DE60219358T2 - DIFFERENTIALLY INTERRUPTED NONWOVENS AS WIPE CLOTH - Google Patents

Description

TECHNICAL AREA

The The invention disclosed herein relates to wipes, preferably wipes for use in of graphics or lithography, made from a hydro-entangled one Nonwoven fabric, wherein the fibers are on the outside surface of a single fibrous web strongly hydroentangled and the inner fibers of the single fibrous web be slightly vortexed, causing the resulting fabric a low fuzziness, an airy structure and a favorable tactile and shows ductile softness while a sufficient physical strength is obtained.

BACKGROUND OF THE INVENTION

The Use of natural Fiber materials in industrial applications has been in situations Determined as very beneficial where a non-linting, absorbent pillow or wiper is required. A material used in such Applications used was in the Webril material of the Kendall Company of Massachusetts found. The Webril material is a compressed, mercerised cotton fiber pile. The mercerization process includes the swelling of the band-like profile of the natural cotton to an approximately round Profile with larger diameter. Typically, alkali washes used while out the cotton pile is under a tensile stress to the springs of cotton fiber. Because of The use of an alkaline solution requires that Cotton material afterwards with an acid solution so as to neutralize the material and make it usable close. A number of complicated steps are required to perform the process successfully, with a significant Amount of polluting Wastewater is generated.

in the Interest in the formation of natural Nonwoven pads or wipers without the by-products of mercerisation has been the use of a resin binder in conjunction with the Hydroentanglement is explored as disclosed in U.S. Patent No. 2,862,251, No. 3033721, No. 3769659 and No. 3931436 to Kalwaites and co-workers and U.S. Patent Nos. 3,081,515 and 3,025,585 to Griswold et al Employee was proved. It was determined that the application of the resin binder has a detrimental effect on softness of the corresponding nonwoven fabric.

The Investigations by Evans, U.S. Patent No. 3,485,706, refer to that the impedance of the energetic water flows on a batt Nonwoven fabric by the turbulence of those fibers with each other over the Could create depth of the fibrous web, eliminating the need for a resin binder is turned off. The effect of water flows on the Fluff and the effect of swirling the fibers, however, result to a fabric with a significantly reduced bulkiness and a correspondingly reduced tactile and ductile softness.

It Various attempts have been made to have a durable natural one To obtain nonwoven fabric while sufficient strength and softness are maintained. in the U.S. Patent No. 5,849,647 to Neveu becomes a hydrophilic cotton-coated Structure by inserting an air-tangled core between two previously formed highly fiber-oriented carded layers. The layered layers are then treated with a soda cooking liquor treated, which is then boiled to an integrated structure to effect. While a cotton structure made by the described manner final Submit material that shows a low linting, must the material is a significant processing in the formation of the separate and individual layers and the juxtaposition of those layers during the experienced alkaline integration step. U.S. Patent No. 4,647,490 At Bailey and co-workers shows the formation of one with openings hydroentangled cotton fiber nonwoven material, which is caused by reciprocating streams of water. At the Bailey's method will down the fibers of the batt and down washed through the batt to swirl the fibers and openings to form in the fabric. U.S. Patent No. 4,426,417 to Meitner et al includes the use of melt blown thermoplastic during the Forming a fibrous web as a means of achieving airiness for the absorbency and keeps sufficient physical strength by bonding the fibers together. Since the essence of the Meitner process on the whole and effective bonding of the fibers to the melt blown Thermoplastic based, there are potential problems with unbound or loosely bonded fibers that are released from the meltblown.

WO 02 / 31249A discloses a nonwoven fabric having a single batt, wherein the single batt represents the application of hydraulic energy in the range of 0.027 to 0.046 hp-hr / lb. swirled to form a nonwoven fabric, the nonwoven fabric having a highly swirled outer surface region and a weakly swirled inner core region.

The EP-A-0602881 discloses a nonwoven wipe comprising a single wipe Fibrous, wherein the single batt by the application is swirled by hydraulic energy. WO 98/23804A and EP-A-0473325 reveal same wipes.

At the Attempted prior art to form not lint, soft yet strong absorbent materials remains one Demand for a nonwoven fabric consist of these properties shows and yet formed in a fast and straightforward way becomes.

One A process for forming a suitable nonwoven fabric, the preceding mentioned Meets requirements, was identified in the application of fluidic energy, so that a single batt with a strongly swirled surface of outer fibers is effected while the airiness and absorbency maintained a weakly swirled middle layer of core fibers becomes.

SUMMARY OF THE INVENTION

The The present invention relates to a process for producing a Nonwoven fabric whose outer surface is strong has entangled fibers, whereas the inner layer slightly swirled Fibers shows. In particular, the present invention contemplates that a fabric is formed from a batt, which is a fluidic Energy is exposed, preferably a hydraulic energy, the on one or both surfaces a Faserflores is applied. The hydraulic energy is compared to the grammage steamed of the fiber pile, to the desired Degree of surface turbulence to reach.

In accordance with the present invention is a wiper of nonwoven fabric provided with a single batt, whereupon the Single FIB consists of fibers made of 100% cotton fibers and a blend of cotton and synthetic staple fibers selected be, and by the application of hydraulic energy in the area from about 233.4 to 350.1 J / g (0.040 to 0.060 hp.hr/lb.) Being a differentially swirled nonwoven wipe to form, wherein the wiper of nonwoven fabric swirled a strong Outside area and a weakly swirled inner core region, wherein the strongly swirling area and the weakly swirling area each from one of the selected Fibers are formed under the restriction that the applied Hydraulic energy is more than 268.4 J / g (0.046 hp.hr/lb.).

While the Use of natural fibers usual The fiber matrix can be synthetic fibers or mixtures of natural and synthetic fibers. The synthetic fibers become selected from the group, from viscose, polyacrylates, polyolefins, polyamides, Polyester and their combinations exists. In addition, the synthetic fibers homogeneous, bicomponent and / or multi-component profiles and their Have mixtures.

at a specially preferred form of the batt is carded and cross-lapped, to form a batt. The batt subsequently becomes continuous relayed by a station, which consists of a rotating porous area and a fluid collection manifold. Fluid flows from the fluid manifold encounter the fiber web at a controlled energy level, so as to integrate a portion of the total fiber content. The energy level is controlled so that the energy is sufficient is to high levels of turbulence in the surface fibers but has insufficient transmitted energy, to cause high levels of turbulence of the internal fibers. A variety of such stations can be used, wherein fluid streams are at the same or different energy levels that impinge on one or alternately both surfaces of the fibrous web. The resulting differential entangled nonwoven fabric shows a strongly swirled fiber outer surface and a slightly swirled fiber core.

Afterwards Hydro turbulence also draws the present method Providing a three-dimensional image transmission device, the one moving picture surface having. Such three-dimensional image transfer devices become in U.S. Patent No. 5,098,764. In a typical configuration can the image transfer device a drum-like device, with reference to rotatable one or more hydrodynamic manifolds.

It is within the scope of this invention that tension control means be employed to further improve the physical performance of the resulting airy material.

One Another aspect of the present invention relates to a method for producing a nonwoven fabric of a sufficient degree shows softness and a non-fuzz performance, while the Required resistance to tearing and abrasion resistance be deployed to use in a wide variety of applications easier. The fabric shows a high degree in airiness and absorbency, thereby allowing its use in those applications the fabric is used as a cleaning wipe. Also shows the material has a pleasing aesthetics, thereby it is for an application for medical purposes.

One Process for the preparation of the present durable nonwoven fabric has the steps of providing a fiber matrix or -flores subjected to the controlled levels of hydraulic energy becomes. It has been found that a homogeneous cotton fiber pile is desirable a fabric with a soft feel and good absorbency supplies. The batt becomes a differentially swirled Nonwoven fabric formed by the application of sufficient energy, around only the outer layers of the fibrous web. Consequently, the substance can over a Image transfer device guided which is defined by three-dimensional elements against which the differentially entangled nonwoven fabric during the further application of pressed further energy which causes the fibrous constituents of the nonwoven to move in areas between the three-dimensional elements of the transfer device be imaged and patterned.

It is within the scope of the present invention that chemical Compositions which alter the physical property, in the resulting differentially entangled material are incorporated can. Such chemical compositions include, for example, antimicrobial and antistatic agents, which are based on the fibrous constituents of the fibrous web, on the fleece during the production and / or the resulting material permanently applied can be.

Further Characteristics and advantages of the present invention will be readily apparent from the following detailed description accompanying drawings and the annexed claims become.

BRIEF DESCRIPTION OF THE DRAWINGS

It demonstrate:

1 FIG. 4 is a diagram of an apparatus for producing a differentially entangled nonwoven embodying the principles of the present invention; FIG. and

2 a graphical representation of five consecutive Verwirbelungsabschnitten and an image transfer station.

DETAILED DESCRIPTION

While the present invention for an execution accessible in different forms is in the drawings, a presently preferred embodiment of Invention and hereinafter described, to be understood is that the present disclosure as an explanation of the invention by examples, and not The invention is intended to be specific to the illustrated execution to restrict.

The The present invention relates to a process for the preparation of Nonwovens by hydroentanglement, wherein the outer surface of the Substance essentially stronger is swirled as the core situation. Hydro turbulence by means of this process is controlled by the application of fluid energy, so that the energy given into the fibers of the substance is sufficient is to only the outer fibers strongly to swirl. The inner fibers are slightly swirled, so that the entire structure is resistant to a separation of the layers, but still a big one Part of the airiness or buoyancy of the fiber core layer which maintains for the tactile and ductile softness as well as absorbency responsible for. By moving forward the fibrous web with a relatively low tensile stress by a or multiple swirl stations becomes a differential fiber swirl causes, the physical properties, both aesthetic and aesthetic also mechanical, of the resulting substance desirably achieved become.

In accordance with a further aspect of the present invention may be a nonwoven fabric for a use as a wiping cloth can be made so that the level of surface turbulence can be controlled, resulting in surface layers that are extremely resistant to are a lint, while the Fabric maintains a certain airiness of the fiber inner layer. It will determines that a material of this nature in the polygraphy and lithography as it is used as an abrasion-resistant drapable absorbent wiper can be used. An excessive linting from the wipe for the Application disadvantageous; thus, the reinforcement of the level of turbulence should be the surface fibers act to lint the heavily swirled surface layer to reduce that as a barrier to the loss of fibers or Particles from the weakly fluidized core should act. The level the turbulence energy can be continuously varied to to modify the physical properties of the wipe material, to meet the required performance. It lies within the Area of the present invention, the level of turbulence in the resulting material to control materials with changing Degrees of airiness, absorbency, To maintain firmness and linting performance.

nonwovens become common produced using staple fibers; the fabric typically has one Degree of exposed surface fibers which will show linting if not sufficient be kept in the structure of the substance. The present invention delivers a finished fabric that is cut, processed or treated and for the retail sale can be packed. The costs in connection with the shaping and equipment steps can desirably be reduced.

With reference to 2 An apparatus for practicing the present process for making a nonwoven fabric is illustrated. The fabric is formed from a batt typically having natural fibers but which may comprise staple synthetic fibers and natural / synthetic fiber blends. The batt is preferably candied and cross-paneled to form a batt labeled P. In a current embodiment, the batt has 100% cross-paneled fibers, ie, all the fibers of the batt were formed by cross-beating a carded web so that the fibers are oriented at an angle relative to the direction of manufacture of the resultant web. In this current embodiment, the batt has a draw ratio of approximately 2.8 to 1. U.S. Patent No. 5,475,903 illustrates a nonwoven stretching apparatus.

2 FIG. 12 illustrates a hydro-entangling apparatus for making nonwovens in accordance with the present invention. The device comprises a porous shaping surface in the form of the band 02 on which the batt P for a Vorverwirbelung by means of Verwirbelungsverteilers 01 to a wetted, slightly fluidized nonwoven P 'is positioned. The Vorverwirbelung of the fibrous web is then by the movement of the web P 'sequentially via a drum 10 having a porous shaping surface, the swirling distributor 12 causes the swirling of the web. Further swirling of the web may occur on the porous forming surface of a drum 20 by means of the swirl distributor 22 be effected, wherein the nonwoven subsequently over successive porous drums 30 . 40 and 50 for a sequential swirling treatment by means of the swirl distributors 32 . 42 and 51 to be led. The total optimum energy input into the batt to obtain the desired level of surface entanglement is in the range of about 233.4 to 350.1 J / g (0.040 to 0.060 hp-hr / lb.), with the limitation that the applied hydraulic energy is more than 268.4 J / g (0.046 hp-hr / lb.).

The swirling device 2 may also have an imaging and patterning drum 18 comprising a three-dimensional image transfer device for effecting imaging and patterning of the now swirled nonwoven precursor. The image transfer device includes a movable imaging surface that is relative to a plurality of swirl manifolds 61 . 62 . 63 and 64 which cooperate with three-dimensional elements defined by the imaging surface of the image transfer device to effect imaging and patterning of the fabric being produced. The total energy of the imaging manifold applied to the batt is regulated to maintain the energy input in the range of about 233.4 to 350.1 J / g (0.040 to 0.060 hp-hr / lb.), with the limitation that the applied Hydraulic energy is more than 268.4 J / g (0.046 hp-hr / lb.).

The present invention contemplates that the nonwoven fabric P 'is transported onto the movable imaging surface of the image transfer device at a speed substantially equal to the speed of movement of the imaging surface. A J box or box may be used to support the nonwoven precursor P 'while it is being transferred to the image transfer device, thereby minimizing the tension within the nonwoven fabric. By controlling the speed of transport of the fibrous web P and the web P 'throughout the process, so as to achieve To minimize or substantially eliminate tensile stress within the web, it is desirable to effect differential hydroentanglement of the nonwoven web.

The preparation of a durable nonwoven fabric embodying the principles of the present invention is initiated by providing the nonwoven precursor preferably in the form of natural and / or synthetic fibers, most preferably a cotton or cotton blend, desirably good tactile and ductile softness and absorbency provides. During development, fabric weights were found to be on the order of about 33.97 to 271.76 g / m ² (1 to 8 oz / yd ² ), with the range of 67.94 to 169.85 g / m ² ( 2 to 5 oz / yd ² ) which gave the best combination of airiness, softness, drapability, absorbency and durability.

EXAMPLES

example 1

When using a manufacturing device as described in 1 For example, a nonwoven fabric in accordance with the present invention was prepared by providing a batt comprising 100% by weight of cotton fibers. The batt exhibited a basis weight of 115.49 g / m ² (3.4 oz / yd ² ) (plus or minus 7%). The nonwoven fabric was carded 100% and cross-screened at a draw ratio of 2.8 to 1.

The fabric had 100% by weight of cotton as sold by the Barnhardt Manufacturing Company under code no. RMC # 2811 is available. The batt was swirled by means of a series of swirl distribution stations, such as those shown graphically in FIG 1 and more detailed in 2 be illustrated. 2 illustrates the placement of the fibrous web P on a porous forming surface in the form of the belt 02 , wherein on the pile through a Vorverwirbelungsverteil 01 working with 55 bar to form a wetted and slightly swirled fiber fleece. The web then passes through a series of swirl stations having drums with porous forming surfaces for swirling by means of swirl distributors, the web. then around the porous forming surface of a drum 10 for swirling by means of the swirl distributor 12 who works with 40 bar. The nonwoven is then passed over successive porous drums 20 . 30 . 40 and 50 in a successive swirl treatment by means of swirl distributors 22 . 32 . 42 and 51 guided. In the present examples, each of the swirl manifolds comprised 120 micron holes spaced at 16.65 per cm (42.3 per inch), with the manifolds 22 . 32 . 42 and 51 operated sequentially at 55, 40, 55 and 0 bar at a rate of 45 meters per minute. The total energy input into the batt is calculated to be 303.5 J / g (0.052 hp-hr / lb.). A nonwoven having a cut width of 322.58 cm (127 in.) Was used.

Comparative example

The Comparative example is from a commercially available product selected in the form of Webril 100% Cotton Handi-Pad, the available from the Kendall Company is. This product is made by molding cotton fibers during one Mercerization process produced.

The accompanying Table 1 explained Comparative test data for a fabric made according to the present invention, compared to a commercially available mercerized cotton fabric. The exam was in agreement with the following test methods.

The physical experimental data for Example 1 and Comparative Example are presented in Table 1. The data in Table 1 show that the two materials have the same basis weights, but the nonwoven fabric made according to the present invention has a much greater tensile strength in both the manufacturing and transverse directions, each 20 and 40 times greater than the Comparative material on has. In addition, the tensile properties of Example 1 are more uniform when the tensile and elongation properties in the manufacturing direction are compared with the transverse direction. TABLE 1

Claims (5)

Nonwoven wiping cloth, which is a single Fibrous pile, whereupon the individual batt formed from fibers made of 100% cotton fibers and a blend of cotton and synthetic staple fibers are selected, and by the application of hydraulic energy in the range of about 233.4 to 350.1 J / g (0.040 to 0.060 hp.hr/lb.) is vortexed to give a differentially swirled Wipe made of nonwoven fabric, with the wipe made of nonwoven fabric a strongly swirled outer surface area and a weakly swirled inner core region, wherein the strongly swirling area and the weakly swirling area each from one of the selected Fibers are formed under the restriction that the applied Hydraulic energy is more than 268.4 J / g (0.046 hp.hr/lb.). The nonwoven wipe of claim 1, wherein the synthetic staple fibers under viscose cellulose, polyacrylates, Polyolefins, polyamides, polyesters and combinations thereof are selected. Nonwoven fabric wipe according to claim 1 or 2, in which the substance by the application of hydraulic energy on one three-dimensional image transmission device is imaged with a movable imaging surface. Nonwoven wipe according to claim 1, 2 or 3, where the fabric as well having an antimicrobial agent. Nonwoven wiper according to one of claims 1 to 4, where the fabric as well has an antistatic agent.