CA2792831A1 - Process for making nonwoven webs - Google Patents

Process for making nonwoven webs Download PDF

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Publication number
CA2792831A1
CA2792831A1 CA2792831A CA2792831A CA2792831A1 CA 2792831 A1 CA2792831 A1 CA 2792831A1 CA 2792831 A CA2792831 A CA 2792831A CA 2792831 A CA2792831 A CA 2792831A CA 2792831 A1 CA2792831 A1 CA 2792831A1
Authority
CA
Canada
Prior art keywords
o2cr
additive
group
polyarylene sulfide
iodide
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.)
Abandoned
Application number
CA2792831A
Other languages
French (fr)
Inventor
Lakshmi Krishnamurthy
Joachim C. Ritter
Joel M. Pollino
Michael T. Pottiger
John C. Howe
David Matthews Laura, Jr.
Harry Vaughn Samuelson
Robert John Duff
Zheng-zheng HUANG
Zuohong Yin
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.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
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 EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Publication of CA2792831A1 publication Critical patent/CA2792831A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/16—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one other macromolecular compound obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds as constituent
    • 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
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Multicomponent Fibers (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)

Abstract

A nonwoven web comprising bicomponent fibers. The fibers have continuous phases each of a first polyarylene sulfide (PAS) component and a polymer component. The polymer component may also be a second polyarylene sulfide. The first polyarylene sulfide component contains a tin or a zinc additive or both, and the first polyarylene sulfide component of any given fiber is at least partially exposed to the external surface of that fiber.

Claims (24)

1. A process for manufacturing a nonwoven web comprising the steps of (i) spinning bicomponent fibers into a nonwoven web, said fibers comprising continuous phases each of a first polyarylene sulfide (PAS) component and a polymer component, in which the first polyarylene sulfide component contains a tin or a zinc additive or both, and the first polyarylene sulfide component of any given fiber is at least partially exposed to the external surface of that fiber, and (ii) calendaring the nonwoven web.
2. The process of claim 1 in which the step of spinning is a spunbond process.
3. The process of claim 1 in which the polymer component comprises a polymer selected from the group consisting or polyether ether ketone (PEEK), polyether ketone (PEK), polyester, polypropylene, polyamide, and mixtures thereof.
4. The process of claim 3 in which the polyester comprises polyethylene terephthalate (PET), polytrimethylene terephthalate, or polybutylene terephthalate (PBT).
5. The process of claim 1 in which the second polymer component comprises a second polyarylene sulfide.
6. The process of claim 5 in which the second polyarylene sulfide is blended with a calcium salt.
7. The process of claim 6 in which the calcium salt is calcium stearate.
8. The process of claim 1 in which the tin additive is a branched carboxylate selected from the group consisting of Sn(O2CR)2, Sn(O2CR)(O2CR'), Sn(O2CR)(O2CR"), and mixtures thereof, where the carboxylate moieties O2CR
and O2CR' independently represent branched carboxylate anions and the carboxylate moiety O2CR" represents a linear carboxylate anion
9. The process of claim 8 in which tin additive further comprises a linear tin(II) carboxylate Sn(O2CR")2
10. The process of claim 8 in which the sum of the branched carboxylate moieties O2CR and O2CR' is at least about 25% on a molar basis of the total carboxylate moieties O2CR, O2CR' and O2CR" contained in the tin additive.
11. The process of claim 8 in which the radical R" is a primary alkyl group comprising from 6 to 30 carbon atoms.
12. The process of claim 11 in which the radical R" is substituted with a group selected form the group consisting of fluoride, chloride, bromide, iodide, nitro, hydroxyl, carboxylate, and any combination thereof.
13. The process of claim 8 in which the radicals R and R' independently or both have a structure represented by Formula (I), wherein R1, R2, and R3 are selected from the group consisting of:
H;
a primary, secondary, or tertiary alkyl group having from 6 to 18 carbon atoms, optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups;
an aromatic group having from 6 to 18 carbon atoms, optionally substituted with alkyl, fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups; and a cycloaliphatic group having from 6 to 18 carbon atoms, optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups;
with the proviso that when R2 and R3 are H, R1 is:
a secondary or tertiary alkyl group having from 6 to 18 carbon atoms, optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups;
an aromatic group having from 6 to 18 carbons atoms and substituted with a secondary or tertiary alkyl group having from 6 to 18 carbon atoms, the aromatic group and/or the secondary or tertiary alkyl group being optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups; and a cycloaliphatic group having from 6 to 18 carbon atoms, optionally substituted with fluoride, chloride, bromide, iodide, nitro, hydroxyl, and carboxyl groups.
14. The process of claim 8 in which the radicals R and R' independently or both have a structure represented by Formula (I), and R3 is H.
15. The process of claim 8 in which the radicals R and R' independently or both have a structure represented by Formula (II), wherein R4 is a primary, secondary, or tertiary alkyl group having from 4 to 6 carbon atoms, optionally substituted with fluoride, chloride, bromide, iodide, nitro, and hydroxyl groups; and R5 is a methyl, ethyl, n-propyl, sec-propyl, n-butyl, sec-butyl, or tert-butyl group, optionally substituted with fluoride, chloride, bromide, iodide, nitro, and hydroxyl groups.
16. The process of claim 8 in which the radicals R and R' are the same and both have a structure represented by Formula (II), R4 is n-butyl, and R5 is ethyl.
17. The process of claim 1 in which the tin additive is present at a concentration of about 10 weight percent or less of the weight of the first polyarylene sulfide component.
18. The process of claim 1 in which the zinc additive comprises a zinc(II) additive or zinc metal [Zn(0)] or a mixture of both.
19. The process of claim 18 in which the zinc(II) additive is an organic additive or an inorganic additive or a mixture of both.
20. The process of claim 19, wherein the Zn(II) additive is selected from the group consisting of zinc oxide, zinc stearate, zinc sulfate and mixtures thereof.
21. The process of claim 1, wherein the zinc and tin additives are present at a total concentration of equal to or less than about 25 weight percent, based on the weight of the polyarylene sulfide.
22. The process of claim 21, wherein the Zn(II) additive and zinc metal are present at a total concentration of zero to about about 10 weight percent or less, based on the weight of the polyarylene sulfide.
23. The process of claim 5, wherein the first polyarylene sulfide, or the second polyarylene sulfide, or both are polyphenylene sulfide.
24. The process of Claim 1 comprising calendaring the nonwoven web for a time and temperature sufficient to bond at least a subset of the individual fibers.
CA2792831A 2010-03-22 2011-03-17 Process for making nonwoven webs Abandoned CA2792831A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US31606510P 2010-03-22 2010-03-22
US61/316,065 2010-03-22
PCT/US2011/028752 WO2011119397A2 (en) 2010-03-22 2011-03-17 Process for making nonwoven webs

Publications (1)

Publication Number Publication Date
CA2792831A1 true CA2792831A1 (en) 2011-09-29

Family

ID=44673808

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2792831A Abandoned CA2792831A1 (en) 2010-03-22 2011-03-17 Process for making nonwoven webs

Country Status (8)

Country Link
US (1) US20130009333A1 (en)
EP (1) EP2550386A4 (en)
JP (1) JP2013522495A (en)
KR (1) KR20130007619A (en)
CN (1) CN102918191A (en)
BR (1) BR112012023944A2 (en)
CA (1) CA2792831A1 (en)
WO (1) WO2011119397A2 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104480566A (en) * 2014-12-31 2015-04-01 江苏恒力化纤股份有限公司 High-strength wicking-resistance polyester industrial yarn and preparation method thereof
CN104562280A (en) * 2014-12-31 2015-04-29 江苏恒力化纤股份有限公司 Anti-wicking ultra-low shrinkage polyester industrial yarn and manufacturing method thereof

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011119546A2 (en) 2010-03-22 2011-09-29 E. I. Du Pont De Nemours And Company Cure acceleration of polymeric structures
AU2012232449A1 (en) * 2011-03-22 2013-10-03 Toray Industries, Inc. Polyphenylene sulfide composite fiber and nonwoven fabric
US20130273799A1 (en) * 2012-04-13 2013-10-17 Ticona Llc Polyarylene Sulfide Fibers and Composites Including the Fibers
JP6102932B2 (en) * 2012-09-21 2017-03-29 東レ株式会社 Polyphenylene sulfide composite fiber and non-woven fabric
CN103510184B (en) * 2013-09-26 2015-07-01 江苏立新化纤科技有限公司 Fluorine-containing PET-PBT (polyethylene terephthalate- polybutylene terephthalate) copolyester DTY (draw texturing yarn) fiber and preparation method thereof
EP3134568A4 (en) * 2014-05-13 2018-01-03 First Quality Nonwovens, Inc. Patterned nonwoven and method of making the same using a through-air drying process

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CN102099514B (en) * 2008-07-18 2013-03-13 东丽株式会社 Polyphenylene sulfide fiber, process for producing the same, wet-laid nonwoven fabric, and process for producing wet-laid nonwoven fabric
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104480566A (en) * 2014-12-31 2015-04-01 江苏恒力化纤股份有限公司 High-strength wicking-resistance polyester industrial yarn and preparation method thereof
CN104562280A (en) * 2014-12-31 2015-04-29 江苏恒力化纤股份有限公司 Anti-wicking ultra-low shrinkage polyester industrial yarn and manufacturing method thereof
CN104562280B (en) * 2014-12-31 2016-10-05 江苏恒力化纤股份有限公司 A kind of anti-core suction type ultralow contraction terylene industry silk and manufacture method thereof

Also Published As

Publication number Publication date
EP2550386A4 (en) 2013-12-25
CN102918191A (en) 2013-02-06
KR20130007619A (en) 2013-01-18
BR112012023944A2 (en) 2017-08-08
WO2011119397A3 (en) 2012-01-26
US20130009333A1 (en) 2013-01-10
JP2013522495A (en) 2013-06-13
EP2550386A2 (en) 2013-01-30
WO2011119397A2 (en) 2011-09-29

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Legal Events

Date Code Title Description
FZDE Discontinued

Effective date: 20150317