EP2630297B1 - Composition de pâte humide en feuilles et procédés associés - Google Patents

Composition de pâte humide en feuilles et procédés associés Download PDF

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Publication number
EP2630297B1
EP2630297B1 EP11835114.7A EP11835114A EP2630297B1 EP 2630297 B1 EP2630297 B1 EP 2630297B1 EP 11835114 A EP11835114 A EP 11835114A EP 2630297 B1 EP2630297 B1 EP 2630297B1
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EP
European Patent Office
Prior art keywords
sulfopolyester
water
fibers
dispersible
fiber
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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.)
Not-in-force
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EP11835114.7A
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German (de)
English (en)
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EP2630297A4 (fr
EP2630297A1 (fr
Inventor
Rakesh Kumar Gupta
Melvin Glenn Mitchell
Daniel William Klosiewicz
Mark Dwight Clark
Chris Delbert Anderson
Marvin Lynn Mitchell
Paula Hines Mitchell
Amber Layne Wolfe
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Eastman Chemical Co
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Eastman Chemical Co
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Publication of EP2630297A4 publication Critical patent/EP2630297A4/fr
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Publication of EP2630297B1 publication Critical patent/EP2630297B1/fr
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    • 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
    • D01D5/08—Melt spinning methods
    • D01D5/098—Melt spinning methods with simultaneous stretching
    • D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
    • 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
    • D01D5/36—Matrix structure; Spinnerette packs therefor
    • 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
    • D01F6/78—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products
    • D01F6/84—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolycondensation products from copolyesters
    • 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
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester 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
    • D04H1/42—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
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • 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
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/20—Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/20—Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/24—Polyesters
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/38—Inorganic fibres or flakes siliceous
    • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H15/00—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
    • D21H15/02—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution characterised by configuration
    • D21H15/10—Composite fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H5/00—Special paper or cardboard not otherwise provided for
    • D21H5/12—Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials
    • D21H5/20—Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials of organic non-cellulosic fibres too short for spinning, with or without cellulose fibres
    • D21H5/207—Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials of organic non-cellulosic fibres too short for spinning, with or without cellulose fibres polyester fibres

Definitions

  • the present invention pertains to a wet lap composition comprising a sulfopolyester dispersion and a plurality of water nondispersable synthetic polymer microfibers.
  • the invention also pertains to a process using the wet lap composition for making a nonwoven article and to a wet-laid process for producing a nonwoven article.
  • the fibers and fibrous articles have applications in flushable personal care products and medical products.
  • Fibers, melt blown webs and other melt spun fibrous articles have been made from thermoplastic polymers, such as poly(propylene), polyamides, and polyesters.
  • thermoplastic polymers such as poly(propylene), polyamides, and polyesters.
  • One common application of these fibers and fibrous articles are nonwoven fabrics and, in particular, in personal care products such as wipes, feminine hygiene products, baby diapers, adult incontinence briefs, hospital/surgical and other medical disposables, protective fabrics and layers, geotextiles, industrial wipes, and filter media.
  • personal care products made from conventional thermoplastic polymers are difficult to dispose of and are usually placed in landfills.
  • One promising alternative method of disposal is to make these products or their components "flushable", i.e., compatible with public sewerage systems.
  • thermoplastic polymers now used in personal care products are not inherently water-dispersible or soluble and, hence, do not produce articles that readily disintegrate and can be disposed of in a sewerage system or recycled easily.
  • typical nonwoven technology is based on the multidirectional deposition of fibers that are treated with a resin binding adhesive to form a web having strong integrity and other desirable properties.
  • the resulting assemblies generally have poor water-responsivity and are not suitable for flushable applications.
  • the presence of binder also may result in undesirable properties in the final product, such as reduced sheet wettability, increased stiffness, stickiness, and higher production costs. It is also difficult to produce a binder that will exhibit adequate wet strength during use and yet disperse quickly upon disposal.
  • nonwoven assemblies using these binders may either disintegrate slowly under ambient conditions or have less than adequate wet strength properties in the presence of body fluids.
  • pH and ion-sensitive water-dispersible binders such as lattices containing acrylic or methacrylic acid with or without added salts, are known and described, for example, in U.S. Patent No. 6,548,592 B1 .
  • Ion concentrations and pH levels in public sewerage and residential septic systems can vary widely among geographical locations and may not be sufficient for the binder to become soluble and disperse. In this case, the fibrous articles will not disintegrate after disposal and can clog drains or sewer laterals.
  • Multicomponent fibers containing a water-dispersible component and a thermoplastic water non-dispersible component have been described, for example, in U.S. Patent No.'s 5,916,678 ; 5,405,698 ; 4,966,808 ; 5,525282 ; 5,366,804 ; 5,486,418 .
  • these multicomponent fibers may be a bicomponent fiber having a shaped or engineered transverse cross section such as, for example, an islands-in-the-sea, sheath core, side-by-side, or segmented pie configuration.
  • the multicomponent fiber can be subjected to water or a dilute alkaline solution where the water-dispersible component is dissolved away to leave the water non-dispersible component behind as separate, independent fibers of extremely small fineness.
  • Polymers which have good water dispersibility often impart tackiness to the resulting multicomponent fibers, which causes the fiber to stick together, block, or fuse during winding or storage after several days, especially under hot, humid conditions.
  • a fatty acid or oil-based finish is applied to the surface of the fiber.
  • large proportions of pigments or fillers are sometimes added to water dispersible polymers to prevent fusing of the fibers as described, for example, in U.S. Patent No. 6,171,685 .
  • Such oil finishes, pigments, and fillers require additional processing steps and can impart undesirable properties to the final fiber.
  • Many water-dispersible polymers also require alkaline solutions for their removal which can cause degradation of the other polymer components of the fiber such as, for example, reduction of inherent viscosity, tenacity, and melt strength. Further, some water-dispersible polymers can not withstand exposure to water during hydroentanglement and, thus, are not suitable for the manufacture of nonwoven webs and fabrics.
  • the water-dispersible component may serve as a bonding agent for the thermoplastic fibers in nonwoven webs. Upon exposure to water, the fiber to fiber bonds come apart such that the nonwoven web loses its integrity and breaks down into individual fibers.
  • the thermoplastic fiber components of these nonwoven webs are not water-dispersible and remain present in the aqueous medium and, thus, must eventually be removed from municipal wastewater treatment plants. Hydroentanglement may be used to produce disintegratable nonwoven fabrics without or with very low levels ( ⁇ 5 wt%) of added binder to hold the fibers together. Although these fabrics may disintegrate upon disposal, they often utilize fibers that are not water soluble or water-dispersible and may result in entanglement and plugging within sewer systems. Any added water-dispersible binders also must be minimally affected by hydroentangling and not form gelatinous buildup or cross-link, and thereby contribute to fabric handling or sewer related problems.
  • a few water-soluble or water-dispersible polymers are available, but are generally not applicable to melt blown fiber forming operations or melt spinning in general.
  • Polymers such as polyvinyl alcohol, polyvinyl pyrrolidone, and polyacrylic acid are not melt processable as a result of thermal decomposition that occurs at temperatures below the point where a suitable melt viscosity is attained.
  • High molecular weight polyethylene oxide may have suitable thermal stability, but would provide a high viscosity solution at the polymer interface resulting in a slow rate of disintegration.
  • Water-dispersible sulfopolyesters have been described, for example, in U.S.
  • Patent No.'s 6,171,685 ; 5,543,488 ; 5,853,701 ; 4,304,901 ; 6,211,309 ; 5,570,605 ; 6,428,900 ; and 3,779,993 are low molecular weight thermoplastics that are brittle and lack the flexibility to withstand a winding operation to yield a roll of material that does not fracture or crumble. Sulfopolyesters also can exhibit blocking or fusing during processing into film or fibers, which may require the use of oil finishes or large amounts of pigments or fillers to avoid.
  • Low molecular weight polyethylene oxide (more commonly known as polyethylene glycol) is a weak/brittle polymer that also does not have the required physical properties for fiber applications. Forming fibers from known water-soluble polymers via solution techniques is an alternative, but the added complexity of removing solvent, especially water, increases manufacturing costs.
  • US 2008/311815 A1 discloses a water non-dispersible polymer microfiber comprising at least one water non-dispersible polymer wherein the water non-dispersible polymer microfiber has an equivalent diameter of less than 5 microns and length of less than 25 millimeters as well as a process for producing water non-dispersible polymer microfibers and nonwoven articles.
  • JP 2010/070870 A discloses a nonwoven fabric obtained by the following steps: Staple fibers A made from a fiber-forming thermoplastic polymer, having a single fiber diameter(D) of 10-1,000 nm, at a ratio (L/D) of the fiber length (L) to the single fiber fiameter (D) of 100-2,000, are dispersed in water into an aqueous dispersion, the staple fibers are then sprayed by a spray system to form a web, the web is then dried. Accordingly, there is a need for a water-dispersible fiber and fibrous articles prepared therefrom that exhibit adequate tensile strength, absorptivity, flexibility, and fabric integrity in the presence of moisture, especially upon exposure to human bodily fluids.
  • a fibrous article is needed that does not require a binder and completely disperses or dissolves in residential or municipal sewerage systems.
  • Potential uses include, but are not limited to, melt blown webs, spunbond fabrics, hydroentangled fabrics, wet-laid nonwovens, dry-laid non-wovens, bicomponent fiber components, adhesive promoting layers, binders for cellulosics, flushable nonwovens and films, dissolvable binder fibers, protective layers, and carriers for active ingredients to be released or dissolved in water.
  • multicomponent fiber having a water-dispersible component that does not exhibit excessive blocking or fusing of filaments during spinning operations, is easily removed by hot water at neutral or slightly acidic pH, and is suitable for hydroentangling processes to manufacture nonwoven fabrics.
  • These multicomponent fibers can be utilized to produce microfibers that can be used to produce various articles. Other extrudable and melt spun fibrous materials are also possible.
  • the present invention provides a wet lap composition comprising:
  • the present invention furthermore provides a process for making a nonwoven article, said process comprising using said wet lap composition in a wet-laid nonwoven process.
  • the present invention provides a wet-laid process to produce a nonwoven article, said wet-laid process comprising:
  • the fibers used in the present invention may be unicomponent fibers that rapidly disperse or dissolve in water and may be produced by melt-blowing or melt-spinning.
  • the fibers may be prepared from a single sulfopolyester or a blend of the sulfopolyester with a water-dispersible or water non-dispersible polymer.
  • the fiber used in the present invention optionally, may include a water-dispersible polymer blended with the sulfopolyester.
  • the fiber may include a water non-dispersible polymer blended with the sulfopolyester, provided that the blend is an immiscible blend.
  • Our invention also produces fibrous articles comprising our water-dispersible fibers.
  • the fibers used in our invention may be used to prepare various fibrous articles, such as yarns, melt-blown webs, spunbonded webs, and nonwoven fabrics that are, in turn, water-dispersible or flushable. Staple fibers can also be blended with natural or synthetic fibers in paper, nonwoven webs, and textile yarns.
  • a water-dispersible fiber comprising:
  • the water-dispersible, fibrous articles include personal care articles such as, for example, wipes, gauze, tissue, diapers, training pants, sanitary napkins, bandages, wound care, and surgical dressings.
  • the fibrous articles are flushable, that is, compatible with and suitable for disposal in residential and municipal sewerage systems.
  • a multicomponent fiber comprising a water-dispersible sulfopolyester and one or more water non-dispersible polymers.
  • the fiber has an engineered geometry such that the water non-dispersible polymers are present as segments substantially isolated from each other by the intervening sulfopolyester, which acts as a binder or encapsulating matrix for the water non-dispersible segments.
  • a multicomponent fiber having a shaped cross section comprising:
  • the sulfopolyester has a glass transition temperature of at least 57°C which greatly reduces blocking and fusion of the fiber during winding and long term storage.
  • the sulfopolyester may be removed by contacting the multicomponent fiber with water to leave behind the water non-dispersible segments as microdenier fibers.
  • Our invention therefore, also uses a process for microdenier fibers comprising:
  • the water non-dispersible polymers may be biodistintegratable as determined by DIN Standard 54900 and/or biodegradable as determined by ASTM Standard Method, D6340-98.
  • the multicomponent fiber also may be used to prepare a fibrous article such as a yarn, fabric, melt-blown web, spun-bonded web, or non-woven fabric and which may comprise one or more layers of fibers.
  • the fibrous article having multicomponent fibers may be contacted with water to produce fibrous articles containing microdenier fibers.
  • microdenier fiber web comprising:
  • a multicomponent fiber having a shaped cross section, comprising:
  • a multicomponent extrudate having a shaped cross section, comprising:
  • a process for making a multicomponent fiber having a shaped cross section comprising spinning at least one water dispersible sulfopolyester and one or more water non-dispersible polymers immiscible with the sulfopolyester, wherein the multicomponent fiber has a plurality of domains comprising the water non-dispersible polymers and the domains are substantially isolated from each other by the sulfopolyester intervening between the domains; wherein the multicomponent fiber has an as-spun denier of less than about 6 denier per filament; wherein the water dispersible sulfopolyester exhibits a melt viscosity of less than about 12,000 poise measured at 240°C at a strain rate of 1 rad/sec, and wherein the sulfopolyester comprises less than about 25 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol residues
  • a process for making a multicomponent fiber having a shaped cross section comprising extruding at least one water dispersible sulfopolyester and one or more water non-dispersible polymers immiscible with the sulfopolyester to produce a multicomponent extrudate, wherein the multicomponent extrudate has a plurality of domains comprising said water non-dispersible polymers and said domains are substantially isolated from each other by said sulfopolyester intervening between said domains; and melt drawing the multicomponent extrudate at a speed of at least about 2000 m/min to produce the multicomponent fiber.
  • the present invention uses a process for producing microdenier fibers comprising:
  • the present invention uses a process for producing microdenier fibers comprising:
  • microdenier fiber web comprising:
  • microdenier fiber web comprising:
  • a process for producing a water non-dispersible polymer microfiber comprising:
  • a water non-dispersible polymer microfiber comprising at least one water non-dispersible polymer wherein the water non-dispersible polymer microfiber has an equivalent diameter of less than 5 microns and length of less than 25 millimeters.
  • FIGS. 1a, 1b, and 1c are cross-sectional views of three differently-configured fibers, particularly illustrating how various measurements relating to the size and shape of the fibers are determined.
  • the present invention provides wet lap compositions and a process using said wet lap compositions as well as a wet-laid process to produce nonwoven articles.
  • the articles show tensile strength, absorptivity, flexibility, and fabric integrity in the presence of moisture, especially upon exposure to human bodily fluids.
  • the fibers and fibrous articles disclosed herein do not require the presence of oil, wax, or fatty acid finishes or the use of large amounts (typically 10 wt% or greater) of pigments or fillers to prevent blocking or fusing of the fibers during processing.
  • the fibrous articles prepared from our novel fibers do not require a binder and readily disperse or dissolve in home or public sewerage systems.
  • a water-dispersible fiber comprising a sulfopolyester having a glass transition temperature (Tg) of at least 25°C, wherein the sulfopolyester comprises:
  • the fibers used in our invention may be unicomponent fibers, bicomponent or multicomponent fibers.
  • the fibers used in the present invention may be prepared by melt spinning a single sulfopolyester or sulfopolyester blend and include staple, monofilament, and multifilament fibers with a shaped cross-section.
  • our invention uses multicomponent fibers, such as described, for example, in U.S. Patent No.
  • 5,916,678 which may be prepared by extruding the sulfopolyester and one or more water non-dispersible polymers, which are immiscible with the sulfopolyester, separately through a spinneret having a shaped or engineered transverse geometry such as, for example, an "islands-in-the-sea", sheath-core, side-by-side, or segmented pie configuration.
  • the sulfopolyester may be later removed by dissolving the interfacial layers or pie segments and leaving the smaller filaments or microdenier fibers of the water non-dispersible polymer(s).
  • These fibers of the water non-dispersible polymer have fiber size much smaller than the multi-component fiber before removing the sulfopolyester.
  • the sulfopolyester and water non-dispersible polymers may be fed to a polymer distribution system where the polymers are introduced into a segmented spinneret plate.
  • the polymers follow separate paths to the fiber spinneret and are combined at the spinneret hole which comprises either two concentric circular holes thus providing a sheath-core type fiber, or a circular spinneret hole divided along a diameter into multiple parts to provide a fiber having a side-by-side type.
  • the immiscible water dispersible sulfopolyester and water non-dispersible polymers may be introduced separately into a spinneret having a plurality of radial channels to produce a multicomponent fiber having a segmented pie cross section.
  • the sulfopolyester will form the "sheath" component of a sheath core configuration.
  • the water non-dispersible segments typically, are substantially isolated from each other by the sulfopolyester.
  • multicomponent fibers may be formed by melting the sulfopolyester and water non-dispersible polymers in separate extruders and directing the polymer flows into one spinneret with a plurality of distribution flow paths in form of small thin tubes or segments to provide a fiber having an islands-in-the-sea shaped cross section.
  • a spinneret is described in U.S. Patent No. 5,366,804 .
  • the sulfopolyester will form the "sea” component and the water non-dispersible polymer will form the "islands" component.
  • the unicomponent fibers and fibrous articles produced from the unicomponent fibers used in the present invention are water-dispersible and, typically, completely disperse at room temperature. Higher water temperatures can be used to accelerate their dispersibility or rate of removal from the nonwoven or multicomponent fiber.
  • water-dispersible as used herein with respect to unicomponent fibers and fibrous articles prepared from unicomponent fibers, is intended to be synonymous with the terms “water-dissipatable”, “water-disintegratable”, “water-dissolvable”, “water-dispellable”, “water soluble”, water-removable”, “hydrosoluble”, and “hydrodispersible” and is intended to mean that the fiber or fibrous article is therein or therethrough dispersed or dissolved by the action of water.
  • dissipate means that, using a sufficient amount of deionized water (e.g., 100:1 water:fiber by weight) to form a loose suspension or slurry of the fibers or fibrous article, at a temperature of about 60°C, and within a time period of up to 5 days, the fiber or fibrous article dissolves, disintegrates, or separates into a plurality of incoherent pieces or particles distributed more or less throughout the medium such that no recognizable filaments are recoverable from the medium upon removal of the water, for example, by filtration or evaporation.
  • deionized water e.g. 100:1 water:fiber by weight
  • water-dispersible is not intended to include the simple disintegration of an assembly of entangled or bound, but otherwise water insoluble or nondispersible, fibers wherein the fiber assembly simply breaks apart in water to produce a slurry of fibers in water which could be recovered by removal of the water.
  • all of these terms refer to the activity of water or a mixture of water and a water-miscible cosolvent on the sulfopolyesters described herein. Examples of such water-miscible cosolvents includes alcohols, ketones, glycol ethers, esters and the like.
  • water-dispersible as used herein in reference to the sulfopolyester as one component of a multicomponent fiber or fibrous article, also is intended to be synonymous with the terms “water-dissipatable”, “water-disintegratable”, “water-dissolvable”, “water-dispellable”, “water soluble”, “water-removable”, “hydrosoluble”, and “hydrodispersible” and is intended to mean that the sulfopolyester component is sufficiently removed from the multicomponent fiber and is dispersed or dissolved by the action of water to enable the release and separation of the water non-dispersible fibers contained therein.
  • dissipate means that, using a sufficient amount of deionized water (e.g., 100:1 water:fiber by weight) to form a loose suspension or slurry of the fibers or fibrous article, at a temperature of about 60°C, and within a time period of up to 5 days, sulfopolyester component dissolves, disintegrates, or separates from the multicomponent fiber, leaving behind a plurality of microdenier fibers from the water non-dispersible segments.
  • deionized water e.g., 100:1 water:fiber by weight
  • segment or “domain” or “zone” when used to describe the shaped cross section of a multicomponent fiber refers to the area within the cross section comprising the water non-dispersible polymers where these domains or segments are substantially isolated from each other by the water-dispersible sulfopolyester intervening between the segments or domains.
  • substantially isolated as used herein, is intended to mean that the segments or domains are set apart from each other to permit the segments domains to form individual fibers upon removal of the sulfopolyester.
  • Segments or domains or zones can be of similar size and shape or varying size and shape. Again, segments or domains or zones can be arranged in any configuration.
  • segments or domains or zones are “substantially continuous” along the length of the multicomponent extrudate or fiber.
  • the term “substantially continuous” means continuous along at least 10 cm length of the multicomponent fiber.
  • the shaped cross section of a multicomponent fiber can, for example, be in the form of a sheath core, islands-in-the sea, segmented pie, hollow segmented pie; off-centered segmented pie, etc..
  • the water-dispersible fiber used in the present invention is prepared from polyesters or, more specifically sulfopolyesters, comprising dicarboxylic acid monomer residues, sulfomonomer residues, diol monomer residues, and repeating units.
  • the sulfomonomer may be a dicarboxylic acid, a diol, or hydroxycarboxylic acid.
  • the term "monomer residue”, as used herein, means a residue of a dicarboxylic acid, a diol, or a hydroxycarboxylic acid.
  • a “repeating unit”, as used herein, means an organic structure having 2 monomer residues bonded through a carbonyloxy group.
  • the sulfopolyesters used in the present invention contain substantially equal molar proportions of acid residues (100 mole %) and diol residues (100 mole %) which react in substantially equal proportions such that the total moles of repeating units is equal to 100 mole %.
  • the mole percentages provided in the present disclosure therefore, may be based on the total moles of acid residues, the total moles of diol residues, or the total moles of repeating units.
  • a sulfopolyester containing 30 mole% of a sulfomonomer, which may be a dicarboxylic acid, a diol, or hydroxycarboxylic acid, based on the total repeating units means that the sulfopolyester contains 30 mole% sulfomonomer out of a total of 100 mole% repeating units. Thus, there are 30 moles of sulfomonomer residues among every 100 moles of repeating units.
  • a sulfopolyester containing 30 mole% of a dicarboxylic acid sulfomonomer, based on the total acid residues means the sulfopolyester contains 30 mole% sulfomonomer out of a total of 100 mole% acid residues.
  • the sulfopolyesters described herein have an inherent viscosity, abbreviated hereinafter as "Ih.V.”, of at least about 0.1 dL/g, preferably about 0.2 to 0.3 dL/g, and most preferably greater than about 0.3 dL/g, measured in a 60/40 parts by weight solution of phenol/tetrachloroethane solvent at 25°C and at a concentration of about 0.5 g of sulfopolyester in 100 mL of solvent.
  • Ih.V inherent viscosity
  • polystyrene resin encompasses both “homopolyesters” and “copolyesters” and means a synthetic polymer prepared by the polycondensation of difunctional carboxylic acids with difunctional hydroxyl compound.
  • sulfopolyester means any polyester comprising a sulfomonomer.
  • the difunctional carboxylic acid is a dicarboxylic acid and the difunctional hydroxyl compound is a dihydric alcohol such as, for example glycols and diols.
  • the difunctional carboxylic acid may be a hydroxy carboxylic acid such as, for example, p-hydroxybenzoic acid
  • the difunctional hydroxyl compound may be a aromatic nucleus bearing 2 hydroxy substituents such as, for example, hydroquinone.
  • the term "residue”, as used herein, means any organic structure incorporated into the polymer through a polycondensation reaction involving the corresponding monomer.
  • the dicarboxylic acid residue may be derived from a dicarboxylic acid monomer or its associated acid halides, esters, salts, anhydrides, or mixtures thereof.
  • dicarboxylic acid is intended to include dicarboxylic acids and any derivative of a dicarboxylic acid, including its associated acid halides, esters, half-esters, salts, half-salts, anhydrides, mixed anhydrides, or mixtures thereof, useful in a polycondensation process with a diol to make a high molecular weight polyester.
  • the sulfopolyester used in the present invention includes one or more dicarboxylic acid residues.
  • the dicarboxylic acid residue may comprise from about 50 to about 100 mole% of the acid residues.
  • concentration ranges of dicarboxylic acid residues are from about 60 mole% to about 95 mole%, and about 70 mole% to about 95 mole%.
  • dicarboxylic acids that may be used include aliphatic dicarboxylic acids, alicyclic dicarboxylic acids, aromatic dicarboxylic acids, or mixtures of two or more of these acids.
  • suitable dicarboxylic acids include, but are not limited to, succinic; glutaric; adipic; azelaic; sebacic; fumaric; maleic; itaconic; 1,3-cyclohexanedicarboxylic; 1,4-cyclohexanedicarboxylic; diglycolic; 2,5-norbornanedicarboxylic; phthalic; terephthalic; 1,4-naphthalenedicarboxylic; 2,5-naphthalenedicarboxylic; diphenic; 4,4'-oxydibenzoic; 4,4'-sulfonyidibenzoic; and isophthalic.
  • the preferred dicarboxylic acid residues are isophthalic, terephthalic, and 1,4-cyclohexanedicarboxylic acids, or if diesters are used, dimethyl terephthalate, dimethyl isophthalate, and dimethyl-1,4-cyclohexanedicarboxylate with the residues of isophthalic and terephthalic acid being especially preferred.
  • dicarboxylic acid methyl ester is the most preferred embodiment, it is also acceptable to include higher order alkyl esters, such as ethyl, propyl, isopropyl, butyl, and so forth.
  • aromatic esters, particularly phenyl also may be employed.
  • the sulfopolyester includes about 4 to about 40 mole%, based on the total repeating units, of residues of at least one sulfomonomer having 2 functional groups and one or more sulfonate groups attached to an aromatic or cycloaliphatic ring wherein the functional groups are hydroxyl, carboxyl, or a combination thereof. Additional examples of concentration ranges for the sulfomonomer residues are about 4 to about 35 mole%, about 8 to about 30 mole%, and about 8 to about 25 mole%, based on the total repeating units.
  • the sulfomonomer may be a dicarboxylic acid or ester thereof containing a sulfonate group, a diol containing a sulfonate group, or a hydroxy acid containing a sulfonate group.
  • sulfonate refers to a salt of a sulfonic acid having the structure "-SO 3 M" wherein M is the cation of the sulfonate salt.
  • the cation of the sulfonate salt may be a metal ion such as Li + , Na + , K + , Mg ++ , Ca ++ , Ni ++ , Fe ++ , and the like.
  • the cation of the sulfonate salt may be non-metallic such as a nitrogenous base as described, for example, in U.S. Patent No. 4,304,901 .
  • Nitrogen-based cations are derived from nitrogen-containing bases, which may be aliphatic, cycloaliphatic, or aromatic compounds. Examples of such nitrogen containing bases include ammonia, dimethylethanolamine, diethanolamine, triethanolamine, pyridine, morpholine, and piperidine.
  • the method of this invention for preparing sulfopolyesters containing nitrogen-based sulfonate salt groups is to disperse, dissipate, or dissolve the polymer containing the required amount of sulfonate group in the form of its alkali metal salt in water and then exchange the alkali metal cation for a nitrogen-based cation.
  • the resulting sulfopolyester is completely dispersible in water with the rate of dispersion dependent on the content of sulfomonomer in the polymer, temperature of the water, surface area/thickness of the sulfopolyester, and so forth.
  • a divalent metal ion is used, the resulting sulfopolyesters are not readily dispersed by cold water but are more easily dispersed by hot water. Utilization of more than one counterion within a single polymer composition is possible and may offer a means to tailor or fine-tune the water-responsivity of the resulting article of manufacture.
  • sulfomonomers residues include monomer residues where the sulfonate salt group is attached to an aromatic acid nucleus, such as, for example, benzene; naphthalene; diphenyl; oxydiphenyl; sulfonyldiphenyl; and methylenediphenyl or cycloaliphatic rings, such as, for example, cyclohexyl; cyclopentyl; cyclobutyl; cycloheptyl; and cyclooctyl.
  • aromatic acid nucleus such as, for example, benzene; naphthalene; diphenyl; oxydiphenyl; sulfonyldiphenyl; and methylenediphenyl or cycloaliphatic rings, such as, for example, cyclohexyl; cyclopentyl; cyclobutyl; cycloheptyl; and cyclooctyl.
  • sulfomonomer residues which may be used in the present invention are the metal sulfonate salt of sulfophthalic acid, sulfoterephthalic acid, sulfoisophthalic acid, or combinations thereof.
  • sulfomonomers which may be used are 5-sodiosulfoisophthalic acid and esters thereof. If the sulfomonomer residue is from 5-sodiosulfoisophthalic acid, typical sulfomonomer concentration ranges are about 4 to about 35 mole%, about 8 to about 30 mole %, and about 8 to 25 mole %, based on the total moles of acid residues.
  • the sulfomonomers used in the preparation of the sulfopolyesters are known compounds and may be prepared using methods well known in the art.
  • sulfomonomers in which the sulfonate group is attached to an aromatic ring may be prepared by sulfonating the aromatic compound with oleum to obtain the corresponding sulfonic acid and followed by reaction with a metal oxide or base, for example, sodium acetate, to prepare the sulfonate salt.
  • Procedures for preparation of various sulfomonomers are described, for example, in U.S. Patent No.'s 3,779,993 ; 3,018,272 ; and 3,528,947 .
  • polyester using, for example, a sodium sulfonate salt, and ion-exchange methods to replace the sodium with a different ion, such as zinc, when the polymer is in the dispersed form.
  • a sodium sulfonate salt and ion-exchange methods to replace the sodium with a different ion, such as zinc, when the polymer is in the dispersed form.
  • This type of ion exchange procedure is generally superior to preparing the polymer with divalent salts insofar as the sodium salts are usually more soluble in the polymer reactant melt-phase.
  • the sulfopolyester includes one or more diol residues which may include aliphatic, cycloaliphatic, and aralkyl glycols.
  • the cycloaliphatic diols for example, 1,3- and 1,4-cyclohexanedimethanol, may be present as their pure cis or trans isomers or as a mixture of cis and trans isomers.
  • diol is synonymous with the term "glycol” and means any dihydric alcohol.
  • diols include, but are not limited to, ethylene glycol; diethylene glycol; triethylene glycol; polyethylene glycols; 1,3-propanediol; 2,4-dimethyl-2-ethylhexane-1,3-diol; 2,2-dimethyl-1,3-propanediol; 2-ethyl-2-butyl-1,3-propanediol; 2-ethyl-2-isobutyl-1,3-propanediol; 1,3-butanediol; 1,4-butanediol; 1,5-pentanediol; 1,6-hexanediol; 2,2,4-trimethyl-1,6-hexanediol; thiodiethanol; 1,2-cyclohexanedimethanol; 1,3-cyclohexanedimethanol; 1,4-cyclohexanedimethanol; 2,2,4,4-tetramethyl-1,3
  • the diol residues may include from about 25 mole% to about 100 mole%, based on the total diol residues, of residue of a poly(ethylene glycol) having a structure H-(OCH 2 -CH 2 ) n -OH wherein n is an integer in the range of 2 to about 500.
  • a poly(ethylene glycol) having a structure H-(OCH 2 -CH 2 ) n -OH wherein n is an integer in the range of 2 to about 500 Non-limiting examples of lower molecular weight polyethylene glycols, e.g., wherein n is from 2 to 6, are diethylene glycol, triethylene glycol, and tetraethylene glycol. Of these lower molecular weight glycols, diethylene and triethylene glycol are most preferred.
  • PEG polyethylene glycols
  • CARBOWAX® a product of Dow Chemical Company (formerly Union Carbide).
  • ethylene glycol ethylene glycol
  • the molecular weight may range from greater than 300 to about 22,000 g/mol.
  • the molecular weight and the mole% are inversely proportional to each other; specifically, as the molecular weight is increased, the mole % will be decreased in order to achieve a designated degree of hydrophilicity.
  • a PEG having a molecular weight of 1000 may constitute up to 10 mole% of the total diol, while a PEG having a molecular weight of 10,000 would typically be incorporated at a level of less than 1 mole% of the total diol.
  • dimer, trimer, and tetramer diols may be formed in situ due to side reactions that may be controlled by varying the process conditions.
  • varying amounts of diethylene, triethylene, and tetraethylene glycols may be formed from ethylene glycol from an acid-catalyzed dehydration reaction which occurs readily when the polycondensation reaction is carried out under acidic conditions.
  • the presence of buffer solutions may be added to the reaction mixture to retard these side reactions. Additional compositional latitude is possible, however, if the buffer is omitted and the dimerization, trimerization, and tetramerization reactions are allowed to proceed.
  • the sulfopolyester used in the present invention may include from 0 to about 25 mole%, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein the functional groups are hydroxyl, carboxyl, or a combination thereof.
  • branching monomers are 1,1,1-trimethylol propane, 1,1,1-trimethylolethane, glycerin, pentaerythritol, erythritol, threitol, dipentaerythritol, sorbitol, trimellitic anhydride, pyromellitic dianhydride, dimethylol propionic acid, or combinations thereof.
  • branching monomer concentration ranges are from 0 to about 20 mole% and from 0 to about 10 mole%.
  • the presence of a branching monomer may result in a number of possible benefits to the sulfopolyester used in the present invention, including but not limited to, the ability to tailor rheological, solubility, and tensile properties.
  • a branched sulfopolyester compared to a linear analog, will also have a greater concentration of end groups that may facilitate post-polymerization crosslinking reactions.
  • branching agent At high concentrations of branching agent, however, the sulfopolyester may be prone to gelation.
  • the sulfopolyester used for the present invention has a glass transition temperature, abbreviated herein as "Tg", of at least 25°C as measured on the dry polymer using standard techniques, such as differential scanning calorimetry ("DSC"), well known to persons skilled in the art.
  • Tg measurements of the sulfopolyesters used in the present invention are conducted using a "dry polymer", that is, a polymer sample in which adventitious or absorbed water is driven off by heating to polymer to a temperature of about 200°C and allowing the sample to return to room temperature.
  • the sulfopolyester is dried in the DSC apparatus by conducting a first thermal scan in which the sample is heated to a temperature above the water vaporization temperature, holding the sample at that temperature until the vaporization of the water absorbed in the polymer is complete (as indicated by an a large, broad endotherm), cooling the sample to room temperature, and then conducting a second thermal scan to obtain the Tg measurement.
  • Further examples of glass transition temperatures exhibited by the sulfopolyester are at least 30°C, at least 35°C, at least 40°C, at least 50°C, at least 60°C, at least 65°C, at least 80°C, and at least 90°C.
  • typical glass transition temperatures of the dry sulfopolyesters used in our invention are about 30°C, about 48°C, about 55°C, about 65°C, about 70°C, about 75°C, about 85°C, and about 90°C.
  • the fibers used herein may consist essentially of or, consist of, the sulfopolyesters described hereinabove.
  • the sulfopolyesters used in this invention may be a single polyester or may be blended with one or more supplemental polymers to modify the properties of the resulting fiber.
  • the supplemental polymer may or may not be water-dispersible depending on the application and may be miscible or immiscible with the sulfopolyester. If the supplemental polymer is water non-dispersible, it is preferred that the blend with the sulfopolyester is immiscible.
  • miscible is intended to mean that the blend has a single, homogeneous amorphous phase as indicated by a single composition-dependent Tg.
  • a first polymer that is miscible with second polymer may be used to "plasticize” the second polymer as illustrated, for example, in U.S. Patent No. 6,211,309 .
  • the term “immiscible”, as used herein denotes a blend that shows at least 2, randomly mixed, phases and exhibits more than one Tg. Some polymers may be immiscible and yet compatible with the sulfopolyester.
  • Non-limiting examples of water-dispersible polymers that may be blended with the sulfopolyester are polymethacrylic acid, polyvinyl pyrrolidone, polyethylene-acrylic acid copolymers, polyvinyl methyl ether, polyvinyl alcohol, polyethylene oxide, hydroxy propyl cellulose, hydroxypropyl methyl cellulose, methyl cellulose, ethyl hydroxyethyl cellulose, isopropyl cellulose, methyl ether starch, polyacrylamides, poly(N-vinyl caprolactam), polyethyl oxazoline, poly(2-isopropyl-2-oxazoline), polyvinyl methyl oxazolidone, water-dispersible sulfopolyesters, polyvinyl methyl oxazolidimone, poly(2,4-dimethyl-6-triazinylethylene), and ethylene oxide-propylene oxide copolymers.
  • polymers which are water non-dispersible that may be blended with the sulfopolyester include, but are not limited to, polyolefins, such as homo- and copolymers of polyethylene and polypropylene; poly(ethylene terephthalate); poly(butylene terephthalate); and polyamides, such as nylon-6; polylactides; caprolactone; Eastar Bio ® (poly(tetramethylene adipate-co-terephthalate), a product of Eastman Chemical Company); polycarbonate; polyurethane; and polyvinyl chloride.
  • polyolefins such as homo- and copolymers of polyethylene and polypropylene
  • poly(ethylene terephthalate) poly(butylene terephthalate)
  • polyamides such as nylon-6
  • polylactides caprolactone
  • Eastar Bio ® poly(tetramethylene adipate-co-terephthalate), a product of Eastman Chemical Company
  • polycarbonate
  • blends of more than one sulfopolyester may be used to tailor the end-use properties of the resulting fiber or fibrous article, for example, a nonwoven fabric or web.
  • the blends of one or more sulfopolyesters will have Tg's of at least 25°C for the water-dispersible, unicomponent fibers and at least 57°C for the multicomponent fibers.
  • Tg's of at least 25°C for the water-dispersible, unicomponent fibers and at least 57°C for the multicomponent fibers.
  • blending may also be exploited to alter the processing characteristics of a sulfopolyester to facilitate the fabrication of a nonwoven.
  • an immiscible blend of polypropylene and sulfopolyester may provide a conventional nonwoven web that will break apart and completely disperse in water as true solubility is not needed.
  • the desired performance is related to maintaining the physical properties of the polypropylene while the sulfopolyester is only a spectator during the actual use of the product or, alternatively, the sulfopolyester is fugitive and is removed before the final form of the product is utilized.
  • the sulfopolyester and supplemental polymer may be blended in batch, semicontinuous, or continuous processes. Small scale batches may be readily prepared in any high-intensity mixing devices well-known to those skilled in the art, such as Banbury mixers, prior to melt-spinning fibers. The components may also be blended in solution in an appropriate solvent.
  • the melt blending method includes blending the sulfopolyester and supplemental polymer at a temperature sufficient to melt the polymers. The blend may be cooled and pelletized for further use or the melt blend can be melt spun directly from this molten blend into fiber form.
  • the term "melt" as used herein includes, but is not limited to, merely softening the polyester. For melt mixing methods generally known in the polymers art, see Mixing and Compounding of Polymers (I. Manas-Zloczower & Z. Tadmor editors, Carl Hanser Verlag Publisher, 1994, New York, N. Y .).
  • our invention also uses a water-dispersible fiber comprising a sulfopolyester having a glass transition temperature (Tg) of at least 25°C, wherein the sulfopolyester comprises:
  • the sulfopolyesters used in the instant invention are readily prepared from the appropriate dicarboxylic acids, esters, anhydrides, or salts, sulfomonomer, and the appropriate diol or diol mixtures using typical polycondensation reaction conditions. They may be made by continuous, semi-continuous, and batch modes of operation and may utilize a variety of reactor types. Examples of suitable reactor types include, but are not limited to, stirred tank, continuous stirred tank, slurry, tubular, wiped-film, falling film, or extrusion reactors.
  • continuous as used herein means a process wherein reactants are introduced and products withdrawn simultaneously in an uninterrupted manner.
  • continuous it is meant that the process is substantially or completely continuous in operation and is to be contrasted with a “batch” process.
  • Continuous is not meant in any way to prohibit normal interruptions in the continuity of the process due to, for example, start-up, reactor maintenance, or scheduled shut down periods.
  • batch process as used herein means a process wherein all the reactants are added to the reactor and then processed according to a predetermined course of reaction during which no material is fed or removed into the reactor.
  • continuous means a process where some of the reactants are charged at the beginning of the process and the remaining reactants are fed continuously as the reaction progresses.
  • a semicontinuous process may also include a process similar to a batch process in which all the reactants are added at the beginning of the process except that one or more of the products are removed continuously as the reaction progresses.
  • the process is operated advantageously as a continuous process for economic reasons and to produce superior coloration of the polymer as the sulfopolyester may deteriorate in appearance if allowed to reside in a reactor at an elevated temperature for too long a duration.
  • the sulfopolyesters used in the present invention are prepared by procedures known to persons skilled in the art.
  • the sulfomonomer is most often added directly to the reaction mixture from which the polymer is made, although other processes are known and may also be employed, for example, as described in U. S. Patent No.'s 3,018,272 , 3,075,952 , and 3,033,822 .
  • the reaction of the sulfomonomer, diol component and the dicarboxylic acid component may be carried out using conventional polyester polymerization conditions.
  • the reaction process may comprise two steps.
  • the diol component and the dicarboxylic acid component are reacted at elevated temperatures, typically, about 150°C to about 250°C for about 0.5 to about 8 hours at pressures ranging from about 0.0 kPa gauge to about 414 kPa gauge (60 pounds per square inch, "psig").
  • the temperature for the ester interchange reaction ranges from about 180°C to about 230°C for about 1 to about 4 hours while the preferred pressure ranges from about 103 kPa gauge (15 psig) to about 276 kPa gauge (40 psig).
  • reaction product is heated under higher temperatures and under reduced pressure to form sulfopolyester with the elimination of diol, which is readily volatilized under these conditions and removed from the system.
  • This second step, or polycondensation step is continued under higher vacuum and a temperature which generally ranges from about 230°C. to about 350°C, preferably about 250°C to about 310°C and most preferably about 260°C to about 290°C for about 0.1 to about 6 hours, or preferably, for about 0.2 to about 2 hours, until a polymer having the desired degree of polymerization, as determined by inherent viscosity, is obtained.
  • the polycondensation step may be conducted under reduced pressure which ranges from about 53 kPa (400 torr) to about 0.013 kPa (0.1 torr). Stirring or appropriate conditions are used in both stages to ensure adequate heat transfer and surface renewal of the reaction mixture.
  • the reactions of both stages are facilitated by appropriate catalysts such as, for example, alkoxy titanium compounds, alkali metal hydroxides and alcoholates, salts of organic carboxylic acids, alkyl tin compounds, metal oxides, and the like.
  • a three-stage manufacturing procedure similar to that described in U.S. Patent No. 5,290,631 , may also be used, particularly when a mixed monomer feed of acids and esters is employed.
  • sulfopolyesters are produced by reacting the dicarboxylic acid or a mixture of dicarboxylic acids with the diol component or a mixture of diol components.
  • the reaction is conducted at a pressure of from about 7 kPa gauge (1 psig) to about 1379 kPa gauge (200 psig), preferably less than 689 kPa (100 psig) to produce a low molecular weight, linear or branched sulfopolyester product having an average degree of polymerization of from about 1.4 to about 10.
  • the temperatures employed during the direct esterification reaction typically range from about 180°C to about 280°C, more preferably ranging from about 220°C to about 270°C. This low molecular weight polymer may then be polymerized by a polycondensation reaction.
  • the water dispersible and multicomponent fibers and fibrous articles disclosed herein also may contain other conventional additives and ingredients which do not deleteriously affect their end use.
  • additives such as fillers, surface friction modifiers, light and heat stabilizers, extrusion aids, antistatic agents, colorants, dyes, pigments, fluorescent brighteners, antimicrobials, anticounterfeiting markers, hydrophobic and hydrophilic enhancers, viscosity modifiers, slip agents, tougheners, adhesion promoters, and the like may be used.
  • the fibers and fibrous articles do not require the presence of additives such as, for example, pigments, fillers, oils, waxes, or fatty acid finishes, to prevent blocking or fusing of the fibers during processing.
  • additives such as, for example, pigments, fillers, oils, waxes, or fatty acid finishes
  • blocking or fusing is understood to mean that the fibers or fibrous articles stick together or fuse into a mass such that the fiber cannot be processed or used for its intended purpose. Blocking and fusing can occur during processing of the fiber or fibrous article or during storage over a period of days or weeks and is exacerbated under hot, humid conditions.
  • the fibers and fibrous articles will contain less than 10 wt% of such anti-blocking additives, based on the total weight of the fiber or fibrous article.
  • the fibers and fibrous articles may contain less than 10 wt% of a pigment or filler.
  • the fibers and fibrous articles may contain less than 9 wt%, less than 5 wt%, less than 3 wt%, less than 1 wt%, and 0 wt% of a pigment or filler, based on the total weight of the fiber.
  • Colorants sometimes referred to as toners, may be added to impart a desired neutral hue and/or brightness to the sulfopolyester.
  • pigments or colorants may be included in the sulfopolyester reaction mixture during the reaction of the diol monomer and the dicarboxylic acid monomer or they may be melt blended with the preformed sulfopolyester.
  • a preferred method of including colorants is to use a colorant having thermally stable organic colored compounds having reactive groups such that the colorant is copolymerized and incorporated into the sulfopolyester to improve its hue.
  • colorants such as dyes possessing reactive hydroxyl and/or carboxyl groups, including, but not limited to, blue and red substituted anthraquinones, may be copolymerized into the polymer chain.
  • dyes When dyes are employed as colorants, they may be added to the copolyester reaction process after an ester interchange or direct esterification reaction.
  • the term “fiber” refers to a polymeric body of high aspect ratio capable of being formed into two or three dimensional articles such as woven or nonwoven fabrics.
  • the term “fiber” is synonymous with “fibers” and intended to mean one or more fibers.
  • the fibers used in our invention may be unicomponent fibers, bicomponent, or multicomponent fibers.
  • the term "unicomponent fiber”, as used herein, is intended to mean a fiber prepared by melt spinning a single sulfopolyester, blends of one or more sulfopolyesters, or blends of one or more sulfopolyesters with one or more additional polymers and includes staple, monofilament, and multifilament fibers.
  • Unicomponent is intended to be synonymous with the term “monocomponent” and includes “biconstituent” or “multiconstituent” fibers, and refers to fibers which have been formed from at least two polymers extruded from the same extruder as a blend. Unicomponent or biconstituent fibers do not have the various polymer components arranged in relatively constantly positioned distinct zones across the cross-sectional area of the fiber and the various polymers are usually not continuous along the entire length of the fiber, instead usually forming fibrils or protofibrils which start and end at random. Thus, the term “unicomponent” is not intended to exclude fibers formed from a polymer or blends of one or more polymers to which small amounts of additives may be added for coloration, anti-static properties, lubrication, hydrophilicity, etc.
  • multicomponent fiber intended to mean a fiber prepared by melting the two or more fiber forming polymers in separate extruders and by directing the resulting multiple polymer flows into one spinneret with a plurality of distribution flow paths but spun together to form one fiber.
  • Multicomponent fibers are also sometimes referred to as conjugate or bicomponent fibers.
  • the polymers are arranged in substantially constantly positioned distinct segments or zones across the cross-section of the conjugate fibers and extend continuously along the length of the conjugate fibers.
  • the configuration of such a multicomponent fiber may be, for example, a sheath/core arrangement wherein one polymer is surrounded by another or may be a side by side arrangement, a pie arrangement or an "islands-in-the-sea" arrangement.
  • a multicomponent fiber may be prepared by extruding the sulfopolyester and one or more water non-dispersible polymers separately through a spinneret having a shaped or engineered transverse geometry such as, for example, an "islands-in-the-sea" or segmented pie configuration.
  • Multicomponent fibers typically, are staple, monofilament or multifilament fibers that have a shaped or round cross-section. Most fiber forms are heatset.
  • the fiber may include the various antioxidants, pigments, and additives as described herein.
  • Monofilament fibers generally range in size from about 15 to about 8000 denier per filament (abbreviated herein as "d/f"). Our novel fibers typically will have d/f values in the range of about 40 to about 5000. Monofilaments may be in the form of unicomponent or multicomponent fibers.
  • the multifilament fibers used in our invention will preferably range in size from about 1.5 micrometers for melt blown webs, about 0.5 to about 50 d/f for staple fibers, and up to about 5000 d/f for monofilament fibers.
  • Multifilament fibers may also be used as crimped or uncrimped yarns and tows. Fibers used in melt blown web and melt spun fabrics may be produced in microdenier sizes.
  • microdenier is intended to mean a d/f value of 1 d/f or less.
  • the microdenier fibers disclosed herein typically have d/f values of 1 or less, 0.5 or less, or 0.1 or less. Nanofibers can also be produced by electrostatic spinning.
  • the sulfopolyesters also are advantageous for the preparation of bicomponent and multicomponent fibers having a shaped cross section.
  • sulfopolyesters or blends of sulfopolyesters having a glass transition temperature (Tg) of at least 57°C are particularly useful for multicomponent fibers to prevent blocking and fusing of the fiber during spinning and take up.
  • Tg glass transition temperature
  • a multicomponent fiber having shaped cross section comprising:
  • the dicarboxylic acids, diols, sulfopolyester, sulfomonomers, and branching monomers residues are as described previously for other embodiments of the invention.
  • the sulfopolyester have a Tg of at least 57°C.
  • Further examples of glass transition temperatures that may be exhibited by the sulfopolyester or sulfopolyester blend of our multicomponent fiber are at least 60°C, at least 65°C, at least 70°C, at least 75°C, at least 80°C, at least 85°C, and at least 90°C.
  • blends of one or more sulfopolyesters may be used in varying proportions to obtain a sulfopolyester blend having the desired Tg.
  • the Tg of a sulfopolyester blend may be calculated by using a weighted average of the Tg's of the sulfopolyester components. For example, sulfopolyester having a Tg of 48°C may be blended in a 25:75 wt:wt ratio with another sulfopolyester having Tg of 65°C to give a sulfopolyester blend having a Tg of approximately 61°C.
  • the water dispersible sulfopolyester component of the multicomponent fiber presents properties which allow at least one of the following:
  • a multicomponent fiber having a shaped cross section comprising:
  • the sulfopolyester utilized in these multicomponent fibers has a melt viscosity of generally less than about 12,000 poise.
  • the melt viscosity of the sulfopolyester is less than 10,000 poise, more preferably, less than 6,000, and most preferably, less than 4,000 poise measured at 240°C and 1 rad/sec shear rate.
  • the sulfopolyester exhibits a melt viscosity of between about 1000-12000 poise, more preferably between 2000-6000 poise, and most preferably between 2500-4000 poise measured at 240°C and 1 rad/sec shear rate.
  • the samples Prior to determining the viscosity, the samples are dried at 60°C in a vacuum oven for 2 days.
  • the melt viscosity is measured on rheometer using a 25 mm diameter parallel-plate geometry at 1mm gap setting. A dynamic frequency sweep is run at a strain rate range of 1 to 400 rad/sec and 10% strain amplitude. The viscosity is then measured at 240° C and strain rate of 1 rad/sec.
  • the level of sulfomonomer residues in the sulfopolyester polymers for use in accordance with this aspect of the present invention is generally less than about 25 mole %, and preferably, less than 20 mole %, reported as a percentage of the total diacid or diol residues in the sulfopolyester. More preferably, this level is between about 4 to about 20 mole %, even more preferably between about 5 to about 12 mole %, and most preferably between about 7 to about 10 mole %.
  • Sulfomonomers for use with the invention preferably have 2 functional groups and one or more sulfonate groups attached to an aromatic or cycloaliphatic ring wherein the functional groups are hydroxyl, carboxyl, or a combination thereof.
  • a sodiosulfo-isophthalic acid monomer is particularly preferred.
  • the sulfopolyester preferably comprises residues of one or more dicarboxylic acids, one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H-(OCH 2 -CH 2 ) n -OH wherein n is an integer in the range of 2 to about 500, and 0 to about 20 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein the functional groups are hydroxyl, carboxyl, or a combination thereof.
  • the sulfopolyester comprises from about 80-96 mole % dicarboxylic acid residues, from about 4 to about 20 mole % sulfomonomer residues, and 100 mole % diol residues (there being a total mole % of 200%, i.e., 100 mole % diacid and 100 mole % diol). More specifically, the dicarboxylic portion of the sulfopolyester comprises between about 60-80 mole % terephthalic acid, about 0-30 mole % isophthalic acid, and about 4-20 mole % 5-sodiosulfoisophthalic acid (5-SSIPA).
  • 5-SSIPA 5-sodiosulfoisophthalic acid
  • the diol portion comprises from about 0-50 mole % diethylene glycol and from about 50-100 mole % ethylene glycol.
  • An exemplary formulation as used in this embodiment of the invention is set forth subsequently. Approximate Mole % (based on total moles of diol or diacid residues) Terephthalic acid 71 Isophthalic acid 20 5-SSIPA 9 Diethylene glycol 35 Ethylene glycol 65
  • the water non-dispersible component of the multicomponent fiber may comprise any of those water non-dispersible polymers described herein. Spinning of the fiber may also occur according to any method described herein. However, the improved rheological properties of multicomponent fibers in accordance with this aspect of the invention provide for enhanced drawings speeds.
  • the multicomponent extrudate is capable of being melt drawn to produce the multicomponent fiber, using any of the methods disclosed herein, at a speed of at least about 2000 m/min, more preferably at least about 3000 m/min, even more preferably at least about 4000 m/min, and most preferably at least about 4500 m/min.
  • melt drawing of the multicomponent extrudates at these speeds results in at least some oriented crystallinity in the water non-dispersible component of the multicomponent fiber. This oriented crystallinity can increase the dimensional stability of non-woven materials made from the multicomponent fibers during subsequent processing.
  • multicomponent extrudate Another advantage of the multicomponent extrudate is that it can be melt drawn to a multicomponent fiber having an as-spun denier of less than 6 deniers per filament.
  • Other ranges of multicomponent fiber sizes include an as-spun denier of less than 4 deniers per filament and less than 2.5 deniers per filament.
  • a multicomponent extrudate having a shaped cross section, comprising:
  • the multicomponent fiber comprises a plurality of segments or domains of one or more water non-dispersible polymers immiscible with the sulfopolyester in which the segments or domains are substantially isolated from each other by the sulfopolyester intervening between the segments or domains.
  • substantially isolated is intended to mean that the segments or domains are set apart from each other to permit the segments domains to form individual fibers upon removal of the sulfopolyester.
  • the segments or domains may be touching each others as in, for example, a segmented pie configuration but can be split apart by impact or when the sulfopolyester is removed.
  • the ratio by weight of the sulfopolyester to water non-dispersible polymer component in the multicomponent fiber used in the invention is generally in the range of about 60:40 to about 2:98 or, in another example, in the range of about 50:50 to about 5:95.
  • the sulfopolyester comprises 50% by weight or less of the total weight of the multicomponent fiber.
  • the segments or domains of multicomponent fiber may comprise one of more water non-dispersible polymers.
  • water non-dispersible polymers which may be used in segments of the multicomponent fiber include, but are not limited to, polyolefins, polyesters, polyamides, polylactides, polycaprolactone, polycarbonate, polyurethane, cellulose ester, and polyvinyl chloride.
  • the water non-dispersible polymer may be polyester such as poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(cyclohexylene) cyclohexanedicarboxylate, poly(cyclohexylene) terephthalate, poly(trimethylene) terephthalate, and the like.
  • the water non-dispersible polymer can be biodistintegratable as determined by DIN Standard 54900 and/or biodegradable as determined by ASTM Standard Method, D6340-98. Examples of biodegradable polyesters and polyester blends are disclosed in U.S.
  • biodegradable as used herein in reference to the water non-dispersible polymers used in the present invention, is understood to mean that the polymers are degraded under environmental influences such as, for example, in a composting environment, in an appropriate and demonstrable time span as defined, for example, by ASTM Standard Method, D6340-98, entitled "Standard Test Methods for Determining Aerobic Biodegradation of Radiolabeled Plastic Materials in an Aqueous or Compost Environment".
  • the water non-dispersible polymers used in the present invention also may be "biodisintegratable", meaning that the polymers are easily fragmented in a composting environment as defined, for example, by DIN Standard 54900.
  • the biodegradable polymer is initially reduced in molecular weight in the environment by the action of heat, water, air, microbes and other factors. This reduction in molecular weight results in a loss of physical properties (tenacity) and often in fiber breakage.
  • the monomers and oligomers are then assimilated by the microbes. In an aerobic environment, these monomers or oligomers are ultimately oxidized to CO 2 , H 2 O, and new cell biomass. In an anaerobic environment, the monomers or oligomers are ultimately converted to CO 2 , H 2 , acetate, methane, and cell biomass.
  • water non-dispersible polymer may be an aliphatic-aromatic polyester, abbreviated herein as "AAPE".
  • aliphatic-aromatic polyester means a polyester comprising a mixture of residues from aliphatic or cycloaliphatic dicarboxylic acids or diols and aromatic dicarboxylic acids or diols.
  • non-aromatic as used herein with respect to the dicarboxylic acid and diol monomers used in the present invention, means that carboxyl or hydroxyl groups of the monomer are not connected through an aromatic nucleus.
  • adipic acid contains no aromatic nucleus in its backbone, i.e., the chain of carbon atoms connecting the carboxylic acid groups, thus is “non-aromatic".
  • aromatic means the dicarboxylic acid or diol contains an aromatic nucleus in the backbone such as, for example, terephthalic acid or 2,6-naphthalene dicarboxylic acid.
  • Non-aromatic is intended to include both aliphatic and cycloaliphatic structures such as, for example, diols and dicarboxylic acids, which contain as a backbone a straight or branched chain or cyclic arrangement of the constituent carbon atoms which may be saturated or paraffinic in nature, unsaturated, i.e., containing non-aromatic carbon-carbon double bonds, or acetylenic, i.e., containing carbon-carbon triple bonds.
  • diols and dicarboxylic acids which contain as a backbone a straight or branched chain or cyclic arrangement of the constituent carbon atoms which may be saturated or paraffinic in nature, unsaturated, i.e., containing non-aromatic carbon-carbon double bonds, or acetylenic, i.e., containing carbon-carbon triple bonds.
  • non-aromatic is intended to include linear and branched, chain structures (referred to herein as “aliphatic”) and cyclic structures (referred to herein as “alicyclic” or “cycloaliphatic”).
  • aliphatic chain structures
  • cyclic cycloaliphatic
  • the difunctional carboxylic acid typically is a aliphatic dicarboxylic acid such as, for example, adipic acid, or an aromatic dicarboxylic acid such as, for example, terephthalic acid.
  • the difunctional hydroxyl compound may be cycloaliphatic diol such as, for example, 1,4-cyclohexanedimethanol, a linear or branched aliphatic diol such as, for example, 1,4-butanediol, or an aromatic diol such as, for example, hydroquinone.
  • cycloaliphatic diol such as, for example, 1,4-cyclohexanedimethanol
  • a linear or branched aliphatic diol such as, for example, 1,4-butanediol
  • an aromatic diol such as, for example, hydroquinone.
  • the AAPE may be a linear or branched random copolyester and/or chain extended copolyester comprising diol residues which comprise the residues of one or more substituted or unsubstituted, linear or branched, diols selected from aliphatic diols containing 2 to about 8 carbon atoms, polyalkylene ether glycols containing 2 to 8 carbon atoms, and cycloaliphatic diols containing about 4 to about 12 carbon atoms.
  • the substituted diols typically, will comprise 1 to about 4 substituents independently selected from halo, C 6 -C 10 aryl, and C 1 -C 4 alkoxy.
  • diols which may be used include, but are not limited to, ethylene glycol, diethylene glycol, propylene glycol, 1,3-propanediol, 2,2-dimethyl-1,3-propanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, polyethylene glycol, diethylene glycol, 2,2,4-trimethyl-1,6-hexanediol, thiodiethanol, 1,3-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, triethylene glycol, and tetraethylene glycol with the preferred diols comprising one or more diols selected from 1,4-butanediol; 1,3-propanediol; ethylene glycol; 1,6-hexy
  • the AAPE also comprises diacid residues which contain about 35 to about 99 mole%, based on the total moles of diacid residues, of the residues of one or more substituted or unsubstituted, linear or branched, non-aromatic dicarboxylic acids selected from aliphatic dicarboxylic acids containing 2 to about 12 carbon atoms and cycloaliphatic acids containing about 5 to about 10 carbon atoms.
  • the substituted non-aromatic dicarboxylic acids will typically contain 1 to about 4 substituents selected from halo, C 6 -C 10 aryl, and C 1 -C 4 alkoxy.
  • Non-limiting examples of non-aromatic diacids include malonic, succinic, glutaric, adipic, pimelic, azelaic, sebacic, fumaric, 2,2-dimethyl glutaric, suberic, 1,3-cyclopentanedicarboxylic, 1,4-cyclohexanedicarboxylic, 1,3-cyclohexanedicarboxylic, diglycolic, itaconic, maleic, and 2,5-norbornane-dicarboxylic.
  • the AAPE comprises about 1 to about 65 mole%, based on the total moles of diacid residues, of the residues of one or more substituted or unsubstituted aromatic dicarboxylic acids containing 6 to about 10 carbon atoms.
  • substituted aromatic dicarboxylic acids they will typically contain 1 to about 4 substituents selected from halo, C 6 -C 10 aryl, and C 1 -C 4 alkoxy.
  • Non-limiting examples of aromatic dicarboxylic acids which may be used in the AAPE used in our invention are terephthalic acid, isophthalic acid, salts of 5-sulfoisophthalic acid, and 2,6-naphthalenedicarboxylic acid. More preferably, the non-aromatic dicarboxylic acid will comprise adipic acid, the aromatic dicarboxylic acid will comprise terephthalic acid, and the diol will comprise 1,4-butanediol.
  • compositions for the AAPE's used in our invention are those prepared from the following diols and dicarboxylic acids (or polyester-forming equivalents thereof such as diesters) in the following mole percentages, based on 100 mole percent of a diacid component and 100 mole percent of a diol component:
  • the modifying diol preferably is selected from 1,4-cyclohexanedimethanol, triethylene glycol, polyethylene glycol and neopentyl glycol.
  • the most preferred AAPE's are linear, branched or chain extended copolyesters comprising about 50 to about 60 mole percent adipic acid residues, about 40 to about 50 mole percent terephthalic acid residues, and at least 95 mole percent 1,4-butanediol residues. Even more preferably, the adipic acid residues comprise about 55 to about 60 mole percent, the terephthalic acid residues comprise about 40 to about 45 mole percent, and the diol residues comprise about 95 mole percent 1,4-butanediol residues.
  • Such compositions are commercially available under the trademark EASTAR BIO ® copolyester from Eastman Chemical Company, Kingsport, TN, and under the trademark ECOFLEX ® from BASF Corporation.
  • AAPE's include a poly(tetramethylene glutarate-co-terephthalate) containing (a) 50 mole percent glutaric acid residues, 50 mole percent terephthalic acid residues, and 100 mole percent 1,4-butanediol residues, (b) 60 mole percent glutaric acid residues, 40 mole percent terephthalic acid residues, and100 mole percent 1,4-butanediol residues or (c) 40 mole percent glutaric acid residues, 60 mole percent terephthalic acid residues, and 100 mole percent 1,4-butanediol residues; a poly(tetramethylene succinate-co-terephthalate) containing (a) 85 mole percent succinic acid residues, 15 mole percent terephthalic acid residues, and 100 mole percent 1,4-butanediol residues or (b) 70 mole percent succinic acid residues, 30 mole percent ter
  • the AAPE preferably comprises from about 10 to about 1,000 repeating units and preferably, from about 15 to about 600 repeating units.
  • the AAPE may have an inherent viscosity of about 0.4 to about 2.0 dL/g, or more preferably about 0.7 to about 1.6 dL/g, as measured at a temperature of 25°C using a concentration of 0.5 gram copolyester in 100 ml of a 60/40 by weight solution of phenol/tetrachloroethane.
  • the AAPE may contain the residues of a branching agent.
  • the mole percentage ranges for the branching agent are from about 0 to about 2 mole%, preferably about 0.1 to about 1 mole%, and most preferably about 0.1 to about 0.5 mole% based on the total moles of diacid or diol residues (depending on whether the branching agent contains carboxyl or hydroxyl groups).
  • the branching agent preferably has a weight average molecular weight of about 50 to about 5000, more preferably about 92 to about 3000, and a functionality of about 3 to about 6.
  • the branching agent may be the esterified residue of a polyol having 3 to 6 hydroxyl groups, a polycarboxylic acid having 3 or 4 carboxyl groups (or ester-forming equivalent groups) or a hydroxy acid having a total of 3 to 6 hydroxyl and carboxyl groups.
  • the AAPE may be branched by the addition of a peroxide during reactive extrusion.
  • Each segment of the water non-dispersible polymer may be different from others in fineness and may be arranged in any shaped or engineered cross-sectional geometry known to persons skilled in the art.
  • the sulfopolyester and a water non-dispersible polymer may be used to prepare a bicomponent fiber having an engineered geometry such as, for example, a side-by-side, "islands-in-the-sea", segmented pie, other splitables, sheath/core, or other configurations known to persons skilled in the art.
  • Other multicomponent configurations are also possible. Subsequent removal of a side, the "sea", or a portion of the "pie” can result in very fine fibers.
  • the process of preparing bicomponent fibers also is well known to persons skilled in the art.
  • the sulfopolyester fibers used in this invention may be present in amounts of about 10 to about 90 weight% and will generally be used in the sheath portion of sheath/core fibers.
  • the resulting bicomponent or multicomponent fiber is not completely water-dispersible.
  • Side by side combinations with significant differences in thermal shrinkage can be utilized for the development of a spiral crimp. If crimping is desired, a saw tooth or stuffer box crimp is generally suitable for many applications.
  • the second polymer component is in the core of a sheath/core configuration, such a core optionally may be stabilized.
  • the sulfopolyesters are particularly useful for fibers having an "islands-in-the-sea” or “segmented pie” cross section as they only requires neutral or slightly acidic (i.e., "soft” water) to disperse, as compared to the caustic-containing solutions that are sometimes required to remove other water dispersible polymers from multicomponent fibers.
  • soft water as used in this disclosure means that the water has up to 5 grains per gallon as CaCO 3 (1 grain of CaCO 3 per gallon is equivalent to 17.1 ppm).
  • a multicomponent fiber comprising:
  • sulfopolyester have a Tg of at least 57°C.
  • the sulfopolyester may be a single sulfopolyester or a blend of one or more sulfopolyester polymers.
  • Further examples of glass transition temperatures that may be exhibited by the sulfopolyester or sulfopolyester blends are at least 65°C, at least 70°C, at least 75°C, at least 85°C, and at least 90°C.
  • the sulfopolyester may comprise about 75 to about 96 mole% of one or more residues of isophthalic acid or terephthalic acid and about 25 to about 95 mole% of a residue of diethylene glycol.
  • examples of the water non-dispersible polymers are polyolefins, polyesters, polyamides, polylactides, polycaprolactones, polycarbonates, polyurethanes, cellulose esters, and polyvinyl chlorides.
  • the water non-dispersible polymer may be biodegradable or biodisintegratable.
  • the water non-dispersible polymer may be an aliphatic-aromatic polyester as described previously.
  • the multicomponent fiber used herein may be prepared by any number of methods known to persons skilled in the art. Disclosed herein is thus a process for a multicomponent fiber having a shaped cross section comprising: spinning a water dispersible sulfopolyester having a glass transition temperature (Tg) of at least 57°C and one or more water non-dispersible polymers immiscible with the sulfopolyester into a fiber, the sulfopolyester comprising:
  • the dicarboxylic acids, diols, sulfopolyester, sulfomonomers, branching monomers residues, and water non-dispersible polymers are as described previously.
  • the sulfopolyester has a glass transition temperature of at least 57°C. Further examples of glass transition temperatures that may be exhibited by the sulfopolyester or sulfopolyester blend are at least 65°C, at least 70°C, at least 75°C, at least 85°C, and at least 90°C.
  • the sulfopolyester may comprise about 50 to about 96 mole% of one or more residues of isophthalic acid or terephthalic acid, based on the total acid residues; and about 4 to about 30 mole%, based on the total acid residues, of a residue of sodiosulfoisophthalic acid; and 0 to about 20 mole%, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein the functional groups are hydroxyl, carboxyl, or a combination thereof.
  • the sulfopolyester may comprise about 75 to about 96 mole% of one or more residues of isophthalic acid or terephthalic acid and about 25 to about 95 mole% of a residue of diethylene glycol.
  • examples of the water non-dispersible polymers are polyolefins, polyesters, polyamides, polylactides, polycaprolactone, polycarbonate, polyurethane, and polyvinyl chloride.
  • the water non-dispersible polymer may be biodegradable or biodisintegratable.
  • the water non-dispersible polymer may be an aliphatic-aromatic polyester as described previously. Examples of shaped cross sections include, but are not limited to, islands-in-the-sea, side-by-side, sheath-core, or segmented pie configurations.
  • a process for making a multicomponent fiber having a shaped cross section comprising: spinning at least one water dispersible sulfopolyester and one or more water non-dispersible polymers immiscible with the sulfopolyester to produce a multicomponent fiber, wherein the multicomponent fiber has a plurality of domains comprising the water non-dispersible polymers and the domains are substantially isolated from each other by the sulfopolyester intervening between the domains; wherein the water dispersible sulfopolyester exhibits a melt viscosity of less than about 12,000 poise measured at 240°C at a strain rate of 1 rad/sec, and wherein the sulfopolyester comprising less than about 25 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol residues; and wherein the multicomponent fiber has an as-spun de
  • a process for making a multicomponent fiber having a shaped cross section comprising:
  • the process includes the step of melt drawing the multicomponent extrudate at a speed of at least about 2000 m/min, more preferably, at least about 3000 m/min, and most preferably at least 4500 m/min.
  • the fibers are quenched with a cross flow of air whereupon the fibers solidify.
  • Various finishes and sizes may be applied to the fiber at this stage.
  • the cooled fibers typically, are subsequently drawn and wound up on a take up spool.
  • Other additives may be incorporated in the finish in effective amounts like emulsifiers, antistatics, antimicrobials, antifoams, lubricants, thermostabilizers, UV stabilizers, and the like.
  • the drawn fibers may be textured and wound-up to form a bulky continuous filament.
  • This one-step technique is known in the art as spin-draw-texturing.
  • Other embodiments include flat filament (non-textured) yarns, or cut staple fiber, either crimped or uncrimped.
  • the sulfopolyester may be later removed by dissolving the interfacial layers or pie segments and leaving the smaller filaments or microdenier fibers of the water non-dispersible polymer(s). Disclosed herein is thus a process for microdenier fibers comprising:
  • the multicomponent fiber is contacted with water at a temperature of about 25°C to about 100°C, preferably about 50°C to about 80°C for a time period of from about 10 to about 600 seconds whereby the sulfopolyester is dissipated or dissolved.
  • the remaining water non-dispersible polymer microfibers typically will have an average fineness of 1 d/f or less, typically, 0.5 d/f or less, or more typically, 0.1 d/f or less.
  • Typical applications of these remaining water non-dispersible polymer microfibers include nonwoven fabrics, such as, for example, artificial leathers, suedes, wipes, and filter media.
  • Filter media produce from these microfibers can be utilized to filter air or liquids.
  • Filter media for liquids include, but are not limited to, water, bodily fluids, solvents, and hydrocarbons.
  • the ionic nature of sulfopolyesters also results in advantageously poor "solubility" in saline media, such as body fluids. Such properties are desirable in personal care products and cleaning wipes that are flushable or otherwise disposed in sanitary sewage systems.
  • Selected sulfopolyesters have also been utilized as dispersing agents in dye baths and soil redeposition preventative agents during laundry cycles.
  • a process for making microdenier fibers comprising spinning at least one water dispersible sulfopolyester and one or more water non-dispersible polymers immiscible with the water dispersible sulfopolyester into multicomponent fibers, wherein said multicomponent fibers have a plurality of domains comprising said water non-dispersible polymers wherein the domains are substantially isolated from each other by the sulfopolyester intervening between the domains; wherein the fiber has an as-spun denier of less than about 6 denier per filament; wherein the water dispersible sulfopolyester exhibits a melt viscosity of less than about 12,000 poise measured at 240°C at a strain rate of 1 rad/sec, and wherein the sulfopolyester comprising less than about 25 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol
  • microdenier fibers comprising:
  • melt drawing of the multicomponent extrudates at a speed of at least about 2000 m/min, more preferably at least about 3000 m/min, and most preferably at least 4500 m/min.
  • the water used to remove the sulfopolyester from the multicomponent fibers be above room temperature, more preferably the water is at least about 45°C, even more preferably at least about 60°C, and most preferably at least about 80°C.
  • Another process is used, to produce water non-dispersible polymer microfibers.
  • the process comprises:
  • the multicomponent fiber can be cut into any length that can be utilized to produce nonwoven articles.
  • the multicomponent fiber is cut into lengths ranging from about 1 mm to about 25 mm.
  • the multicomponent fiber can be cut into a mixture of different lengths.
  • the fiber-containing feedstock can comprise any other type of fiber that is useful in the production of nonwoven articles.
  • the fiber-containing feedstock further comprises at least one fiber selected from the group consisting of cellulosic fiber pulp, glass fiber, polyester fibers, nylon fibers, polyolefin fibers, rayon fibers and cellulose ester fibers.
  • the fiber-containing feedstock is mixed with water to produce a fiber mix slurry.
  • the water utilized can be soft water or deionized water.
  • Soft water has been previously defined in this disclosure.
  • at least one water softening agent may be used to facilitate the removal of the water-dispersible sulfopolyester from the multicomponent fiber. Any water softening agent known in the art can be utilized.
  • the water softening agent is a chelating agent or calcium ion sequestrant.
  • Applicable chelating agents or calcium ion sequestrants are compounds containing a plurality of carboxylic acid groups per molecule where the carboxylic groups in the molecular structure of the chelating agent are separated by 2 to 6 atoms.
  • Tetrasodium ethylene diamine tetraacetic acid (EDTA) is an example of the most common chelating agent, containing four carboxylic acid moieties per molecular structure with a separation of 3 atoms between adjacent carboxylic acid groups.
  • Poly acrylic acid, sodium salt is an example of a calcium sequestrant containing carboxylic acid groups separated by two atoms between carboxylic groups.
  • Sodium salts of maleic acid or succinic acid are examples of the most basic chelating agent compounds.
  • applicable chelating agents include compounds which have in common the presence of multiple carboxylic acid groups in the molecular structure where the carboxylic acid groups are separated by the required distance (2 to 6 atom units) which yield a favorable steric interaction with di- or multi- valent cations such as calcium which cause the chelating agent to preferentially bind to di- or multi valent cations.
  • Such compounds include, but are not limited to, diethylenetriaminepentaacetic acid; diethylenetriamine-N,N,N',N',N"-pentaacetic acid; pentetic acid; N,N-bis(2-(bis-(carboxymethyl)amino)ethyl)-glycine; diethylenetriamine pentaacetic acid; [[(carboxymethyl)imino]bis(ethylenenitrilo)]-tetra-acetic acid; edetic acid; ethylenedinitrilotetraacetic acid; EDTA, free base; EDTA free acid; ethylenediamine-N,N,N',N'-tetraacetic acid; hampene; versene; N,N'-1,2-ethane diylbis-(N-(carboxymethyl)glycine); ethylenediamine tetra-acetic acid; N,N-bis(carboxymethyl)glycine; triglycollamic acid; trilone
  • the amount of water softening agent needed depends on the hardness of the water utilized in terms of Ca ++ and other multivalent ions.
  • the fiber mix slurry is heated to produce a heated fiber mix slurry.
  • the temperature is that which is sufficient to remove a portion of the sulfopolyester from the multicomponent fiber.
  • the fiber mix slurry is heated to a temperature ranging from about 50°C to about 100°C. Other temperature ranges are from about 70°C to about 100°C, about 80°C to about 100°C, and about 90°C to about 100°C.
  • the fiber mix slurry is mixed in a shearing zone.
  • the amount of mixing is that which is sufficient to disperse and remove a portion of the water dispersible sulfopolyester from the multicomponent fiber and separate the water non-dispersible polymer microfibers.
  • 90% of the sulfopolyester is removed.
  • 95% of the sulfopolyester is removed, and in yet another embodiment, 98% or greater of the sulfopolyester is removed.
  • the shearing zone can comprise any type of equipment that can provide shearing action necessary to disperse and remove a portion of the water dispersible sulfopolyester from the multicomponent fiber and separate the water non-dispersible polymer microfibers.
  • examples of such equipment include, but is not limited to, pulpers and refiners.
  • the water dispersible sulfopolyester in the multicomponent fiber after contact with water and heating disperse and separate from the water non-dispersible polymer fiber to produce a slurry mixture comprising a sulfopolyester dispersion and the water non-dispersible polymer microfibers.
  • the water non-dispersible polymer microfibers can then be separated from the sulfopolyester dispersion by any means known in the art.
  • the slurry mixture can be routed through separating equipment, such as for example, screens and filters.
  • the water non-dispersible polymer microfibers may be washed once or numerous times to remove more of the water-dispersible sulfopolyester.
  • the removal of the water-dispersible sulfopolyester can be determined by physical observation of the slurry mixture.
  • the water utilized to rinse the water non-dispersible polymer microfibers is clear if the water-dispersible sulfopolyester has been mostly removed. If the water-dispersible sulfopolyester is still being removed, the water utilized to rinse the water non-dispersible polymer microfibers can be milky. Further, if water-dispersible sulfopolyester remains on the water non-dispersible polymer microfibers, the microfibers can be somewhat sticky to the touch.
  • the water-dispersible sulfopolyester can be recovered from the sulfopolyester dispersion by any method known in the art.
  • a water non-dispersible polymer microfiber comprising at least one water non-dispersible polymer wherein the water non-dispersible polymer microfiber has an equivalent diameter of less than 5 microns and length of less than 25 millimeters.
  • This water non-dispersible polymer microfiber is produced by the processes previously described to produce microfibers.
  • the water non-dispersible polymer microfiber has an equivalent diameter of less than 3 microns and length of less than 25 millimeters.
  • the water non-dispersible polymer microfiber has an equivalent diameter of less than 5 microns or less than 3 microns.
  • the water non-dispersible polymer microfiber can have lengths of less than 12 millimeters; less than 10 millimeters, less than 6.5 millimeters, and less than 3.5 millimeters.
  • the domains or segments in the multicomponent fiber once separated yield the water non-dispersible polymer microfibers.
  • fibrous article comprising the water-dispersible fiber, the multicomponent fiber, microdenier fibers, or water non-dispersible polymer microfibers described hereinabove.
  • fibrous article is understood to mean any article having or resembling fibers.
  • Non-limiting examples of fibrous articles include multifilament fibers, yarns, cords, tapes, fabrics, wet-laid webs, dry-laid webs, melt blown webs, spunbonded webs, thermobonded webs, hydroentangled webs, nonwoven webs and fabrics, and combinations thereof; items having one or more layers of fibers, such as, for example, multilayer nonwovens, laminates, and composites from such fibers, gauzes, bandages, diapers, training pants, tampons, surgical gowns and masks, feminine napkins; and the like.
  • the water non-dispersible microdfibers can be utilized in filter media for air filtration, liquid filtration, filtration for food preparation, filtration for medical applications, and for paper making processes and paper products.
  • the fibrous articles may include replacement inserts for various personal hygiene and cleaning products.
  • the fibrous article may be bonded, laminated, attached to, or used in conjunction with other materials which may or may not be water-dispersible.
  • the fibrous article for example, a nonwoven fabric layer, may be bonded to a flexible plastic film or backing of a water non-dispersible material, such as polyethylene.
  • a water non-dispersible material such as polyethylene.
  • Such an assembly for example, could be used as one component of a disposable diaper.
  • the fibrous article may result from overblowing fibers onto another substrate to form highly assorted combinations of engineered melt blown, spunbond, film, or membrane structures.
  • the fibrous articles include nonwoven fabrics and webs.
  • a nonwoven fabric is defined as a fabric made directly from fibrous webs without weaving or knitting operations.
  • the Textile Institue defines nonwovens as textile structures made directly from fibre rather than yarn. These fabrics are normally made from continuous filments or from fibre webs or batts strengthened by bonding using various techniques, which include, but are not limited to, adhesive bonding, mechanical interlocking by needling or fluid jet entanglement, thermal bonding, and stitch bonding.
  • the multicomponent fiber may be formed into a fabric by any known fabric forming process.
  • the resulting fabric or web may be converted into a microdenier fiber web by exerting sufficient force to cause the multicomponent fibers to split or by contacting the web with water to remove the sulfopolyester leaving the remaining microdenier fibers behind.
  • Our invention thus provides a process for a microdenier fiber web, comprising:
  • a process for a microdenier fiber web which comprises:
  • a process for a microdenier fiber web which comprises:
  • the process also preferably comprises prior to Step (C) the step of hydroentangling the multicomponent fibers of the non-woven web. It is also preferable that the hydroentangling step results in a loss of less than about 20 wt. % of the sulfopolyester contained in the multicomponent fibers, more preferably this loss is less than 15 wt. %, and most preferably is less than 10 wt. %.
  • the water used during this process preferably has a temperature of less than about 45°C, more preferably less than about 35°C, and most preferably less than about 30°C.
  • the water used during hydroentanglement be as close to room temperature as possible to minimize loss of sulfopolyester from the multicomponent fibers.
  • removal of the sulfopolyester polymer during Step (C) is preferably carried out using water having a temperature of at least about 45°C, more preferably at least about 60°C, and most preferably at least about 80°C.
  • the non-woven web may under go a heat setting step comprising heating the non-woven web to a temperature of at least about 100°C, and more preferably at least about 120°C.
  • the heat setting step relaxes out internal fiber stresses and aids in producing a dimensionally stable fabric product. It is preferred that when the heat set material is reheated to the temperature to which it was heated during the heat setting step that it exhibits surface area shrinkage of less than about 5% of its original surface area. More preferably, the shrinkage is less than about 2% of the original surface area, and most preferably the shrinkage is less than about 1%.
  • the method disclosed herein preferably comprises the step of drawing the multicomponent fiber at a fiber velocity of at least 2000 m/min, more preferably at least about 3000 m/min, even more preferably at least about 4000 m/min, and most preferably at least about 5000 m/min.
  • nonwoven articles comprising water non-dispersible polymer microfibers can be produced.
  • the nonwoven article comprises water non-dispersible polymer microfibers and is produced by a wet-laid process. Multicomponent fibers and processes for producing water non-dispersible polymer microfibers were previously disclosed in the specification.
  • At least 1% of the water non-dispersible polymer microfiber is contained in the nonwoven article.
  • Other amounts of water non-dispersible polymer microfiber contained in the nonwoven article are at least 10%, at least 25%, and at least 50%.
  • the nonwoven article can further comprise at least one other fiber.
  • the other fiber can be any that is known in the art depending on the type of nonwoven article to be produced.
  • the other fiber can be selected from the group consisting cellulosic fiber pulp, glass fiber, polyester fibers, nylon fibers, polyolefin fibers, rayon fibers cellulose ester fibers, and mixtures thereof.
  • the nonwoven article can also further comprise at least one additive.
  • Additives include, but are not limited to, starches, fillers, and binders. Other additives are discussed in other sections of this disclosure.
  • manufacturing processes to produce nonwoven articles from water non-dispersible microfibers produced from multicomponent fibers can be split into the following groups: dry-laid webs, wet-laid webs, and combinations of these processes with each other or other nonwoven processes.
  • dry-laid nonwoven articles are made with staple fiber processing machinery which is designed to manipulate fibers in the dry state. These include mechnical processes, such as, carding, aerodynamic, and other air-laid routes. Also included in this category are nonwoven articles made from filaments in the form of tow, and fabrics composed of staple fibers and stitching filaments or yards i.e. stitchbonded nonwovens. Carding is the process of disentangling, cleaning, and intermixing fibers to make a web for further processing into a nonwoven article. The process predominantly aligns the fibers which are held together as a web by mechanical entanglement and fiber-fiber friction.
  • Cards are generally configured with one or more main cylinders, roller or stationary tops, one or more doffers, or various combinations of these principal components.
  • a card On example of a card is a roller card.
  • the carding action is the combing or working of the water non-dispersible polymer microfibers between the points of the card on a series of interworking card rollers.
  • Other types of cards include woolen, cotton, and random cards. Garnetts can also be used to align these fibers.
  • the water non-dispersible polymer microfibers in the dried-laid process can also be aligned by air-laying. These fibers are directed by air current onto a collector which can be a flat conveyor or a drum.
  • Extrusion-formed webs can also be produced from the multicomponents fibers. Examples include spunbonded and melt-blown. Extrusion technology is used to produce spunbond, meltblown, and porous-film nonwoven articles. These nonwoven articles are made with machinery associated with polymer extrusion methods such as melt spinning, film casting, and extrusion coating. The nonwoven article is then contacted with water to remove the water dispersible sulfopolyester thus producing a nonwoven article comprising water non-dispersible polymer microfibers.
  • the water dispersible sulfopolyester and water non-dispersible polymer are transformed directly to fabric by extruding multicomponent filaments, orienting them as bundles or groupings, layering them on a conveying screen, and interlocking them.
  • the interlocking can be conducted by thermal fusion, mechnical entanglement, hydroentangling, chemical binders, or combinations of these processes.
  • Meltblown fabrics are also made directly from the water dispersible sulfopolyester and the water non-dispersible polymer.
  • the polymers are melted and extruded. As soon as the melt passes through the extrusion orifice, it is blown with air at high temperature. The air stream attenuates and solidifies the molten polymers.
  • the multicomponent fibers can then be separated from the air stream as a web and compressed between heated rolls.
  • Combined spunbond and meltbond processes can also be utilized to produce nonwoven articles.
  • Wet laid processes involve the use of papermaking technology to produce nonwoven articles. These nonwoven articles are made with machinery associated with pulp fiberizing, such as hammer mills, and paperforming. For example, slurry pumping onto continous screens which are designed to manipulate short fibers in a fluid.
  • water non-dispersible polymer microfibers are suspended in water, brought to a forming unit where the water is drained off through a forming screen, and the fibers are deposited on the screen wire.
  • water non-dispersible polymer microfibers are dewatered on a sieve or a wire mesh which revolves at the beginning of hydraulic formers over dewatering modules (suction boxes, foils and curatures) at high speeds of up to 1500 meters per minute.
  • dewatering modules suction boxes, foils and curatures
  • the sheet is then set on this wire and dewatering proceeds to a solid content of approximately 20-30%.
  • the sheet can then be pressed and dried.
  • Step a the number of rinses depends on the particular use chosen for the water non-dispersible polymer microfibers.
  • Step b) sufficient water is added to the microfibers to allow them to be routed to the wet-laid nonwoven zone.
  • the wet-laid nonwoven zone comprises any equipment known in the art to produce wet-laid nonwoven articles.
  • the wet-laid nonwoven zone comprises at least one screen, mesh, or sieve in order to remove the water from the water non-dispersible polymer microfiber slurry.
  • the water non-dispersible polymer microfiber slurry is mixed prior to transferring to the wet-laid nonwoven zone.
  • Web-bonding processes can also be utilized to produce nonwoven articles. These can be split into chemical and physical processes. Chemical bonding refers to the use of water-based and solvent-based polymers to bind together the fibers and/or fibrous webs. These binders can be applied by saturation, impregnation, spraying, printing, or application as a foam. Physical bonding processes include thermal processes such as calendaring and hot air bonding, and mechanical processes such as needling and hydroentangling. Needling or needle-punching processes mechanically interlock the fibers by physically moving some of the fibers from a near-horizontal to a near-vertical position. Needle-punching can be conducted by a needleloom. A needleloom generally contains a web-feeding mechanism, a needle beam which comprises a needleboard which holds the needles, a stripper plate, a bed plate, and a fabric take-up mechanism.
  • Stitchbonding is a mechanical bonding method that uses knitting elements, with or without yarn, to interlock the fiber webs.
  • stitchbonding machines include, but are not limited to, Maliwatt, Arachne, Malivlies, and Arabeva.
  • the nonwoven article can be held together by 1) mechanical fiber cohesion and interlocking in a web or mat; 2) various techniques of fusing of fibers, including the use of binder fibers, utilizing the thermoplastic properties of certain polymers and polymer blends; 3) use of a binding resin such as starch, casein, a cellulose derivative, or a synthetic resin, such as an acrylic latex or urethane; 4) powder adhesive binders; or 5) combinations thereof.
  • the fibers are often deposited in a random manner, although orientation in one direction is possible, followed by bonding using one of the methods described above.
  • the fibrous articles further also may comprise one or more layers of water-dispersible fibers, multicomponent fibers, or microdenier fibers.
  • the fiber layers may be one or more nonwoven fabric layers, a layer of loosely bound overlapping fibers, or a combination thereof.
  • the fibrous articles may include personal and health care products such as, but not limited to, child care products, such as infant diapers; child training pants; adult care products, such as adult diapers and adult incontinence pads; feminine care products, such as feminine napkins, panty liners, and tampons; wipes; fiber-containing cleaning products; medical and surgical care products, such as medical wipes, tissues, gauzes, examination bed coverings, surgical masks, gowns, bandages, and wound dressings; fabrics; elastomeric yarns, wipes, tapes, other protective barriers, and packaging material.
  • the fibrous articles may be used to absorb liquids or may be pre-moistened with various liquid compositions and used to deliver these compositions to a surface.
  • Non-limiting examples of liquid compositions include detergents; wetting agents; cleaning agents; skin care products, such as cosmetics, ointments, medications, emollients, and fragrances.
  • the fibrous articles also may include various powders and particulates to improve absorbency or as delivery vehicles. Examples of powders and particulates include, but are not limited to, talc, starches, various water absorbent, water-dispersible, or water swellable polymers, such as super absorbent polymers, sulfopolyesters, and poly(vinylalcohols), silica, pigments, and microcapsules. Additives may also be present, but are not required, as needed for specific applications.
  • additives include, but are not limited to, oxidative stabilizers, UV absorbers, colorants, pigments, opacifiers (delustrants), optical brighteners, fillers, nucleating agents, plasticizers, viscosity modifiers, surface modifiers, antimicrobials, disinfectants, cold flow inhibitors, branching agents, and catalysts.
  • the fibrous articles described above may be flushable.
  • flushable means capable of being flushed in a conventional toilet, and being introduced into a municipal sewage or residential septic system, without causing an obstruction or blockage in the toilet or sewage system.
  • the fibrous article may further comprise a water-dispersible film comprising a second water-dispersible polymer.
  • the second water-dispersible polymer may be the same as or different from the previously described water-dispersible polymers used in the fibers and fibrous articles of the present invention.
  • the second water-dispersible polymer may be an additional sulfopolyester which, in turn, comprises:
  • the additional sulfopolyester may contain other concentrations of isophthalic acid residues, for example, about 60 to about 95 mole%, and about 75 to about 95 mole%. Further examples of isophthalic acid residue concentrations ranges are about 70 to about 85 mole%, about 85 to about 95 mole% and about 90 to about 95 mole%.
  • the additional sulfopolyester also may comprise about 25 to about 95 mole% of the residues of diethylene glycol. Further examples of diethylene glycol residue concentration ranges include about 50 to about 95 mole%, about 70 to about 95 mole%, and about 75 to about 95 mole%.
  • the additional sulfopolyester also may include the residues of ethylene glycol and/or 1,4-cyclohexanedimethanol. Typical concentration ranges of CHDM residues are about 10 to about 75 mole%, about 25 to about 65 mole%, and about 40 to about 60 mole%. Typical concentration ranges of ethylene glycol residues are about 10 to about 75 mole%, about 25 to about 65 mole%, and about 40 to about 60 mole%. In another embodiment, the additional sulfopolyester comprises is about 75 to about 96 mole% of the residues of isophthalic acid and about 25 to about 95 mole% of the residues of diethylene glycol.
  • the sulfopolyester film component of the fibrous article may be produced as a monolayer or multilayer film.
  • the monolayer film may be produced by conventional casting techniques.
  • the multilayered films may be produced by conventional lamination methods or the like.
  • the film may be of any convenient thickness, but total thickness will normally be between about 2 and about 50 mil.
  • the film-containing fibrous articles may include one or more layers of water-dispersible fibers as described above.
  • the fiber layers may be one or more nonwoven fabric layers, a layer of loosely bound overlapping fibers, or a combination thereof.
  • the film-containing fibrous articles may include personal and health care products as described hereinabove.
  • the fibrous articles also may include various powders and particulates to improve absorbency or as delivery vehicles.
  • our fibrous article comprises a powder comprising a third water-dispersible polymer that may be the same as or different from the water-dispersible polymer components described previously herein.
  • powders and particulates include, but are not limited to, talc, starches, various water absorbent, water-dispersible, or water swellable polymers, such as poly(acrylonitiles), sulfopolyesters, and poly(vinyl alcohols), silica, pigments, and microcapsules.
  • One novel application involves the melt blowing a film or nonwoven fabric onto flat, curved, or shaped surfaces to provide a protective layer.
  • One such layer might provide surface protection to durable equipment during shipping.
  • the outer layers of sulfopolyester could be washed off.
  • a further embodiment of this general application concept could involve articles of personal protection to provide temporary barrier layers for some reusable or limited use garments or coverings.
  • activated carbon and chemical absorbers could be sprayed onto the attenuating filament pattern just prior to the collector to allow the melt blown matrix to anchor these entities on the exposed surface. The chemical absorbers can even be changed in the forward operations area as the threat evolves by melt blowing on another layer.
  • a major advantage inherent to sulfopolyesters is the facile ability to remove or recover the polymer from aqueous dispersions via flocculation or precipitation by adding ionic moieties (i.e., salts). Other methods, such as pH adjustment, adding nonsolvents, freezing, and so forth may also be employed. Therefore, fibrous articles, such as outer wear protective garments, after successful protective barrier use and even if the polymer is rendered as hazardous waste, can potentially be handled safely at much lower volumes for disposal using accepted protocols, such as incineration.
  • Undissolved or dried sulfopolyesters are known to form strong adhesive bonds to a wide array of substrates, including, but not limited to fluff pulp, cotton, acrylics, rayon, lyocell, PLA (polylactides), cellulose acetate, cellulose acetate propionate, poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(trimethylene) terephthalate, poly(cyclohexylene) terephthalate, copolyesters, polyamides (nylons), stainless steel, aluminum, treated polyolefins, PAN (polyacrylonitriles), and polycarbonates.
  • substrates including, but not limited to fluff pulp, cotton, acrylics, rayon, lyocell, PLA (polylactides), cellulose acetate, cellulose acetate propionate, poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(trimethylene) terephthalate, poly(cyclo
  • our nonwoven fabrics may be used as laminating adhesives or binders that may be bonded by known techniques, such as thermal, radio frequency (RF), microwave, and ultrasonic methods. Adaptation of sulfopolyesters to enable RF activation is disclosed in a number of recent patents.
  • our novel nonwoven fabrics may have dual or even multifunctionality in addition to adhesive properties. For example, a disposable baby diaper could be obtained where a nonwoven serves as both a water-responsive adhesive as well as a fluid managing component of the final assembly.
  • the sulfomonomer may be a dicarboxylic acid or ester thereof containing a sulfonate group, a diol containing a sulfonate group, or a hydroxy acid containing a sulfonate group. Additional examples of concentration ranges for the sulfomonomer residues are about 4 to about 25 mole%, about 4 to about 20 mole%, about 4 to about 15 mole%, and about 4 to about 10 mole%, based on the total repeating units.
  • the cation of the sulfonate salt may be a metal ion such as Li + , Na + , K + , Mg ++ , Ca ++ , Ni ++ , Fe ++ , and the like.
  • the cation of the sulfonate salt may be non-metallic such as a nitrogenous base as described previously.
  • sulfomonomer residues which may be used in the process of the present invention are the metal sulfonate salt of sulfophthalic acid, sulfoterephthalic acid, sulfoisophthalic acid, or combinations thereof.
  • sulfomonomer which may be used is 5-sodiosulfoisophthalic acid or esters thereof. If the sulfomonomer residue is from 5-sodiosulfoisophthalic acid, typical sulfomonomer concentration ranges are about 4 to about 35 mole%, about 8 to about 30 mole %, and about 10 to 25 mole %, based on the total acid residues.
  • the sulfopolyester includes one or more diol residues which may include aliphatic, cycloaliphatic, and aralkyl glycols.
  • the cycloaliphatic diols for example, 1,3- and 1,4-cyclohexanedimethanol, may be present as their pure cis or trans isomers or as a mixture of cis and trans isomers.
  • the sulfopolyester may optionally include a branching monomer.
  • branching monomers are as described hereinabove. Further examples of branching monomer concentration ranges are from 0 to about 20 mole% and from 0 to about 10 mole%.
  • the sulfopolyester used in our novel process has a Tg of at least 25°C. Further examples of glass transition temperatures exhibited by the sulfopolyester are at least 30°C, at least 35°C, at least 40°C, at least 50°C, at least 60°C, at least 65°C, at least 80°C, and at least 90°C.
  • typical glass transition temperatures of the dry sulfopolyesters our invention are about 30°C, about 48°C, about 55°C, about 65°C, about 70°C, about 75°C, about 85°C, and about 90°C.
  • the water-dispersible fibers are prepared by a melt blowing process.
  • the polymer is melted in an extruder and forced through a die.
  • the extrudate exiting the die is rapidly attenuated to ultrafine diameters by hot, high velocity air.
  • the orientation, rate of cooling, glass transition temperature (Tg), and rate of crystallization of the fiber are important because they affect the viscosity and processing properties of the polymer during attenuation.
  • the filament is collected on a renewable surface, such as a moving belt, cylindrical drum, rotating mandrel, and so forth.
  • Predrying of pellets are all factors that influence product characteristics such as filament diameters, basis weight, web thickness, pore size, softness, and shrinkage.
  • the high velocity air also may be used to move the filaments in a somewhat random fashion that results in extensive interlacing. If a moving belt is passed under the die, a nonwoven fabric can be produced by a combination of overlapping laydown, mechanical cohesiveness, and thermal bonding of the filaments. Overblowing onto another substrate, such as a spunbond or backing layer, is also possible. If the filaments are taken up on an rotating mandrel, a cylindrical product is formed. A water-dispersible fiber lay-down can also be prepared by the spunbond process.
  • the water-wet microfibrous product (wet lap) produced after the multicomponent fibers have been cut, washed, and drained of exess water can be directly used (i.e., without further drying) in a wet-laid nonwoven process.
  • Direct use of the wet lap product in a wet-laid nonwoven process avoids the need for complete drying of the wet lap, thereby saving significant energy and equipment costs.
  • the wet lap production facility is located remotely from the facility for making wet-laid nonwovens, the wet lap can be packaged and transported from the wet lap production location to the nonwoven production location.
  • Such a wet lap composition is described in further detail immediately below.
  • the present invention is further directed to a wet lap composition
  • a wet lap composition comprising water and a plurality of synthetic fibers.
  • Water can make up at least 50, 55, or 60 weight percent and/or not more than 90, 85, or 80 weight percent of the wet lap composition.
  • the synthetic fibers can make up at least 10, 15, or 20 weight percent and/or not more than 50, 45, or 40 weight percent of the wet lap composition.
  • the water and the synthetic fibers in combination make up at least 95, 98, or 99 weight percent of the wet lap composition.
  • the synthetic fibers can have a length of at least 0.25, 0.5, or 1 millimeter. They have a length of not more than 25, 10, or 2 millimeters.
  • the synthetic fibers can have a minimum transverse dimension at least 0.1, 0.5, or 0.75 microns. The minimum transverse dimension is not more than 5, or 2 microns.
  • minimum transverse dimension denotes the minimum dimension of a fiber measured perpendicular to the axis of elongation of the fiber by an external caliper method.
  • maximum transverse dimension is the maximum dimension of a fiber measured perpendicular to the axis of elongation of the fiber by the external caliper.
  • FIGS. 1a, 1b, and 1c depict how these dimensions may be measured in various fiber cross-sections.
  • TDmin is the minimum transverse dimension
  • TDmax is the maximum transverse dimension.
  • exital caliper method denotes a method of measuring an outer dimension of a fiber where the measured dimension is the distance separating two coplanar parallel lines between which the fiber is located and where each of the parallel lines touches the external surface of the fiber on generally opposite sides of the fiber. All fiber dimensions provided herein (e.g., length, minimum transverse dimension, and maximum transverse dimension) are the average dimensions of the fibers belonging to the specified group.
  • the wet lap composition can further comprise a fiber finishing composition in an amount of at least 10, 50, or 100 ppmw and/or not more than 1,000, 500, 250 ppmw.
  • the fiber finishing composition can comprise an oil, a wax, and/or a fatty acid.
  • the fiber finishing composition can comprise a naturally-derived fatty acid and/or a naturally-derived oil.
  • the wherein the fiber finishing composition comprises mineral oil, stearate esters, sorbitan esters, and/or neatsfoot oil.
  • the fiiber finishing composition comprises mineral oil.
  • the wet lap composition can further comprise a water dispersible polymer in an amount of at least 0.001, 0.01, or 0.1 and/or not more than 5, 2, or 1 weight percent.
  • the water dispersible polymer comprises at least one sulfopolyester.
  • the sulfopolyester comprises:
  • the sulfopolyester can have a glass transition temperature (Tg) of at least 40°C or at least 50°C, an inherent viscosity of at least 0.2 dL/g measured in a 60/40 parts by weight solution of phenol/tetrachloroethane solvent at 40°C and at a concentration of 0.5 grams of sulfopolyester in 100 mL of solvent, and a melt viscosity of less than about 12,000, 8,000, or 6,000 poise measured at 240°C at a strain rate of 1 rad/sec.
  • Tg glass transition temperature
  • the water non-dispersible synthetic polymer of the wet lap compostition can be selected from the group consisting of polyolefins, polyesters, copolyesters, polyamides, polylactides, polycaprolactones, polycarbonates, polyurethanes, cellulose esters, acrylics, polyvinyl chlorides, and blends thereof.
  • the water non-dispersible synthetic polymer is selected from the group consisting of polyethylene terephthalate homopolymer, polyethylene terephthalate copolymers, polybutylene terephthalate, polypropylene terephthalate, nylon 6, nylon 66, and blends thereof.
  • the wet-lap composition can be made by a process comprising the following steps:
  • the wet lap composition can be used directly in a wet-laid process to make a nonwoven articles.
  • the wet lap compostion is transferred from its place of production to a wet-laid nonwoven zone.
  • the wet lap composition can be combined with additional fibers in the wet-laid nonwoven zone and/or immediately upstream of the wet-laid nonwoven zone.
  • the additional fibers can be selected from a group consisting of cellulosic fiber pulp, inorganic fibers, polyester fibers, nylon fibers, lyocell fibers, polyolefin fibers, rayon fibers, cellulose ester fibers, and combinations thereof.
  • the wet lap composition can be combined with dilution water in the wet-laid nonwoven zone and/or immediately upstream of the wet-laid nonwoven zone.
  • the dilution water and wet lap can be combined in amounts such that at least 50, 75, 90, or 95 parts by weight of the dilution water is used per one part of the wetlap.
  • a sulfopolyester containing 76 mole%, isophthalic acid, 24 mole% of sodio-sulfoisophthalic acid, 76 mole% diethylene glycol, and 24 mole% 1,4-cyclohexanedimethanol with an Ih.V. of 0.29 and a Tg of 48°C was meltblown through a nominal 152 mm (6-inch) die (11.8 holes/cm [30 holes/inch] in the nosepiece) onto a cylindrical collector using the conditions shown in Table 1. Interleafing paper was not required. A soft, handleable, flexible web was obtained that did not block during the roll winding operation. Physical properties are provided in Table 2.
  • a sulfopolyester containing 89 mole%, isophthalic acid, 11 mole% of sodiosulfoisophthalic acid, 72 mole% diethylene glycol, and 28 mole% ethylene glycol with an Ih.V. of 0.4 and a Tg of 35°C was meltblown through a 152 mm (6-inch) die using conditions similar to those in Table 1.
  • a soft, handleable, flexible web was obtained that did not block during a roll winding operation. Physical properties are provided in Table 2.
  • a small piece (1" x 2") of the nonwoven fabric was easily and completely dispersed at 50°C and 80°C; at RT (23°C), the fabric required a longer period of time for complete dispersion as shown by the data in Table 3.
  • compositions in Examples 1 and 2 can be overblown onto other nonwoven substrates. It is also possible to condense and wrap shaped or contoured forms that are used instead of conventional web collectors. Thus, it is possible to obtain circular "roving" or plug forms of the webs.
  • Pellets of a sulfopolyester containing 89 mole%, isophthalic acid, 11 mole% of sodiosulfoisophthalic acid, 72 mole% diethylene glycol, and 28 mole% ethylene glycol with an Ih.V. of 0.4 and a Tg of 35°C were combined with polypropylene (Basell PF 008) pellets in bicomponent ratios (by wt%) of:
  • the PP had a MFR (melt flow rate) of 800.
  • a melt blowing operation was performed on a line equipped with a 610 mm (24-inch) wide die to yield handleable, soft, flexible, but nonblocking webs with the physical properties provided in Table 2.
  • Small pieces (1" x 4") of nonwoven fabric readily disintegrated as reported in Table 3. None of the fibers, however, were completely water-dispersible because of the insoluble polypropylene component.
  • a circular piece (4" diameter) of the nonwoven produced in Example 2 was used as an adhesive layer between two sheets of cotton fabric.
  • a Hannifin melt press was used to fuse the two sheets of cotton together by applying a pressure 241 kPa gauge (35 psig) at 200°C for 30 seconds.
  • the resultant assembly exhibited exceptionally strong bond strength.
  • the cotton substrate shredded before adhesive or bond failure. Similar results have also been obtained with other cellulosics and with PET polyester substrates. Strong bonds were also produced by ultrasonic bonding techniques.
  • a PP (Exxon 3356G) with a 1200 MFR was melt blown using a 24" die to yield a flexible nonwoven fabric that did not block and was easily unwound from a roll. Small pieces (1" x 4") did not show any response (i.e., no disintegration or loss in basis weight) to water when immersed in water at RT or 50°C for 15 minutes.
  • Unicomponent fibers of a sulfopolyester containing 82 mole% isophthalic acid, 18 mole% of sodiosulfoisophthalic acid, 54 mole% diethylene glycol, and 46 mole% 1,4-cyclohexanedimethanol with a Tg of 55°C were melt spun at melt temperatures of 245°C (473°F) on a lab staple spinning line. As-spun denier was approximately 8 d/f. Some blocking was encountered on the take-up tubes, but the 10-filament strand readily dissolved within 10 - 19 seconds in unagitated, demineralized water at 82°C and a pH between 5 and 6.
  • the blend has a Tg of 57°C as calculated by taking a weighted average of the Tg's of the component sulfopolyesters.
  • the 10-filament strands did not show any blocking on the take-up tubes, but readily dissolved within 20 - 43 seconds in unagitated, demineralized water at 82° C and a pH between 5 and 6.
  • Example 5 The blend described in Example 5 was co-spun with PET to yield bicomponent islands-in-the-sea fibers.
  • a configuration was obtained where the sulfopolyester “sea” is 20 wt% of the fiber containing 80 wt% of PET "islands".
  • the spun yarn elongation was 190% immediately after spinning. Blocking was not encountered as the yarn was satisfactorily unwound from the bobbins and processed a week after spinning.
  • the "sea” was dissolved by passing the yarn through an 88°C soft water bath leaving only fine PET filaments.
  • This prophetic example illustrates the possible application of the multicomponent and microdenier fibers to the preparation of specialty papers.
  • the blend described in Example 5 is co-spun with PET to yield bicomponent islands-in-the-sea fibers.
  • the fiber contains approximately 35 wt% sulfopolyester "sea” component and approximately 65 wt% of PET "islands".
  • the uncrimped fiber is cut to 3.2 mm (1/8 inch) lengths.
  • these short-cut bicomponent fibers are added to the refining operation.
  • the sulfopolyester "sea” is removed in the agitated, aqueous slurry thereby releasing the microdenier PET fibers into the mix.
  • the microdenier PET fibers (“islands") are more effective to increase paper tensile strength than the addition of coarse PET fibers.
  • Bicomponent fibers were made having a 108 islands in the sea structure on a spunbond line using a 24" wide bicomponent spinneret die from Hills Inc., Melbourne, FL, having a total of 2222 die holes in the die plate.
  • Two extruders were connected to melt pumps which were in turn connected to the inlets for both components in the fiber spin die.
  • the primary extruder (A) was connected to the inlet which metered a flow of Eastman F61HC PET polyester to form the island domains in the islands in the sea fiber cross-section structure.
  • the extrusion zones were set to melt the PET entering the die at a temperature of 285°C.
  • the secondary extruder (B) processed Eastman AQ 55S sulfopolyester polymer from Eastman Chemical Company, Kingsport, TN having an inherent viscosity of about 0.35 and a melt viscosity of about 15,000 poise, measured at 240°C and 1 rad/sec sheer rate and 9,700 poise measured at 240°C and 100 rad/sec sheer rate in a Rheometric Dynamic Analyzer RDAII (Rheometrics Inc. Piscataway, New Jersey) rheometer. Prior to performing a melt viscosity measurement, the sample was dried for two days in a vacuum oven at 60°C. The viscosity test was performed using a 25 mm diameter parallel-plate geometry at 1mm gap setting.
  • a dynamic frequency sweep was run at a strain rate range of 1 to 400 rad/sec and 10% strain amplitude. Then, the viscosity was measured at 240° C and strain rate of 1 rad/sec. This procedure was followed in determining the viscosity of the sulfopolyester materials used in the subsequent examples.
  • the secondary extruder was set to melt and feed the AQ 55S polymer at a melt temperature of 255°C to the spinnerette die.
  • the two polymers were formed into bicomponent extrudates by extrusion at a throughput rate of 0.6 g/hole/min.
  • the volume ratio of PET to AQ 55S in the bicomponent extrudates was adjusted to yield 60/40 and 70/30 ratios.
  • An aspirator device was used to melt draw the bicomponent extrudates to produce the bicomponent fibers.
  • the flow of air through the aspirator chamber pulled the resultant fibers down.
  • the amount of air flowing downward through the aspirator assembly was controlled by the pressure of the air entering the aspirator.
  • the maximum pressure of the air used in the aspirator to melt draw the bicomponent extrudates was 172 kPa (25 psi). Above this value, the airflow through the aspirator caused the extrudates to break during this melt draw spinning process as the melt draw rate imposed on the bicomponent extrudates was greater than the inherent ductility of the bicomponent extrudates.
  • the bicomponent fibers were laid down into a non-woven web having a fabric weight of 95 grams per square meter (gsm). Evaluation of the bicomponent fibers in this nonwoven web by optical microscopy showed that the PET was present as islands in the center of the fiber structure, but the PET islands around the outer periphery of the bicomponent fiber nearly coalesced together to form a nearly continuous ring of PET polymer around the circumference of the fibers which is not desireable. Microscopy found that the diameter of the bicomponent fibers in the nonwoven web was generally between 15-19 microns, corresponding to an average fiber as-spun denier of about 2.5 denier per filament (dpf). This represents a melt drawn fiber speed of about 2160 meters per minute.
  • dpf denier per filament
  • As-spun denier is defined as the denier of the fiber (weight in grams of 9000 meters length of fiber) obtained by the melt extrusion and melt drawing steps.
  • the variation in bicomponent fiber diameter indicated non-uniformity in spun-drawing of the fibers.
  • the non-woven web samples were conditioned in a forced-air oven for five minutes at 120°C.
  • the heat treated web exhibited significant shrinkage with the area of the nonwoven web being decreased to only about 12% of the initial area of the web before heating.
  • the bicomponent extrudates could not be melt drawn to the degree required to cause strain induced crystallization of the PET segments in the fibers.
  • the AQ 55S sulfopolyester having this specific inherent viscosity and melt viscosity was not acceptable as the bicomponent extrudates could not be uniformly melt drawn to the desired fine denier.
  • a sulfopolyester polymer with the same chemical composition as commercial Eastman AQ55S polymer was produced, however, the molecular weight was controlled to a lower value characterized by an inherent viscosity of about 0.25.
  • the melt viscosity of this polymer was 3300 poise measured at 240°C and 1 rad/sec shear rate.
  • Bicomponent extrudates having a 16-segment segmented pie structure were made using a bicomponent spinneret die from Hills Inc., Melbourne, FL, having a total of 2222 die holes in the 610 mm (24 inch) wide die plate on a spunbond equipment. Two extruders were used to melt and feed two polymers to this spinnerette die.
  • the primary extruder (A) was connected to the inlet which fed Eastman F61HC PET polyester melt to form the domains or segment slices in the segmented pie cross-section structure.
  • the extrusion zones were set to melt the PET entering the spinnerette die at a temperature of 285°C.
  • the secondary extruder (B) melted and fed the sulfopolyester polymer of Example 8.
  • the secondary extruder was set to extrude the sulfopolyester polymer at a melt temperature of 255°C into the spinnerette die. Except for the spinnerette die used and melt viscosity of the sulfopolyester polymer, the procedure employed in this example was the same as in Comparative Example 8. The melt throughput per hole was 0.6 gm/min. The volume ratio of PET to sulfopolyester in the bicomponent extrudates was set at 70/30 which represents a weight ratio of about 70/30.
  • the bicomponent extrudates were melt drawn using the same aspirator used in Comparative Example 8 to produce the bicomponent fibers. Initially, the input air to the aspirator was set to 172 kPa (25 psi) and the fibers had as-spun denier of about 2.0 with the bicomponent fibers exhibiting a uniform diameter profile of about 14-15 microns. The air to the aspirator was increased to a maximum available pressure of 310 kPa (45 psi) without breaking the melt extrudates during melt drawing.
  • the bicomponent extrudates were melt drawn down to a fiber as-spun denier of about 1.2 with the bicomponent fibers exhibiting a diameter of 11-12 microns when viewed under a microscope.
  • the speed during the melt draw process was calculated to be about 4500 m/min.
  • strain induced crystallization of the PET during the melt drawing process begins to occur.
  • the bicomponent fibers using 310 kPa (45 psi) aspirator air pressure were laid down into a nonwoven web with a weight of 140 grams per square meter (gsm).
  • the shrinkage of the nonwoven web was measured by conditioning the material in a forced-air oven for five minutes at 120°C. This example represents a significant reduction in shrinkage compared to the fibers and fabric of Comparative Example 8.
  • This nonwoven web having 140 gsm fabric weight was soaked for five minutes in a static deionized water bath at various temperatures.
  • the soaked nonwoven web was dried, and the percent weight loss due to soaking in deionized water at the various temperatures was measured as shown in Table 4.
  • Table 4 Soaking Temperature 25°C 33°C 40°C 72°C Nonwoven Web Weight Loss (%) 3.3 21.7 31.4 31.7
  • the sulfopolyester dissipated very readily into deionized water at a temperature of about 25°C. Removal of the sulfopolyester from the bicomponent fibers in the nonwoven web is indicated by the % weight loss. Extensive or complete removal of the sulfopolyester from the bicomponent fibers were observed at temperatures at or above 33°C. If hydroentanglement is used to produce a nonwoven web of these bicomponent fibers comprising the present sulfopolyester polymer of Example 8, it would be expected that the sulfopolyester polymer would be extensively or completely removed by the hydroentangling water jets if the water temperature was above ambient. If it is desired that very little sulfopolyester polymer be removed from these bicomponent fibers during the hydroentanglement step, low water temperature, less than about 25°C , should be used.
  • a sulfopolyester polymer was prepared with the following diacid and diol composition: diacid composition (71 mol % terephthalic acid, 20 mol % isophthalic acid, and 9 mol % 5-(sodiosulfo) isophthalic acid) and diol composition (60 mol % ethylene glycol and 40 mol % diethylene glycol).
  • the sulfopolyester was prepared by high temperature polyesterification under vacuum. The esterification conditions were controlled to produce a sulfopolyester having an inherent viscosity of about 0.31. The melt viscosity of this sulfopolyester was measured to be in the range of about 3000-4000 poise at 240°C and 1 rad/sec shear rate.
  • the sulfopolyester polymer of Example 10 was spun into bicomponent segmented pie fibers and nonwoven web according to the same procedure described in Example 9.
  • the primary extruder (A) fed Eastman F61HC PET polyester melt to form the larger segment slices in the segmented pie structure.
  • the extrusion zones were set to melt the PET entering the spinnerette die at a temperature of 285°C.
  • the secondary extruder (B) processed the sulfopolyester polymer of Example 10 which was fed at a melt temperature of 255°C into the spinnerette die.
  • the melt throughput rate per hole was 0.6 gm/min.
  • the volume ratio of PET to sulfopolyester in the bicomponent extrudates was set at 70/30 which represents the weight ratio of about 70/30.
  • the cross-section of the bicomponent extrudates had wedge shaped domains of PET with sulfopolyester polymer separating these domains.
  • the bicomponent extrudates were melt drawn using the same aspirator assembly used in Comparative Example 8 to produce the bicomponent fiber.
  • the maximum available pressure of the air to the aspirator without breaking the bicomponent fibers during drawing was 310 kPa (45 psi).
  • 310 kPa (45 psi) air the bicomponent extrudates were melt drawn down to bicomponent fibers with as-spun denier of about 1.2 with the bicomponent fibers exhibiting a diameter of about 11-12 microns when viewed under a microscope.
  • the speed during the melt drawing process was calculated to be about 4500 m/min.
  • the bicomponent fibers were laid down into nonwoven webs having weights of 140 gsm and 110 gsm.
  • the shrinkage of the webs was measured by conditioning the material in a forced-air oven for five minutes at 120°C.
  • the area of the nonwoven webs after shrinkage was about 29% of the webs' starting areas.
  • the nonwoven web having 110 gsm fabric weight, was soaked for eight minutes in a static deionized water bath at various temperatures. The soaked nonwoven web was dried and the percent weight loss due to soaking in deionized water at the various temperatures was measured as shown in Table 5.
  • Table 5 Soaking Temperature 36°C 41°C 46°C 51°C 56°C 72°C Nonwoven Web Weight Loss (%) 1.1 2.2 14.4 25.9 28.5 30.5
  • the sulfopolyester polymer dissipated very readily into deionized water at temperatures above about 46°C, with the removal of the sulfopolyester polymer from the fibers being very extensive or complete at temperatures above 51 °C as shown by the weight loss.
  • a weight loss of about 30% represented complete removal of the sulfopolyester from the bicomponent fibers in the nonwoven web. If hydroentanglement is used to process this non-woven web of bicomponent fibers comprising this sulfopolyester, it would be expected that the polymer would not be extensively removed by the hydroentangling water jets at water temperatures below 40°C.
  • the nonwoven webs of Example 11 having basis weights of both 140 gsm and 110 gsm were hydroentangled using a hydroentangling apparatus manufactured by Fleissner, GmbH, Egelsbach, Germany.
  • the machine had five total hydroentangling stations wherein three sets of jets contacted the top side of the nonwoven web and two sets of jets contacted the opposite side of the nonwoven web.
  • the water jets comprised a series of fine orifices about 100 microns in diameter machined in two-feet wide jet strips.
  • the water pressure to the jets was set at 60 bar (Jet Strip # 1), 190 bar (Jet Strips # 2 and 3), and 230 bar (Jet Strips # 4 and 5).
  • the temperature of the water to the jets was found to be in the range of about 40-45°C.
  • the nonwoven fabric exiting the hydroentangling unit was strongly tied together.
  • the continuous fibers were knotted together to produce a hydroentangled nonwoven fabric with high resistance to tearing when stretched in both directions.
  • the hydroentangled nonwoven fabric was fastened onto a tenter frame comprising a rigid rectangular frame with a series of pins around the periphery thereof.
  • the fabric was fastened to the pins to restrain the fabric from shrinking as it was heated.
  • the frame with the fabric sample was placed in a forced-air oven for three minutes at 130°C to cause the fabric to heat set while being restrained.
  • the conditioned fabric was cut into a sample specimen of measured size, and the specimen was conditioned at 130°C without restraint by a tenter frame.
  • the dimensions of the hydroentangled nonwoven fabric after this conditioning were measured and only minimal shrinkage ( ⁇ 0.5% reduction in dimension) was observed. It was apparent that heat setting of the hydroentangled nonwoven fabric was sufficient to produce a dimensionally stable nonwoven fabric.
  • the hydroentangled nonwoven fabric after being heat set as described above, was washed in 90°C deionized water to remove the sulfopolyester polymer and leave the PET monocomponent fiber segments remaining in the hydroentangled fabric. After repeated washings, the dried fabric exhibited a weight loss of approximately 26 %. Washing the nonwoven web before hydroentangling demonstrated a weight loss of 31.3 %. Therefore, the hydroentangling process removed some of the sulfopolyester from the nonwoven web, but this amount was relatively small. In order to lessen the amount of sulfopolyester removed during hydroentanglement, the water temperature of the hydroentanglement jets should be lowered to below 40°C.
  • the sulfopolyester of Example 10 was found to give segmented pie fibers having good segment distribution where the water non-dispersable polymer segments formed individual fibers of similar size and shape after removal of the sulfopolyester polymer.
  • the rheology of the sulfopolyester was suitable to allow the bicomponent extrudates to be melt drawn at high rates to achieve fine denier bicomponent fibers with as-spun denier as low as about 1.0. These bicomponent fibers are capable of being laid down into a non-woven web which could be hydroentangled without experiencing significant loss of sulfopolyester polymer to produce the nonwoven fabric.
  • the nonwoven fabric produced by hydroentangling the non-woven web exhibited high strength and could be heat set at temperatures of about 120°C or higher to produce nonwoven fabric with excellent dimensional stability.
  • the sulfopolyester polymer was removed from the hydroentangled nonwoven fabric in a washing step. This resulted in a strong nonwoven fabric product with lighter fabric weight and much greater flexibility and softer hand.
  • the monocomponent PET fibers in this nonwoven fabric product were wedge shaped and exhibited an average denier of about 0.1.
  • a sulfopolyester polymer was prepared with the following diacid and diol composition: diacid composition (69 mol % terephthalic acid, 22.5 mol % isophthalic acid, and 8.5 mol % 5-(sodiosulfo) isophthalic acid) and diol composition (65 mol % ethylene glycol and 35 mol % diethylene glycol).
  • the sulfopolyester was prepared by high temperature polyesterification under vacuum. The esterification conditions were controlled to produce a sulfopolyester having an inherent viscosity of about 0.33. The melt viscosity of this sulfopolyester was measured to be in the range of about 3000-4000 poise at 240°C and 1 rad/sec shear rate.
  • the sulfopolyester polymer of Example 13 was spun into bicomponent islands-in-sea cross-section configuration with 16 islands on a spunbond line.
  • the extrusion zones were set to melt the PET entering the spinnerette die at a temperature of about 290°C.
  • the secondary extruder (B) processed the sulfopolyester polymer of Example 13 which was fed at a melt temperature of about 260°C into the spinnerette die.
  • the volume ratio of PET to sulfopolyester in the bicomponent extrudates was set at 70/30 which represents the weight ratio of about 70/30.
  • the melt throughput rate through the spinneret was 0.6 g/hole/minute.
  • the cross-section of the bicomponent extrudates had round shaped island domains of PET with sulfopolyester polymer separating these domain
  • the bicomponent extrudates were melt drawn using an aspirator assembly.
  • the maximum available pressure of the air to the aspirator without breaking the bicomponent fibers during melt drawing was 345 kPa (50 psi).
  • 345 kPa (50 psi) air the bicomponent extrudates were melt drawn down to bicomponent fibers with as-spun denier of about 1.4 with the bicomponent fibers exhibiting a diameter of about 12 microns when viewed under a microscope.
  • the speed during the drawing process was calculated to be about 3900 m/min.
  • the sulfopolyester polymer of Example 13 was spun into bicomponent islands-in-the-sea cross-section fibers with 64 islands fibers using a bicomponent extrusion line.
  • the primary extruder fed Eastman F61HC polyester melt to form the islands in the islands-in-the-sea fiber cross-section structure.
  • the inherent viscosity of polyester was 0.61 dL/g while the melt viscosity of dry sulfopolyester was about 7000 poise measured at 240°C and 1 rad/sec strain rate using the melt viscosity measurement procedure described earlier.
  • These islands-in-sea bicomponent fibers were made using a spinneret with 198 holes and a throughput rate of 0.85 gms/minute/hole.
  • the polymer ratio between "islands" polyester and “sea” sulfopolyester was 65% to 35%.
  • These bicomponent fibers were spun using an extrusion temperature of 280°C for the polyester component and 260°C for the sulfopolyester component.
  • the bicomponent fiber contains a multiplicity of filaments (198 filaments) and was melt spun at a speed of about 530 meters/minute, forming filaments with a nominal denier per filament of about 14.
  • a finish solution of 24 wt% PT 769 finish from Goulston Technologies was applied to the bicomponent fiber using a kiss roll applicator.
  • the filaments of the bicomponent fiber were then drawn in line using a set of two godet rolls, heated to 90°C and 130°C respectively, and the final draw roll operating at a speed of about 1750 meters/minute, to provide a filament draw ratio of about 3.3X forming the drawn islands-in-sea bicomponent filaments with a nominal denier per filament of about 4.5 or an average diameter of about 25 microns.
  • These filaments comprised the polyester microfiber "islands" having an average diameter of about 2.5 microns.
  • the drawn islands-in-sea bicomponent fibers of Example 15 were cut into short length fibers of 3.2 millimeters and 6.4 millimeters cut lengths, thereby, producing short length bicomponent fibers with 64 islands-in-sea cross-section configurations.
  • These short cut bicomponent fibers comprised "islands" of polyester and "sea” of water dispersible sulfopolyester polymer.
  • the cross-sectional distribution of islands and sea was essentially consistent along the length of these short cut bicomponent fibers.
  • the drawn islands-in-sea bicomponent fibers of Example 15 were soaked in soft water for about 24 hours and then cut into short length fibers of 3.2 millimeters and 6.4 millimeters cut lengths.
  • the water dispersible sulfopolyester was at least partially emulsified prior to cutting into short length fibers. Partial separation of islands from the sea component was therefore effected, thereby, producing partially emulsified short length islands-in-sea bicomponent fibers.
  • the short cut length islands-in-sea bicomponent fibers of Example 16 were washed using soft water at 80°C to remove the water dispersible sulfopolyester "sea" component, thereby, releasing the polyester microfibers which were the "islands" component of the bicomponent fibers.
  • the washed polyester microfibers were rinsed using soft water at 25°C to essentially remove most of the "sea” component.
  • the optical microscopic observation of the washed polyester microfibers showed an average diameter of about 2.5 microns and lengths of 3.2 and 6.4 millimeters.
  • the short cut length partially emulsified islands-in-sea bicomponent fibers of Example 17 were washed using soft water at 80°C to remove the water dispersible sulfopolyester "sea" component, thereby, releasing the polyester microfibers which were the "islands" component of the fibers.
  • the washed polyester microfibers were rinsed using soft water at 25°C to essentially remove most of the "sea” component.
  • the optical microscopic observation of the washed polyester microfibers showed polyester microfibers of average diameter of about 2.5 microns and lengths of 3.2 and 6.4 millimeters.
  • Wet-laid hand sheets were prepared using the following procedure. 7.5 gms of Albacel Southern Bleached Softwood Kraft (SBSK) from International Paper, Memphis, Tennessee, U.S.A. and 188 gms of room temperature water were placed in a 1000 ml pulper and pulped for 30 seconds at 7000 rpm to produce a pulped mixture. This pulped mixture was transferred into an 8 liter metal beaker along with 7312 gms of room temperature water to make about 0.1 % consistency (7500 gms water and 7.5 gms fibrous material) pulp slurry. This pulp slurry was agitated using a high speed impeller mixer for 60 seconds. Procedure to make the hand sheet from this pulp slurry was as follows.
  • the pulp slurry was poured into a 25 centimeters x 30 centimeters hand sheet mold while continuing to stir.
  • the drop valve was pulled, and the pulp fibers were allowed to drain on a screen to form a hand sheet.
  • 750 grams per square meter (gsm) blotter paper was placed on top of the formed hand sheet, and the blotter paper was flattened onto the hand sheet.
  • the screen frame was raised and inverted onto a clean release paper and allowed to sit for 10 minutes.
  • the screen was raised vertically away from the formed hand sheet.
  • Two two sheets of 750 gsm blotter paper were placed on top of the formed hand sheet.
  • the hand sheet was dried along with the three blotter papers using a Norwood Dryer at about 88°C for 15 minutes.
  • One blotter paper was removed leaving one blotter paper on each side of the hand sheet.
  • the hand sheet was dried using a Williams Dryer at 65°C for 15 minutes.
  • the hand sheet was then further dried for 12 to 24 hours using a 40 kg dry press.
  • the blotter paper was removed to obtain the dry hand sheet sample.
  • the hand sheet was trimmed to 21.6 centimeters by 27.9 centimeters dimensions for testing.
  • Wet-laid hand sheets were prepared using the following procedure. 7.5 gms of Albacel Southern Bleached Softwood Kraft (SBSK) from International Paper, Memphis, Tennessee, U.S.A., 0.3 gms of Solivitose N pre-gelatinized quaternary cationic potato starch from Avebe, Foxhol, the Netherlands, and 188 gms of room temperature water were placed in a 1000 ml pulper and pulped for 30 seconds at 7000 rpm to produce a pulped mixture.
  • SBSK Albacel Southern Bleached Softwood Kraft
  • This pulped mixture was transferred into an 8 liter metal beaker along with 7312 gms of room temperature water to make about 0.1% consistency (7500 gms water and 7.5 gms fibrous material) to produce a pulp slurry.
  • This pulp slurry was agitated using a high speed impeller mixer for 60 seconds. The rest of procedure for making hand sheet from this pulp slurry was same as in Example 20.
  • Wet-laid hand sheets were prepared using the following procedure. 6.0 gms of Albacel Southern Bleached Softwood Kraft (SBSK) from International Paper, Memphis, Tennessee, U.S.A., 0.3 gms of Solivitose N pre-gelatinized quaternary cationic potato starch from Avebe, Foxhol, the Netherlands, 1.5 gms of 3.2 millimeter cut length islands-in-sea fibers of Example 16, and 188 gms of room temperature water were placed in a 1000 ml pulper and pulped for 30 seconds at 7000 rpm to produce a fiber mix slurry.
  • SBSK Albacel Southern Bleached Softwood Kraft
  • This fiber mix slurry was heated to 82°C for 10 seconds to emulsify and remove the water dispersible sulfopolyester component in the islands-in-sea fibers and release polyester microfibers.
  • the fiber mix slurry was then strained to produce a sulfopolyester dispersion comprising the sulfopolyester and a microfiber-containing mixture comprising pulp fibers and polyester microfiber.
  • the microfiber-containing mixture was further rinsed using 500 gms of room temperature water to further remove the water dispersible sulfopolyester from the microfiber-containing mixture.
  • This microfiber-containing mixture was transferred into an 8 liter metal beaker along with 7312 gms of room temperature water to make about 0.1 % consistency (7500 gms water and 7.5 gms fibrous material) to produce a microfiber-containing slurry.
  • This microfiber-containing slurry was agitated using a high speed impeller mixer for 60 seconds. The rest of procedure for making hand sheet from this microfiber-containing slurry was same as in Example 20.
  • Wet-laid hand sheets were prepared using the following procedure. 7.5 gms of MicroStrand 475-106 micro glass fiber available from Johns Manville, Denver, Colorado, U.S.A., 0.3 gms of Solivitose N pre-gelatinized quaternary cationic potato starch from Avebe, Foxhol, the Netherlands, and 188 gms of room temperature water were placed in a 1000 ml pulper and pulped for 30 seconds at 7000 rpm to produce a glass fiber mixture.
  • This glass fiber mixture was transferred into an 8 liter metal beaker along with 7312 gms of room temperature water to make about 0.1 % consistency (7500 gms water and 7.5 gms fibrous material) to produce a glass fiber slurry.
  • This glass fiber slurry was agitated using a high speed impeller mixer for 60 seconds. The rest of procedure for making hand sheet from this glass fiber slurry was same as in Example 20.
  • Wet-laid hand sheets were prepared using the following procedure. 3.8 gms of MicroStrand 475-106 micro glass fiber available from Johns Manville, Denver, Colorado, U.S.A., 3.8 gms of 3.2 millimeter cut length islands-in-sea fibers of Example 16, 0.3 gms of Solivitose N pre-gelatinized quaternary cationic potato starch from Avebe, Foxhol, the Netherlands, and 188 gms of room temperature water were placed in a 1000 ml pulper and pulped for 30 seconds at 7000 rpm to produce a fiber mix slurry.
  • This fiber mix slurry was heated to 82°C for 10 seconds to emulsify and remove the water dispersible sulfopolyester component in the islands-in-sea bicomponent fibers and release polyester microfibers.
  • the fiber mix slurry was then strained to produce a sulfopolyester dispersion comprising the sulfopolyester and a microfiber-containing mixture comprising glass microfibers and polyester microfiber.
  • the microfiber-containing mixture was further rinsed using 500 gms of room temperature water to further remove the sulfopolyester from the microfiber-containing mixture.
  • This microfiber-containing mixture was transferred into an 8 liter metal beaker along with 7312 gms of room temperature water to make about 0.1% consistency (7500 gms water and 7.5 gms fibrous material) to produce a microfiber-containing slurry.
  • This microfiber-containing slurry was agitated using a high speed impeller mixer for 60 seconds. The rest of procedure for making hand sheet from this microfiber-containing slurry was same as in Example 20.
  • Wet-laid hand sheets were prepared using the following procedure. 7.5 gms of 3.2 millimeter cut length islands-in-sea fibers of Example 16, 0.3 gms of Solivitose N pre-gelatinized quaternary cationic potato starch from Avebe, Foxhol, the Netherlands, and 188 gms of room temperature water were placed in a 1000 ml pulper and pulped for 30 seconds at 7000 rpm to produce a fiber mix slurry. This fiber mix slurry was heated to 82°C for 10 seconds to emulsify and remove the water dispersible sulfopolyester component in the islands-in-sea fibers and release polyester microfibers.
  • the fiber mix slurry was then strained to produce a sulfopolyester dispersion and polyester microfibers.
  • the sulfopolyester dispersion was comprised of water dispersible sulfopolyester.
  • the polyester microfibers were rinsed using 500 gms of room temperature water to further remove the sulfopolyester from the polyester microfibers.
  • These polyester microfibers were transferred into an 8 liter metal beaker along with 7312 gms of room temperature water to make about 0.1% consistency (7500 gms water and 7.5 gms fibrous material) to produce a microfiber slurry.
  • This microfiber slurry was agitated using a high speed impeller mixer for 60 seconds. The rest of procedure for making hand sheet from this microfiber slurry was same as in Example 20.
  • the hand sheet basis weight was determined by weighing the hand sheet and calculating weight in grams per square meter (gsm).
  • Hand sheet thickness was measured using an Ono Sokki EG-233 thickness gauge and reported as thickness in millimeters. Density was calculated as weight in grams per cubic centimeter.
  • Porosity was measured using a Greiner Porosity Manometer with 1.9 x 1.9 cm square opening head and 100 cc capacity. Porosity is reported as average time in seconds (4 replicates) for 100 cc of water to pass through the sample.
  • Tensile properties were measured using an Instron Model TM for six 30 mm x 105 mm test strips. An average of six measurements is reported for each example. It can be observed from these test data that significant improvement in tensile properties of wet-laid fibrous structures is obtained by the addition of polyester microfibers.
  • the sulfopolyester polymer of Example 13 was spun into bicomponent islands-in-the-sea cross-section fibers with 37 islands fibers using a bicomponent extrusion line.
  • the primary extruder fed Eastman F61HC polyester to form the "islands" in the islands-in-the-sea cross-section structure.
  • the secondary extruder fed the water dispersible sulfopolyester polymer to form the "sea" in the islands-in-sea bicomponent fiber.
  • the inherent viscosity of the polyester was 0.61 dL/g while the melt viscosity of dry sulfopolyester was about 7000 poise measured at 240°C and 1 rad/sec strain rate using the melt viscosity measurement procedure described previously.
  • These islands-in-sea bicomponent fibers were made using a spinneret with 72 holes and a throughput rate of 1.15gms/minute/hole.
  • the polymer ratio between "islands" polyester and "sea" sulfopolyester was 2 to 1. These bicomponent fibers were spun using an extrusion temperature of 280°C for the polyester component and 255°C for the water dispersible sulfopolyester component.
  • This bicomponent fiber contained a multiplicity of filaments (198 filaments) and was melt spun at a speed of about 530 meters/minute forming filaments with a nominal denier per filament of 19.5.
  • a finish solution of 24% by weight PT 769 finish from Goulston Technologies was applied to the bicomponent fiber using a kiss roll applicator.
  • the filaments of the bicomponent fiber were then drawn in line using a set of two godet rolls, heated to 95°C and 130°C respectively, and the final draw roll operating at a speed of about 1750 meters/minute, to provide a filament draw ratio of about 3.3X forming the drawn islands-in-sea bicomponent filaments with a nominal denier per filament of about 5.9 or an average diameter of about 29 microns.
  • These filaments comprised the polyester microfiber islands of average diameter of about 3.9 microns.
  • the drawn islands-in-sea bicomponent fibers of Example 26 were cut into short length bicomponent fibers of 3.2 millimeters and 6.4 millimeters cut length, thereby, producing short length fibers with 37 islands-in-sea cross-section configurations.
  • These fibers comprised "islands” of polyester and "sea” of water dispersible sulfopolyester polymers.
  • the cross-sectional distribution of "islands” and "sea” was essentially consistent along the length of these bicomponent fibers.
  • the short cut length islands-in-sea fibers of Example 27 were washed using soft water at 80°C to remove the water dispersible sulfopolyester "sea" component, thereby, releasing the polyester microfibers which were the "islands" component of the bicomponent fibers.
  • the washed polyester microfibers were rinsed using soft water at 25°C to essentially remove most of the "sea” component.
  • the optical microscopic observation of the washed polyester microfibers had an average diameter of about 3.9 microns and lengths of 3.2 and 6.4 millimeters.
  • the sulfopolyester polymer of Example 13 was spun into bicomponent islands-in-the-sea cross-section fibers with 37 islands fibers using a bicomponent extrusion line.
  • the primary extruder fed polyester to form the "islands" in the islands-in-the-sea fiber cross-section structure.
  • the secondary extruder fed the water dispersible sulfopolyester polymer to form the "sea" in the islands-in-sea bicomponent fiber.
  • the inherent viscosity of the polyester was 0.52 dL/g while the melt viscosity of the dry water dispersible sulfopolyester was about 3500 poise measured at 240°C and 1 rad/sec strain rate using the melt viscosity measurement procedure described previously.
  • These islands-in-sea bicomponent fibers were made using two spinnerets with 175 holes each and throughput rate of 1.0 gms/minute/hole.
  • the polymer ratio between "islands" polyester and "sea" sulfopolyester was 70% to 30%. These bicomponent fibers were spun using an extrusion temperature of 280°C for the polyester component and 255°C for the sulfopolyester component.
  • the bicomponent fibers contained a multiplicity of filaments (350 filaments) and were melt spun at a speed of about 1000 meters/minute using a take-up roll heated to 100°C forming filaments with a nominal denier per filament of about 9 and an average fiber diameter of about 36 microns.
  • a finish solution of 24 wt% PT 769 finish was applied to the bicomponent fiber using a kiss roll applicator.
  • the filaments of the bicomponent fiber were combined and were then drawn 3.0x on a draw line at draw roll speed of 100 m/minute and temperature of 38°C forming drawn islands-in-sea bicomponent filaments with an average denier per filament of about 3 and average diameter of about 20 microns.
  • These drawn island-in-sea bicomponent fibers were cut into short length fibers of about 6.4 millimeters length. These short length islands-in-sea bicomponent fibers were comprised of polyester microfiber "islands" of average diameter of about 2.8 microns.
  • the short cut length islands-in-sea bicomponent fibers of Example 29 were washed using soft water at 80°C to remove the water dispersible sulfopolyester "sea" component, thereby, releasing the polyester microfibers which were the "islands” component of the fibers.
  • the washed polyester microfibers were rinsed using soft water at 25°C to essentially remove most of the "sea” component.
  • the optical microscopic observation of washed fibers showed polyester microfibers of average diameter of about 2.8 microns and lengths of about 6.4 millimeters.
  • Wet-laid microfiber stock hand sheets were prepared using the following procedure. 56.3 gms of 3.2 millimeter cut length islands-in-sea bicomponent fibers of Example 16, 2.3 gms of Solivitose N pre-gelatinized quaternary cationic potato starch from Avebe, Foxhol, the Netherlands, and 1410 gms of room temperature water were placed in a 2 liter beaker to produce a fiber slurry. The fiber slurry was stirred. One quarter amount of this fiber slurry, about 352 ml, was placed in 1000 ml pulper and pulped for 30 seconds at 7000 rpm.
  • This fiber slurry was heated to 82°C for 10 seconds to emulsify and remove the water dispersible sulfopolyester component in the islands-in-sea bicomponent fibers and release polyester microfibers.
  • the fiber slurry was then strained to produce a sulfopolyester dispersion and polyester microfibers.
  • These polyester microfibers were rinsed using 500 gms of room temperature water to further remove the sulfopolyester from the polyester microfibers. Sufficient room temperature water was added to produce 352 ml of microfiber slurry.
  • This microfiber slurry was re-pulped for 30 seconds at 7000 rpm. These microfibers were transferred into an 8 liter metal beaker.
  • the remaining three quarters of the fiber slurry were similarly pulped, washed, rinsed and re-pulped and transferred to the 8 liter metal beaker. 6090 gms of room temperature water was then added to make about 0.49% consistency (7500 gms water and 36.6 gms of polyester microfibers) to produce a microfiber slurry. This microfiber slurry was agitated using a high speed impeller mixer for 60 seconds. The rest of procedure for making hand sheet from this microfiber slurry was same as in Example 20.
  • the microfiber stock hand sheet with the basis weight of about 490 gsm was comprised of polyester microfibers of average diameter of about 2.5 microns and average length of about 3.2 millimeters.
  • Wet-laid hand sheets were prepared using the following procedure. 7.5 gms of polyester microfiber stock hand sheet of Example 31, 0.3 gms of Solivitose N pre-gelatinized quaternary cationic potato starch from Avebe, Foxhol, the Netherlands, and 188 gms of room temperature water were placed in a 1000 ml pulper and pulped for 30 seconds at 7000 rpm. The microfibers were transferred into an 8 liter metal beaker along with 7312 gms of room temperature water to make about 0.1 % consistency (7500 gms water and 7.5 gms fibrous material) to produce a microfiber slurry. This microfiber slurry was agitated using a high speed impeller mixer for 60 seconds. The rest of procedure for making hand sheet from this slurry was same as in Example 20. A 100 gsm wet-laid hand sheet of polyester microfibers was obtained having an average diameter of about 2.5 microns.
  • the 6.4 millimeter cut length islands-in-sea bicomponent fibers of Example 29 were washed using soft water at 80°C to remove the water dispersible sulfopolyester "sea" component, thereby, releasing the polyester microfibers which were the "islands" component of the bicomponent fibers.
  • the washed polyester microfibers were rinsed using soft water at 25°C to essentially remove most of the "sea” component.
  • the optical microscopic observation of the washed polyester microfibers showed an average diameter of about 2.5 microns and lengths of 6.4 millimeters.
  • Example 16 The short cut length islands-in-sea bicomponent fibers of Example 16, Example 27 and Example 29 were washed separately using soft water at 80°C containing about 1% by weight based on the weight of the bicomponent fibers of ethylene diamine tetra acetic acid tetra sodium salt (Na 4 EDTA) from Sigma-Aldrich Company, Atlanta, Georgia to remove the water dispersible sulfopolyester "sea" component, thereby, releasing the polyester microfibers which were the "islands" component of the bicomponent fibers.
  • Na 4 EDTA ethylene diamine tetra acetic acid tetra sodium salt
  • the washed polyester microfibers were rinsed using soft water at 25°C to essentially remove most of the "sea" component.
  • the optical microscopic observation of washed polyester microfibers showed excellent release and separation of polyester microfibers.
  • Use of a water softing agent, such as Na 4 EDTA in the water prevents any Ca ++ ion exchange on the sulfopolyester which can adversely affect the water dispersiblity of sulfopolyester.
  • Typical soft water may contain up to 15 ppm of Ca ++ ion concentration. It is desirable that the soft water used in the processes described here should have essentially zero concentration of Ca ++ and other multi-valent ions or alternately use sufficient amount of water softening agent, such as Na 4 EDTA, to bind these Ca ++ ions and other multi-valent ions.
  • water softening agent such as Na 4 EDTA
  • the short cut length islands-in-sea bicomponent fibers of Example 16 and Example 27 were processed separately using the following procedure. 17 grams of Solivitose N pre-gelatinized quaternary cationic potato starch from Avebe, Foxhol, the Netherlands were added to the distilled water. After the starch was fully dissolved or hydrolyzed, then 429 grams of short cut length islands-in-sea bicomponent fibers were slowly added to the distilled water to produce a fiber slurry. A Williams Rotary Continuous Feed Refiner (127 mm [5 inch] diameter) was turned on to refine or mix the fiber slurry in order to provide sufficient shearing action for the water dispersible sulfopolyester to be separated from the polyester microfibers.
  • the contents of the stock chest were poured into a 24 liter stainless steel container, and the lid was secured.
  • the stainless steel container was placed on a propane cooker and heated until the fiber slurry began to boil at about 97°C in order to remove the sulfopolyester component in the island-in-sea fibers and release polyester microfibers. After the fiber slurry reached boiling, it was agitated with a manual agitating paddle.
  • the contents of the stainless steel container were poured into a 27in x 15in x 6 in deep False Bottom Knuche with a 30 mesh screen to produce a sulfopolyester dispersion and polyester microfibers.
  • the sulfopolyester dispersion comprised water and water dispersible sulfopolyester.
  • the polyester microfibers were rinsed in the Knuche for 15 seconds with 10 liters of soft water at 17°C, and squeezed to remove excess water.
  • polyester microfiber dry fiber basis
  • Handsheets were made using the procedure described previously in Example 20.

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Claims (15)

  1. Composition de pâte humide comprenant :
    un mélange d'une dispersion de sulfopolyester et d'une pluralité de microfibres polymères synthétiques non dispersibles dans l'eau,
    dans laquelle lesdites microfibres ont un diamètre équivalent inférieur à 5 microns et une longueur inférieure à 25 millimètres,
    dans laquelle ladite dispersion de sulfopolyester comprend au moins un sulfopolyester et de l'eau,
    dans laquelle ledit au moins un sulfopolyester comprend :
    (i) d'environ 50 à environ 96 %, sur la base des résidus acides totaux, de résidus d'un ou de plusieurs acides dicarboxyliques, dans laquelle ledit ou lesdits acides dicarboxyliques comprennent l'acide téréphtalique et l'acide isophtalique,
    (ii) d'environ 4 à environ 40 % en moles, sur la base des résidus acide totaux, de résidus d'au moins un sulfomonomère ayant deux groupes fonctionnels et un ou plusieurs groupes sulfonate liés à un cycle aromatique ou cycloaliphatique dans lequel les groupes fonctionnels sont des groupes hydroxyle, carboxyle, ou une combinaison de ceux-ci, et
    (iii) un ou plusieurs résidus diol,
    dans laquelle ledit sulfopolyester a une température de transition vitreuse (telle que mesurée sur le polymère anhydre en utilisant un DSC) d'au moins 40 °C,
    dans laquelle ledit sulfopolyester a une viscosité intrinsèque d'au moins 0,2 dl/g mesurée dans une solution à 60/40 parties en poids de solvant phénol/tétrachloroéthane à 40 °C et à une concentration de 0,5 gramme de sulfopolyester dans 100 ml de solvant,
    dans laquelle ledit sulfopolyester présente une viscosité en fusion inférieure à 10 000 poises mesurée à 240 °C à une vitesse de déformation de 1 rad/sec,
    dans laquelle la composition de pâte humide comprend au moins 50 % en poids mais pas plus de 90 % en poids d'eau.
  2. Composition de pâte humide selon la revendication 1, sensiblement constituée de ladite dispersion de sulfopolyester et desdites microfibres.
  3. Composition de pâte humide selon la revendication 1, dans laquelle lesdites microfibres et ledit sulfopolyester sont dérivés de fibres à composants multiples ayant lesdites microfibres sous la forme d'un composant non dispersible dans l'eau de celles-ci et ayant ledit sulfopolyester sous la forme d'un composant dispersible dans l'eau de celui-ci.
  4. Composition de pâte humide selon la revendication 1, dans laquelle ledit sulfopolyester a une température de transition vitreuse (telle que mesurée sur le polymère anhydre en utilisant un DSC) d'au moins 50 °C, et une viscosité en fusion d'au moins 6 000 poises mesurée à 240 °C à une vitesse de déformation de 1 rad/sec.
  5. Composition de pâte humide selon la revendication 1, dans laquelle ledit sulfopolyester comprend d'environ 80 à environ 96 % en moles, sur la base des résidus acides totaux, de résidus dudit ou desdits acides dicarboxyliques.
  6. Composition de pâte humide selon la revendication 1, dans laquelle ledit sulfopolyester comprend d'environ 4 à environ 20 % en moles, sur la base des résidus acide totaux, de résidus dudit ou desdits sulfomonomères.
  7. Composition de pâte humide selon la revendication 1, dans laquelle lesdites microfibres ont un diamètre équivalent inférieur à 3 microns.
  8. Composition de pâte humide selon la revendication 1, dans laquelle lesdites microfibres ont une longueur inférieure à 3,5 millimètres.
  9. Composition de pâte humide selon la revendication 1, dans laquelle lesdites microfibres sont formées en un matériau non dispersible dans l'eau sélectionné dans le groupe constitué des polyoléfines, des polyesters, des polyamides, des polylactides, du polycaprolactone, du polycarbonate, du polyuréthane, de l'ester de cellulose, du chlorure de polyvinyle, et de mélanges de ceux-ci.
  10. Procédé de fabrication d'un article non tissé, ledit procédé comprenant l'utilisation de ladite composition de pâte humide selon la revendication 1 dans un procédé de fabrication de non tissé par voie humide.
  11. Procédé selon la revendication 10, dans lequel ladite utilisation de ladite composition de pâte humide dans lesdits procédés par voie humide comprend le mélange de ladite composition de pâte humide avec de l'eau et le transfert du mélange obtenu à une zone de fabrication de non tissé par voie humide.
  12. Procédé selon la revendication 10, dans lequel ladite utilisation de ladite composition de pâte humide dans lesdits procédés par voie humide comprend le mélange de ladite composition de pâte humide avec de l'eau et des fibres supplémentaires puis le transfert du mélange obtenu à une zone de fabrication de non tissé par voie humide.
  13. Procédé par voie humide de production d'un article non tissé, ledit procédé par voie humide comprenant :
    (a) la production de fibres à composants multiples comprenant au moins un sulfopolyester dispersible dans l'eau et un ou plusieurs polymères synthétiques non dispersibles dans l'eau, immiscibles avec ledit sulfopolyester, dans lequel lesdites fibres à composants multiples ont un denier filé inférieur à 15 dpf ;
    (b) la découpe desdites fibres à composants multiples en fibres à composants multiples coupées ayant une longueur inférieure à 25 millimètres ;
    (c) la mise en contact desdites fibres à composants multiples avec de l'eau pour éliminer ledit sulfopolyester et ainsi former une suspension de fibres synthétiques dans une dispersion de sulfopolyester, dans lequel ladite dispersion de sulfopolyester comprend de l'eau et au moins une partie dudit sulfopolyester ; et
    (d) le retrait d'au moins une partie de ladite dispersion de sulfopolyester de ladite suspension pour ainsi produire une composition de pâte humide, dans lequel ladite composition de pâte humide comprend de l'eau et une pluralité desdites fibres synthétiques, dans lequel ladite eau représente dans la plage de 50 à 90 % en poids de ladite composition de pâte humide, dans lequel lesdites fibres représentent dans la plage de 10 à 50 % en poids de ladite composition de pâte humide, dans lequel ladite eau et lesdites fibres synthétiques en combinaison représentent au moins 95 % en poids de ladite composition de pâte humide, dans lequel lesdites fibres synthétiques ont une longueur inférieure à 25 millimètres et une dimension transversale minimale inférieure à 5 microns.
  14. Procédé par voie humide selon la revendication 13, comprenant en outre le transfert de ladite composition de pâte humide à une zone de fabrication de non tissé par voie humide pour produire ledit article non tissé.
  15. Procédé par voie humide selon la revendication 13, comprenant en outre la combinaison de ladite composition de pâte humide avec des fibres supplémentaires dans ladite zone de fabrication de non tissé par voie humide et/ou immédiatement en amont de ladite zone de fabrication de non tissé par voie humide ; dans lequel lesdites fibres supplémentaires sont sélectionnées dans un groupe constitué de pâte de fibres cellulosiques, de fibres inorganiques, de fibres de polyester, de fibres de nylon, de fibres de lyocell, de fibres de polyoléfines, de fibres de rayonne, de fibres d'ester de cellulose, et de combinaisons de celles-ci.
EP11835114.7A 2010-10-21 2011-10-20 Composition de pâte humide en feuilles et procédés associés Not-in-force EP2630297B1 (fr)

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US20110139386A1 (en) 2011-06-16
EP2630297A4 (fr) 2014-03-26
WO2012054674A1 (fr) 2012-04-26
KR20130132442A (ko) 2013-12-04
BR112013009684A2 (pt) 2016-07-12
JP2013540212A (ja) 2013-10-31
EP2630297A1 (fr) 2013-08-28

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