CA2273284A1 - High performance elastic composite materials made from high molecular weight thermoplastic triblock elastomers - Google Patents

High performance elastic composite materials made from high molecular weight thermoplastic triblock elastomers Download PDF

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Publication number
CA2273284A1
CA2273284A1 CA002273284A CA2273284A CA2273284A1 CA 2273284 A1 CA2273284 A1 CA 2273284A1 CA 002273284 A CA002273284 A CA 002273284A CA 2273284 A CA2273284 A CA 2273284A CA 2273284 A1 CA2273284 A1 CA 2273284A1
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Canada
Prior art keywords
elastic material
composite elastic
layer
polymer
elastomeric
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Granted
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CA002273284A
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French (fr)
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CA2273284C (en
Inventor
Oomman Painumoottil Thomas
James Russell Fitts Jr.
Richard Macferran Shane
Donald Vincent Willitts
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Kimberly Clark Worldwide Inc
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Individual
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/16—Layered products comprising a layer of natural or synthetic rubber comprising polydienes homopolymers or poly-halodienes homopolymers
    • 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
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • B32B2038/0028—Stretching, elongating
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B32B2038/0048—Annealing, relaxing
    • 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
    • B32B2262/0207—Elastomeric fibres
    • 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
    • B32B2262/0207—Elastomeric fibres
    • B32B2262/0215—Thermoplastic elastomer fibers
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51—Elastic
    • 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
    • B32B2437/00—Clothing
    • 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
    • B32B2555/00—Personal care
    • B32B2555/02—Diapers or napkins

Abstract

The present invention comprises a continuous feed spun bonded laminate having improved elastic properties measured at body temperature. The laminate comprises at least one first and second nonelastic layers between which is sandwiched at least one elastic layer, the elastic layer being comprised of a triblock polystyrene-poly(ethylene/propylene)-polystyrene ("SEPS") copolymer having a number average molecular weight of about 81.000 g/mol. The weight percent of styrene is approximately 18 % and the weight percent of ethylene/propylene is approximately 82 %. The molecular weight increase in the EP block, while holding the molecular weight of the styrene block constant, increases the entanglement density, polymer chain persistence length and the relaxation time. The resulting laminate load decay rate and load loss measurements over a period of 12 hours at body temperature showed marked improvement over known CFSBL product. The laminate is particularly useful as side panel material in training pants because of the resistance to sagging at body temperature.

Claims (40)

1. A composite elastic material having improved elastic properties at body temperature, comprising:
A) a first layer of substantially parallel filaments formed of an elastomeric polymer, said polymer having a number average molecular weight of from about 65,000 g/mol to about 100,000 g/mol;
B) a second layer of elastomeric meltblown fibers, said meltblown fibers bonded to at least a portion of the first layer filaments;
C) a third layer of spunbond fibers; and, D) a fourth layer of spunbond fibers;
wherein said first and second layers are disposed between said third and fourth layers.
2. The composite elastic material of Claim 1, wherein said elastomeric polymer of said first layer comprises an A-B-A' triblock copolymer wherein A and A' are the same or different thermoplastic polymer, and wherein B is an elastomeric polymer block.
3. The composite elastic material of Claim 2, wherein A is a styrene-based polymer.
4. The composite elastic material of Claim 2, wherein B is selected from the group consisting of ethylene/propylene and ethylene/butylene.
5. The composite elastic material of Claim 4, wherein said ethylene/propylene and ethylene/butylene are saturated.
6. The composite elastic material of Claim 4, wherein said ethylene/propylene and ethylene/butylene are unsaturated.
7. The composite elastic material of Claim 2, wherein said elastomeric material comprises about 18% styrene-based material and about 82% midblock material.
8. The composite elastic material of Claim 1, wherein said elastomeric polymer of said first layer is substantially free of diblock polymer.
9. The composite elastic material of Claim 1, wherein said material has a percent load loss at body temperature over a twelve hour period of less than about 40%.
10. The composite elastic material of Claim 1, wherein said material has a percent load loss at body temperature over a twelve hour period of less than about 50%.
11. The composite elastic material of Claim 1, wherein said material has a load decay slope at body temperature over a twelve hour period of about -0.08.
12. The composite elastic material of Claim 1, wherein said material has a load decay slope at body temperature over a twelve hour period of about -0.10.
13. The composite elastic material of Claim 1, wherein said polymer has a number average molecular weight of from about 65,000 g/mol to about 100,000 g/mol.
14. The composite elastic material of Claim 1, wherein said polymer has a number average molecular weight of from about 75,000 g/mol to about 90,000 g/mol.
15. The composite elastic material of Claim 1, wherein said material has a number average molecular weight of about 81,000 g/mol.
16. The composite elastic material of Claim 1, wherein said meltblown fibers comprise an elastomeric polymer selected from the group consisting of elastic polyesters, elastic polyurethanes, elastic polyamides, elastic copolymers of ethylene and at least one vinyl monomer, and elastic A-B-A' block copolymers wherein A and A' are the same or different thermoplastic polymers, and wherein B is an elastomeric polymer block.
17. The composite elastic material of Claim 16, wherein said elastomeric polymer is blended with a processing aid.
18. The composite elastic material of Claim 16, wherein said elastomeric polymer is blended with a tackifying resin.
19. The composite elastic material of Claim 1, further comprising a fifth layer of meltblown material.
20. The composite elastic material of Claim 12, wherein said second and said fifth layers of meltblown material are bonded to both sides of said first layer.
21. A process for forming a composite elastic material having improved elastic properties at body temperature, comprising:
A) providing a first layer of substantially parallel filaments formed of an elastomeric polymer, said polymer having a number average molecular weight of from about 65,000 g/mol to about 100,000 g/mol;
B) a second layer of elastomeric meltblown fibers, said meltblown fibers bonded to at least a portion of the first layer filaments so that the elastic fibrous web is anisotropic;
C) adhering said first and said second layers together to form a first web;
D) stretching said first web in the machine direction;
E) providing a third layer of spunbond fibers;
F) providing a fourth layer of spunbond fibers; and, G) adhering said third and fourth layers to both sides of said first web to form a second web.
22. The process of Claim 21, further comprising passing said second web through at least one pair of calendar rolls.
23. The process of Claim 22, further comprising relaxing said second web.
24. The composite elastic material of Claim 21 , wherein said elastomeric polymer of said first layer comprises an A-B-A' triblock copolymer wherein A and A' are the same or different thermoplastic polymer, and wherein B is an elastomeric polymer block.
25. The composite elastic material of Claim 24, wherein A is a styrene-based polymer.
26. The composite elastic material of Claim 24, wherein B is selected from the group consisting of ethylene/propylene and ethylene/butylene.
27. The composite elastic material of Claim 24, wherein elastomeric material comprises about 18% styrene-based material and about 82% midblock material.
28. The composite elastic material of Claim 21, wherein said elastomeric polymer of said first layer is substantially free of diblock polymer.
29. The composite elastic material of Claim 21, wherein said material has a percent load loss at body temperature over a twelve hour period of about 40%.
30. The composite elastic material of Claim 21, wherein said material has a load decay slope at body temperature over a twelve hour period of about -0.08.
31. The composite elastic material of Claim 21, wherein said meltblown fibers comprise an elastomeric polymer selected from the group consisting of elastic polyesters, elastic polyurethanes, elastic polyamides, elastic copolymers of ethylene and at least one vinyl monomer, and elastic A-B-A' block copolymers wherein A and A' are the same or different thermoplastic polymers, and wherein B is an elastomeric polymer block.
32. The composite elastic material of Claim 21, wherein said elastomeric polymer is blended with a processing aid.
33. The composite elastic material of Claim 21, wherein said elastomeric polymer is blended with a tackifying resin.
34. The composite elastic material of Claim 2l, further comprising a fifth layer of meltblown material.
35. The composite elastic material of Claim 34, wherein said second and said fifth layers of meltblown material are bonded to both sides of said first layer.
36. An article of manufacture incorporating a composite elastic material made according to the process of Claim 21.
37. The article of manufacture of Claim 36, wherein said article is selected from the group consisting of, pads, diapers, incontinence undergarments and personal care products.
38. A training pants article having side panels incorporating a composite elastic material, said elastic material comprising:
A) a first layer of substantially parallel filaments formed of an elastomeric polymer, said polymer having a number average molecular weight of from about 65,000 g/mol to about 100,000 g/mol;
B) a second layer of elastomeric meltblown fibers, said meltblown fibers bonded to at least a portion of the first layer filaments so that the elastic fibrous web is anisotropic;
C) a third layer of spunbond fibers; and, D) a fourth layer of spunbond fibers;
wherein said first and second layers are disposed between said third and fourth layers.
39. A polymer suitable for use in an elastic material, said polymer comprising an A-B-A' triblock copolymer wherein A and A' are the same or different thermoplastic polymer, and wherein B is an elastomeric polymer block, said polymer having a number average molecular weight of from about 65,000 g/mol to about 100,000 g/mol; said A and A' being a styrene-based polymer and B is selected from the group consisting of ethylene/propylene and ethylene/butylene.
40. The composite elastic material of Claim 39, wherein said elastomeric material comprises about 18% A and A' and about 82% B.
CA002273284A 1997-10-03 1998-10-02 High performance elastic composite materials made from high molecular weight thermoplastic triblock elastomers Expired - Fee Related CA2273284C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US6455497P 1997-10-03 1997-10-03
US60/064,554 1997-10-03
PCT/US1998/020911 WO1999017926A1 (en) 1997-10-03 1998-10-02 High performance elastic composite materials made from high molecular weight thermoplastic triblock elastomers

Publications (2)

Publication Number Publication Date
CA2273284A1 true CA2273284A1 (en) 1999-04-15
CA2273284C CA2273284C (en) 2009-12-15

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CA002273284A Expired - Fee Related CA2273284C (en) 1997-10-03 1998-10-02 High performance elastic composite materials made from high molecular weight thermoplastic triblock elastomers

Country Status (7)

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US (2) US6323389B1 (en)
AU (1) AU9601298A (en)
BR (1) BR9806292A (en)
CA (1) CA2273284C (en)
DE (1) DE19881634T1 (en)
GB (1) GB2334476B (en)
WO (1) WO1999017926A1 (en)

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US6323389B1 (en) 2001-11-27
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GB9912745D0 (en) 1999-08-04
CA2273284C (en) 2009-12-15

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