) 0 (EO/A) m (A) n H] x, wherein EO is an ethylene oxide group and PO is a propylene oxide group.
  • a and b are each independently 0 to 100, or any value or range of values there between.
  • R 2 can be an EO and/or PO polymer or an EO/PO block/heteric copolymer.
  • [(EO/A) m (A) n H] x , x is typically 1 to 6, m is typically 0 to 110, and n is typically 0 to 110.
  • Relative to the formula [(A) 0 (EO) m (A) n H] x , x is typically 1 to 6, m is typically 0 to 110, n is typically 0 to 110, and o is typically 0 to 110.
  • x is typically 1 to 6
  • m is typically 0 to 110
  • n is typically 0 to 110
  • o is typically 0 to 110.
  • A is typically chosen from propylene oxide, butylene oxide, tetrahydrofuran, and combinations thereof.
  • suitable softness additives include polyether functional siloxanes, such as, Nuwet ® 237 and Nuwet ® 550, each of which are commercially available from Momentive.
  • the softness additive has the formula R-Si (OR')3 and is a silane that can be non-hydrolyzed, and/or partially hydrolyzed, and/or fully hydrolyzed; wherein R is -CH 2 CH 2 CH 2 0(EO) n (PO) m H and/or -CH 2 CH 2 CH 2 0(CF 2 ) n CF 3 , R' is H, or CH 3 , or CH 2 CH 3 , and m and n are as described above.
  • the softness additive has the formula MD a D' b D" c M wherein M is typically (R 1 )(CH )SiOi 2 , D is typically (CH ) 2 SiOi 2 , D' is typically (CH 3 )SiOi /2 (CH 2 CH 2 CH 2 0(R 2 )H), D" is typically (CH 3 )SiOi /2 (CH 2 CH 2 CH 2 NR 3 R 4 ), R 1 is typically OH, OCH 3 , or OCH 2 CH 3 , R 2 is typically (EO) n , (PO) n , [(EO/A) m (A) n H] x , [(A) o (EO) m (A) dislikeH] x , or [(A) 0 (EO/A) m (A) threadH] x , R 3 is typically H or an alkyl amine group having from 1 to 10 carbon atoms, R 4 is typically or an
  • R 2 can be an EO and/or PO polymer or an EO/PO block/heteric copolymer.
  • x is typically 1 to 6, m is typically 0 to 110, and n is typically 0 to 110.
  • x is typically 1 to 6
  • m is typically 0 to 110
  • n is typically 0 to 110
  • o is typically 0 to 110.
  • A is typically chosen from propylene oxide, butylene oxide, tetrahydrofuran, and combinations thereof.
  • suitable softness additives include alkylamine and Polyether functional siloxanes, such as, Magnasoft ® CJS, which is commercially available from Momentive. Softness can be qualitatively assessed via touch.
  • the additives may be antioxidants and/or light stabilizers.
  • the antioxidant may be or include a first and/or a second antioxidant.
  • the fiber may include any number of antioxidants.
  • the light stabilizer may be or include hindered amine light stabilizers (HALS).
  • HALS hindered amine light stabilizers
  • the first antioxidant may be present in the plurality of the fibers in an amount of from 0.001 to 1 part(s) by weight, of from 0.01 to 0.2 parts by weight, or of from 0.05 to 0.15 parts by weight, each based on 100 parts by weight of each of the plurality of fibers.
  • a non- limiting example of a suitable primary antioxidant is commercially available from BASF Corporation of Florham Park, NJ, under the trade name of Irganox ® , such as Irganox ® 3114 (AO) and Irganox ® B 1411 (AO).
  • Irganox ® such as Irganox ® 3114 (AO) and Irganox ® B 1411 (AO).
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges are hereby expressly contemplated.
  • the second antioxidant may be present in the plurality of fibers in an amount of from 0.001 to 1 part(s) by weight, of from 0.01 to 0.2 parts by weight, or of from 0.05 to 0.15 parts by weight, each based on 100 parts by weight of each of the plurality of fibers.
  • a non- limiting example of a suitable secondary antioxidant is commercially available from BASF Corporation of Florham Park, NJ, under the trade name of Irgafos ® , such as Irgafos ® 168 (AO).
  • Irgafos ® such as Irgafos ® 168 (AO).
  • all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges are hereby expressly contemplated.
  • the method includes the step of combining the polyolefin and the surface energy modifier to disperse the surface energy modifier throughout the matrix structure to form a mixture.
  • the surface energy modifier may be dispersed homogeneously or heterogeneously throughout the matrix structure.
  • the polyolefin and the surface energy modifier may be combined by any method known in the art and may be blended dry and then compounded by extrusion to form extrudates. These extrudates may then be extruded, spun, and then drawn to form the plurality of fibers.
  • the polyolefin and the surface energy modifier are combined to form a mixture prior to forming the plurality of fibers.
  • the mixture may be described as a masterbatch.
  • the polyolefin and the surface energy modifier may be combined by any method known in the art to form the mixture.
  • the polyolefin and the surface energy modifier may be combined in a mixing vessel and/or a blender, such as a Henschell blender or Mixaco mixer.
  • the method includes the step of forming the plurality of fibers and the non-woven fabric from the mixture (e.g. from the combination of the polyolefin and the surface energy modifier that is dispersed throughout the matrix structure).
  • the plurality of fibers may be formed by any method in the art.
  • the plurality of fibers may be extruded and/or spun, e.g. via wet spinning, dry spinning, melt spinning, extrusion spinning, direct spinning, gel spinning, and/or electro spinning.
  • the step of combining the polyolefin and the surface energy modifier includes extruding the polyolefin and the surface energy modifier through a first extruder at a temperature of from 185° C to 215° C to form at least one strand.
  • the step of extruding the polyolefin and the surface energy modifier to form at least one strand may alternatively be described as compounding.
  • the polyolefin and the surface energy modifier may be extruded by any extrusion process known in the art, such as direct extrusion, indirect extrusion and/or hydrostatic extrusion.
  • the first extruder may be any extruder known in the art to form the at least one strand.
  • the first extruder may be further defined as a single screw extruder, twin screw, or multiscrew extruder.
  • the first extruder is further defined as a single screw extruder.
  • the first extruder is further defined as a twin screw extruder.
  • the first extruder may be further defined as a (fully) intermeshing extruder.
  • the first extruder may be further defined as a co-rotating extruder.
  • the first extruder may have a length to diameter ratio (L/D) of from 35 to 1 to 45 to 1 , alternatively, 36 to 1 to 44 to 1 , 37 to 1 to 43 to 1, 38 to 1 to 42 to 1 , or 39 to 1 to 41 to 1.
  • the first extruder may include a screw rotating at a speed of 140 to 160 revolutions per minute (RPM), alternatively, 145 to 155 RPM, 146 to 154 RPM, 147 to 153 RPM, 148 to 152 RPM, 149 to 151 RPM.
  • the screw of the first extruder may be primarily conveying the mixture of the polyolefin and the surface energy modifier.
  • the first extruder may be a Leistritz 27 mm co-rotating twin screw extruder. In additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
  • the first extruder includes multiple heating zones, e.g. nine heating zones, with each heating zone at a temperature of from 185° C to 215° C.
  • the first extruder may operate at any temperature known in the art. More specifically, the polyolefin and the surface energy modifier may be extruded as a hot extrusion and/or a warm extrusion which may depend on the melt temperature of the polyolefin and the surface energy modifier. It is also to be appreciated that the first extruder may have any number of heating zones such as 1, 2, 3, 4, 5, 6, 7, 8, 10, 11 , 12, 13, 14, 15, etc. with each heating zone independently at a temperature of from 185° C to 215° C. In additional non- limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.
  • the step of combining the polyolefin and the surface energy modifier includes quenching the at least one strand with water and subsequently cutting the at least one strand quenched with water to form pellets.
  • the at least one strand may be quenched in a water bath, by spray quenching, and/or by water wall quenching.
  • the at least one strand is quenched by air quenching to form pellets.
  • Cutting the at least one strand quenched with water (or by air quenching) may be performed by any cutting method known in the art such as with a ConAir pelletizer.
  • the pellets may have any dimensions and/or size distribution known in the art. In various embodiments, the pellets have a diameter of from 1/16 to 1/4 inch and a length of from 1/16 to 1/4 inch.
  • the step of combining the polyolefin and the surface energy modifier includes extruding the pellets through a second extruder to form the plurality of fibers.
  • the second extruder may be any extruder known in the art to form the plurality of fibers.
  • the pellets may be extruded by extrusion spinning.
  • the plurality of fibers may be cut such that each of the plurality of fibers has a length of 1/4 to 3 inches. However, it is to be appreciated that the plurality of fibers may be cut to a length of any size known in the art.
  • the non-woven fabric may be manufactured by binding the plurality of fibers together in the form of a sheet or web.
  • the plurality of fibers may be bound together mechanically (e.g. by interlocking with serrated needles such that inter-fiber friction results in a stronger fabric), with an adhesive, or thermally (e.g. by applying binder (in the form of powder, paste, or polymer melt) and melting the binder onto the web by increasing temperature).
  • the non-woven fabric is further defined as a staple non-woven fabric.
  • the staple non-woven fabric may, for example, be constructed using a number of steps.
  • the plurality of fibers is spun, cut to length, and put into bales.
  • the plurality of fibers may then be blended, opened in a one or multistep process, dispersed (e.g. using a conveyor) and spread in a uniform or non-uniform web by a wetlaid, airlaid, or carding/crosslapping process.
  • Wetlaid processes typically utilize 1/4 to 3 ⁇ 4 inch long fibers, but are not limited in this manner.
  • Airlaid processing typically utilizes 0.5 to 4.0 inch long fibers.
  • Carding operations typically utilize 1.5 inch long fibers.
  • Staple non- woven fabrics are typically bonded either thermally or by using resin. Bonding can be throughout the web by resin saturation or overall thermal bonding or in a distinct pattern via resin printing or thermal spot bonding.
  • melt blown non-woven fabrics may be produced by extruding melted fibers through a spinneret or die with 1162 to 2222 holes per 0.5 meter to form the plurality of fibers which are stretched and cooled by passing hot air over the plurality of fibers as they fall from the die.
  • the resultant web may be collected into rolls and subsequently converted to finished products.
  • melt blown fibers may be added to spun bond fibers to form spun-melt or spun-melt-spun webs.
  • the non-woven fabric is further described as a spunlaid non-woven fabric.
  • Spunlaid non-woven fabrics can be formed using a continuous process.
  • the plurality of fibers may be spun and dispersed into a web using deflectors or with air streams.
  • the non-woven fabric may be described as a wet laid mat, e.g. wherein the plurality of fibers has a denier of 1.0 to 30.
  • the non-woven fabric typically includes the plurality of fibers bonded to each other.
  • one or more of the plurality of fibers may be bonded via thermal bonding, e.g. using a heat sealer, an oven, or via calendaring using heated rollers.
  • one or more of the plurality of fibers may be bonded via hydro-entanglement, e.g. by mechanical intertwining the one or more fibers using water jets.
  • one or more of the plurality of fibers may be bonded using ultrasonic pattern bonding, needlepunching/needlefelting (i.e., mechanical intertwining of one or more fibers by needles), or via chemical bonding.
  • the chemical bonding may be further described as a wetlaid process and may include use of binders to chemically bond one or more fibers together.
  • one or more of the plurality of fibers may be bonded using meltblowing techniques, e.g. bonding fibers as air attenuated fibers intertangle with themselves during simultaneous fiber and web formation.
  • a series of mixtures of the polyolefin and the surface energy modifier are formed. More specifically, the surface energy modifier is compounded into a polypropylene resin to disperse the surface energy modifier in the matrix structure of the polypropylene in a masterbatch. Subsequently, samples of non-woven fabrics (i.e., a plurality of fibers) are formed using the masterbatch and evaluated to determine a variety of physical properties.
  • Hydrophilization of polypropylene is accomplished by blending and compounding a polypropylene resin with a surface energy modifier chosen from alcohol alkoxylates, alcohol block alkoxylates, and polyoxyalkylene block polymers in varying amounts. More specifically, the blending and compounding are accomplished using the conditions and surface energy modifiers described below.
  • Hydrophobization of polypropylene is accomplished by compounding a polypropylene resin with a surface energy modifier chosen from copolymers of maleic acid and acrylic acid and anionically modified copolymers of polycarboxylate and polyethylene. More specifically, the blending and compounding are accomplished using the conditions and surface energy modifiers described below.
  • Polypropylene and a surface energy modifier are combined to form mixtures in a Henschell or Mixaco mixer. More specifically, the polypropylene is in solid form as a powder or pellet and formed from a 500 melt flow index polypropylene homopolymer. The mixture is blended thoroughly into masterbatch such that the surfactant and the additives are uniformly dispersed with the polypropylene. The mixture is compounded in a Leistritz 27 mm co- rotating twin screw extruder (first extruder) to form at least one strand.
  • the first extruder is a co-rotating and fully intermeshing extruder. The screw of the first extruder is primarily conveying and rotating at a speed of 150 RPM.
  • the first extruder has a L/D of 40 to 1.
  • the first extruder is equipped with a K-tron screw type feeder. The first extruder has nine heating zones with each zone having a temperature profile as shown below.
  • the mixture is heated in Zone #2 and Zone #4 and the die is heated in Zone #9.
  • the at least one strand is quenched in a water bath, and subsequently cut with a ConAir pelletizer to form pellets such that the masterbatch pellets have a diameter of approximately 1/8 inch and a length of approximately 1/8 inch.
  • the masterbatch pellets are extruded in a second extruder to form the plurality of fibers (i.e., the non-woven fabric).
  • the masterbatch is subsequently diluted with 35 melt flow index polypropylene homopolymer to the desired surface modifier concentration.
  • Control/comparative examples of polypropylene are also formed.
  • the polypropylene is subjected to the same conditions described above except that no surface energy modifier whatsoever is utilized.
  • These pluralities of fibers are molded into plaques using the same conditions as described above. The plaques are evaluated to determine water contact angle. Samples of non- woven fabrics (i.e., a plurality of fibers) are utilized to determine other physical properties such as hydrophilicity/hydrophobicity and strike through times.
  • LAC x 100
  • m k is the mass, in grams, of the dry test pile
  • m n is the mass, in grams, of the test piece and absorbed liquid at the end of the pile The average liquid capacity of the five pieces is then calculated.
  • Example 1 includes 4 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 45 gsm and a linear mass density of 2 denier.
  • Example 2 includes 5 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol, sheath only in a sheath/core fiber configuration as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 45 gsm and a linear mass density of 2 denier.
  • the sheath/core is a bicomponent fiber where two different polymers are extruded from the same spinneret hole and both polymers contained within the same filament.
  • the sheath is the surface energy modifier and it surrounds the core while the core is polypropylene homopolymer.
  • Example 3 includes 4 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol, sheath only in a sheath/core fiber configuration as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 45 gsm and a linear mass density of 2 denier.
  • Example 4 includes 3 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 45 gsm and a linear mass density of 2 denier.
  • Example 5 includes 3 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 45 gsm and a linear mass density of 2 denier.
  • Example 6 includes 2 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 45 gsm and a linear mass density of 2 denier.
  • Example 7 includes 1 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 45 gsm and a linear mass density of 2 denier.
  • Comparative Example 1 does not include any surface modifier.
  • the plurality of spunbound fibers has a basis weight of 45 gsm and a linear mass density of 2 denier.
  • Additional pluralities of fibers are also formed as described above. These pluralities of fibers are evaluated using ED ANA 150.5 - 02 to determine Strike- Through Time with 0.9% Sodium Chloride solution. The results are set forth in Table 2 below and graphically represented in Figure 2. Each example is evaluated three times and the values below are reported as an average thereof.
  • Example 8 includes 5 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol on sheath using sheath/core fiber configuration (as described above) as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Example 9 includes 4 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol on sheath using sheath/core fiber configuration as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Example 10 includes 4 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Example 11 includes 3 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Example 12 includes 4 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol and 2 wt. % polyamide PA 6 with bulk density of 640 - 740 kg/m 3 as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Example 13 includes 2 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol and 2 wt. % polyamide PA 6 with bulk density of 640 - 740 kg/m 3 as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Example 14 includes 2 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Example 15 includes 1 wt. % of EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol as a surface modifier and a balance of polypropylene, as described above.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Comparative Example 2 does not include any surface modifier.
  • the plurality of spunbound fibers has a basis weight of 16 gsm and a linear mass density of 2 denier.
  • Additional molded plaques are also formed as described above. These molded plaques are evaluated using ASTM D7490-13 to determine Water Contact Angle. The results are set forth in Figures 3A and 3B. Each example is evaluated 1 time.
  • Example 16 includes 1 wt % EO/PO block copolymer having a weight average molecular weight of 12,600 g/mol (Surface Modifier 1) with the balance being stabilizers and polypropylene homopolymer
  • Example 17 includes 1 wt % EO/PO block copolymer having a weight average molecular weight of 7,700 g/mol (Surface Modifier 2) with the balance being stabilizers and polypropylene homopolymer.
  • Example 18 includes 1 wt % Polyethylene wax based on ethylene copolymer with comonomer content of 25-29% having a weight average molecular weight of 90,000 g/mol (Surface Modifier 3) with the balance being stabilizers and polypropylene homopolymer.
  • Example 19 includes 1 wt % of a polycarboxylate homopolymer of polyvinylpyrrolidone having a weight average molecular weight of 48,000 to 60,000 g/mol (Surface Modifier 4) with the balance being stabilizers and polypropylene homopolymer.
  • Example 20 includes 1 wt% of a sodium salt of copolymer of maleic and acrylic acid having a weight average molecular weight of from 60,000 and 70,000 g/mol (Surface Modifier 5) with the balance being stabilizers and polypropylene homopolymer.
  • the surface energy modifiers can give hydrophilic properties targeted to specific applications, such as, cleaning wipes, filters, adult incontinence, feminine napkins, and diapers to allow fast strike through time as in diaper applications or increase absorption as in cleaning wipes or medical garments.
  • hydrophobic properties can be provided.
  • Blending and compounding of polyolefins with the surface energy modifiers, followed by co- spinning into a plurality of fibers and formation into non-woven fabric is economical, durable and permanent.
  • the instant method is effective in improving the hydrophilicity or hydrophobicity of the non-woven fabric and allows for customization of other properties, such as antibacterial and antifungal control.
  • the instant method provides permanent and sustainable hydrophilicity and hydrophobicity properties to the non-woven fabrics.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne un procédé permettant d'influencer l'énergie de surface d'une étoffe non-tissée qui comprend une pluralité de fibres. Le procédé comprend les étapes consistant à fournir une polyoléfine qui comprend une structure de matrice et à fournir un modificateur d'énergie de surface. Le modificateur d'énergie de surface est choisi parmi les alcoxylates d'alcool, les alcoxylates séquencés d'alcool, les polymères séquencés de polyoxyalkylène, les copolymères d'acide maléique et d'acide acrylique, les copolymères de polycarboxylate et de polyéthylène, les copolymères de cire de polyéthylène, et les combinaisons de ces éléments. Le procédé comprend également l'étape consistant à combiner la polyoléfine et le modificateur d'énergie de surface pour disperser le modificateur d'énergie de surface dans l'ensemble de la structure de matrice afin de former un mélange. Le procédé comprend ensuite l'étape de formation de la pluralité de fibres et du tissu non-tissé à partir du mélange.
PCT/US2015/021798 2014-03-21 2015-03-20 Procédé permettant d'influencer l'énergie de surface d'une étoffe non tissée Ceased WO2015143352A1 (fr)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017117198A1 (fr) * 2015-12-30 2017-07-06 Maxterial, Inc. Revêtements et surfaces revêtues présentant des caractéristiques et éléments de surface sélectionnés
US12163208B2 (en) 2021-06-18 2024-12-10 Maxterial, Inc. Hydraulic devices including coated surfaces
US12173166B2 (en) 2017-09-28 2024-12-24 Maxterial, Inc. Articles including surface coatings and methods to produce them

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5033172A (en) * 1989-06-01 1991-07-23 Hercules Incorporated Rewettable polyolefin fiber and corresponding nonwovens
WO1995010648A1 (fr) * 1993-10-13 1995-04-20 Kimberly-Clark Corporation Tissu non tisse ayant une aptitude au mouillage durable
WO1997044508A1 (fr) * 1996-05-21 1997-11-27 Minnesota Mining And Manufacturing Company Melanges de tensioactifs fluorochimiques et hydrocarbures utilises en qualite d'additifs hydrophiles dans des polymeres thermoplastiques
US6146757A (en) * 1998-06-29 2000-11-14 Techmer Pm Wettable polymer fibers, compositions for preparaing same and articles made therefrom
WO2007137609A1 (fr) * 2006-05-25 2007-12-06 Tesalca-99, S.A. Tissu non tissé multicouche asymétrique
US20090203276A1 (en) * 2008-02-13 2009-08-13 Goulston Technologies, Inc. Polymer additive for providing an alcohol repellency for polypropylene nonwoven medical barrier fabrics
EP2319970A1 (fr) * 2008-08-25 2011-05-11 Mitsui Chemicals, Inc. Fibre, tissu non tissé et leur utilisation

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5033172A (en) * 1989-06-01 1991-07-23 Hercules Incorporated Rewettable polyolefin fiber and corresponding nonwovens
WO1995010648A1 (fr) * 1993-10-13 1995-04-20 Kimberly-Clark Corporation Tissu non tisse ayant une aptitude au mouillage durable
WO1997044508A1 (fr) * 1996-05-21 1997-11-27 Minnesota Mining And Manufacturing Company Melanges de tensioactifs fluorochimiques et hydrocarbures utilises en qualite d'additifs hydrophiles dans des polymeres thermoplastiques
US6146757A (en) * 1998-06-29 2000-11-14 Techmer Pm Wettable polymer fibers, compositions for preparaing same and articles made therefrom
WO2007137609A1 (fr) * 2006-05-25 2007-12-06 Tesalca-99, S.A. Tissu non tissé multicouche asymétrique
US20090203276A1 (en) * 2008-02-13 2009-08-13 Goulston Technologies, Inc. Polymer additive for providing an alcohol repellency for polypropylene nonwoven medical barrier fabrics
EP2319970A1 (fr) * 2008-08-25 2011-05-11 Mitsui Chemicals, Inc. Fibre, tissu non tissé et leur utilisation

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017117198A1 (fr) * 2015-12-30 2017-07-06 Maxterial, Inc. Revêtements et surfaces revêtues présentant des caractéristiques et éléments de surface sélectionnés
US12173166B2 (en) 2017-09-28 2024-12-24 Maxterial, Inc. Articles including surface coatings and methods to produce them
US12163208B2 (en) 2021-06-18 2024-12-10 Maxterial, Inc. Hydraulic devices including coated surfaces

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