EP0799922A1 - Méthode de réglage du procédé de thermoliage des produits non-tissés à base de fibres synthétiques - Google Patents

Méthode de réglage du procédé de thermoliage des produits non-tissés à base de fibres synthétiques Download PDF

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EP0799922A1
EP0799922A1 EP97660030A EP97660030A EP0799922A1 EP 0799922 A1 EP0799922 A1 EP 0799922A1 EP 97660030 A EP97660030 A EP 97660030A EP 97660030 A EP97660030 A EP 97660030A EP 0799922 A1 EP0799922 A1 EP 0799922A1
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fibre
bonding
temperature
strength
range
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EP0799922B1 (fr
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Simo Mäkipirtti
Erkki Lampila
Heikki Bergholm
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Jw Suominen Oy
Suominen J W Oy
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Jw Suominen Oy
Suominen J W Oy
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    • 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
    • D04H1/4326—Condensation or reaction polymers
    • 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
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
    • 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

Definitions

  • fibres are made from a polymer, especially polyolefin polymers, using melt spinning methods, and from such fibres, fibre fabric is made using thermal bonding methods.
  • the regulation method according to the invention and associated regulation model the central processing conditions for both the fibre and the fabric production are adapted so that the thermal bonding results in the desired nonwoven fabric with regulated and desired strength characteristics.
  • the regulation method according to the invention simulates both pilot and production scale test results, and constitutes an empirical method based on these results as such and the observations made, for which method also natural scientific basis can be found.
  • thermobonding regulating method When implementing the regulation method according to the invention it is to be taken into account that in fibre manufacture and in thermobonding on production scale, the quality of the fibre polymers, the spinning and bonding capacities, the fabric weights, the distribution of the "bonding points", the pattern design and the bonding surface of the bonding rolls are unchanged or subject to only small changes during long periods of time. In the development of the thermobonding regulating method, these variables have been treated as parameters, the effect of which on the regulation equation always has to be experimentally determined after changes have taken place.
  • thermobon-ding There are many points in common between the disclosed regulation method and the rather extensive patent and technical scientific literature relating to thermobon-ding. In this context only a very limited part of the publications can be discussed. These generally include a very broad number of patent and other reference publications. Separate aspects relating to the regulation method according to the invention are to be found in almost all ther-mobonding and fibre production methods using synthetic and natural fibres.
  • thermobonding technique As well as some patent publications, are discussed briefly.
  • thermobonding S.B. Warner /2/ indicates the various thermomechanical processes in thermobonding and evaluates the effect of each process on thermobonding.
  • limitations of conductive heat transfer in thermobonding is discussed, as well as the importance of nip pressure facilitated flow in heat transfer.
  • the contribution of roll bonding induced deformation heating (30-35 °C) in the web is small but important.
  • a consideration of the Clapeyron effect indicates only a limited amount of melting (effect appr. 10°C) taking place at high pressures.
  • the effect of diffusion in the material transfer in bonding is not important: a diffusion distance (with associated effects) of the order of magnitude of the gyration radius ( ⁇ 500 ⁇ ) requires a delay time of 1-2 seconds, when the delay time of the "web bond" in the roll nip is of the order of only 10 ms. In the bond periphery, also the thermomechanical and the still uncontrolled thermomechanical history of the polymer restricts product strength.
  • D. Müller /3/ has studied, in the thermobonding process, especially the significance of roll pressure in the conduction of heat, the effect of production speed, temperature, pressure and bonding pattern on the bonding process.
  • D. Müller /3/ and S. Klöcker /3, 4/ have developed a process model which is applicable to nonwoven thermo-bonding.
  • the model enables a description of the nonwoven deformation characteristics in the processing conditions between the bonding rolls.
  • the model allows a correlation between the fibre material characteristics and the process parameters.
  • the Zerner 3 p solid material model is used, which, in addition to the temperature, time and pressure contains the elasticity and damping characteristics of the material.
  • the fibre material characteristics are easily obtained from elasticity and relaxation measurements.
  • the elasticity characteristic is significantly reduced, because in the roll nip part of the volume looses its elastical properties.
  • partial melting is an axiom and it is accepted as such (parameter)
  • the bonding strength is a function on the roll nip pressure
  • the conductive heat transfer is substantially improved due to the effect of the nip pressure.
  • the measuring results show that for a given fibre material and unit weight, the production speed, required roll pressure and finally roll geometry, can be predicted more accurately than before. Furthermore, the mechanical nonwoven deformation characteristics described by the model can be combined with the calculations and control system for the roll deflection compensation.
  • T. G. Gilmore uses /6, 1994/ in a computer model based on the Box-Hunter model, in addition to regression coefficients, four process variables (roll temperature, - load, line speed and web weight) for evaluating the physical properties of a thermobonded product.
  • process variables roll temperature, - load, line speed and web weight
  • the model equations comprise the Ziabick crystallization rate equation and an empirical parameter for the pressure effect of the crystallization rate.
  • the models make it possible to estimate i.a . the starting point and position of crystallization as it advances along the spinning line.
  • the computer results and the experimental results are in agreement.
  • thermobonding technique will be examined briefly by means of some patent publications.
  • the patent publications deal mainly with spunbonding as this includes the essential factors affecting thermobonding both as regards fibre making and bonding.
  • R. V. Schwartz (/11/: US 4,100,319/1978) describes the manufacture of a web from fast-spun fibres (as in the process US 3,855,046) and the immediate thermobonding of the web (contrary to the process US 3,692,618) without using pre-heating. It is believed that in the process the web filament may not exceed a specified low degree of crystallinity before the formation of the bond, thus a rapid heating of the web thus being necessary. 12 patented processes are mentioned in the publication /11/ in order to illustrate the prior art corresponding to the method.
  • a patent publication (/12/: US 5,282,378/1994) relating to the preparation and bonding of a peripherically oxidized fibre, describes the oxidation of a polymer for high melt temperature spinning, which polymer is spundelayed and exhibits a "high" MWD dispersion, to produce a fibre having a skin-core structure with good thermobonding properties.
  • the 'Finnish' patent applications FIA 943072/23.06.94 and FIA 942889/16.06.94 refer to the same peripheral oxidation.
  • thermo-bonding techniques did not reveal any general, basically "temperature controlled” method or control model comparable to the new thermobonding regulation method.
  • temperature in addition to the pressure, was held to be relevant in the formation of the bonding strength.
  • the subexample 1.1 describes the fibre and fabric manufacturing apparatuses and the function thereof for use in the process development according to the examples of the description of the invention.
  • the spinning and drawing test series were predominantly carried out in pilot scale apparatuses, which differed from production scale apparatuses only as regards the number of spinning units, but not as regards size. Compared to production apparatuses the pilot apparatuses were better equipped with regard to measuring technique.
  • the number of nozzles in the nozzle plate commonly used in a short-spinning apparatus was 30500 and the diameter of the nozzles was 0.25 mm.
  • the high speed-spinning apparatus contained two parallell nozzle plates, the number of nozzles were altogether 1200 and the exit diameter of the flow designed nozzle was 0.4 mm.
  • the high speed- and short-spinning apparatuses were similar as to their capacities, but there was an about 10-fold difference between the speeds of their 1-godets (appr. 1000 and 100 m min -1 ).
  • the high speed-spinning methods there is an effective cooling apparatus for the cooling air for the fibres, the cooling being easily regulated, is even and fibre-specific, which is difficult to implement in short-spinning methods.
  • the sub-parts of the short-spinning-drawing apparatus are: 1. extruder, 2. melt spinning device, 3. 1-godet, 4. drawing oven, 5. 2-godet, 6. 2-finishing (avivage), 7. crimping device, 8. stabilizing and drying oven and 9. staple fibre cutter.
  • the apparatus diagram for the high speed-spinning method is substantially analogous to the diagram of Fig. 1.
  • Part of the fibre series in the examples were prepared with a production scale short-spinning drawing apparatus. In part of the fabric production tests, fibres made with high speed-spinning methods were used. Part of the samples used for analyzing details of the invention were pre-pared under controlled conditions on a Haake-Rheocord-9-apparatus, which was provided also with a mechanical drawing apparatus and oven.
  • FIG. 2 A diagram for a conventional apparatus for use in the preparation and bonding of fibre webs is shown in the Figure 2.
  • the parts of the apparatus are: 1. opener, 2. fine opener, 3. storage silo, 4. feeder, 5. carder, 6. bonding rolls and 7. winder.
  • the devices in the diagram are all of production scale.
  • the production and bonding speed of the web in the bonding line can be regulated in the range of 25-100 m min -1 .
  • the temperature and the pressure of the upper roll provided with a diamond- or circular-shaped raised pattern and of the smooth lower roll could be regulated.
  • the diameter of the bonding rolls was of production scale, but their width was only 2.2 m.
  • the changes of the long identity period and the degree of crystallinity of a fibre polymer (here polypropylene) as a function of temperature and time are studied. From the (statistical) value of the long identity period, using the value for the degree of crystallinity, i.a . the statistical value of the crystalline (as also the amorphous) layer thickness of the polymer as a function of time and temperature, can be calculated.
  • the time dependency of the long period is also a function of the temperature.
  • the value for the long period grows rapidly as a function of temperature, especially when approaching the melting point of the polymer.
  • the long identity period (L ⁇ , ⁇ ) being the sum of the amorphous and crystalline lamellar thickness of the polymer, the crystalline lamellar thickness (D ⁇ , ⁇ ) is obtained from the product f c x L ⁇ , where f c is the crystallinity degree fraction.
  • L z , ⁇ the Lorenz-corrected measurement value
  • the changes in the crystallinity degree of the fibre polymer in bonding are quite important in the regulation method, but difficult to determine and estimate, as the delay time in bonding is of the order of magnitude of only a millisecond per bonding point.
  • the increase of the crystalline lamellar thickness is monotonic as a function of the temperature.
  • the amorphous lamellar thickness (1-f c )L z , is characterized by a deep minimum.
  • the amorphous lamellar thickness first decreases when the temperature and the crystallinity degree increase (that is, the amorphous fraction decreases), but starts thereafter to increase sharply after the minimum range in the temperature range of 100-130°C.
  • the crystalline lamella thus increases in length and becomes narrower, whereby the amorphous lamella can increase in thickness even though the amorphous fraction of the matrix decreases.
  • the crystalline, as well as the amorphous lamellar thickness of the polymer and its changes can, based on the study, be quite precisely regulated by regulating the crystallinity degree of the polymer matrix and its long identity period.
  • the regulation of the crystallinity degree takes place especially by regulating the temperature of the polymer matrix.
  • the regulation of the long period takes place by regulating both the matrix temperature and time.
  • the primary value of the long period can be affected upon i.a . by regulating the cooling rate of the spinning polymer and the quenching temperature.
  • the choice of molecular weight and the weight distribution of the polymer is of importance in this connection.
  • the structure contains increasingly monoclinic phase besides the smectic and amorphous phases ( ⁇ : 20-40%) as the cooling temperature decreases.
  • ⁇ 90 ⁇ 20°C the smectic phase has disappeared completely ( ⁇ : 40-60%).
  • thermobonding of synthetic fibres is a rather complicated process, which is governed by different mechanisms at varying temperature and speed ranges.
  • an attempt is made at studying the thermobonding results by means of two bonding equations simulating these, while not considering precisely the details of various material transfer mechanisms.
  • the bonding mechanism is divided into three stages to form a work hypothesis:
  • the web fibres are formed, apparently as a dislocation-mediated translational slipping process.
  • the effective compression pressure (from the bonding rolls) in the bonding point is above the yield limit of the polymer material.
  • this bonding stage takes place almost momentarily at an increasing temperature (the material constants are a function of temperature; the bonding rolls are at a high temperature but the web is cold) and stops when the displacement movement is prevented as the compression pressure decreases below the yield limit.
  • the second bonding stage takes place as a thermally activated, time dependent slip flow, which takes place below the yield limit of the material. Thereby the displacements circumvent the flow bars for example by means of dislocation-mediated, diffusion-controlled 'climbing'.
  • the third bonding stage there is formed, due to the partly melting of the polymer, so much molten phase that the contact formation takes place based on a viscotic flow mechanism.
  • other significant phenomena take place in the system: i.a . diffusional material flow, melting of the finely divided crystalline portion of the polymer and re-crystallization etc.
  • the temperature increases further the bonding strength starts to decrease due to the effect of shrinkage of the bonding fibres, thermal degradation (a function of the anti-oxidant concentration and type), excessive melt formation and other factors.
  • variable property of the fabric resulting from bonding (longitudinal and transverse strengths, -elongations, - toughness etc.) is marked with the letter ⁇ .
  • C" is a constant
  • E is the activation energy
  • R is the general gas constant
  • T is the absolute temperature
  • v is the heating rate of the fibre web.
  • the Table 1. contains a compilation of measurement results in equation form obtained from the bonding of various types of test fibres.
  • the appended Table 2. contains a compilation of values for the properties of web test fibres used in the bonding tests.
  • the maximum value of the tensile strength of a thermobonded fibre fabric is taken to be the intersection point of the bonding equations according to the subexample 1.3 for the low and high bonding temperature ranges.
  • the measurement values of the test fabric tensile strengths require the use of two separate equations for illustrating the bonding process, although there is a transitional zone in the near vicinity of the intersection points, where the measurement results remain slightly below the calculated values. This transitional area is, however, narrow, especially for conventional fabric strengths, whereby the change in strength as a function of temperature is lower than for high strength fabrics.
  • the maximum tensile strengths corresponding to the intersection point of the bonding equations have been included in the Table 1., in addition to the bonding equations.
  • the crystallinity degree, the Lorenz-corrected long period and the crystalline lamellar thickness have been determined in the manner taught in the subexample 1.2 for fibres corresponding to the bonding equations.
  • the value for the crystalline lamellar thickness for each fibre has been indicated in the Table 1.
  • the equation /16/ combines the maximum strength in thermobonding with the fibre chain orientation values from corresponding manufacturing conditions and thus also with the spinning orientation.
  • the maximum strength values for the fibre fabrics obtainable by fibre web thermobonding can thus be regulated by regulating the crystalline lamellar thickness of the spinning fibre. This regulation, in turn, can take place by regulating the long period, the crystallinity degree or both of the spinning fibre, in accordance with the subexample 1.2.
  • Fibres were made in a conventional fibre line (Fig. 1) from melt spun propylene fibres using mechanical drawing at varying draw ratios.
  • the properties of the fibre polymer, the strength values of the product fibres as a function of draw ratio, as well as the drawing conditions, are indicated in the Table 2 (fibres D-10-14).
  • Test fabrics were made in a fabric line from the test fibres obtained using conventional techniques (Fig. 2) as a function of temperature.
  • the bonding equations for the longitudinal tensile strength and the elongation for the test fabrics with intersection points are indicated in the Table 4.
  • the maximal tensile strength and elongation values are almost of the same magnitude and quite close to each other with respect to the temperature (42.1 N/161.2 °C and 42.2 %/161.0 °C). Both the tensile strength and the elongation values for the fabrics made from the fibres B-1 and B-9 are quite close to each other with respect to the temperature, but the tensile strength values are high (81.5 and 79.8 N) and the elongation values are low (38.2 and 37.7 %).
  • the strength values of the fabrics made from the fibres A-1 and A-8 differ from each other both as to the maximal elongations and the corresponding temperatures, the maximal strength values being quite low (Table 1.).
  • the elongation of a fabric generally reacts more strongly to exterior effects (temperature, high energy and light radiation, etc) than the tensile strength. These characteristics, which vary for each polymer spunbonding system, form the basis for the regulation of the strength properties for thermobonded fabrics.
  • Loop bonding is carried out using a thermomechanical fibre analyzing device (Metler 3000). To each socket of the analyzing device a fibre sample (50 x 2.2 dtex) is fastened at both ends and so that the fibre portions of the formed loops form a cross loop with each other. This fibre loop system is loaded with a constant load (1 mN/tex) and heated at a constant rate (10-50 °C/min) while simul-taneously registering the elongation and temperature, to the desired "bonding temperature” and is cooled.
  • a bond is formed at the cross of the loops, the strength of which is measured with a drawing apparatus (Zwick-1435) after one leg has been cut from each loop.
  • the activation energy values in bonding fibres of diffe-rent draw ratios are independent of the draw ratios and thus correspond to the bonding result of the afore mentioned conventional webs.
  • Fibres of the test series (E 2-4) were radiated ( ⁇ -radiation: 3.40 Mrad, storage 70 days) and loop bonding tests were carried out on the fib-res obtained.
  • the loop strengths obtained for the radiated samples were substantially of similar magnitude, that is the draw ratio (orientation) effect on the bonding strength of the bond had disappeared (within the limits of measuring accuracy).
  • ⁇ e,s 7.7752 x 10 36 x T 2 x exp[-76679/RT]
  • the bonding result from the loop test series can be seen in the Figure 5.
  • the bonding results for individual fibres (E:1-5) have been displaced by using a factor obtainable from the equation /25/ to correspond to the result for the fibre E-4, which has been taken to be the reference state. From the Figure it can be seen that the re-sulting equations fit the measurement values.
  • a fairly light mechanical load is applied to the bond, and thus the fibre to be bonded is not deformed in the bonding point as is the case in conventional thermobonding with rolls.
  • the partial melt formed in the loop bonding initially primarily wets the fibre bundle and when the mass of partial melt increases, it glues the wetted fibre bundles together and finally surrounds the whole cross loop.
  • thermobonding as shown in the subexample 1.5 on the tensile strength and elongation values of a fabric product obtained from fibres made with mechanical draw ratios of differing magnitude, as well as on their relationship, i.a. the following observations can be made as regards the regulation method:
  • thermobonding As regards different fibre qualities and thermobonding methods, a relationship according to the equation /14/ can be seen as a common characteristic, wherein the maximal bonding strength (when operating under the same manufacturing conditions) is obtained with mechanically undrawn fibres, that is with spinning fibres.
  • the maximal strength values in thermobonding can be regulated primarily by regulating the crystalline lamellar thickness of the spinning fibre, that is thus by regulating the polymer chain length and -distribution, the spinnning draw ratio in the spinning process, the cooling rate and temperature of the spinning fibre.
  • a special problem constitutes the regulation of the strength properties of fabrics to be thermobonded using a bonding apparatus (i.a . roll bonding) with high compression and simultaneously rapid mechanical shear.
  • a bonding apparatus i.a . roll bonding
  • the fibres in the bonding region are deformed, which leads to fibre breaks especially in the periphery of the bonding region.
  • the regulation of the thermobonding has to be carried out individually for the polymer and the apparatus, in which case the regulation of the mechanical draw ratio in the fibre manufacture as well as the regulation of the bonding temperatures for the web are of substantial importance.
  • Regulating the elongation-draw ratio in product fabrics always means operating below the maximal fabric strength values as regards elongation, draw ratio or both.
  • the sensitivity to shear in roll-thermobonding can be decreased to some degree by using fibres with a skin-core structure, especially if the melting range of the skin layer is lowered by blending into the fibre (or otherwise produced) of a short chained polymer fraction of a similar quality (spinning distribution) or by using a fibre coated with a low melting polymer of a completely different quality.
  • thermobonding methods with light bonding shear (i.a. hot air and oven bonding methods) some of the afore mentioned bonding problems can be avoided. In such a case the regulation of the bonding can be simpler than for methods based on shear. These methods are, however, poorly suited for the large scale production of many thin fabric qualities (from fibre web).
  • thermobonding of the fibre web as regards a variable characteristic of the product fabric, complies with the general dynamic kinetic law /10/, wherein the heating rate of the fibre web was taken to be constant. The heating of the fibre web cannot take place exactly in this manner in a production apparatus.
  • a test series was carried out, wherein the transport speed of the web and simultaneously the hot rolling speed was increased. Thereby the function for the heating rate of the web was presumed to remain of the same form.
  • the characteristics of the used test fibre and polymer are indicated (F-1, F-2) in the Table 2.
  • the constant terms in the tensile strength and elongation equations for the product fabrics corresponding to different web speeds are indicated in the Table 5.
  • the change in tensile strength of the product fabric above the temperature corresponding to the maximal value is in this case (within the limits of applied measuring accuracy) independent of the web speed. In accordance with the measuring results, however, a reduction in tensile strength can be established for each studied speed at high bonding temperatures (after the maximal value) (in this case: ⁇ si > 165°C, ⁇ ⁇ 155°C). In the case under study, the value for the maximal strength is appr. 40 ( ⁇ 2) N.
  • the intersection temperatures for the equations corresponding to this maximal strength as well as the equation parameters are indicated in the Table 5.
  • the change in product fabric elongation is characterized by substantial scattering.
  • the measurement values for the change in elongation can, in the vicinity of the maximal values, be simulated by means of one equation.
  • This equation, and the maximal values for elongation with temperatures at corresponding speeds, are indicated in the Table 5.
  • the elongation starts to decrease rapidly (too much molten phase is formed with respect to that required for bonding, machining deformation increases, oxidation-induced ageing starts, etc).
  • This rapid decrease in elongation seems to start at the higher a temperature range, the higher the web speed is.
  • the equations for the product fabric elongation ( ⁇ 2 ) at high temperatures have been introduced.
  • thermobonding line used in the bonding speed tests the differences in speed between the carding rolls and between the carding rolls and bonding rolls were so adjusted that the final compression values were constant for the different web speeds used in the test series.
  • the uniformity of the compression values was monitored by analyzing the ratio between the longitudinal and transverse tensile strength. According to the calculations, only when using the highest web speed, only a 4.7 % deviation was observed in the compression values.
  • Chain orientation developing in melt spinning is largely controlled by the melt flow rate field and, opposite thereto, the structural relaxation resulting from the molecular thermal movement.
  • the orientation developed in in the range of capillary flow (in the dies) is of low stability and of little importance due to the low speed gradient and the short relaxation times resulting from the high die temperature.
  • a kinetically stable fibre chain orientation is developed only during the melt elongation flow, the velocity of the orientation-controlling flow parallel to the fibre axis being high and the melt viscosity, which increases due to the decreasing temperature, increasing the molecular relaxation time (preventing disorientation) and finally the melt solidification free-zing the formed orientation.
  • the tension affecting the fibre filament at the solidification point and the birefringence of the fibre polymer both relate in the same way to the melt draw ratio at spinning, and thus also birefringence and tensile strength at the solidification point are directly proportional to each other.
  • the tensile strength at the solidification point is again substantially the same as the tensile strength at the 1-godet ( Figure 1.).
  • the factors affecting the increase in spinning tension also increase the chain orientation of the fibre filament. I.a . the following factors facilitate the increase in spinning tension: increase in polymer viscosity, decrease in spinning temperature, increase in spinning capacity (at constant gauge), decrease in fibre gauge, increase in quenching speed etc.
  • the Figure 7 shows the results of thermobonding corresponding to the test fibres H-1 and H-2 (SLT: 41 and 57N) as tensile strength-elongation function values, the bonding temperatures and line tension being the parameters.
  • the fabric strength values in a manner corresponding to the bonding equations, pass through a maximal value as a function of temperature.
  • the SLT value decreases, the strength value increases on all isotherms before the maximal value and decreases thereafter.
  • the changes in the strength values as a function of the SLT-values are quite substantial, but on the subsequent isotherms, low.
  • the fibre samples H-3 and H-4 have been prepared from a polymer having a melt index of the same magnitude, but a substantially narrower chain distribution as compared to the polymer of the samples H-1 and H-2. From the Table 7. it can be seen that the fabrics obtained from the test fibres (H-3 and H-4) are of low strength over the whole bonding range as compared to the test series studied earlier. From the graphs of the bonding equations it can be seen that the effect of SLT on the elongation values below the elongation maximum is low, but substantial on the isotherms above.
  • a third object under study is melt spinning of a polymer with a melt index of 25 and a broad chain distribution is taken.
  • the tensile strength-elongation graphs for the test fabrics corresponding to the fibres H-5 and H-6, are given in the Figure 7.
  • the chain dispersion of the polymer is thus the highest of the tested polymers.
  • the highest line tension values at melt spinning are obtained for this polymer.
  • a decrease in the spin-ning line tension increases both the tensile strength and the elongation values on each isotherm in the whole temperature range. The changes in strength are, however, the biggest on the isotherms prior to the strength maximum.
  • thermobonding of some fibres with skin-core structure factors affecting thermobonding of some fibres with skin-core structure are studied.
  • the subexample is directed at studying the behaviour in thermobon-ding of 'concentric layer fibres' containing either two different or two similar polymers, and one similar polymer, but modified after spinning.
  • bi-component fibres are studied which have been prepared from two polymers of a different quality (mutually dissolving to a limited degree) by using concentric dies in spinning.
  • the polymer pairs forming the skin-core-structure of the fibres to be thermo-bonded were polyethylene/polypropylene (PE/PP-fibres I-1 and -2, Table 2.), polyethylene/polyethylene terephtalate (PE/PET-fibre I-3) and polypropylene/polyethylene terephtalate (PP/PET-fibre I-4).
  • the constant values of the bonding equations /12/ corresponding to the strength values ( ⁇ ja ⁇ ) of the fabrics obtained in thermobonding of the polyethylene/polypropylene-test fibres I-1 and -2 are indicated in the Table 7.
  • the graphs for the equations and some measuring points are indicated in the Figure 8. From the Figure it can be seen that the measuring results for both test fibres are similar within the accuracy of measurment used. There is a transitional region between the measuring values corresponding to the low and the high temperature ranges of the equations, in which range the measuring values satisfy neither equation. It is also to be noted that the activation energy terms for the bonding equations corresponding to the tensile strength of both measuring ranges are of the same sign, wherefore the tensile strength increases in both ranges when the temperature increases.
  • the Figure 9 includes a calculation of the temperature distributions of a cross-section of a bonding point of a pure polypropylene fibre fabric (normal to the fabric surface) as a function of the transitional speed of the fibre web.
  • the known Binder-Smith differential method has been used, and on the starting values, the Gröber distribution function. It has been assumed in the calculations that during each delay time determined by the web speed, the quantity of heat needed for bonding has been transferred to the bond.
  • the temperature profile of the bonding point resembles, according to Figure 9, to its shape rather a parabola. When the bonding velocity increases, the temperature decreases rapidly in the interior parts of the bond close to room temperature and increases substantially in the surface areas of the bond and on the surface (with the amount of heat supplied for reaching heat equilibrium). In the system, the temperature difference between the roll surfaces does not seem to have a big effect on the position of the temperature minimum in the cross-section.
  • the observed scattering of the strength values in this range is a consequence of both the increase of the PP-solubility in the PE-phase as a consequence of the long melting times in the loop tests and the solidification of the PE+PP-melt phase as a separate or as the same crystallization as a result of the slow cooling of the molten phase (separate crystallization: PE solidifies in the area of 115-119 °C and PP in the area 136-140 °C, aggregate crystallization: PE+PP solidifies in the area of 115-119 °C). A corresponding phenomenon did not exist in the thermobonding of some production fibre batches.
  • melt portion (mutually soluble PE+PP-partial melt) cannot be advantageous in thermobonding.
  • excess melt can flow into the fibre bundle above and below the bonding point. From the high temperature range TMA results of the loop bonding tests, a partial melting of polypropylene is evident as well as an associated substantial increase in thermal contraction and also loop bonding strength of the system.
  • the structural factors of the polymer affecting solidification and partial melt temperature, and thermobonding tensile strengths are, in addition to the quenching temperature and rate and crystallinity degree, the values for the polymer chain length and distribution. Especially a high value for the chain distribution is a prerequisite for the good strength properties of the fabrics. For bi-component fibres this applies especially to the polyethylene of the shell layer, the dispersion value of which is low for the common qualities.
  • some chain size values (Mw/D) for polyethylene can be given: 33110/2.56, 42650/2.94, 55500/3.35, 48960/4.36, 56000/5.17 etc.
  • thermobonding of the fibre webs the temperatures of the bonding roll have been used ( ⁇ si).
  • Bi-component fibres having a fibre core of polyethylene terephtalate and a shell layer of either polyethylene or polypropylene behave, according to the TMA results, in thermobonding in an analogous manner to the fibre systems studied earlier.
  • the polyester fibre did not, however, participate in the bonding process in the temperature range studied.
  • melt bonding of the PE- and PP-phases of fibres coated with polyethylene and polypropylene (I:3-5) is followed by a decrease in the bonding strength both as a result of ageing and for other reasons (Table 8.).
  • the bonding of the shell layer at its melting range corresponds to the PE/PP-fibre system (for example I-3 and I-6).
  • thermobonding of two skin-core fibre series are studied, which have been made in a different manner from polypropylene.
  • the skin core structure is obtained as a result of polymer chain degradation resulting from peripheral oxidation and simultaneous retarded quenching of a superheated spinning fibre.
  • a layer of a low melting, short-chain polymer is formed, which is coherent with the long-chained core polymer.
  • the product fibre has a high crystallinity degree.
  • the manufacturing method of the peripherically oxidized layered fibre has been disclosed i.a . in the description and the prior art section of US patent 5,281,378/1994.
  • the skin-core structure is obtained in a simultaneous high-speed spinning process of a very short-chained and a long-chained polymer.
  • the product fibre has, in this case, a low monoclinic crystallinity degree and a 'para-crystalline' superstructure.
  • the values for the constants of the bonding equations corresponding to the tensile strengths of the fibres produced by the peripheral oxidation method are given in the Table 9., wherefrom also the DSC-analysis results of the corresponding fibres can be seen.
  • the behaviour of skin-core fibres made from polypropylene by means of a spinning and quenching process in the ther-mobonding of a fibre web and fibre loop is studied briefly.
  • the WAXS analysis of the test fibres usually shows a smectic structure and thus very low monoclinic crystallinity.
  • the SAXS analysis shows structure dependant anomaly.
  • the SAXS peak of the first order is difficult to establish from the intensity and angle values. From the Lorenz-corrected intensity values, besides the first order peak, usually a strong peak is obtained, which primarily is zero angle scattering.
  • the SAXS-anomaly is a result of the differences in the lamellar structural systems between the shell and the core layers, of which a scattering sum is obtained in the analysis.
  • a clear yield limit characterizes the tensile strength-elongation ratios for the fibres.
  • thermomechanical loop tests of the fibre series B under study Based on the results of the thermomechanical loop tests of the fibre series B under study, it can be seen that the elongation maximum values of the various fibre qualities differ from each other both as regards position and magnitude. Also in the fibre-specific elongation results there seems to be scatter apparently due to the nature of the loop bonding (low initial load: 1 mN/tex). The position of the thermomechanical contraction with respect to temperature is (for the same fibre quality) the same for different fibre samples, and there is no scattering. The interbonding of loop fibres always starts at temperatures of the base part of the TM-contraction peak and reaches its maximum strength usually at the temperatures of the TM-peak. When the temperature increases above the temperature corresponding to the TM-contraction peak, the bonding strength decreases instantly.
  • the values for the activation energies for the loop and web bonding (Tables L and Y) of the fibre qualities B-4, -6 and -8 are for each fibre close to each other.
  • the bonding temperatures corresponding to loop strengths of 100 mN and 1000 mN have been calculated into the Table from the bonding equations. These strength values are close to both initial and terminating strength development.
  • bonding with the said fibres starting at the temperature 131.4 ⁇ 0.4°C reaches the limit 1000 mN depending on the activation energy values at the temperature range of 148-151 °C.
  • the favourable positioning of the fibre quaility A-1 in loop bonding is primarily due to the fact that in this manner of bonding, the finishing agent for the fibre surface does not disturb the strengthening of the bond as is the case in bonding under stress.
  • the fibre quality B-12 positions in a manner corresponding to the values of the fibre quality B-1.
  • this fibre quality which is close to a conventional homogenous polypropylene fibre, also a high temperature 'region of ageing' can be observed.
  • the bonding equation corresponding to the fibre denomination A-15 is an average of the bonding equations for 15 fibre batches of the A-series.
  • the fibre C-2 is a bi-component fibre wherein both the core and the shell layer are of propylene polymers of two different melting ranges.
  • the fraction of the maximum strength ( ⁇ ) corresponding to minimum strength has been given in the Table, as well as the derivative d ⁇ /dT, at the fraction corresponding to minimum strength.
  • the bonding strength in the B-1 series as compared to the maximum value is, however, only 37 % and in the A-15-series already 78 % (100 ⁇ ), the derivatives, d ⁇ /dT being close to each other at temperatures corresponding to the minimum strengths. Even though the temperatures corresponding the maximum bonding strength are close to each other, a bonding strength corresponding to minimum level is reached in the B-1-series at a temperature which is 11.9 °C lower than in the A-15-series. With the A-1-fibre quality, which bonds only at high temperatures and has poor strength properties, the minimum strength is reached only at a temperature 18 °C higher than that of the series B-1.
  • the fibre quality B-2 in the Table shows the effect of the unusually low activation energy in bonding on the ⁇ 30 -temperature.
  • the ⁇ m-values remain substantially of the same magnitude, a lowering of the ⁇ m-temperatures takes place.
  • the activation energy values decrease and a resulting increasing lowering of the ⁇ 30 -temperature as compared to the ⁇ m-temperature.
  • thermobonding can be considered a thermally activated process, which, due to the narrowness of the operational temperature range, complies with an Arrhenius-type temperature dependency.
  • the speed of the web has been used in place of the value for the linear heating rate of the bond, assuming a simple dependency existing between these speed values. According to measurements, this dependency can be described within the range studied, using in addition to a constant factor, a speed exponent having a value close to one.
  • the bonding strength of the fibre web decreases exponentially as the draw ratio increases, which also shows that the best strength properties in nonwoven-fabrics are obtained with spinning fibres.
  • the draw ratio effect does not lower the bonding strength values when bonding, for example, set multi-component fibres with a skin core structure, wherein the bonding takes place by means of the skin layer phase having a lower melting point than the core layer phase, and at a temperature range exceeding the skin layer phase melting temperature.
  • the increase in strength properties as a function of temperature according to the bonding equation is followed by a decrease in the strength values at high temperatures as a result of thermal ageing of the polymer, autogenic oxidation, mechanical deformation, increase in melt portion and other factors.
  • a regulation equation of the same form is used (for analogy and other reasons) as that used at lower temperatures.
  • the intersecting point of these regulation equations is used in the method as the so-called regulation technical maximum strength, the value of which is usually close to the measured maximal strength value (and corresponding temperatures).
  • the regulation technical strength values of the nonwoven fabrics and corresponding temperatures are fibre-specific functions of the reciprocal value of the crystalline lamellar thickness of the polymer structure of the spinning fibre.
  • thermal bonding starts at a temperature range where the thermomechanical contraction and the disorientation of the molecular chains of the fibres start.
  • This temperature also indicating the onset of partial melting of the polymeric structure, is a function of the reciprocal value of the crystalline lamellar thickness of the polymer structure.
  • the crystalline lamellar thickness of the polymer structure is thus a very important regulation parameter in the regulation method.
  • the crystalline lamellar thickness of the polymer structure for use in the regulation method is expressed as the product of the Lorenz-corrected long indentity period and the crystallinity degree fraction of the polymer.
  • Each product factor is determined directly from the fibre with x-ray diffraction analysis (SAXS and WAXS).
  • SAXS and WAXS x-ray diffraction analysis
  • the regulation of the crystalline lamellar thickness of the fibre polymer is based on the regulation of the values of its long period and crystallinity degree, both during manfucature of the spinning fibre and, if necessary, by heating the fibres in connection with processing under the control of the said period and crystallinity degree equations.
  • the regulation method it is possible to use in parallel the said period equation and the spinning fibre period values, while still maintaining a good regulation accuracy, irrespective of their different manners of derivation (and also of a slight magnitude difference from the point of view of regulation).
  • the long identity period of the spinning fibre polymer structure is almost solely a function of the degree of supercooling of the polymer melt and it can be regulated (especially with regard to the minimum value) by means of conventional regulation of the quenching temperature of the melt spinning fibre.
  • the crystallinity degree of the spinning fibre polymer is regulated by means of the quenching rate of the melt. It has been observed that the temperature of the spinning melt corresponding to the quenching rate and relevant for the future polymer structure corresponds to the temperature of maximum crystallization rate of the polymer.
  • the desired spinning fibre structures and crystallinity degrees are obtained as an almost linear function of the logarithm of the quenching rate corresponding to this temperature.
  • the values for the activation energy of the regulation equation for thermobonding are dependent on the fibre structure and its defective states, on the bonding method ( i.a . the applied bonding pressure), melt formation and - quantity and many other factors. For this reason it is advisable to determine the activation energy value for bonding of each fibre quality either with pilot or TM-loop measurements, or also from the temperature dependency of the unloaded thermal contraction of the fibre. Below the temperature corresponding to the maximum values for the strength properties in thermobonding, activation energy values for the longitudinal and transverse tensile strength are mutually of equal magnitude. The same applies for the product elongations.
  • the activation energy values corresponding to the tensile strength and elongation values for the product fabrics can differ from each other substantially depending on the fibre quality (for example fibres with a plastic component and skin-core structure). At a temperature range exceeding the temperature corresponding to the maximum values for the strength properties, the activation energy values are usually below the values corresponding to low temperatures, and they are susceptible to pressure variations and melt quantities.
  • an activation energy value of E 40 ⁇ 3 kcal/mole can be used at the low temperature range, especially when the values for the maximum strength and corresponding temperatures are determined using the crystalline lamellar thickness of the fibre structure.
  • the viscous flow values for the polymer quality can be used in the estimation, as well as the common dependency function, according to which the pre-exponential factor, as a logarithm, is the same linear function of the activation energy in both temperature ranges.
  • the line tension from spinning fibre manufacture (SLT) and the roll temperature difference have been used as parametric variables, which both affect the tensile strength and elongation values of the nonwoven fabric.
  • parametric variables these are included in the pre-exponential term (c) of the temperature function of the regulation equation.
  • the spinning fibre line tension is a function of the molecular size and size distribution of the polymer chains and the cooling technique of the spinning melt.
  • the line tension affects i.a . the molecular chain orientation of the spinning polymer and the spinning fibre strength via the lamellar crystal thickness formed in spinning.
  • the SLT-effect can be quite important in the regulation and standardization of fabric strength properties. Due to their multifunc-tionality, the SLT-values applied in spinning should preferably be used in fibre-specific parametric form in processing, but under continuous strict control.
  • the temperature difference between the web bonding rolls in processing is polyfunctional and determined by the nonwoven web speed and surface weight (i.e. temperature load), the required melt quantities, the assymetric temperature profile of the bond cross-section, the magnitude (and position in the bond) of fibre deformation, the processing apparatus (regulation accuracy) and other factors.
  • temperature load i.e. temperature load
  • required melt quantities i.e. melt quantities
  • assymetric temperature profile of the bond cross-section i.e. temperature profile of the bond cross-section
  • the magnitude (and position in the bond) of fibre deformation i.e. temperature load
  • the processing apparatus regulation accuracy
  • thermomechanical test runs correlating directly with air and oven bonding have, however, been carried out as well as comparative measurements for the different bonding methods using gamma-irradiated fibres.
  • the bonding strengths follow the conventional exponential dependency in roll bonding of the mechanical draw ratio from fibre manufacture (or correspondingly, from the average molecular chain orientation of the fibre structure) and decrease markedly when the draw ratio (chain orientation) increases.
  • This draw ratio effect does not, however, apply to fibres with a skin-core structure, wherein the polymer of the skin layer exhibits a substantially lower melting range as compared to the core fibre polymer and a high proportion of molten phase at the bonding temperature (for example a polyethylene-polypropylene skin-core fibre).
  • thermobonding corresponds to bonding above the temperature of maximum strength values.
  • These fibres can, if necessary, be drawn to a high chain orientation degree already in the spinning process, or also mechanically after spinning.
  • the said exponential draw ratio effect disappears from the bonding strengths of irradiated fibres and the bonding strengths correspond to strengths of spinning fibres, that is the bonding strengths in air and oven bonding improved substantially as a result of irradiating the fibres.
  • the bonding temperatures decreased, the decrease being a power function of the fibre draw ratio.
  • the strength properties of the irradiated fibres decreased substantially, but the bonding temperatures decreased in an advantageous manner as a function of the draw ratio in substantially the same degree as in air bonding.
  • thermobonded nonwoven fabrics takes place under the control of the regulation equation, the main variables being the bonding temperature, the speed of the web and the mechanical draw ratio of the fibres to be bonded.
  • Variable parameters which are more seldom subject to change in production processing, but none the less not less important than the said practical variables, are especially the crystalline lamellar thickness of the spinning fibre structure, the spinning line tension, the temperature difference between the bonding rolls and especially the pressure between the rolls when operating at a temperature above the temperature corresponding to the maximum strength values.
  • variable parameters can, if desired, naturally be included in the regulation equation in a manner corresponding to the web speed and the fibre draw ratio, and this is also advantageous in product development when combining desired fabric properties in pilot and production tests under the control of the regulation equation.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Artificial Filaments (AREA)
  • Medicines That Contain Protein Lipid Enzymes And Other Medicines (AREA)
EP97660030A 1996-03-18 1997-03-14 Méthode de réglage du procédé de thermoliage des produits non-tissés à base de fibres synthétiques Expired - Lifetime EP0799922B1 (fr)

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FI961252A FI101087B (fi) 1996-03-18 1996-03-18 Synteesikuituharsojen termosidonta- ja synteesikuitujen valmistusprose ssien säätömenetelmä halutut lujuusominaisuudet omaavien nonwoven kuit ukankaiden valmistamiseksi

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0846793A1 (fr) * 1996-04-25 1998-06-10 Chisso Corporation Fibres de polyolefine et non-tisse fabrique a partir desdites fibres
EP0915192A2 (fr) * 1997-11-07 1999-05-12 J.W. Suominen Oy Procédé de fabrication et régulation de fibres de polyoléfine âme-gaine thermosoudables et non-tissés fabriqués à partir de celles-ci
DE19813341A1 (de) * 1998-03-26 1999-09-30 Truetzschler Gmbh & Co Kg Vorrichtung an einer Krempel oder Karde zur Herstellung eines Faservlieses

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0667406A1 (fr) * 1994-02-11 1995-08-16 J.W. Suominen Oy Procédé de fabrication d'une fibre de polypropylène résistant aux rayons gamma pour tissu non-tissé stérilisable
EP0753606A2 (fr) * 1995-07-03 1997-01-15 J.W. Suominen Oy Méthode pour régler le transport interne d'adjuvants et additifs d'un polymer

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0667406A1 (fr) * 1994-02-11 1995-08-16 J.W. Suominen Oy Procédé de fabrication d'une fibre de polypropylène résistant aux rayons gamma pour tissu non-tissé stérilisable
EP0753606A2 (fr) * 1995-07-03 1997-01-15 J.W. Suominen Oy Méthode pour régler le transport interne d'adjuvants et additifs d'un polymer

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WATZL A: "THERMOFUSION, THERMOBONDING UND THERMOFIXIERUNG FUER NONWOVENS THEORETISCHE GRUNDLAGEN, PRAKTISCHE ERFAHRUNGEN, MARKTENTWICKLUNG", MELLIAND TEXTILBERICHTE, INTERNATIONAL TEXTILE REPORTS, vol. 75, no. 10, 1 October 1994 (1994-10-01), pages 840 - 850, XP000471110 *

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0846793A1 (fr) * 1996-04-25 1998-06-10 Chisso Corporation Fibres de polyolefine et non-tisse fabrique a partir desdites fibres
EP0846793A4 (fr) * 1996-04-25 2000-02-23 Chisso Corp Fibres de polyolefine et non-tisse fabrique a partir desdites fibres
EP0915192A2 (fr) * 1997-11-07 1999-05-12 J.W. Suominen Oy Procédé de fabrication et régulation de fibres de polyoléfine âme-gaine thermosoudables et non-tissés fabriqués à partir de celles-ci
EP0915192A3 (fr) * 1997-11-07 1999-10-13 J.W. Suominen Oy Procédé de fabrication et régulation de fibres de polyoléfine âme-gaine thermosoudables et non-tissés fabriqués à partir de celles-ci
DE19813341A1 (de) * 1998-03-26 1999-09-30 Truetzschler Gmbh & Co Kg Vorrichtung an einer Krempel oder Karde zur Herstellung eines Faservlieses
US6223398B1 (en) 1998-03-26 2001-05-01 Trutzschler Gmbh & Co., Kg Web heating device for a fiber processing machine

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EP0799922B1 (fr) 1999-11-03
DE69700715D1 (de) 1999-12-09
FI101087B (fi) 1998-04-15
DE69700715T2 (de) 2000-06-15
FI961252A (fi) 1997-09-19
FI961252A0 (fi) 1996-03-18

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