CA2563984A1 - Polypropylene blends for non-woven fabrics - Google Patents

Polypropylene blends for non-woven fabrics Download PDF

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Publication number
CA2563984A1
CA2563984A1 CA002563984A CA2563984A CA2563984A1 CA 2563984 A1 CA2563984 A1 CA 2563984A1 CA 002563984 A CA002563984 A CA 002563984A CA 2563984 A CA2563984 A CA 2563984A CA 2563984 A1 CA2563984 A1 CA 2563984A1
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CA
Canada
Prior art keywords
percent
weight
polypropylene composition
ethylene
less
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.)
Granted
Application number
CA002563984A
Other languages
French (fr)
Other versions
CA2563984C (en
Inventor
Kimberly M. Mcloughlin
Sehyun Kim
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.)
Braskem America Inc
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2563984A1 publication Critical patent/CA2563984A1/en
Application granted granted Critical
Publication of CA2563984C publication Critical patent/CA2563984C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/12—Polypropene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/14—Copolymers of propene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • 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
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/66—Additional nonwoven fabric is a spun-bonded fabric
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/68—Melt-blown nonwoven fabric
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/681—Spun-bonded nonwoven fabric
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/69—Autogenously bonded nonwoven fabric

Abstract

The present invention provides polypropylene blends for use in the production fibers and fabrics. The polypropylene blends according to the current invention comprise from about 85 to about 95 percent by weight of a propylene homopolymer and from about 5 to about 15 percent by weight of an ethylene/propylene random copolymer having an ethylene content of about 7 percent by weight or less. The overall ethylene content of the blends according to the present invention is about 1 percent by weight or less.
Polypropylene blends according to the current invention provide lower bonding temperatures and wider bonding windows without the increased smoke generation associated with high solubles homopolymers.

Claims (23)

1. A polypropylene composition comprising:

from about 80 to about 95 percent by weight of a propylene homopolymer, said propylene homopolymer having a decalin solubles content of about 4 percent by weight or less;
and from about 5 to about 20 percent by weight of an ethylene/propylene random copolymer, said ethylene/propylene random copolymer having an ethylene content of about 7 percent by weight or less;

said propylene composition having a total ethylene content of about 1 percent by weight or less, and a decalin solubles content of about 6 percent by weight or less.
2. The polypropylene composition according to claim 1, wherein said ethylene/propylene random copolymer has an ethylene content of from about 2 to about 3 percent by weight.
3. The polypropylene composition according to claim 1, wherein said propylene homopolymer has a decalin solubles content of from about 2 to about 4 percent by weight.
4. The polypropylene composition according to claim 1, wherein said polypropylene composition has a melt flow index of from about 8 to about 55 dg/min at 230° C.
5. The polypropylene composition according to claim 4, wherein said polypropylene composition is visbroken from a material having a melt flow index of less than 12 dg/min at 230°
C.
6. The polypropylene composition according to claim 1, wherein said polypropylene composition is produced by in-reactor blending.
7. The polypropylene composition according to claim 1, wherein said polypropylene composition is produced by melt blending a propylene homopolymer with an ethylene/propylene random copolymer.
8. A non-woven fabric comprising:

a polypropylene composition comprising from about 80 to about 95 percent by weight of a propylene homopolymer, said propylene homopolymer having a decalin solubles content of about 4 percent by weight or less; and from about 5 to about 20 percent by weight of an ethylene/propylene random copolymer, said ethylene/propylene random copolymer having an ethylene content of about 7 percent by weight or less;

said polypropylene composition having a total ethylene content of about 1 percent by weight or less, and a decalin solubles content of about 6 percent by weight or less.
9. The non-woven fabric according to claim 8, wherein said ethylene/propylene random copolymer has an ethylene content of from about 2 to about 3 percent by weight.
10. The non-woven fabric according to claim 8, wherein said propylene homopolymer has a decalin solubles content of from about 2 to about 4 percent by weight.
11. The non-woven fabric according to claim 8, wherein said polypropylene composition has a melt flow index of from about 8 to about 55 dg/min at 230° C.
12. The non-woven fabric according to claim 11, wherein said polypropylene composition is visbroken from a material having a melt flow index of less than 12 dg/min at 230° C.
13. The non-woven fabric according to claim 8, wherein said polypropylene composition is produced by in-reactor blending.
14. The non-woven fabric according to claim 8, wherein said polypropylene composition is produced by melt blending a propylene homopolymer with an ethylene/propylene random copolymer.
15. A multilayer non-woven fabric construction comprising:

at least one first layer comprising a spunbond web and at least one second layer comprising a meltblown web;

said spunbond web comprising a polypropylene composition comprising from about to about 95 percent by weight of a propylene homopolymer, said propylene homopolymer having a decalin solubles content of about 4 percent by weight or less; and from about 5 to about 20 percent by weight of an ethylene/propylene random copolymer having an ethylene content of about 7 percent by weight of the ethylene/propylene random copolymer or less;

said polypropylene composition having a total ethylene content of about 1 percent by weight or less, and a decalin solubles content of about 6 percent by weight or less.
16. The multilayer non-woven fabric construction according to claim 15, wherein said ethylene/propylene random copolymer has an ethylene content of from about 2 to about 3 percent by weight.
17. The multilayer non-woven fabric construction according to claim 15, wherein said propylene homopolymer has an decalin solubles content of from about 2 to about 4 percent by weight.
18. The multilayer non-woven fabric construction according to claim 15, wherein said polypropylene composition has a melt flow index of from about 8 to about 55 dg/min at 230° C.
19. The multilayer non-woven fabric construction according to claim 18, wherein said polypropylene composition is visbroken from a material having a melt flow index of less than 12 dg/min at 230° C.
20. The multilayer non-woven fabric construction according to claim 15, wherein said polypropylene composition is produced by in-reactor blending.
21. The multilayer non-woven fabric construction according to claim 15, wherein said polypropylene composition is produced by melt blending a propylene homopolymer with an ethylene/propylene random copolymer.
22. The multilayer non-woven fabric construction according to claim 15, comprising a meltblown web sandwiched between two spunbond webs.
23. The multilayer non-woven fabric construction according to claim 15, wherein said at least one first web and said at least one second web are bonded by calendering.
CA002563984A 2004-05-12 2005-04-05 Polypropylene blends for non-woven fabrics Expired - Fee Related CA2563984C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/844,640 2004-05-12
US10/844,640 US7655582B2 (en) 2004-05-12 2004-05-12 Polypropylene blends for non-woven fabrics
PCT/US2005/011823 WO2005113674A1 (en) 2004-05-12 2005-04-05 Polypropylene blends for non-woven fabrics

Publications (2)

Publication Number Publication Date
CA2563984A1 true CA2563984A1 (en) 2005-12-01
CA2563984C CA2563984C (en) 2010-01-12

Family

ID=34964694

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002563984A Expired - Fee Related CA2563984C (en) 2004-05-12 2005-04-05 Polypropylene blends for non-woven fabrics

Country Status (5)

Country Link
US (1) US7655582B2 (en)
EP (1) EP1745101A1 (en)
CA (1) CA2563984C (en)
MX (1) MXPA06013107A (en)
WO (1) WO2005113674A1 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8466235B2 (en) 2002-08-27 2013-06-18 Braskem America, Inc. Polypropylene blends for non-woven production
US6733898B2 (en) * 2002-08-27 2004-05-11 Sunoco Inc. Resin compositions for producing biaxially oriented polypropylene films
US20070167576A1 (en) * 2002-08-27 2007-07-19 Sehyun Kim Resin compositions for producing biaxially oriented polypropylene films
US8399587B2 (en) * 2003-12-08 2013-03-19 Fina Technology, Inc. Mini-random copolymer resins having improved mechanical toughness and related properties suitable for thin wall thermoforming applications

Family Cites Families (19)

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Publication number Priority date Publication date Assignee Title
US5182162A (en) 1990-10-24 1993-01-26 Amoco Corporation Self-bonded nonwoven web and net-like web composites
EP0538749B1 (en) * 1991-10-21 1995-01-11 Mitsubishi Petrochemical Co., Ltd. Propylene copolymer composition
CN1094419C (en) 1994-05-24 2002-11-20 埃克森美孚化学专利公司 Fibers and fabrics incorporating lower melting propylene polymers
US5691043A (en) 1994-07-15 1997-11-25 Mobil Oil Corporation Uniaxially shrinkable biaxially oriented polypropylene film and its method of preparation
US5460884A (en) * 1994-08-25 1995-10-24 Kimberly-Clark Corporation Soft and strong thermoplastic polymer fibers and nonwoven fabric made therefrom
US6309736B1 (en) 1994-12-20 2001-10-30 Kimberly-Clark Worldwide, Inc. Low gauge films and film/nonwoven laminates
US5652051A (en) 1995-02-27 1997-07-29 Kimberly-Clark Worldwide, Inc. Nonwoven fabric from polymers containing particular types of copolymers and having an aesthetically pleasing hand
US6437048B1 (en) * 1995-12-01 2002-08-20 Chisso Corporation Molded resin articles
US6444774B1 (en) 1997-10-10 2002-09-03 Exxonmobil Chemical Patents, Inc. Propylene polymers for fibers and fabrics
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US6187494B1 (en) * 1998-07-24 2001-02-13 Ricoh Company, Ltd. Electrophotographic photoconductor and aromatic polycarbonate resin for use in the photoconductor
US6225411B1 (en) 1999-04-19 2001-05-01 Montell Technology Company Bv Soft propylene polymer blend with high melt strength
JP4438138B2 (en) 1999-09-17 2010-03-24 住友化学株式会社 Thermoplastic resin composition
US6248833B1 (en) 2000-02-29 2001-06-19 Exxon Mobil Chemical Patents Inc. Fibers and fabrics prepared with propylene impact copolymers
JP3921951B2 (en) 2001-02-27 2007-05-30 住友化学株式会社 Polypropylene resin composition and method for producing the same
US6906160B2 (en) 2001-11-06 2005-06-14 Dow Global Technologies Inc. Isotactic propylene copolymer fibers, their preparation and use
US6733898B2 (en) 2002-08-27 2004-05-11 Sunoco Inc. Resin compositions for producing biaxially oriented polypropylene films
PL374316A1 (en) 2002-09-25 2005-10-03 Basell Poliolefine Italia S.P.A. Polypropylene fibres suitable for spunbonded non-woven fabrics
JP2006500486A (en) 2002-09-25 2006-01-05 バセル ポリオレフィン イタリア エス．アール．エス． Polypropylene fiber suitable for thermal bonding nonwoven fabric

Also Published As

Publication number Publication date
WO2005113674A1 (en) 2005-12-01
CA2563984C (en) 2010-01-12
EP1745101A1 (en) 2007-01-24
US20050255777A1 (en) 2005-11-17
US7655582B2 (en) 2010-02-02
MXPA06013107A (en) 2007-02-14

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Effective date: 20210406