WO2024254048A1 - Bandes non tissées fabriquées à partir de filaments multicomposants ayant des caractéristiques de gonflant et de douceur élevées - Google Patents

Bandes non tissées fabriquées à partir de filaments multicomposants ayant des caractéristiques de gonflant et de douceur élevées Download PDF

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Publication number
WO2024254048A1
WO2024254048A1 PCT/US2024/032373 US2024032373W WO2024254048A1 WO 2024254048 A1 WO2024254048 A1 WO 2024254048A1 US 2024032373 W US2024032373 W US 2024032373W WO 2024254048 A1 WO2024254048 A1 WO 2024254048A1
Authority
WO
WIPO (PCT)
Prior art keywords
nonwoven web
less
filaments
component
gsm
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/US2024/032373
Other languages
English (en)
Inventor
Timothy D. Ferguson
Sara Honarbakhsh
Esfandiar KHATIBLOU
Jeffrey Krueger
Eric E. Lennon
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Original Assignee
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Worldwide Inc, Kimberly Clark Corp filed Critical Kimberly Clark Worldwide Inc
Priority to AU2024284006A priority Critical patent/AU2024284006A1/en
Priority to CN202480033400.4A priority patent/CN121152907A/zh
Priority to KR1020267000229A priority patent/KR20260023007A/ko
Publication of WO2024254048A1 publication Critical patent/WO2024254048A1/fr
Priority to MX2025014005A priority patent/MX2025014005A/es
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • 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
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • 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
    • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
    • D04H1/06—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres by treatment to produce shrinking, swelling, crimping or curling of 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
    • D04H13/00—Other non-woven fabrics
    • 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
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • 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
    • D04H3/147—Composite yarns or filaments
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene

Definitions

  • the present disclosure is generally directed to multicomponent filaments, nonwoven webs made from the multicomponent filaments, and processes for forming the nonwoven webs.
  • the multicomponent filaments contain a crimp enhancement additive. More particularly, the present disclosure is directed to incorporating an additive into one of the polymers used to make multicomponent filaments in combination with a thermal bonding pattern that produces nonwoven webs with unexpectedly better bulk and/or softness properties.
  • Nonwoven fabrics are used to make a variety of products which desirably have particular levels of softness, strength, uniformity, liquid handling properties such as absorbency, and other physical properties.
  • Such products include towels, industrial wipers, incontinence products, filter products, infant care products such as baby diapers, absorbent feminine care products, and garments such as safety and other protective apparel.
  • These products are often made with multiple layers of nonwoven fabrics to obtain the desired combination of properties.
  • disposable baby diapers made from polymeric nonwoven fabrics may include a soft and porous liner layer which fits next to the baby’s skin, an impervious outer cover layer which is strong and soft, and one or more interior liquid handling layers which are soft, bulky and absorbent.
  • Nonwoven fabrics such as the foregoing are commonly made by melt spinning thermoplastic materials, including through spunbond processes. Such fabrics made through a spunbond process are sometimes referred to as spunbond materials or spunbond nonwoven polymeric webs.
  • Spunbond nonwoven polymeric webs are typically made from thermoplastic materials by extruding the thermoplastic material through a spinneret and drawing the extruded material into filaments with a stream of high velocity air to form a random web on a collecting surface.
  • Spunbond materials with desirable combinations of physical properties, especially combinations of softness, strength, and absorbency, have been produced, but limitations have been encountered.
  • polymeric materials such as polypropylene may have a desirable level of strength but not a desirable level of softness.
  • materials such as polyethylene may, in some cases, have a desirable level of softness but not a desirable level of strength.
  • Multicomponent polymeric fibers or filaments include two or more polymeric components which remain distinct, and bicomponent polymeric fibers or filaments include two polymeric components which remain distinct.
  • the terms “filaments” and “fibers” mean strands of material and may be used interchangeably.
  • the filaments of the present disclosure may be continuous or the filaments of the present disclosure may be discontinuous and thus have a definite length.
  • the first and subsequent components of multicomponent filaments are arranged in substantially distinct zones across the cross-section of the filaments and extend continuously along the length of the filaments.
  • one component exhibits different properties than the other so that the filaments exhibit properties of the two components.
  • one component may be polypropylene which is relatively strong and the other component may be polyethylene which is relatively soft. The end result is a strong yet soft nonwoven fabric.
  • use of different polymers in the multicomponent filaments can make recycling the multicomponent filaments and webs made therefrom impractical or impossible if one of the polymers is not recyclable, as it would be difficult to separate the polymers to extract the recyclable one.
  • the bicomponent filaments or fibers are often crimped.
  • Multicomponent filaments may be either mechanically crimped or, if the appropriate polymers are used, naturally crimped.
  • a naturally crimped filament is a filament that is crimped by activating a latent crimp contained in the filaments.
  • filaments can be naturally crimped by subjecting the filaments to a gas, such as a heated gas, after being drawn.
  • filaments that can be naturally crimped in general, it is far more preferable to construct filaments that can be naturally crimped as opposed to having to crimp the filaments in a separate mechanical process. Difficulties have been experienced in the past, however, in producing filaments that will crimp naturally to the extent required for the particular application. Also, it has been found to be very difficult to produce naturally crimped fine filaments, such as filaments having a linear density of less than two denier. Specifically, the draw force used to produce fine filaments usually prevents or removes any meaningful latent crimp attributes that may be contained in the filaments.
  • Another problem experienced in the past is being able to produce a consolidated nonwoven web from the crimped filaments that has sufficient strength while remaining soft. Consequently, a need currently exists for a nonwoven web made from crimped filaments that has high softness characteristics. A need also exists for a nonwoven web made from crimped filaments that has high specific volume characteristics even after being consolidated through a bonding process.
  • the present disclosure is directed to nonwoven webs having excellent softness characteristics and/or high specific volume characteristics.
  • the nonwoven webs contain crimped multicomponent filaments.
  • a crimping enhancement additive is incorporated into the filaments that causes the filaments to inherently crimp.
  • the crimped multicomponent filaments contained within the nonwoven web are combined with a particular thermal bonding pattern that has been found to dramatically and unexpectedly increase specific volume and/or softness.
  • the present disclosure is directed to a nonwoven web comprising crimped multicomponent filaments.
  • the multicomponent filaments include a first component comprising a polyolefin and a second component comprising a polyolefin blended with a crimp enhancement additive.
  • the nonwoven web has been thermally bonded according to a bonding pattern that covers less than 16% of the surface area of a surface of the nonwoven web.
  • the bonding pattern can cover less than about 15% of the surface area, such as less than about 14% of the surface area, such as less than about 13% of the surface area, such as less than about 12% of the surface area, such as less than about 11 % of the surface area, and generally greater than about 5% of the surface area, such as greater than about 8% of the surface area, such as greater than about 9% of the surface area.
  • the bonding pattern can vary depending upon the particular application.
  • the bonding pattern is comprised of point bonds.
  • the point bonds can form discrete shapes, such as wave-like shapes, or can comprise a grid pattern.
  • the nonwoven web displays excellent specific volume characteristics.
  • the specific volume of the web can be greater than 19.3 cm 3 /g, such as greater than about 20 cm 3 /g, such as greater than about 21 cm 3 /g, such as greater than about 22 cm 3 /g, such as greater than about 23 cm 3 /g, such as greater than about 24 cm 3 /g, such as greater than about 25 cm 3 /g, such as greater than about 26 cm 3 /g, such as greater than about 27 cm 3 /g, and generally less than about 40 cm 3 /g.
  • the nonwoven web can also display excellent softness characteristics.
  • the nonwoven web can display a TS7 softness of less than about 3.8, such as less than about 3.7, such as less than about 3.5, such as less than about 3.3, such as less than about 3.1 , such as less than about 2.9, such as less than about 2.7, such as less than about 2.5, and generally greater than 1 .
  • the nonwoven web can also display a TS750 softness of less than about 3.5, such as less than about 3.3, such as less than about 3.1 , such as less than about 2.9, such as less than about 2.7, such as less than about 2.5, such as less than about 2.3, and generally greater than about 1 .
  • the TS7 softness and the TS750 softness can be determined using a TSA analyzer.
  • Nonwoven webs made according to the present disclosure can generally have a basis weight of from about 10 gsm to about 60 gsm, such as from about 13 gsm to about 45 gsm, such as from about 15 gsm to about 40 gsm, such as from about 15 gsm to about 30 gsm.
  • the crimped multicomponent filaments can generally have greater than about 5 crimps per inch, such as at least about 10 crimps per inch, such as at least about 15 crimps per inch, such as at least about 20 crimps per inch, and generally less than about 50 crimps per inch.
  • the filaments can be continuous filaments or discontinuous filaments.
  • the crimp enhancement additive used in accordance with the present disclosure can comprise a polyolefin homopolymer, such as a polypropylene homopolymer.
  • the crimp enhancement additive can have a melt flow rate of less than about 20 g/10 min, such as from about 8 g/10 min to about 16 g/10 min.
  • the second component of the crimped multicomponent filaments can comprise the crimp enhancement additive as described above combined with a polypropylene polymer.
  • the second component can optionally contain a white pigment and/or a secondary fatty acid amide.
  • the first component contained within the multicomponent filaments can contain a polypropylene polymer blended with a polypropylene copolymer.
  • the polypropylene copolymer can be a random copolymer of propylene and ethylene.
  • the second component can also contain a white pigment and a secondary fatty acid amide.
  • the weight ratio between the first component and the second component can be from about 50:50 to about 90:10, such as from about 50:50 to about 65:35.
  • the crimped multicomponent filaments can have a denier of from about 0.5 to about 3, such as from about 1 to about 2.5.
  • the nonwoven web comprises a spunbond web
  • the multicomponent filaments comprise greater than about 90% polypropylene by weight. Preferably, the multicomponent filaments comprise greater than about 95% polypropylene by weight. Preferably, the multicomponent filaments comprise greater than about 97% polypropylene by weight.
  • FIG. 1 is a schematic drawing of a process line for making an embodiment of the present invention
  • FIG. 2A is a schematic drawing illustrating the cross section of a filament made according to an embodiment of the present disclosure with the polymer components A and B in a side-by-side arrangement;
  • FIG. 2B is a schematic drawing illustrating the cross section of a filament made according to an embodiment of the present disclosure with the polymer components A and B in an eccentric sheath/core arrangement;
  • FIG. 3 is a plan view of one embodiment of a nonwoven web made in accordance with the present disclosure illustrating a bonding pattern
  • FIG. 4 is a plan view of another embodiment of a nonwoven web made in accordance with the present disclosure illustrating a bonding pattern.
  • the present disclosure is generally directed to multicomponent filaments, to nonwoven webs, including spunbond webs, produced from the filaments, and to a process for forming nowoven webs from the filaments.
  • the filaments are inherently crimped into, for instance, a helical arrangement.
  • the nonwoven web containing the crimped filaments is subjected to a thermal bonding pattern that consolidates the web while unexpectedly producing a final product with enhanced softness and/or increased specific volume.
  • the nonwoven webs also have improved fluid management properties and have an enhanced cloth-like appearance and/or feel.
  • Multicomponent filaments for use in the present disclosure contain at least two polymeric components.
  • the polymeric components can be, for instance, in a side-by-side configuration or in an eccentric sheath-core configuration.
  • the polymeric components are selected from semi-crystalline and crystalline thermoplastic polymers which have different crystallization and/or solidification rates with respect to each other in order for the filaments to undergo inherent crimping. More particularly, one of the polymeric components has a faster solidifying and/or crystallizing rate than the other polymeric component.
  • the solidification and/or crystallization rate of a polymer refers to the rate at which a softened or melted polymer hardens and forms a fixed structure. It is believed that the solidification and/or crystallization rate of a polymer is influenced by different parameters including the melting temperature and the rate of crystallization of the polymer. For instance, a fast solidifying and/or crystallizing polymer typically has a melting point that is about 10°F or higher, more desirably about 20°F or higher, and most desirably about 30°F or higher than a polymer that has a slower solidifying and/or crystallizing rate. It should be understood, however, that both polymeric components may have similar melting points if their crystallization rates are measurably different.
  • the present disclosure is directed to adding a crimp enhancement additive to one of the polymeric components to produce a faster solidification and/or crystallization rate in that component.
  • the differences between the solidification and/or crystallization rates of the two (or more) polymeric components creates multicomponent filaments exhibiting an inherent crimping.
  • the crimp enhancement additive of the present disclosure is a polyolefin homopolymer, preferably a polypropylene homopolymer.
  • inherent crimping means that the multicomponent filaments crimp upon solidifying and/or crystallizing without the use of any further crimping treatments, i.e., treatments to produce or activate crimp.
  • Prior methods of producing crimp in multicomponent filaments have required that the filaments be subjected to additional steps to produce, enhance, or activate crimping in the filaments. Such steps include using heat to activate crimping during the drawing of the filaments or through air drying or the use of an air knife.
  • the multicomponent filaments of the present disclosure exhibit a high degree of crimp without the use of any of these additional or subsequent crimping treatments. Accordingly, the present disclosure allows for simplified and less energy intensive processes for the production of highly crimped multicomponent filaments and nonwoven webs formed therefrom.
  • the multicomponent filaments have an average of at least about five crimps per inch.
  • the multicomponent filaments have an average of at least about 10 crimps per inch or at least about twenty crimps per inch or at least about 30 crimps per inch or at least about 40 crimps per inch or at least about 50 crimps per inch.
  • the present disclosure is also directed to applying a particular bond pattern to nonwoven webs containing the crimped multicomponent filaments. It was discovered that the combination of the crimped filaments with a thermal bond pattern can produce webs having unexpectedly better softness properties and/or increased specific volume.
  • the bond pattern for instance, can be applied to a surface of the nonwoven web in a manner that occupies a relatively low surface area of the web while providing consolidation of the web.
  • the bond pattern can be comprised of point bonds that are applied to a surface of the nonwoven web in a pattern.
  • the overall pattern may comprise a plurality of discrete shapes or can comprise a grid-like pattern. For instance, fabrics and webs made from the filaments have a higher specific volume and a lower density.
  • the webs and fabrics of the present disclosure are particularly useful for making various products including liquid and gas filters, personal care articles and garment materials.
  • Personal care articles include infant care products such as disposable baby diapers, child care products such as training pants, and adult care products such as incontinence products and feminine care products.
  • Suitable garments include safety apparel, work wear, and the like.
  • the fabric of the present disclosure can be made from continuous or discontinuous multicomponent polymeric filaments comprising at least first and second polymeric components.
  • One embodiment of the present disclosure is a polymeric fabric including continuous bicomponent filaments comprising a first polymeric component A and a second polymeric component B.
  • the bicomponent filaments have a cross-section, a length, and a peripheral surface.
  • the first and second components A and B are arranged in substantially distinct zones across the cross-section of the bicomponent filaments and extend continuously along the length of the bicomponent filaments.
  • the second component B in some embodiments, constitutes at least a portion of the peripheral surface of the bicomponent filaments continuously along the length of the bicomponent filaments.
  • the first and second components A and B are arranged in either a side-by-side arrangement as shown in FIG. 2A or an eccentric sheath/core arrangement as shown in FIG. 2B so that the resulting filaments exhibit an inherent helical crimp
  • Polymer component A is the core of the filament and polymer component B is the sheath in the sheath/core arrangement.
  • Methods for extruding multicomponent polymeric filaments into such arrangements are well-known to those of ordinary skill in the art.
  • Polymer component A and polymer component B must be selected so that the resulting bicomponent filament is capable of developing an inherent crimp.
  • polymer component B has a faster solidification rate than polymer component A.
  • polymer component B can have a higher melting temperature than polymer component A.
  • the rate of solidification and/or crystallization of the second component is at least about 5% faster than the rate of solidification and/or crystallization of the first component.
  • polymer component A comprises polypropylene and component B also comprises polypropylene.
  • component A polypropylene and component B is also polypropylene
  • the bicomponent filaments may comprise greater than about 90% by weight polypropylene. More preferably, the bicomponent filaments may comprise greater than about 95% by weight polypropylene and greater than about 97% by weight polypropylene. Constructing the nonwoven web almost exclusively from polypropylene polymers, for instance, can increase the ability of the material to be recycled.
  • the ratio of the first polymeric component (component A) to the second polymeric component (component B) is from about 50:50 to about 90:10 by weight.
  • the ratio of the first polymeric component (component A) to the second polymeric component (component B) is from about 50:50 to about 65:35 or from about 50:50 to about 75:25 by weight.
  • Suitable materials for preparing the multicomponent filaments of the present disclosure include fiber grade polypropylene with a melt flow rate of greater than about 20 g/10 min, such as greater than about 25 g/10 min, such as greater than about 30 g/10 min, such as greater than about 35 g/10 min, and less than about 70 g/10 min, such as between about 20 g/10 min and about 55 g/10 min at 230°C and a load of 2.16 kg as determined in accordance with ASTM D1238, such as PP3155E5, a polypropylene homopolymer, available from ExxonMobil of Houston, Tex.
  • the crimp enhancement additive of the present disclosure is a polyolefin homopolymer. More preferably, the crimp enhancement additive is a polypropylene homopolymer. Preferably, the crimp enhancement additive is free of phthalates.
  • the crimp enhancement additive can be a polypropylene homopolymer having an MFR (melt flow rate) of 14 g/10 min at 230°C and a load of 2.16 kg as determined in accordance with ASTM D1238 and a density of 0.9 g/cm 3 .
  • the crimp enhancement additive is present in the second component (component B) in an amount between about 5% and 50% by weight based on the weight of the second component.
  • the crimp enhancement additive is present in the second component (component B) in an amount between about 10% and 40% by weight based on the weight of the second component or between about 20% and 30% by weight based on the weight of the second component.
  • the crimp enhancement additive has a melt flow rate (MFR) of less than about 20 g/10 min as measured at a temperature of 230°C and a load of 2.16 kg as determined in accordance with ASTM D1238.
  • MFR melt flow rate
  • the crimp enhancement additive has a melt flow rate (MFR) between about 5 g/10 min and about 20 g/10 min or about 8 g/10 min to about 16 g/10 min or about 10 g/10 min to about 15 g/10 min as measured at a temperature of 230°C and a load of 2.16 kg as determined in accordance with ASTM D1238.
  • the multicomponent filaments include two polymeric components A and B.
  • components A and B may also include additional ingredients in minor amounts.
  • the term “minor amount” means less than about 25% by weight of the component to which the ingredient is added.
  • Suitable additional ingredients for use in the multicomponent filaments of the present disclosure include softness/loft enhancers, pigments, and slip aids.
  • Suitable pigments include white pigments such as titanium dioxide zinc dioxide.
  • the pigment is a white pigment such as SCC-4837, titanium dioxide, available from the Standridge Color Corporation, Social Circle, Ga.
  • the white pigment is present in the first component in an amount of about 1% by weight based on the weight of the first component.
  • the white pigment is present in the first component in an amount between about 0.5% and about 3% by weight or between about 1 .0% and about 1 .5% based on the weight of the first component.
  • the white pigment is present in the second component in an amount of about 1% by weight based on the weight of the second component.
  • the white pigment is present in the second component in an amount between about 0.5% and about 3% by weight or between about 1 .0% and about 1 .5% based on the weight of the second component.
  • the white pigment is present in both components in the amounts discussed above.
  • Suitable softness/loft enhancers include polypropy lene/polyethylene copolymers, such as Vistamaxx 7050, a polypropylene/polyethylene copolymer containing 13% by weight of ethylene and having a mass flow rate of 45 g/10 min at 230°C and a load of 2.16 kg as determined in accordance with ASTM D1238, available from ExxonMobil and Americhem 48137, a secondary fatty acid amide, available from Americhem of Cuyahoga Falls, OH.
  • the softness/loft enhancers are present in the first component in an amount between about 10% and about 20% by weight based on the weight of the first component.
  • the softness/loft enhancers are present in the first component in an amount between about 5% and about 25% by weight based on the weight of the first component.
  • softness/loft enhancers are present in the second component in an amount of about 1 .5% by weight based on the weight of the second component.
  • the softness/loft enhancers are present in the second component in an amount between about 0.5% and about 3% by weight based on the weight of the second component.
  • the softness/loft enhancers are present in both components in the amounts discussed above.
  • Suitable slip aids include primary and secondary amides.
  • Primary amide slip aids include erucamide, available from the Sigma Aldrich, St. Louis, MO.
  • the slip aid is present in the first component in an amount of about 0.3% by weight based on the weight of the first component.
  • the slip aid is present in the first component in an amount between about 0.1 % and about 1% by weight or between about 0.2% and about 0.5% based on the weight of the first component.
  • the slip aid is present in the second component in an amount of about 0.3% by weight based on the weight of the second component.
  • the slip aid is present in the second component in an amount between about 0.1% and about 1% by weight or between about 0.2% and about 0.5% based on the weight of the second component.
  • the slip aid is present in both components in the amounts discussed above.
  • component A can include polypropylene, a propylene/ethylene copolymer, a secondary fatty acid amide, and a white pigment.
  • Component B can include polypropylene, the crimp additive, a secondary fatty acid amide, and a white pigment.
  • component A includes polypropylene, a propylene/ethylene copolymer, a secondary fatty acid amide, and a white pigment and component B includes polypropylene, the crimp additive, a secondary fatty acid amide, and a white pigment.
  • the polymers can be dry blended and extruded together during formation of the multicomponent filaments.
  • the crimp enhancement additive and polymer component B can be melt blended prior to being formed into the filaments of the present disclosure.
  • a process line 10 for preparing a preferred embodiment of the present disclosure is disclosed.
  • the filaments described herein can be made through either a “closed” or “open” spunbond system, as described below.
  • the process line 10 is arranged to produce bicomponent continuous filaments, but it should be understood that the present disclosure comprehends nonwoven fabrics made with multicomponent filaments having more than two components.
  • the fabric of the present disclosure can be made with filaments having three or four or more components.
  • the process line 10 includes a pair of extruders 12a and 12b for separately extruding a polymer component A and a polymer component B.
  • Polymer component A is fed into the respective extruder 12a from a first hopper 14a and polymer component B is fed into the respective extruder 12b from a second hopper 14b.
  • Polymer components A and 3 are fed from the extruders 12a and 12b through respective polymer conduits 16a and 16b to a spinneret 18.
  • the spinneret 18 includes a housing containing a spin pack which includes a plurality of plates stacked one on top of the other with a pattern of openings arranged to create flow paths for directing polymer components A and B separately through the spinneret.
  • the spinneret 18 has openings arranged in one or more rows. The spinneret openings form a downwardly extending curtain of filaments when the polymers are extruded through the spinneret.
  • spinneret 18 may be arranged to form side-by-side or eccentric sheath/core bicomponent filaments illustrated in FIGS. 2A and 2B.
  • the process line 10 also includes a quench blower 20 positioned adjacent the curtain of filaments extending from the spinneret 18. Air from the quench air blower 20 quenches the filaments extending from the spinneret 18. The quench air can be directed from one side of the filament curtain as shown FIG. 1 , or both sides of the filament curtain.
  • a fiber draw unit or aspirator 22 is positioned below the spinneret 18 and receives the quenched filaments.
  • Fiber draw units or aspirators for use in melt spinning polymers are well-known as discussed above.
  • Suitable fiber draw units for use in the process of the present disclosure include a linear fiber aspirator of the type shown in U.S. Pat. No. 3,802,817 and educative guns of the type shown in U.S. Patent Nos. 3,692,618 and 3,423,266, or a closed system as shown in U.S. Patent No. 4,340,563, the disclosures of which are incorporated herein by reference.
  • the fiber draw unit 22 includes an elongate vertical passage through which the filaments are drawn by aspirating air entering from the sides of the passage and flowing downwardly through the passage.
  • a compressor (in an open system) or blower (in a closed system) 24 supplies aspirating air to the fiber draw unit 22. The aspirating air draws the filaments and ambient air through the fiber draw unit.
  • An endless foraminous forming surface 26 is positioned below the fiber draw unit 22 and receives the continuous filaments from the outlet opening of the fiber draw unit.
  • the forming surface 26 travels around guide rollers 28.
  • a vacuum 30 positioned below the forming surface 26 where the filaments are deposited draws the filaments against the forming surface.
  • the process line 10 further includes a bonding apparatus such as thermal point bonding rollers 34.
  • the bonding apparatus 34 applies a bonding pattern to the nonwoven web for consolidating the web and increasing strength. It was discovered, however, that certain bonding patterns can greatly enhance softness and/or increase specific volume in a dramatic and unexpected way. For instance, it was discovered that bonding patterns that occupy less surface area on the nonwoven web can produce webs with enhanced softness and increased specific volume. For instance, the bonding pattern applied to the web can occupy less than 16% of the surface area of one side of the nonwoven web.
  • the process line 10 includes a winding roll 42 for taking up the finished fabric.
  • the hoppers 14a and 14b are filled with the respective polymer components A and B.
  • Polymer components A and B are melted and extruded by the respective extruders 12a and 12b through polymer conduits 16a and 16b and the spinneret 18.
  • the temperatures of the molten polymers vary depending on the polymers used, when polypropylene is used for both components A and B, the preferred temperature of the polymers when extruded range from about 370°F to about 530°F and preferably range from 400°F to about 470°F.
  • a stream of air from the quench blower 20 at least partially quenches the filaments to develop an inherent helical crimp in the filaments.
  • the quench air preferably flows in a direction substantially perpendicular to the length of the filaments at a temperature of about 45°F to about 90°F and a velocity of from about 100 feet per minute to about 400 feet per minute.
  • the filaments are drawn into the vertical passage of the fiber draw unit 22 by a flow of a gas, such as air, from the compressor or blower 24 through the fiber draw unit.
  • a gas such as air
  • the fiber draw unit is preferably positioned 30 to 60 inches below the bottom a of the spinneret 18. The filaments inherently crimp during solidification/crystallization during and throughout the drawing process.
  • the crimped filaments are deposited through the outlet opening of the fiber draw unit 22 onto the traveling forming surface 26.
  • the vacuum 20 draws the filaments against the forming surface 26 to form an unbonded, nonwoven web of continuous filaments.
  • the pattern in which the filaments are deposited on the forming surface is not critical. However, preferably, the filaments may be deposited on the forming surface in a uniform manner to produce a web with consistent properties.
  • the fiber draw unit 22 shown in FIG. 1 is an open system. In other embodiments, the fibers or filaments may be directed into a closed quench chamber and contacted with air or other cooling fluid.
  • the multicomponent filaments produced according to the process illustrated in FIG. 1 have a relatively low denier.
  • the crimped multicomponent filaments can have a denier of less than about 3, such as less than about 2.5, such as less than about 2.25, such as less than about 2, such as less than about 1 .75, such as less than about 1 .5.
  • the filaments generally have a denier of greater than about 0.5, such as greater than about 1 .
  • the crimped multicomponent filaments have a denier of between about 1 and about 2.
  • the crimp enhancement additive of the present disclosure allows for the production of highly crimped, fine filaments.
  • naturally crimped fine filaments were difficult if not impossible to produce.
  • filaments having an inherent crimp of at least about 10 crimps per inch can be produced at linear densities less than 2 denier, and particularly at less than about 1 .2 denier.
  • the filaments it is preferable for the filaments to have between about 10 crimps per inch and about 25 crimps per inch.
  • filaments having an inherent crimp in the above range can be produced according to the present disclosure at lower linear densities.
  • the basis weight of the nonwoven web can depend upon various factors, including the particular application and the desired end use.
  • the basis weight of the nonwoven web for instance, can be greater than about 10 gsm, such as greater than about 13 gsm, such as greater than about 15 gsm, such as greater than about 18 gsm.
  • the basis weight can be less than about 60 gsm, such as less than about 50 gsm, such as less than about 45 gsm, such as less than about 40 gsm, such as less than about 30 gsm, such as less than about 25 gsm.
  • a bonding pattern can be applied to the nonwoven web after the web has been formed. It was discovered that enhanced softness and/or increased specific volume can result if the bonding pattern occupies less than 16% of the surface area of one side of the nonwoven web, such as less than about 15% of the surface area, such as less than about 14% of the surface area, such as less than about 13% of the surface area, such as less than about 12% of the surface area, such as less than about 11 % of the surface area, such as less than about 10% of the surface area.
  • the bonding pattern occupies generally greater than about 5% of the surface area of one side of the nonwoven web, such as greater than about 6% of the surface area, such as greater than about 7% of the surface area, such as greater than about 8% of the surface area.
  • many bonding patterns occupied much greater surface area than the bonding patterns of the present disclosure.
  • many conventional bonding patterns occupied at least 16% of the surface area of one side of the nonwoven web, such as at least 18% of the surface area, such as greater than about 20% of the surface area.
  • the bonding pattern comprises a point bonded pattern.
  • Point bonding generally refers to a process in which the nonwoven web is passed between a patterned roll and another roll, which may or may not be patterned. One or both rolls are typically heated.
  • the point bonds form a pattern into at least one surface of the nonwoven web.
  • the point bonds for instance, can create a pattern comprised of discrete shapes or can create a pattern of intersecting lines, such as a grid-like pattern.
  • FIGS. 3 and 4 Exemplary bonding patterns that may be used in accordance with the present disclosure are shown in FIGS. 3 and 4.
  • a nonwoven web 100 made in accordance with the present disclosure is shown.
  • a bonding pattern comprised of point bonds 102 has been applied to at least one surface of the web 100.
  • the point bonds 102 form discrete shapes 104 on a surface of the nonwoven web 100.
  • the discrete shapes 104 can have a wave-like design. The number and density of the wave-like shapes can be adjusted so that the overall pattern occupies less than 16% of the surface area of the web 100
  • FIG. 4 another embodiment of a nonwoven web 200 made in accordance with the present disclosure is shown.
  • the nonwoven web 200 contains crimped multicomponent filaments.
  • Applied to at least one surface of the nonwoven web 200 is a bonding pattern comprised of point bonds 202.
  • the point bonds 202 form lines that intersect.
  • the bonding pattern is comprised of a plurality of interconnected diamonds 204.
  • a bonding pattern that is comprised of discrete shapes or of an interconnected design can depend upon various factors. For instance, when applying a bonding pattern comprised of discrete shapes, the resulting nonwoven web may have a greater specific volume and/or softness. Applying an interconnected bonding pattern, such as a bonding pattern comprised of a grid-like design such as shown in FIG. 4, on the other hand, can reduce necking of the material during processing and use.
  • the fabric of the present disclosure may be treated with conventional surface treatments or contain conventional polymer additives to enhance the wettability of the fabric.
  • the fabric of the present disclosure may be treated with polyalkylene-oxide modified siloxanes and silanes such as polyalkylene-oxide modified polydimethyl-siloxane as disclosed in U.S. Pat. No. 5,057,361. Such a surface treatment enhances the wettability of the fabric.
  • nonwoven webs made according to the present disclosure can display an increased specific volume in combination with enhanced softness.
  • the specific volume of the nonwoven web can be greater than about 19.3 cm 3 /g, such as greater than about 20 cm 3 /g, such as greater than about 21 cm 3 /g, such as greater than about 22 cm 3 /g, such as greater than about 23 cm 3 /g, such as greater than about 24 cm 3 /g, such as greater than about 25 cm 3 /g, such as greater than about 26 cm 3 /g, such as greater than about 27 cm 3 /g.
  • the specific volume is generally less than about 40 cm 3 /g, such as less than about 35 cm 3 /g.
  • the specific volume of the nonwoven web can be increased by greater than about 15%, such as greater than about 20%, such as even greater than about 25% in comparison to an identical nonwoven web bonded with a bonding pattern covering a greater surface area of the web.
  • the nonwoven web can also have excellent softness characteristics.
  • the nonwoven web can display a TS7 softness of less than about 3.8, such as less than about 3.7, such as less than about 3.5, such as less than about 3.3, such as less than about 3.1 , such as less than about 2.9, such as less than about 2.7, such as even less than about 2.5.
  • the TS7 softness is generally greater than about 1
  • the web can display a TS750 softness of less than about 3.5, such as less than about 3.3, such as less than about 3.1 , such as less than about 2.9, such as less than about 2.7, such as less than about 2.5, such as less than about 2.3.
  • the TS750 softness is generally greater than about 1 .
  • the TS7 softness and the TS750 softness can be measured using a TSA analyzer.
  • Spunbond meltblown spunbond (SMS) fabrics are tri laminate nonwoven fabrics. SMS is made up of a top layer of spunbond polypropylene, a middle layer of meltblown polypropylene, and a bottom layer of spunbond polypropylene.
  • the nonwoven webs of the present disclosure are well suited for use in SMS fabrics/laminates.
  • an SMS fabric/laminate is formed from a top layer of a nonwoven web of the present disclosure, a middle layer of meltblown polypropylene, and a bottom layer of a nonwoven web of the present disclosure.
  • the nonwoven webs of the present disclosure can be used in many different and various applications.
  • the webs can be used in filter products, in liquid absorbent products, in personal care articles, in garments, and in various other products.
  • a bulk tester such as Digimatic Indicator Gauge, Type DF 1050E, which is commercially available from Mitutoyo Corporation of Japan, may be used.
  • the bulk tester includes a flat base and a smooth platen connected to an indicator gauge of the tester.
  • the platen can have a diameter of about 3 inches and is capable of applying a uniform pressure of about 0.05 psi over a 3 inch diameter portion of the nonwoven web.
  • a 4 inch x 4 inch sample of the nonwoven web can be placed on the base and the platen applies pressure centrally to the sample such that no part of the platen overhangs the sample.
  • Caliper measurements are made in a room that is about 23°C and about 50% relative humidity.
  • Caliper measurements can be made on a single layer or on multiple layers, such as by stacking four layers together.
  • the specific volume of the nonwoven web is the quotient of the caliper of the nonwoven web divided by the dry basis weight. Sheet specific volume can be expressed in cubic centimeters per gram.
  • TS7 and TS750 values were measured using an EMTEC Tissue Softness Analyzer (“TSA”) (Emtec Electronic GmbH, Leipzig, Germany)
  • TSA comprises a rotor with vertical blades which rotate on the test piece applying a defined contact pressure. Contact between the vertical blades and the test piece creates vibrations, which are sensed by a vibration sensor. The sensor then transmits a signal to a PC for processing and display. The signal is displayed as a frequency spectrum.
  • TS7 and TS750 values the blades are pressed against sample with a load of 100 mN and the rotational speed of the blades is 2 revolutions per second.
  • the first frequency analysis is performed in the range of approximately 200 Hz to 1000 Hz, with the amplitude of the peak occurring at 750 Hz being recorded as the TS750 value.
  • the TS750 value represents the surface smoothness of the sample. A high amplitude peak correlates to a rougher surface.
  • a second frequency analysis is performed in the range from 1 to 10 kHZ, with the amplitude of the peak occurring at 7 kHz being recorded as the TS7 value.
  • the TS7 value represents the softness of sample. A lower amplitude correlates to a softer sample.
  • Both TS750 and TS7 values have the units dB V 2 rms.
  • Nonwoven webs were made according to the present disclosure having the following formula: Component A:
  • Component B is a compound having Component B:
  • Nonwoven webs were made generally according to the process shown in FIG. 1 .
  • the bonding pattern applied to the nonwoven webs was varied. In particular, a bonding pattern was applied to Sample Nos. 1 and 2 that was similar to the bonding pattern illustrated in FIG. 3. The bonding pattern covers 10% of the surface area of one side of the nonwoven web. A bonding pattern was applied to Sample No. 3 similar to the pattern illustrated in FIG. 4. The bonding pattern covered about 10% of the surface area of one side of the nonwoven web. For purposes of comparison, a conventional bonding pattern was applied to Sample Nos. 4 and 5 which covered at least 16% of the surface area of one side of the nonwoven web. The bonding pattern was comprised of a pattern of small ovals. The nonwoven webs produced were tested for TS7 softness, TS750 softness, and caliper based on one sheet of material. The following results were obtained:
  • nonwoven webs made according to the present disclosure displayed a greater caliper and thus a greater specific volume in combination with better softness characteristics.
  • Sample No. 6 was made using the same process as Sample Nos. 1 and 2.
  • Sample No. 7 was made using the same process as Sample No. 3.
  • Sample No. 8 was made using the same process as Sample Nos. 4 and 5.
  • Sample No. 9 was made identical to Sample No. 6 except the multicomponent filaments did not contain the crimp enhancement additive.
  • Sample No. 10 was made similar to Sample No. 8 except the filaments contained in the web were conventional bicomponent filaments containing a polyethylene component and a polypropylene component.
  • Sample No. 11 is a commercially available nonwoven material advertised as having high loft and including a bonding pattern similar to Sample No. 8 and covering at least 18% of the surface area of one side of the web.
  • nonwoven webs made according to the present disclosure displayed much greater specific volume properties.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Multicomponent Fibers (AREA)

Abstract

L'invention divulgue des filaments multicomposants, des bandes non tissées fabriquées à partir de filaments multicomposants et des procédés de formation de bandes non tissées. Selon la présente invention, les filaments multicomposants contiennent un additif d'amélioration de crêpage. L'utilisation de l'additif d'amélioration de crêpage en combinaison avec un motif de liaison thermique conduit à des bandes non tissées ayant une souplesse améliorée et une augmentation du volume en vrac/spécifique.
PCT/US2024/032373 2023-06-09 2024-06-04 Bandes non tissées fabriquées à partir de filaments multicomposants ayant des caractéristiques de gonflant et de douceur élevées Ceased WO2024254048A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
AU2024284006A AU2024284006A1 (en) 2023-06-09 2024-06-04 Nonwoven webs made from multicomponent filaments having high loft and softness characteristics
CN202480033400.4A CN121152907A (zh) 2023-06-09 2024-06-04 由多组分长丝制成的具有高蓬松度和柔软度特性的非织造纤维网
KR1020267000229A KR20260023007A (ko) 2023-06-09 2024-06-04 높은 로프트 및 부드러움 특질을 갖는 다성분 필라멘트로 제조된 부직포 웹
MX2025014005A MX2025014005A (es) 2023-06-09 2025-11-24 Tramas no tejidas fabricadas a partir de filamentos multicomponentes que tienen caracteristicas de alto volumen y suavidad

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202363507281P 2023-06-09 2023-06-09
US63/507,281 2023-06-09

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WO2024254048A1 true WO2024254048A1 (fr) 2024-12-12

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PCT/US2024/032373 Ceased WO2024254048A1 (fr) 2023-06-09 2024-06-04 Bandes non tissées fabriquées à partir de filaments multicomposants ayant des caractéristiques de gonflant et de douceur élevées

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KR (1) KR20260023007A (fr)
CN (1) CN121152907A (fr)
AU (1) AU2024284006A1 (fr)
MX (1) MX2025014005A (fr)
WO (1) WO2024254048A1 (fr)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3855046A (en) * 1970-02-27 1974-12-17 Kimberly Clark Co Pattern bonded continuous filament web
US5800230A (en) * 1996-09-11 1998-09-01 Chisso Corporation Conjugated filament nonwoven fabric and method of manufacturing the same
US20020098764A1 (en) * 1997-09-30 2002-07-25 Mleziva Mark M. Crimped multicomponent filaments and spunbond webs made therefrom
US20140066873A1 (en) * 2011-05-11 2014-03-06 Mitsui Chemicals, Inc. Crimped conjugated fiber and non-woven fabric comprising the fiber
US20200149191A1 (en) * 2017-06-30 2020-05-14 The Procter & Gamble Company Method for Making a Shaped Nonwoven
WO2022065239A1 (fr) * 2020-09-24 2022-03-31 Ｅｓファイバービジョンズ株式会社 Fibre composite pouvant subir un thermoliage, son procédé de production, et non-tissé utilisant une fibre composite pouvant subir un thermoliage

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3855046A (en) * 1970-02-27 1974-12-17 Kimberly Clark Co Pattern bonded continuous filament web
US5800230A (en) * 1996-09-11 1998-09-01 Chisso Corporation Conjugated filament nonwoven fabric and method of manufacturing the same
US20020098764A1 (en) * 1997-09-30 2002-07-25 Mleziva Mark M. Crimped multicomponent filaments and spunbond webs made therefrom
US20140066873A1 (en) * 2011-05-11 2014-03-06 Mitsui Chemicals, Inc. Crimped conjugated fiber and non-woven fabric comprising the fiber
US20200149191A1 (en) * 2017-06-30 2020-05-14 The Procter & Gamble Company Method for Making a Shaped Nonwoven
WO2022065239A1 (fr) * 2020-09-24 2022-03-31 Ｅｓファイバービジョンズ株式会社 Fibre composite pouvant subir un thermoliage, son procédé de production, et non-tissé utilisant une fibre composite pouvant subir un thermoliage

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CN121152907A (zh) 2025-12-16
KR20260023007A (ko) 2026-02-20
AU2024284006A1 (en) 2026-01-22
MX2025014005A (es) 2026-01-07

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