CA2038754C - Nonwoven webs of drawn and unoriented thermoplastic fibers - Google Patents

Nonwoven webs of drawn and unoriented thermoplastic fibers

Info

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
Application number
CA 2038754
Other languages
French (fr)
Other versions
CA2038754A1 (en
Inventor
Diego H. Daponte
Susan E. Shawver
Sharon L. Watkins
Hugo P. Watts
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
Original Assignee
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
Priority claimed from US07/518,904 external-priority patent/US5204174A/en
Application filed by Kimberly Clark Corp filed Critical Kimberly Clark Corp
Publication of CA2038754A1 publication Critical patent/CA2038754A1/en
Application granted granted Critical
Publication of CA2038754C publication Critical patent/CA2038754C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/22Layered 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
    • B32B5/24Layered 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
    • B32B5/26Layered 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15Methods 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
    • B32B37/153Methods 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/02Layered 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
    • B32B5/022Non-woven fabric
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4282Addition polymers
    • D04H1/4291Olefin series
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4374Non-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
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4382Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825Composite fibres
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/54Non-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
    • D04H1/541Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/54Non-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
    • D04H1/542Adhesive fibres
    • D04H1/544Olefin series
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/54Non-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
    • D04H1/559Non-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
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/54Non-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
    • D04H1/56Non-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
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16Non-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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0253Polyolefin fibres
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24124Fibers
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24298Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
    • Y10T428/24306Diamond or hexagonal
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322Composite web or sheet
    • Y10T428/24331Composite web or sheet including nonapertured component
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24496Foamed or cellular component
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24612Composite web or sheet
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628Nonplanar uniform thickness material
    • Y10T428/24669Aligned or parallel nonplanarities
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/184Nonwoven scrim
    • Y10T442/188Metal or metal-coated fiber-containing scrim
    • Y10T442/19Including a paper layer
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/647Including a foamed layer or component
    • Y10T442/651Plural fabric layers
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/68Melt-blown nonwoven fabric
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/681Spun-bonded nonwoven fabric

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.

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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
CA 2038754 1990-05-04 1991-03-21 Nonwoven webs of drawn and unoriented thermoplastic fibers Expired - Fee Related CA2038754C (en)

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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

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ATE131227T1 (en) 1995-12-15
NO911527D0 (en) 1991-04-18
JP3174083B2 (en) 2001-06-11
US5165979A (en) 1992-11-24
ES2080181T3 (en) 1996-02-01
FI912146A0 (en) 1991-05-03
DE69115114D1 (en) 1996-01-18
KR910020238A (en) 1991-12-19
CA2038754A1 (en) 1991-11-05
EP0456044A3 (en) 1991-12-04
DE69115114T2 (en) 1996-06-27
NO911527L (en) 1991-11-05
AU7398791A (en) 1991-11-07
FI912146A (en) 1991-11-05
JPH0693547A (en) 1994-04-05
AU636210B2 (en) 1993-04-22
EP0456044A2 (en) 1991-11-13

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