CA2080453C - High loft rebulkable non-woven fabric: tacker fiber approach - Google Patents
High loft rebulkable non-woven fabric: tacker fiber approachInfo
- Publication number
- CA2080453C CA2080453C CA 2080453 CA2080453A CA2080453C CA 2080453 C CA2080453 C CA 2080453C CA 2080453 CA2080453 CA 2080453 CA 2080453 A CA2080453 A CA 2080453A CA 2080453 C CA2080453 C CA 2080453C
- Authority
- CA
- Canada
- Prior art keywords
- softening point
- nonwoven material
- webs
- loft nonwoven
- bicomponent
- 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
- 239000000835 fiber Substances 0.000 title claims abstract 15
- 239000004745 nonwoven fabric Substances 0.000 title abstract 2
- 239000000463 material Substances 0.000 claims abstract 16
- 238000000034 method Methods 0.000 claims abstract 10
- 238000010438 heat treatment Methods 0.000 claims abstract 5
- 230000006835 compression Effects 0.000 claims abstract 4
- 238000007906 compression Methods 0.000 claims abstract 4
- 229920001169 thermoplastic Polymers 0.000 claims abstract 3
- 239000004416 thermosoftening plastic Substances 0.000 claims abstract 3
- 229920002994 synthetic fiber Polymers 0.000 claims abstract 2
- -1 polyethylene Polymers 0.000 claims 5
- 229920000728 polyester Polymers 0.000 claims 4
- 229920000098 polyolefin Polymers 0.000 claims 3
- 239000004743 Polypropylene Substances 0.000 claims 2
- 229920001155 polypropylene Polymers 0.000 claims 2
- 229920001634 Copolyester Polymers 0.000 claims 1
- 239000004677 Nylon Substances 0.000 claims 1
- 239000004698 Polyethylene Substances 0.000 claims 1
- 229920003232 aliphatic polyester Polymers 0.000 claims 1
- 229920001577 copolymer Polymers 0.000 claims 1
- 239000004744 fabric Substances 0.000 claims 1
- 229920001903 high density polyethylene Polymers 0.000 claims 1
- 239000004700 high-density polyethylene Substances 0.000 claims 1
- 229920000092 linear low density polyethylene Polymers 0.000 claims 1
- 239000004707 linear low-density polyethylene Substances 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 claims 1
- 229920001778 nylon Polymers 0.000 claims 1
- 229920000573 polyethylene Polymers 0.000 claims 1
- 238000009736 wetting Methods 0.000 claims 1
- 238000002844 melting Methods 0.000 abstract 1
- 230000008018 melting Effects 0.000 abstract 1
- 239000012209 synthetic fiber Substances 0.000 abstract 1
Classifications
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Multicomponent Fibers (AREA)
Abstract
b:kozulla3.ffv PATENT
HIGH LOFT REBULKABLE NONWOVENS AND THEIR PROPERTIES
ABSTRACT OF DISCLOSURE
A method for making compressible webs of high loft nonwoven material containing bicomponent synthetic fibers having a thermoplastic component with a lower softening point component, such as a sheath-core bicomponent fiber, and converting the webs into a densified sheet of reduced thickness, and including compiling a plurality of the webs and exposing the fibers to a bonding temperature sufficiently high to soften the lower softening point component of the bicomponent fibers and to obtain a high-loft nonwoven material through inter-fiber contact points without compression of the webs, which method is characterized in that a thermoplastic tacking fiber having a softening point lower than that of all other components of the webs is incorporated within the webs before exposing the fibers to the said bonding temperature, the bonding temperature being sufficiently high to provide a low-density bonding pattern, and then heating the high-loft nonwoven material under compression at a temperature below the softening point of the lower softening point component and at or above the softening point of the tacking fiber to obtain a more densely bonded interim sheet product suitable for storage and/or transportation that can be rebulked by softening the tacking fibers without melting the lower softening point component.
HIGH LOFT REBULKABLE NONWOVENS AND THEIR PROPERTIES
ABSTRACT OF DISCLOSURE
A method for making compressible webs of high loft nonwoven material containing bicomponent synthetic fibers having a thermoplastic component with a lower softening point component, such as a sheath-core bicomponent fiber, and converting the webs into a densified sheet of reduced thickness, and including compiling a plurality of the webs and exposing the fibers to a bonding temperature sufficiently high to soften the lower softening point component of the bicomponent fibers and to obtain a high-loft nonwoven material through inter-fiber contact points without compression of the webs, which method is characterized in that a thermoplastic tacking fiber having a softening point lower than that of all other components of the webs is incorporated within the webs before exposing the fibers to the said bonding temperature, the bonding temperature being sufficiently high to provide a low-density bonding pattern, and then heating the high-loft nonwoven material under compression at a temperature below the softening point of the lower softening point component and at or above the softening point of the tacking fiber to obtain a more densely bonded interim sheet product suitable for storage and/or transportation that can be rebulked by softening the tacking fibers without melting the lower softening point component.
Claims (10)
1. A method of making high loft nonwoven material comprising one or more compressible webs containing bicomponent synthetic fibres having an exposed component with a first softening point, and thermoplastic tacking fibres having a second softening point below said first softening point, and converting the webs or webs into a rebulkable densified sheet of reduced thickness; including exposing the fibres of the nonwoven material to a bonding temperature at or above said first softening point to soften the exposed component of the bicomponent fibres and to obtain a high-loft nonwoven material through inter-fibre contact points providing low density bonding thereof, and subsequently heating the high-loft nonwoven material under compression at a temperature below said first softening point and at or above said second softening point to obtain a more densely bonded interim sheet product suitable for storage and/or transportation that can be rebulked by re-heating same to a temperature between said first and second softening points, not under compression.
2. A method for making high loft nonwoven material as claimed in claim 1, further characterized in that the low density bonding is a level of bonding that provides a high-loft fabric having a basis weight of 15 to 40 grams per square yard.
3. A method for making high loft nonwoven material as claimed in claim 1 or 2, further characterized in that the temperature used to carry out the low density bonding step is within the range of 100°C to 180°C.
4. A method for making high loft nonwoven material as claimed in claim 1, 2 or 3, further characterized in that the bicomponent staple fibre is a sheath/core bicomponent in which the sheath is the said exposed component.
5. A method for making high loft nonwoven material as claimed in any of the preceding claims, further characterized in that the tacking fibre is staple fibre having a dpf range of 1.0 to 30 dpf.
6. A method for making high loft nonwoven material as claimed in any of the preceding claims, further characterized in that it includes the step of rebulking the interim sheet product for its intended use by heating the said interim sheet product to a temperature below said first softening and above said second softening point to weaken or destroy bonding points created in the heating and compressing step and thereby to allow the webs to expand to a high-loft nonwoven material.
7. A method for making high loft nonwoven material as claimed in claim 6, further characterized in that the interim sheet product is heated by exposing it to hot gas.
8. A method as claimed in any one of claims 4 - 7, wherein said bicomponent fibres are sheath/core fibres selected from the group comprising polyolefin sheaths including polyethylene, polypropylene, and co-polymers thereof, with polyester, including polyethylene terephthalate cores, linear low or high density polyethylene sheaths with polypropylene cores, polypropylene sheaths with polyester cores, aliphatic polyester or copolyester sheaths with polyester cores, and polyolefin sheaths with nylon cores.
9. A method as claimed in claim 8, wherein said tacking fibre is a polyolefin or polyester capable of wetting the sheath material of said bicomponent fibre.
10. A high loft non-woven material made according to any one of claims 1 - 9.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US77793191A | 1991-10-17 | 1991-10-17 | |
| US777,931 | 1991-10-17 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2080453A1 CA2080453A1 (en) | 1993-04-18 |
| CA2080453C true CA2080453C (en) | 1999-02-09 |
Family
ID=25111736
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2080453 Expired - Fee Related CA2080453C (en) | 1991-10-17 | 1992-10-13 | High loft rebulkable non-woven fabric: tacker fiber approach |
Country Status (6)
| Country | Link |
|---|---|
| EP (1) | EP0538047B1 (en) |
| JP (1) | JPH05222658A (en) |
| CA (1) | CA2080453C (en) |
| DE (1) | DE69213153T2 (en) |
| DK (1) | DK0538047T3 (en) |
| MX (1) | MX9205979A (en) |
Families Citing this family (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5382400A (en) | 1992-08-21 | 1995-01-17 | Kimberly-Clark Corporation | Nonwoven multicomponent polymeric fabric and method for making same |
| GB9307117D0 (en) * | 1993-04-06 | 1993-05-26 | Hercules Inc | Card bonded comfort barrier fabrics |
| US6238449B1 (en) | 1998-12-22 | 2001-05-29 | 3M Innovative Properties Company | Abrasive article having an abrasive coating containing a siloxane polymer |
| US6312484B1 (en) | 1998-12-22 | 2001-11-06 | 3M Innovative Properties Company | Nonwoven abrasive articles and method of preparing same |
| JP4746256B2 (en) | 2000-09-15 | 2011-08-10 | アールストローム ノンウーブンズ エルエルシー | Disposable non-woven wipe fabric and method for producing the same |
| US6802932B2 (en) * | 2001-06-08 | 2004-10-12 | Uni-Charm Corporation | Absorbent article and method of manufacturing the same |
| DE60320496T2 (en) * | 2002-09-25 | 2009-05-07 | Kao Corp. | Method for recovering the bulkiness of a nonwoven fabric |
| JP5080753B2 (en) * | 2005-06-28 | 2012-11-21 | 日本バイリーン株式会社 | Filter element, manufacturing method and usage thereof |
| EA017477B1 (en) | 2007-12-14 | 2012-12-28 | Шлюмбергер Текнолоджи Б.В. | Proppants, methods of making and use thereof |
| BRPI0821118B1 (en) | 2007-12-14 | 2018-11-06 | Prad Research And Development Limited | method of completing a well, method of treating an underground formation intercepted by a well, using changeable additives, and method |
| US8353344B2 (en) | 2007-12-14 | 2013-01-15 | 3M Innovative Properties Company | Fiber aggregate |
| US11655572B2 (en) | 2018-12-17 | 2023-05-23 | The Procter & Gamble Company | Method and apparatus for relofting a nonwoven substrate |
| US11472132B2 (en) * | 2019-03-19 | 2022-10-18 | Piana Nonwovens, LLC. | Self-rising board molding |
| EP4324970A3 (en) * | 2019-03-19 | 2024-05-22 | Piana Nonwovens | Self rising board molding |
| US12246483B1 (en) | 2024-04-24 | 2025-03-11 | Piana Nonwovens Llc | Self-rising board molding |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5532050A (en) * | 1986-06-30 | 1996-07-02 | Wm. T. Burnett & Co., Inc. | Densified thermo-bonded synthetic fiber batting |
| DE69017762T2 (en) * | 1989-06-20 | 1995-08-24 | Japan Vilene Co Ltd | Recoverable voluminous nonwoven, method of manufacture and method of restoring the original shape. |
| US5183708A (en) * | 1990-05-28 | 1993-02-02 | Teijin Limited | Cushion structure and process for producing the same |
-
1992
- 1992-10-13 CA CA 2080453 patent/CA2080453C/en not_active Expired - Fee Related
- 1992-10-15 DK DK92309439T patent/DK0538047T3/en active
- 1992-10-15 DE DE1992613153 patent/DE69213153T2/en not_active Expired - Fee Related
- 1992-10-15 EP EP19920309439 patent/EP0538047B1/en not_active Expired - Lifetime
- 1992-10-16 MX MX9205979A patent/MX9205979A/en not_active IP Right Cessation
- 1992-10-19 JP JP27978392A patent/JPH05222658A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| DK0538047T3 (en) | 1996-09-16 |
| EP0538047B1 (en) | 1996-08-28 |
| EP0538047A1 (en) | 1993-04-21 |
| DE69213153T2 (en) | 1997-04-03 |
| MX9205979A (en) | 1993-04-01 |
| CA2080453A1 (en) | 1993-04-18 |
| JPH05222658A (en) | 1993-08-31 |
| DE69213153D1 (en) | 1996-10-02 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |