CA2038754C - Nonwoven webs of drawn and unoriented thermoplastic fibers - Google Patents
Nonwoven webs of drawn and unoriented thermoplastic fibersInfo
- Publication number
- CA2038754C CA2038754C CA 2038754 CA2038754A CA2038754C CA 2038754 C CA2038754 C CA 2038754C CA 2038754 CA2038754 CA 2038754 CA 2038754 A CA2038754 A CA 2038754A CA 2038754 C CA2038754 C CA 2038754C
- Authority
- CA
- Canada
- Prior art keywords
- blend
- layer
- butylene
- copolymers
- polybutylene
- 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.)
- Expired - Fee Related
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
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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
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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
- D04H1/4374—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 using different kinds of webs, e.g. by layering webs
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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
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43825—Composite fibres
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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
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
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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
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
- D04H1/544—Olefin series
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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
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
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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
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
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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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
- Y10T428/24124—Fibers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24298—Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
- Y10T428/24306—Diamond or hexagonal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
- Y10T428/24322—Composite web or sheet
- Y10T428/24331—Composite web or sheet including nonapertured component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24496—Foamed or cellular component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24612—Composite web or sheet
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24628—Nonplanar uniform thickness material
- Y10T428/24669—Aligned or parallel nonplanarities
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T442/184—Nonwoven scrim
- Y10T442/188—Metal or metal-coated fiber-containing scrim
- Y10T442/19—Including a paper layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/647—Including a foamed layer or component
- Y10T442/651—Plural fabric layers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/68—Melt-blown nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
There is disclosed a three dimensional nonwoven web consisting of drawn and unoriented thermoplastic fibers formed from a blend of polypropylene and polybutylene, wherein the blend by weight is from 90% to 70%
polypropylene and from 10% to 30% polybutylene. The blend can be a blend of a homopolymer of polypropylene and a homopolymer of polybutylene; a homopolymer of polypropylene and a copolymer of polybutylene; a copolymer of polypropylene and a homopolymer of polybutylene; and a copolymer of polypropylene and a copolymer of polybutylene. In addition, ternary blends comprising polypropylene, polybutylene, and a terpolymer (propylene, ethylene, and 1-butene) are useful. The resulting nonwoven webs have enhanced strength, toughness, and tear resistance.
polypropylene and from 10% to 30% polybutylene. The blend can be a blend of a homopolymer of polypropylene and a homopolymer of polybutylene; a homopolymer of polypropylene and a copolymer of polybutylene; a copolymer of polypropylene and a homopolymer of polybutylene; and a copolymer of polypropylene and a copolymer of polybutylene. In addition, ternary blends comprising polypropylene, polybutylene, and a terpolymer (propylene, ethylene, and 1-butene) are useful. The resulting nonwoven webs have enhanced strength, toughness, and tear resistance.
Claims (50)
1. A nonwoven web comprising at least one layer consisting of drawn unoriented thermoplastic fibers formed from a blend comprising polymers selected from the group consisting of homopolymers and copolymers of propylene and polymers selected from the group consisting of copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30%
butylene polymer.
butylene polymer.
2. A three dimensional nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polymers selected from the group consisting of homopolymers and copolymers of propylene and polymers selected from the group consisting of copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% butylene polymer.
3. A three dimensional nonwoven wiper comprising a nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polymers selected from the group consisting of homopolymers and copolymers of propylene and polymers selected from the group consisting of copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% butylene polymer.
4. A nonwoven wiper comprising a nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polymers selected from the group consisting of homopolymers and copolymers of propylene and polymers selected from the group consisting of copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% butylene polymer.
5. A laminate material comprising at least one nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polymers selected from the group consisting of homopolymers and copolymers of propylene and polymers selected from the group consisting of copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymers and from 10% to 30% butylene polymer.
6. A laminate material comprising at least one three dimensional layer comprising a nonwoven web consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polymers selected from the group consisting of homopolymers and copolymers of propylene and polymers selected from the group consisting of copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% butylene polymer.
7. A three dimensional nonwoven wiper comprising a laminate material comprising at least one nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polymers selected from the group consisting of homopolymers and copolymers of propylene and polymers selected from the group consisting of copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% butylene polymer.
8. A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polymers selected from the group consisting of homopolymers and copolymers of propylene and polymers selected from the group consisting of copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% butylene polymer.
9. A material of one of claims 1, 2, 3, 4, 5, 6, 7 or 8 wherein the propylene polymer is a homopolymer.
10. The material of one of claims 1, 2, 3, 4, 5, 6, 7 or 8 wherein the butylene copolymer is a copolymer of ethylene.
11. A nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising propylene copolymers and butylene polymers selected from the group consisting of homopolymers and copolymers of butylene wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% by weight butylene polymer.
12. A three dimensional nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising propylene copolymers and butylene polymers selected from the group consisting of homopolymers and copolymers of butylene wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% by weight butylene polymer.
13. A three dimensional nonwoven wiper comprising a nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising copolymers of propylene and polymers selected from the group consisting of homopolymers and copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10%
to 30% butylene polymer.
to 30% butylene polymer.
14. A nonwoven wiper comprising a nonwoven web comprising at least one layer consisting of drawn and unoriented theremoplastic fibers formed from a blend comprising copolymers of propylene and polymers selected from the group consisting of homopolymers and copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30% butylene polymer.
15. A laminate material comprising at least one nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising copolymers of propylene and polymers selected from the group consisting of copolymers and homopolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10% to 30%
butylene polymer.
butylene polymer.
16. A laminate material comprising at least one three dimensional layer comprising a nonwoven web consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising copolymers of propylene and polymers selected from the group consisting of homopolymers and copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10%
to 30% butylene polymer.
to 30% butylene polymer.
17. A three dimensional nonwoven wiper comprising a laminate material comprising at least one nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising copolymers of propylene and polymers selected from the group consisting of homopolymers and copolymers of butylene, wherein the blend by weight is from 90% to 70%
propylene polymer and from 10% to 30% butylene polymer.
propylene polymer and from 10% to 30% butylene polymer.
18. A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising copolymers of propylene and polymers selected from the group consisting of homopolymers and copolymers of butylene, wherein the blend by weight is from 90% to 70% propylene polymer and from 10%
to 30% butylene polymer.
to 30% butylene polymer.
19. A material of one of claims 11, 12, 13, 14, 15, 16, 17 or 18 wherein the butylene polymer is a homopolymer.
20. The material of one of claims 11, 12, 13, 14, 15, 16, 17 or 18 wherein the propylene copolymer is a copolymer of ethylene.
21. The material of one of claims 11, 12, 13, 14, 15, 16, 17 or 18 wherein the blend is a ternary blend.
22. The material of one of claims 11, 12, 13, 14, 15, 16, 17 or 18 wherein the blend includes of terpolymer.
23. The material of claim 11, 12, 13, 14, 15, 16, 17 or 18 wherein the blend includes terpolymer comprising propylene, ethylene and 1-butene.
24. A method of forming a nonwoven material comprising the steps of:
a. heating a blend described in one of claims 1, 2, 3, 4, 5, 6, 7, 8, 11, 12, 13, 14, 15, 16, 17 or 18 to form a melt;
b. extruding the melt through a die to form thermoplastic fibers;
c. initially drawing the fibers to a ratio of greater than 14 to 1; and d. depositing fibers onto a forming surface to form a first layer.
a. heating a blend described in one of claims 1, 2, 3, 4, 5, 6, 7, 8, 11, 12, 13, 14, 15, 16, 17 or 18 to form a melt;
b. extruding the melt through a die to form thermoplastic fibers;
c. initially drawing the fibers to a ratio of greater than 14 to 1; and d. depositing fibers onto a forming surface to form a first layer.
25. A method according to Claim 24 wherein the forming surface is shaped to produce a three dimensional material.
26. The method of Claim 24 or 25 including the additional step of bonding said material to a second or third layer to form a laminate.
27. A three dimensional nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
28. A three dimensional nonwoven wiper comprising a web consisting of drawn thermoplastic fibers, wherein the fibers are formed from a blend comprising polypropylene and polybutylene to form thermoplastic fibers wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
29. A laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to
30% polybutylene.
30. A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
30. A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
31. A three dimensional nonwoven web comprising at least one layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
32. A three dimensional nonwoven wiper consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer wherein the ternary blend by weight is from 10% to 30%
polybutylene.
polybutylene.
33. A laminate material comprising at least one three dimensional layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
34. A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
35. The article of claim 31, 32, 33 or 34 wherein the terpolymer comprises propylene, ethylene and 1-butene.
36. A method for forming a layer of three dimensional nonwoven web consisting of thermoplastic fibers, comprising the steps of:
a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
b. heating the blend to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
b. heating the blend to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
37. A method for forming a three dimensional nonwoven wiper consisting of thermoplastic fibers comprising the steps of:
a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
b. heating the blend to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
b. heating the blend to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
38. A method for forming a laminate material comprising at least one three dimensional layer consisting of thermoplastic fibers, comprising the steps of;
a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
b. heating the blend to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
b. heating the blend to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
39. A method for forming a layer of three dimensional nonwoven web consisting of thermoplastic fibers, comprising the steps of:
a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
b. heating the ternary blend to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
b. heating the ternary blend to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
40. A method for forming a three dimensional nonwoven wiper consisting of thermoplastic fibers comprising the steps of:
a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
b. heating the ternary to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
b. heating the ternary to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
41. A method for forming a laminate material comprising at least one three dimensional layer consisting of thermoplastic fibers, comprising the steps of:
a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
b. heating the ternary to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
b. heating the ternary to form a melt;
c. extruding the melt through an orifice to form thermoplastic fibers;
d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
42. The method of claim 39, 40 or 41, wherein the terpolymer comprises propylene, ethylene, and 1-butene.
43. The method of claim 36, 37, 38, 39, 40 or 41, wherein the fibers are quenched prior to being deposited on the forming surface.
44. The method of claim 36, 37, 38, 39, 40 or 41, wherein after the fibers are deposited, the layer is bonded.
45. The method of claim 38, wherein the first layer is bonded to a second layer selected from the group of materials consisting of foam, meltblown, coform, spunbond, scrim, and three dimensional meltblown.
46. The method of claim 45, wherein the second layer is bonded to a third layer.
47. The method of claim 46, wherein the second layer is bonded to a third layer selected from the group of materials consisting of foam, meltblown, coform, spunbond, scrim, and three dimensional meltblown.
48. The method of claim 41, wherein the first layer is bonded to a second layer selected from the group of materials consisting of foam, meltblown, coform, spunbond, scrim, and three dimensional meltblown.
49. The method of claim 48, wherein the second layer is bonded to a third layer.
50. The method of claim 49, wherein the second layer is bonded to a third layer selected from the group of materials consisting of foam, meltblown, coform, spunbond, scrim, and three dimensional meltblown.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US518,904 | 1990-05-04 | ||
US07/518,904 US5204174A (en) | 1990-05-04 | 1990-05-04 | Fine fiber webs with improved physical properties |
US626,817 | 1990-12-13 | ||
US07/626,817 US5165979A (en) | 1990-05-04 | 1990-12-13 | Three-dimensional polymer webs with improved physical properties |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2038754A1 CA2038754A1 (en) | 1991-11-05 |
CA2038754C true CA2038754C (en) | 1998-05-19 |
Family
ID=27059631
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Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA 2038754 Expired - Fee Related CA2038754C (en) | 1990-05-04 | 1991-03-21 | Nonwoven webs of drawn and unoriented thermoplastic fibers |
Country Status (11)
Country | Link |
---|---|
US (1) | US5165979A (en) |
EP (1) | EP0456044B1 (en) |
JP (1) | JP3174083B2 (en) |
KR (1) | KR910020238A (en) |
AT (1) | ATE131227T1 (en) |
AU (1) | AU636210B2 (en) |
CA (1) | CA2038754C (en) |
DE (1) | DE69115114T2 (en) |
ES (1) | ES2080181T3 (en) |
FI (1) | FI912146A (en) |
NO (1) | NO911527L (en) |
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- 1991-03-28 AU AU73987/91A patent/AU636210B2/en not_active Ceased
- 1991-04-18 NO NO91911527A patent/NO911527L/en unknown
- 1991-04-25 AT AT91106709T patent/ATE131227T1/en not_active IP Right Cessation
- 1991-04-25 ES ES91106709T patent/ES2080181T3/en not_active Expired - Lifetime
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- 1991-04-25 DE DE1991615114 patent/DE69115114T2/en not_active Expired - Fee Related
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US6797357B2 (en) | 1997-05-23 | 2004-09-28 | The Procter & Gamble Company | Three dimensional structures useful as cleaning sheets |
US8536074B2 (en) | 1997-05-23 | 2013-09-17 | The Procter & Gamble Company | Three dimensional structures useful as cleaning sheets |
US8999489B2 (en) | 1997-05-23 | 2015-04-07 | The Procter & Gamble Company | Packages containing sheets |
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US9005734B2 (en) | 1997-05-23 | 2015-04-14 | The Procter & Gamble Company | Articles of commerce having three-dimensional sheets |
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US7691760B2 (en) | 2002-03-08 | 2010-04-06 | 3M Innovative Properties Company | Wipe |
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JPH0693547A (en) | 1994-04-05 |
CA2038754A1 (en) | 1991-11-05 |
AU636210B2 (en) | 1993-04-22 |
FI912146A (en) | 1991-11-05 |
JP3174083B2 (en) | 2001-06-11 |
EP0456044A3 (en) | 1991-12-04 |
EP0456044B1 (en) | 1995-12-06 |
NO911527D0 (en) | 1991-04-18 |
US5165979A (en) | 1992-11-24 |
ES2080181T3 (en) | 1996-02-01 |
EP0456044A2 (en) | 1991-11-13 |
FI912146A0 (en) | 1991-05-03 |
NO911527L (en) | 1991-11-05 |
DE69115114T2 (en) | 1996-06-27 |
KR910020238A (en) | 1991-12-19 |
DE69115114D1 (en) | 1996-01-18 |
ATE131227T1 (en) | 1995-12-15 |
AU7398791A (en) | 1991-11-07 |
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