EP3385429A1 - Tissu de fibres de cellulose non tissé ayant des particules de diffusion de rayonnement connectés aux fibres - Google Patents

Tissu de fibres de cellulose non tissé ayant des particules de diffusion de rayonnement connectés aux fibres Download PDF

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Publication number
EP3385429A1
EP3385429A1 EP17164606.0A EP17164606A EP3385429A1 EP 3385429 A1 EP3385429 A1 EP 3385429A1 EP 17164606 A EP17164606 A EP 17164606A EP 3385429 A1 EP3385429 A1 EP 3385429A1
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European Patent Office
Prior art keywords
fabric
electromagnetic radiation
fibers
diffusing particles
radiation diffusing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP17164606.0A
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German (de)
English (en)
Inventor
Tom Carlyle
Mirko Einzmann
Gisela Goldhalm
Malcolm John Hayhurst
Katharina Mayer
Ibrahim Sagerer Foric
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Lenzing AG
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Lenzing AG
Chemiefaser Lenzing AG
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Application filed by Lenzing AG, Chemiefaser Lenzing AG filed Critical Lenzing AG
Priority to EP17164606.0A priority Critical patent/EP3385429A1/fr
Priority to PCT/EP2018/057862 priority patent/WO2018184926A1/fr
Priority to TW107110759A priority patent/TWI782966B/zh
Publication of EP3385429A1 publication Critical patent/EP3385429A1/fr
Withdrawn legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/013—Regenerated cellulose series

Definitions

  • the invention relates to a nonwoven cellulose fiber fabric, a method of manufacturing a nonwoven cellulose fiber fabric, a device for manufacturing a nonwoven cellulose fiber fabric, a product or composite, and a method of use.
  • Lyocell technology relates to the direct dissolution of cellulose wood pulp or other cellulose-based feedstock in a polar solvent (for example n-methyl morpholine n-oxide, which may also be denoted as "amine oxide” or "AO”) to produce a viscous highly shear-thinning solution which can be transformed into a range of useful cellulose-based materials.
  • a polar solvent for example n-methyl morpholine n-oxide, which may also be denoted as "amine oxide” or "AO”
  • AO n-methyl morpholine n-oxide
  • the technology is used to produce a family of cellulose staple fibers (commercially available from Lenzing AG, Lenzing, Austria under the trademark TENCEL®) which are widely used in the textile industry.
  • Other cellulose products from lyocell technology have also been used.
  • Cellulose staple fibers have long been used as a component for conversion to nonwoven webs.
  • adaption of lyocell technology to produce nonwoven webs directly would access properties and performance not possible for current cellulose web products.
  • a nonwoven cellulose fiber fabric In order to achieve the object defined above, a nonwoven cellulose fiber fabric, a method of manufacturing a nonwoven cellulose fiber fabric, a device for manufacturing a nonwoven cellulose fiber fabric, a product or composite, and a method of use according to the independent claims are provided.
  • a (in particular solution-blown) nonwoven cellulose fiber fabric is provided (which is in particular directly (in particular in an in situ process or in a continuous process executable in a continuously operating production line) manufactured from lyocell spinning solution), wherein the fabric comprises a network of substantially endless fibers and at least 0.1 mass % (in particular at least 0.4 mass %) electromagnetic radiation diffusing particles connected to (in particular applied on an exterior fiber surface and/or embedded in an interior of) the fibers.
  • a method of manufacturing (in particular solution-blown) nonwoven cellulose fiber fabric directly from lyocell spinning solution comprises extruding the lyocell spinning solution through a jet (for instance a spinneret) with orifices supported by a gas flow into a coagulation fluid atmosphere (in particular an atmosphere of dispersed coagulation fluid) to thereby form substantially endless fibers, collecting the fibers on a fiber support unit to thereby form the fabric, and adjusting process parameters so that the fabric comprises at least 0.1 mass % electromagnetic radiation diffusing particles connected to the fibers.
  • a jet for instance a spinneret
  • a gas flow into a coagulation fluid atmosphere in particular an atmosphere of dispersed coagulation fluid
  • a device for manufacturing (in particular solution-blown) nonwoven cellulose fiber fabric directly from lyocell spinning solution comprising a jet with orifices configured for extruding the lyocell spinning solution supported by a gas flow, a coagulation unit configured for providing a coagulation fluid atmosphere for the extruded lyocell spinning solution to thereby form substantially endless fibers, a fiber support unit configured for collecting the fibers to thereby form the fabric, and a control unit (such as a processor configured for executing program code for manufacturing the nonwoven cellulose fiber fabric directly from the lyocell spinning solution) configured for adjusting process parameters so that the fabric comprises at least 0.1 mass % electromagnetic radiation diffusing particles connected to the fibers.
  • a control unit such as a processor configured for executing program code for manufacturing the nonwoven cellulose fiber fabric directly from the lyocell spinning solution
  • a product or composite which comprises a fabric having the above mentioned properties.
  • a nonwoven cellulose fiber fabric having the above-mentioned properties is used for at least one of the group consisting of a wipe, a filter, a hygiene product, a medical application product, a geotextile, agrotextile, clothing, a product for building technology, an automotive product, a furnishing, an industrial product, a product related to beauty, leisure, sports or travel, and a product related to school or office.
  • nonwoven cellulose fiber fabric (which may also be denoted as nonwoven cellulose filament fabric) may particularly denote a fabric or web composed of a plurality of substantially endless fibers.
  • the term “substantially endless fibers” has in particular the meaning of filament fibers having a significantly longer length than conventional staple fibers.
  • the term “substantially endless fibers” may in particular have the meaning of a web formed of filament fibers having a significantly smaller amount of fiber ends per volume than conventional staple fibers.
  • endless fibers of a fabric according to an exemplary embodiment of the invention may have an amount of fiber ends per volume of less than 10,000 ends/cm 3 , in particular less than 5,000 ends/cm 3 .
  • substantially endless fibers of the nonwoven cellulose fiber fabric may have a length of at least 200 mm, in particular at least 1000 mm.
  • a person skilled in the art will be aware of the fact that even endless cellulose fibers may have interruptions, which may be formed by processes during and/or after fiber formation.
  • a nonwoven cellulose fiber fabric made of substantially endless cellulose fibers has a significantly lower number of fibers per mass compared to nonwoven fabric made from staple fibers of the same denier.
  • a nonwoven cellulose fiber fabric may be manufactured by spinning a plurality of fibers and by attenuating and stretching the latter towards a preferably moving fiber support unit. Thereby, a three-dimensional network or web of cellulose fibers is formed, constituting the nonwoven cellulose fiber fabric.
  • the fabric may be made of cellulose as main or only constituent.
  • lyocell spinning solution may particularly denote a solvent (for example a polar solution of a material such as N-methyl-morpholine, NMMO, "amine oxide” or "AO") in which cellulose (for instance wood pulp or other cellulose-based feedstock) is dissolved.
  • the lyocell spinning solution is a solution rather than a melt.
  • Cellulose filaments may be generated from the lyocell spinning solution by reducing the concentration of the solvent, for instance by contacting said filaments with water. The process of initial generation of cellulose fibers from a lyocell spinning solution can be described as coagulation.
  • gas flow may particularly denote a flow of gas such as air substantially parallel to the moving direction of the cellulose fiber or its preform (i.e. lyocell spinning solution) while and/or after the lyocell spinning solution leaves or has left the spinneret.
  • coagulation fluid may particularly denote a non-solvent fluid (i.e. a gas and/or a liquid, optionally including solid particles) which has the capability of diluting the lyocell spinning solution and exchanging with the solvent to such an extent that the cellulose fibers are formed from the lyocell filaments.
  • a non-solvent fluid i.e. a gas and/or a liquid, optionally including solid particles
  • such a coagulation fluid may be water mist.
  • process parameters may particularly denote all physical parameters and/or chemical parameters and/or device parameters of substances and/or device components used for manufacturing nonwoven cellulose fiber fabric which may have an impact on the properties of the fibers and/or the fabric, in particular on fiber diameter and/or fiber diameter distribution.
  • process parameters may be adjustable automatically by a control unit and/or manually by a user to thereby tune or adjust the properties of the fibers of the nonwoven cellulose fiber fabric.
  • Physical parameters which may have an impact on the properties of the fibers may be temperature, pressure and/or density of the various media involved in the process (such as the lyocell spinning solution, the coagulation fluid, the gas flow, etc.).
  • Chemical parameters may be concentration, amount, pH value of involved media (such as the lyocell spinning solution, the coagulation fluid, etc.).
  • Device parameters may be size of and/or distances between orifices, distance between orifices and fiber support unit, speed of transportation of fiber support unit, the provision of one or more optional in situ post processing units, the gas flow, etc.
  • Fibers may particularly denote elongated pieces of a material comprising cellulose, for instance roughly round or non-regularly formed in cross-section, optionally twisted with other fibers.
  • Fibers may have an aspect ratio which is larger than 10, particularly larger than 100, more particularly larger than 1000. The aspect ratio is the ratio between the length of the fiber and a diameter of the fiber.
  • Fibers may form networks by being interconnected by merging (so that an integral multi-fiber structure is formed) or by friction (so that the fibers remain separate but are weakly mechanically coupled by a friction force exerted when mutually moving the fibers being in physical contact with one another).
  • Fibers may have a substantially cylindrical form which may however be straight, bent, kinked, or curved. Fibers may consist of a single homogenous material (i.e. cellulose). However, the fibers may also comprise one or more additives. Liquid materials such as water or oil may be accumulated between the fibers.
  • a “jet with orifices” (which may for instance be denoted as an “arrangement of orifices”) may be any structure comprising an arrangement of orifices which are linearly arranged.
  • electromagnetic radiation diffusing particles may particularly denote solid pigments configured for efficiently scattering electromagnetic radiation.
  • electromagnetic radiation diffusing particles may diffusely reflect electromagnetic radiation as a result of a strong scattering or bending of electromagnetic radiation at the particles.
  • electromagnetic radiation diffusing particles of a sufficient amount or concentration a large portion of electromagnetic radiation of a corresponding wavelength striking the electromagnetic radiation diffusing particles will be reflected.
  • the fabric may appear for instance opaque.
  • electromagnetic radiation diffusing particles operating in the visible range from 400 nm to 800 nm may impart opacity when incorporated into a nonwoven cellulose fiber fabric (which may have optically transparent properties under certain conditions, in particular when being wet).
  • electromagnetic radiation diffusing particles efficiently scattering optical light impart whiteness and/or brightness of a nonwoven cellulose fiber fabric.
  • electromagnetic radiation diffusing particles may however also operate in a nonvisible wavelength range:
  • the electromagnetic radiation diffusing particles may be capable of efficiently scattering electromagnetic radiation in the infrared range (in particular in a range of wavelengths between 800 nm and 1 mm) and/or in the ultraviolet range (in particular in a range of wavelengths between 100 nm and 400 nm) and/or in the X-ray range (in particular in a range of wavelengths between 1 pm and 250 pm).
  • a nonwoven cellulose fiber fabric which comprises incorporated electromagnetic radiation diffusing particles capable of diffusing electromagnetic radiation.
  • electromagnetic radiation diffusing particles capable of diffusing electromagnetic radiation.
  • An optically transparent wet fabric may be disturbing for certain applications such as clothing.
  • What concerns the properties of the fabric in the ultraviolet range, opacity for UV radiation is advantageous for other applications, such as a sunlight protection of clothing.
  • Even in the X-ray range or in the range of gamma radiation the absorption of this radiation by the fabric may be advantageous to provide radiation protection, or detection, for instance in terms of medical applications.
  • an operating fluid used for manufacturing the fabric.
  • an operating fluid may be a dope or lyocell spinning solution, a gas flow used for stretching lyocell spinning solution during fiber formation, a coagulation fluid promoting precipitation of the fiber, etc. Since particles may cause harm when being easily removed from the fabric (for instance in view of health issues with respirable dust), a strong bonding or even embedding of the particles on or in the fibers of the fabric is highly advantageous.
  • nonwoven cellulose fiber fabric In the following, further exemplary embodiments of the nonwoven cellulose fiber fabric, the method of manufacturing a nonwoven cellulose fiber fabric, the device for manufacturing a nonwoven cellulose fiber fabric, the product or composite, and the method of use are described.
  • the fabric comprises not more than 15 mass % electromagnetic radiation diffusing particles, in particular not more than 4 mass % electromagnetic radiation diffusing particles. When remaining in these ranges, the electromagnetic radiation diffusing particles can remain rigidly bonded to the fibers within the fabric without being separated therefrom.
  • the electromagnetic radiation diffusing particles are configured for diffusing electromagnetic radiation from at least one wavelength range selected from a group consisting of visible light, infrared light, ultraviolet light, and X-ray light. It is also possible that the electromagnetic radiation diffusing particles have pronounced diffusing properties even in more than one of the mentioned ranges and/or in other wavelength ranges.
  • the electromagnetic radiation diffusing particles comprises at least one of the group consisting of silicates, magnesium oxide, magnesium hydrosilicate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, titanium dioxide, barium sulfate, calcium carbonate, boron nitride, silicon dioxide, and zinc oxide.
  • titanium dioxide is a powerful material for manufacturing electromagnetic radiation diffusing particles operating in the visible range.
  • Barium sulfate is an example for a material of electromagnetic radiation diffusing particles being active in the X-ray range.
  • a preferred choice for the electromagnetic radiation diffusing particles is titanium dioxide. Titanium dioxide pigments are insoluble in coating vehicles in which they are dispersed. Accordingly, performance properties (such as chemical, photochemical and physical characteristics) are determined in particular by the particle size of the pigment and the chemical composition of its surface. This allows a particularly precise and reproducible adjustment of the optical properties of the fabric when using titanium oxide pigments as electromagnetic radiation diffusing particles.
  • a number of at least 80% of the electromagnetic radiation diffusing particles have a diameter of at least 70 nm, in particular of at least 100 nm, more particularly in a range between 70 nm and 3000 nm, preferably in a range between 100 nm and 200 nm.
  • the given percentage value is hence related to a number of particles.
  • the particle size of the electromagnetic radiation diffusing particles may be in the submicron range.
  • the functionality of electromagnetic radiation diffusing particles in terms of light scattering are particularly pronounced in the mentioned ranges.
  • electromagnetic radiation diffusing particles of these dimensions have turned out to remain stably within a fabric without being easily separated therefrom (in particular without being easily washed off from the readily manufactured fabric). By the adjustment of the particle size, a frequency selection of strongly influenced electromagnetic radiation can be made.
  • a number of at least 80% of the electromagnetic radiation diffusing particles are in rutile state (compare Figure 9 ) or anatase state (compare Figure 10 ).
  • electromagnetic radiation diffusing particles in rutile state may be preferred, since they have a particularly pronounced efficiency of light scattering while being at the same time more stable and more durable than pigments in other crystal structures.
  • particles in the anatase state can be appropriately used.
  • the pronounced photocatalytic activity of anatase type titanium dioxide may be advantageously used for providing the fabric with the property of decomposing harmful substances.
  • the electromagnetic radiation diffusing particles may be functionalized, in particular may be rendered photocatalytically active.
  • a photocatalytically active fabric may have a self-cleaning function.
  • Other functionalizations of the fabric by using correspondingly functionalized (for instance intrinsically functionalized or functionalized by coating) electromagnetic radiation diffusing particles are wicking (in particular wicking speed), oil take up, water absorption, cleanability, roughness.
  • At least part, in particular a number of at least 50%, more particularly a number of at least 90%, of the electromagnetic radiation diffusing particles are embedded in an interior of the fibers, i.e. may be fully circumferentially surrounded by fiber material.
  • Arranging the particles embedded in an interior of the fibers may be obtained by adjusting the process parameters by adding the particles to lyocell spinning solution prior to or during coagulation of precipitation of fibers. Embedding the particles within the fibers is a particularly efficient measure for preventing separation of the particles from the fabric even under harsh conditions.
  • At least part, in particular a number of at least 50%, more particularly a number of at least 90%, of the electromagnetic radiation diffusing particles are attached to a surface of the fibers, i.e. may have a partial surface area remaining exposed to an environment and being not covered by the fiber material.
  • Arranging the particles attached to an exterior of the fibers may be obtained by adjusting the process parameters by adding the particles to lyocell spinning solution at the end of the coagulation or precipitation procedure of fibers, or even after completion of the coagulation or precipitation procedure. Attaching the particles to an exterior surface of the fibers promotes a strong interaction between the particles and an environment (for instance in terms of a photocatalytic activity).
  • the electromagnetic radiation diffusing particles have a refraction index (for instance for visible light, more particularly red light) of more than 1.5. This allows to obtain a pronounced opacity even when the nonwoven cellulose fiber fabric is wet.
  • the electromagnetic radiation diffusing particles are configured so that the fabric is opaque in a wet condition, in particular when soaked with water. With a corresponding selection of particle material and particle size as well as with a corresponding selection of particle content in the fabric, it can be ensured that the fabric is not optically transparent even when it is filled with water.
  • At least part, in particular at least a number of 50%, more particularly at least a number of 90%, of the electromagnetic radiation diffusing particles have a spherical shape.
  • the electromagnetic radiation diffusing particles are provided with spherical shape, the described advantageous effects in terms of reinforcement of adhesion and embedding are particularly pronounced.
  • spherical particles show a particularly advantageous dispersion behavior in operating fluid for manufacturing nonwoven cellulose fiber fabric, such as lyocell spinning solution.
  • At least part of the electromagnetic radiation diffusing particles is connected to the lyocell spinning solution prior to completing coagulation. This increases the adhesion forces between fibers and particles and suppresses undesired release of the particles from the fabric.
  • the coagulation fluid is enriched with at least part of the electromagnetic radiation diffusing particles to thereby provide the fabric with the electromagnetic radiation diffusing particles.
  • particles may interact with the strands of lyocell spinning solution for precipitation of the fibers so that the fibers are integrally mixed with the electromagnetic radiation diffusing particles.
  • the gas flow is enriched with at least part of the electromagnetic radiation diffusing particles to thereby provide the fabric with the electromagnetic radiation diffusing particles.
  • the gas flow is used for stretching filaments of lyocell spinning solution prior to coagulation or precipitation.
  • this gas flow is enriched with electromagnetic radiation diffusing particles, the latter can be incorporated in the fabric in a simple way and without a separate manufacturing procedure.
  • the lyocell spinning solution is enriched with at least part of the electromagnetic radiation diffusing particles upstream of the orifices to thereby provide the fabric with the electromagnetic radiation diffusing particles.
  • the dope of lyocell spinning solution is provided with the electromagnetic radiation diffusing particles, it is possible that a sufficiently large amount of the particles is embedded in an interior of the fibers so that the particles can be efficiently protected against separation from the fabric.
  • the collected fibers are made subject to a washing procedure washing out electromagnetic radiation diffusing particles from the fabric which are only weakly connected to the fibers. While being transported along the fiber support unit, the nonwoven cellulose fiber fabric can be washed by washing unit supplying wash liquor to remove not only residual solvent, but also those particles which have not been connected strong enough to the fibers during manufacture. This prevents undesired release of particles during use of the fabric.
  • the fibers have (in particular the fiber fabric has) a copper content of less than 5 ppm (in particular 5 mass ppm, i.e. 5 mg/kg) and/or have a nickel content of less than 2 ppm (in particular 2 mass ppm, i.e. 2 mg/kg).
  • a lyocell spinning solution as a basis for the formation of the endless fiber-based fabric (in particular when involving a solvent such as N-methyl-morpholine, NMMO)
  • the contamination of the fabric with the mentioned particularly harmful heavy metals copper which may be harmful to health for human beings, in particular for children, when exceeding a certain dose
  • nickel which may cause allergic reactions of a user
  • the very small amount of copper contamination can be ensured by omitting a copper salt solution for preparing the spinning solution.
  • At least part of (in particular at least 10% of) the fibers are integrally merged at merging positions.
  • the term "merging" may particularly denote an integral interconnection of different fibers at the respective merging position which results in the formation of one integrally connected fiber structure composed of the previously separate fiber preforms. Merging may be denoted as a fiber-fiber connection being established during coagulation of one, some or all of the merged fibers. Interconnected fibers may strongly adhere to one another at a respective merging position without a different additional material (such as a separate adhesive) so as to form a common structure. Separation of merged fibers may require destruction of the fiber network or part thereof.
  • a nonwoven cellulose fiber fabric in which some or all of the fibers are integrally connected to one another by merging.
  • Merging may be triggered by a corresponding control of the process parameters of a method of manufacturing the nonwoven cellulose fiber fabric.
  • coagulation of filaments of lyocell spinning solution may be triggered (or at least completed) after the first contact between these filaments being not yet in the precipitated solid fiber state.
  • a degree of merging is a powerful parameter which can be used for adjusting the properties of the manufactured fabric.
  • mechanical stability of the network is the larger the higher the density of merging positions is.
  • By an inhomogeneous distribution of merging positions over the volume of the fabric it is also possible to adjust regions of high mechanical stability and other regions of low mechanical stability. For instance, separation of the fabric into separate parts can be precisely defined to happen locally at mechanical weak regions with a low number of merging positions.
  • merging between fibers is triggered by bringing different fiber preforms in form of lyocell spinning solution in direct contact with one another prior to coagulation.
  • the merging positions consist of the same material as the merged fibers.
  • the merging positions may be formed by cellulose material resulting directly from the coagulation of lyocell spinning solution. This not only renders the separate provision of a fiber connection material (such as an adhesive or a binder) dispensable, but also keeps the fabric clean and made substantially of a single material.
  • Merging may have the additional advantageous effect that merged endless fibers additionally inhibit electromagnetic radiation diffusing particles from leaving the fabric, as the overall fiber surface in the fabric is reduced.
  • different ones of the fibers are located at least partially in different distinguishable (i.e. showing a visible separation or interface region in between the layers) layers. More specifically, fibers of different layers are integrally merged at at least one merging position between the layers. Hence, different ones of the fibers being located at least partially in different distinguishable layers (which may be identical or which may differ concerning one or more parameters such as merging factor, average fiber diameter, etc.) may be integrally connected at at least one merging position.
  • two (or more) different layers of a fabric may be formed by serially aligning two (or more) jets with orifices through which lyocell spinning solution is extruded for coagulation and fiber formation.
  • a moving fiber support unit such as a conveyor belt with a fiber accommodation surface
  • a first layer of fibers is formed on the fiber support unit by the first jet
  • the second jet forms a second layer of fibers on the first layer when the moving fiber support unit reaches the position of the second jet.
  • the process parameters of this method may be adjusted so that merging points are formed between the first layer and the second layer.
  • fibers of the second layer under formation being not yet fully cured or solidified by coagulation may for example still have exterior skin or surface regions which are still in the liquid lyocell solution phase and not yet in the fully cured solid state.
  • pre-fiber structures come into contact with one another and fully cure into the solid fiber state thereafter, this may result in the formation of two merged fibers at an interface between different layers.
  • controlling merging allows to control rigidity of the connection between the layers of the fabric.
  • Merging can be controlled, for example, by adjusting the degree of curing or coagulation before pre-fiber structures of a respective layer reach the fiber support plate on an underlying layer of fibers or pre-fiber structures.
  • the merging between the different layers is adjusted so that pulling on the layers in opposite directions results in a separation of the fabric at an interface between the different layers. This can be achieved when the merging is adjusted so that merging-based adhesion between the different layers is smaller than merging based adhesion within a respective one of the different layers.
  • a number of merging points or merging positions per volume may be larger in an interior of a respective one of the connected layers than at in an interface region between the layers. This can be manufactured by controlling the relation between inter -layer coagulation and intra -layer coagulation.
  • an average diameter of the fibers of one of the layers is different from an average diameter of the fibers of another one of the layers.
  • a ratio between the average diameter of the fibers of the one layer and the average diameter of the fibers of the other layer may be at least 1.5, in particular may be at least 2.5, more particularly may be at least 4.
  • a nonwoven cellulose fiber fabric may be provided which can be manufactured as a network of substantially endless cellulose fibers showing a pronounced inhomogeneity in terms of fiber diameter between different layers. It has turned out that the distribution of diameters of the fibers of the nonwoven cellulose fiber fabric is a powerful design parameter for adjusting the physical properties, in particular the mechanical properties, of the obtained fabric.
  • fiber diameter variation can also be a powerful tool for tuning moisture management of the manufactured fabric.
  • electromagnetic radiation diffusing particles By applying electromagnetic radiation diffusing particles to the spinning solution the overall density of the spinning solution changes and thus also the behavior during the spinning process changes. This will also result in a change of fiber diameter distribution and merging behavior and thus further gives the possibility to adjust the properties of the so produced fabric.
  • Different layers may also be provided with different concentrations and/or types of electromagnetic radiation diffusing particles. This may allow to fine tune the optical properties of the multi-layer fabric.
  • the method further comprises further processing the fibers and/or the fabric after collection on the fiber support unit but preferably still in situ with the formation of the nonwoven cellulose fiber fabric with endless fibers.
  • in situ processes may be those processes being carried out before the manufactured (in particular substantially endless) fabric is stored (for instance wound by a winder) for shipping to a product manufacture destination.
  • a further processing or post processing may involve hydroentanglement.
  • Hydroentanglement may be denoted as a bonding process for wet or dry fibrous webs, the resulting bonded fabric being a nonwoven. Hydroentanglement may use fine, high pressure jets of water which penetrate the web, hit a fiber support unit (in particular a conveyor belt) and bounce back causing the fibers to entangle.
  • a corresponding compression of the fabric may render the fabric more compact and mechanically more stable.
  • steam treatment of the fibers with a pressurized steam may be carried out.
  • such a further processing or post processing may involve a needling treatment of the manufactured fabric.
  • a needle punching system may be used to bond the fibers of the fabric or web. Needle punched fabrics may be produced when barbed needles are pushed through the fibrous web forcing some fibers through the web, where they remain when the needles are withdrawn. If sufficient fibers are suitably displaced the web may be converted into a fabric by the consolidating effect of these fibers plugs.
  • Yet another further processing or post processing treatment of the web or fabric is an impregnating treatment.
  • Impregnating the network of endless fibers may involve the application of one or more chemicals (such as a softener, a hydrophobic agent, an antistatic agent, etc.) on the fabric.
  • calendering may be denoted as a finishing process for treating the fabric and may employ a calender to smooth, coat, and/or compress the fabric.
  • a nonwoven cellulose fiber fabric according to an exemplary embodiment of the invention may also be combined (for instance in situ or in a subsequent process) with one or more other materials, to thereby form a composite according to an exemplary embodiment of the invention.
  • Exemplary materials, which can be combined with the fabric for forming such a composite may be selected from a group of materials comprising, but not being limited to, the following materials or combinations thereof: fluff pulp, a fiber suspension, a wetlaid nonwoven, an airlaid nonwoven, a spunbond web, a meltblown web, a carded spunlaced or needlepunched web or other sheet like structures made of various materials.
  • connection between the different materials can be done by (but not limited to) one or a combination of the following processes: merging, hydroentanglement, needle punching, hydrogen bonding, thermobonding, gluing by a binder, laminating, and/or calendering.
  • the nonwoven cellulose fiber fabric according to exemplary embodiments of the invention is used for manufacturing a filter.
  • a filter may be an air filter, a HVAC, air condition filter, flue gas filter, liquid filters, coffee filters, tea bags, coffee bags, food filters, water purification filter, blood filter, cigarette filter; cabin filters, oil filters, cartridge filter, vacuum filter, vacuum cleaner bag, dust filter, hydraulic filter, kitchen filter, fan filter, moisture exchange filters, pollen filter, HEVAC/HEPA/ULPA filters, beer filter, milk filter, liquid coolant filter and fruit juices filters.
  • the nonwoven cellulose fiber fabric may be used for manufacturing absorbent hygiene products.
  • absorbent hygiene products examples thereof are an acquisition layer, a coverstock, a distribution layer, an absorbent cover, sanitary pads, topsheets, backsheets, leg cuffs, flushable products, pads, nursing pads, disposal underwear, training pants, face masks, beauty facial masks, cosmetic removal pads, washcloths, diapers, and sheets for a laundry dryer releasing an active component (such as a textile softener).
  • the nonwoven cellulose fiber fabric may be used for manufacturing a medical application product.
  • medical application products may be disposable caps, gowns, masks and shoe cover, wound care products, sterile packaging products, coverstock products, dressing materials, one way clothing, dialyses products, nasal strips, adhesives for dental plates, disposal underwear, drapes, wraps and packs, sponges, dressings and wipes, bed linen, transdermal drug delivery, shrouds, underpads, procedure packs, heat packs, ostomy bag liners, fixation tapes and incubator mattresses.
  • the nonwoven cellulose fiber fabric may be used for manufacturing geotextiles. This may involve the production of crop protection covers, capillary matting, water purification, irrigation control, asphalt overlay, soil stabilisation, drainage, sedimentation and erosion control, pond liners, impregnation based, drainage channel liners, ground stabilisation, pit linings, seed blankets, weed control fabrics, greenhouse shading, root bags and biodegradable plant pots. It is also possible to use the nonwoven cellulose fiber fabric for a plant foil (for instance providing a light protection and/or a mechanical protection for a plant, and/or providing the plant or soil with dung or seed).
  • the nonwoven cellulose fiber fabric may be used for manufacturing clothing.
  • interlinings, clothing insulation and protection, handbag components, shoe components, belt liners, industrial headwear/foodwear, disposable workwear, clothing and shoe bags and thermal insulation may be manufactured on the basis of such fabric.
  • the nonwoven cellulose fiber fabric may be used for manufacturing products used for building technology.
  • roofing and tile underlay, underslating, thermal and noise insulation, house wrap, facings for plaster board, pipe wrap, concrete moulding layers, foundations and ground stabilisation, vertical drainages, shingles, roofing felts, noise abatement, reinforcement, sealing material, and damping material (mechanical) may be manufactured using such fabric.
  • the nonwoven cellulose fiber fabric may be used for manufacturing an automotive product.
  • automotive product examples are a cabin filter, boot liners, parcel shelves, heat shields, shelf trim, moulded bonnet liners, boot floor covering, oil filter, headliners, rear parcel shelves, decorative fabrics, airbags, silencer pads, insulation materials, car covers, underpadding, car mats, tapes, backing and tufted carpets, seat covers, door trim, needled carpet, and auto carpet backing.
  • Still another field of application of fabric manufactured according to exemplary embodiments of the invention are furnishings, such as furniture, construction, insulator to arms and backs, cushion thicking, dust covers, linings, stitch reinforcements, edge trim materials, bedding constructions, quilt backing, spring wrap, mattress pad components, mattress covers, window curtains, wall coverings, carpet backings, lampshades, mattress components, spring insulators, sealings, pillow ticking, and mattress ticking.
  • furnishings such as furniture, construction, insulator to arms and backs, cushion thicking, dust covers, linings, stitch reinforcements, edge trim materials, bedding constructions, quilt backing, spring wrap, mattress pad components, mattress covers, window curtains, wall coverings, carpet backings, lampshades, mattress components, spring insulators, sealings, pillow ticking, and mattress ticking.
  • the nonwoven cellulose fiber fabric may be used for manufacturing industrial products. This may involve electronics, floppy disc liners, cable insulation, abrasives, insulation tapes, conveyor belts, noise absorbent layers, air conditioning, battery separators, acid systems, anti-slip matting stain removers, food wraps, adhesive tape, sausage casing, cheese casing, artificial leather, oil recovery booms and socks, and papermaking felts.
  • Nonwoven cellulose fiber fabric according to exemplary embodiments of the invention is also appropriate for manufacturing products related to leisure and travel. Examples for such an application are sleeping bags, tents, luggage, handbags, shopping bags, airline headrests, CD-protection, pillowcases, and sandwich packaging.
  • Still another field of application of exemplary embodiment of the invention relates to school and office products.
  • book covers, mailing envelopes, maps, signs and pennants, towels, and flags shall be mentioned.
  • Figure 1 illustrates a device 100 according to an exemplary embodiment of the invention for manufacturing nonwoven cellulose fiber fabric 102 which is directly formed from lyocell spinning solution 104.
  • the latter is at least partly coagulated by a coagulation fluid 106 to be converted into partly-formed cellulose fibers 108.
  • a lyocell solution blowing process according to an exemplary embodiment of the invention may be carried out.
  • the term "lyocell solution-blowing process” may particularly encompass processes which can result in essentially endless filaments or fibers 108 of a discrete length or mixtures of endless filaments and fibers of discrete length being obtained.
  • nozzles each having an orifice 126 are provided through which cellulose solution or lyocell spinning solution 104 is ejected together with a gas stream or gas flow 146 for manufacturing the nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention.
  • wood pulp 110, other cellulose-based feedstock or the like may be supplied to a storage tank 114 via a metering unit 113.
  • Water from a water container 112 is also supplied to the storage tank 114 via metering unit 113.
  • the metering unit 113 under control of a control unit 140 described below in further detail, may define relative amounts of water and wood pulp 110 to be supplied to the storage tank 114.
  • a solvent such as N-methyl-morpholine, NMMO
  • NMMO N-methyl-morpholine
  • the mixing unit 119 can be controlled by the control unit 140.
  • the water-wood pulp 110 medium is dissolved in the concentrated solvent in a dissolving unit 120 with adjustable relative amounts, thereby obtaining lyocell spinning solution 104.
  • the aqueous lyocell spinning solution 104 can be a honey-viscous medium composed of (for instance 5 mass % to 15 mass %) cellulose comprising wood pulp 110 and (for instance 85 mass % to 95 mass %) solvent.
  • the lyocell spinning solution 104 is forwarded to a fiber formation unit 124 (which may be embodied as or which may comprise a number of spinning beams or jets 122).
  • the number of orifices 126 of the jets 122 may be larger than 50, in particular larger than 100.
  • all orifices 126 of a fiber formation unit 124 (which may comprise a number of spinnerets or jets 122) of orifices 126 of the jets 122 may have the same size and/or shape.
  • size and/or shape of different orifices 126 of one jet 122 and/or orifices 126 of different jets 122 (which may be arranged serially for forming a multilayer fabric) may be different.
  • the lyocell spinning solution 104 passes through the orifices 126 of the jets 122, it is divided into a plurality of parallel strands of lyocell spinning solution 104.
  • a vertically oriented gas flow i.e. being oriented substantially parallel to spinning direction, forces the lyocell spinning solution 104 to transform into increasingly long and thin strands which can be adjusted by changing the process conditions under control of control unit 140.
  • the gas flow may accelerate the lyocell spinning solution 104 along at least a part of its way from the orifices 126 to a fiber support unit 132.
  • the coagulation fluid 106 is advantageously embodied as a vapor mist, for instance an aqueous mist.
  • Process relevant properties of the coagulation fluid 106 are controlled by one or more coagulation units 128, providing the coagulation fluid 106 with adjustable properties.
  • the coagulation units 128 are controlled, in turn, by control unit 140.
  • respective coagulation units 128 are provided between the individual nozzles or orifices 126 for individually adjusting properties of respective layers of fabric 102 being produced.
  • each jet 122 may have two assigned coagulation units 128, one from each side.
  • the individual jets 122 can thus be provided with individual portions of lyocell spinning solution 104 which may also be adjusted to have different controllable properties of different layers of manufactured fabric 102.
  • the solvent concentration of the lyocell spinning solution 104 is reduced, so that the cellulose of the former e.g. wood pulp 110 (or other feedstock) is at least partly coagulated as long and thin cellulose fibers 108 (which may still contain residual solvent and water).
  • the cellulose fibers 108 are deposited on fiber support unit 132, which is here embodied as a conveyor belt with a planar fiber accommodation surface.
  • the cellulose fibers 108 form a nonwoven cellulose fiber fabric 102 (illustrated only schematically in Figure 1 ).
  • the nonwoven cellulose fiber fabric 102 is composed of continuous and substantially endless filaments or fibers 108.
  • the solvent of the lyocell spinning solution 104 removed in coagulation by the coagulation unit 128 and in washing in a washing unit 180 can be at least partially recycled.
  • the nonwoven cellulose fiber fabric 102 can be washed by washing unit 180 supplying wash liquor to remove residual solvent and may then be dried. It can be further processed by an optional but advantageous further processing unit 134.
  • a further processing may involve hydro-entanglement, needle punching, impregnation, steam treatment with a pressurized steam, calendering, etc.
  • the fiber support unit 132 may also transport the nonwoven cellulose fiber fabric 102 to a winder 136 on which the nonwoven cellulose fiber fabric 102 may be collected as a substantially endless sheet.
  • the nonwoven cellulose fiber fabric 102 may then be shipped as roll-good to an entity manufacturing products such as wipes or textiles based on the nonwoven cellulose fiber fabric 102.
  • control unit 140 such as a processor, part of a processor, or a plurality of processors.
  • the control unit 140 is configured for controlling operation of the various units shown in Figure 1 , in particular one or more of the metering unit 113, the mixing unit 119, the fiber formation unit 124, the coagulation unit(s) 128, the further processing unit 134, the dissolution unit 120, the washing unit 118, etc.
  • the control unit 140 (for instance by executing computer executable program code, and/or by executing control commands defined by a user) may precisely and flexibly define the process parameters according to which the nonwoven cellulose fiber fabric 102 is manufactured.
  • Design parameters in this context are air flow along the orifices 126, properties of the coagulation fluid 106, drive speed of the fiber support unit 132, composition, temperature and/or pressure of the lyocell spinning solution 104, etc. Additional design parameters which may be adjusted for adjusting the properties of the nonwoven cellulose fiber fabric 102 are number and/or mutual distance and/or geometric arrangement of the orifices 126, chemical composition and degree of concentration of the lyocell spinning solution 104, etc. Thereby, the properties of the nonwoven cellulose fiber fabric 102 may be properly adjusted, as described below.
  • Such adjustable properties may involve one or more of the following properties: diameter and/or diameter distribution of the fibers 108, amount and/or regions of merging between fibers 108, a purity level of the fibers 108, properties of a multilayer fabric 102, optical properties of the fabric 102, fluid retention and/or fluid release properties of the fabric 102, mechanical stability of the fabric 102, smoothness of a surface of the fabric 102, cross-sectional shape of the fibers 108, etc.
  • each spinning jet 122 may comprise a polymer solution inlet via which the lyocell spinning solution 104 is supplied to the jet 122. Via an air inlet, a gas flow 146 can be applied to the lyocell spinning solution 104.
  • the lyocell spinning solution 104 moves or is accelerated (by the gas flow 146 pulling the lyocell spinning solution 104 downwardly) downwardly through a respective orifice 126 and is laterally narrowed under the influence of the gas flow 146 so that continuously tapering cellulose filaments or cellulose fibers 108 are formed when the lyocell spinning solution 104 moves downwardly together with the gas flow 146 in the environment of the coagulation fluid 106.
  • processes involved in the manufacturing method described by reference to Figure 1 may include that the lyocell spinning solution 104, which may also be denoted as cellulose solution is shaped to form liquid strands or latent filaments, which are drawn by the gas flow 146 and significantly decreased in diameter and increased in length. Partial coagulation of latent filaments or fibers 108 (or preforms thereof) by coagulation fluid 106 prior to or during web formation on the fiber support unit 132 may also be involved.
  • the filaments or fibers 108 are formed into web like fabric 102, washed, dried and may be further processed (see further processing unit 134), as required.
  • the filaments or fibers 108 may for instance be collected, for example on a rotating drum or belt, whereby a web is formed.
  • the fibers 108 have a copper content of less than 5 ppm and have a nickel content of less than 2 ppm. This advantageously improves purity of the fabric 102.
  • the lyocell solution blown web i.e. the nonwoven cellulose fiber fabric 102
  • the lyocell solution blown web preferably exhibits one or more of the following properties:
  • the lyocell solution-blown web exhibits all of said properties (i) to (viii) mentioned above.
  • the process to produce the nonwoven cellulose fiber fabric 102 preferably comprises:
  • Constituents of the nonwoven cellulose fiber fabric 102 may be bonded by merging, intermingling, hydrogen bonding, physical bonding such as hydroentanglement or needle punching, and/or chemical bonding.
  • the nonwoven cellulose fiber fabric 102 may be combined with one or more layers of the same and/or other materials, such as (not shown) layers of synthetic polymers, cellulosic fluff pulp, nonwoven webs of cellulose or synthetic polymer fibers, bicomponent fibers, webs of cellulose pulp, such as airlaid or wetlaid pulp, webs or fabrics of high tenacity fibers, hydrophobic materials, high performance fibers (such as temperature resistant materials or flame retardant materials), layers imparting changed mechanical properties to the final products (such as Polypropylene or Polyester layers), biodegradable materials (e.g. films, fibers or webs from Polylactic acid), and/or high bulk materials.
  • layers of synthetic polymers such as cellulosic fluff pulp, nonwoven webs of cellulose or synthetic polymer fibers, bicomponent fibers, webs of cellulose pulp, such as airlaid or wetlaid pulp, webs or fabrics of high tenacity fibers, hydrophobic materials, high performance fibers (such as
  • nonwoven cellulose fiber fabric 102 It is also possible to combine several distinguishable layers of nonwoven cellulose fiber fabric 102, see for instance Figure 7 .
  • the nonwoven cellulose fiber fabric 102 may essentially consist of cellulose alone. Alternatively, the nonwoven cellulose fiber fabric 102 may comprise a mixture of cellulose and one or more other fiber materials. The nonwoven cellulose fiber fabric 102, furthermore, may comprise a bicomponent fiber material. The fiber material in the nonwoven cellulose fiber fabric 102 may at least partly comprise a modifying substance.
  • the modifying substance may be selected from, for example, the group consisting of a polymeric resin, an inorganic resin, inorganic pigments, antibacterial products, nanoparticles, lotions, fire-retardant products, absorbency-improving additives, such as superabsorbent resins, ion-exchange resins, carbon compounds such as active carbon, graphite, carbon for electrical conductivity, X-ray contrast substances, luminescent pigments, and dye stuffs.
  • a polymeric resin an inorganic resin, inorganic pigments, antibacterial products, nanoparticles, lotions, fire-retardant products, absorbency-improving additives, such as superabsorbent resins, ion-exchange resins, carbon compounds such as active carbon, graphite, carbon for electrical conductivity, X-ray contrast substances, luminescent pigments, and dye stuffs.
  • the cellulose nonwoven web or nonwoven cellulose fiber fabric 102 manufactured directly from the lyocell spinning solution 104 allows access to value added web performance which is not possible via staple fiber route. This includes the possibility to form uniform lightweight webs, to manufacture microfiber products, and to manufacture continuous filaments or fibers 108 forming a web. Moreover, compared to webs from staple fibers, several manufacturing procedures are no longer required.
  • nonwoven cellulose fiber fabric 102 according to exemplary embodiments of the invention is biodegradable and manufactured from sustainably sourced raw material (i.e. wood pulp 110 or the like). Furthermore, it has advantages in terms of purity and absorbency. Beyond this, it has an adjustable mechanical strength, stiffness and softness.
  • nonwoven cellulose fiber fabric 102 may be manufactured with low weight per area (for instance 10 to 30 g/m 2 ). Very fine filaments down to a diameter of not more than 5 ⁇ m, in particular not more than 3 ⁇ m, can be manufactured with this technology. Furthermore, nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention may be formed with a wide range of web aesthetics, for instance in a flat crispy film-like way, in a paper-like way, or in a soft flexible textile-like way. By adapting the process parameters of the described process, it is furthermore possible to precisely adjust stiffness and mechanical rigidity or flexibility and softness of the nonwoven cellulose fiber fabric 102.
  • Figure 2 Figure 3 and Figure 4 show experimentally captured images of nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention in which merging of individual fibers 108 has been accomplished by a corresponding process control.
  • the oval markers in Figure 2 to Figure 4 show such merging regions where multiple fibers 108 are integrally connected to one another. At such merging points, two or more fibers 108 may be interconnected to form an integral structure.
  • Figure 5 and Figure 6 show experimentally captured images of nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention in which swelling of fibers 108 has been accomplished, wherein Figure 5 shows the fiber fabric 102 in a dry non-swollen state and Figure 6 shows the fiber fabric 102 in a humid swollen state.
  • the pore diameters can be measured in both states of Figure 5 and Figure 6 and can be compared to one another. When calculating an average value of 30 measurements, a decrease of the pore size by swelling of the fibers 108 in an aqueous medium up to 47% of their initial diameter could be determined.
  • Figure 7 shows an experimentally captured image of nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention in which formation of two superposed layers 200, 202 of fibers 108 has been accomplished by a corresponding process design, i.e. a serial arrangement of multiple spinnerets.
  • the two separate, but connected layers 200, 202 are indicated by a horizontal line in Figure 7 .
  • an n-layer fabric 102 (n ⁇ 2) can be manufactured by serially arranging n spinnerets or jets 122 along the machine direction.
  • opacity of the fabric 102 may be ensured even when the fiber fabric 102 as such is optically transparent in a wet state of the fabric 102.
  • presence of the electromagnetic radiation diffusing particles 220 such as titanium dioxide may ensure in particular visual opacity, whiteness and brightness of the fabric 102.
  • the optical properties of the obtained fabric 102 may be fine-tuned.
  • the fibers 108 may have an only very small content of certain heavy metals such as a copper content of less than 5 ppm and a nickel content of less than 2 ppm.
  • Figure 8 shows a diagram 250 illustrating a relation between a particle dimension D, plotted along an abscissa 252, and a relative light scattering capability S, plotted along an ordinate 254, of rutile-type titanium oxide electromagnetic radiation diffusing particles 220 of a nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention.
  • Corresponding curves are plotted in Figure 8 for blue light (see reference numeral 256), for green light (see reference numeral 258), and for red light (see reference numeral 260).
  • the scattering strength of the electromagnetic radiation diffusing particles 220 is particularly pronounced in a range between about 70 nm and about 3000 nm so that the implementation of particles 220 in a corresponding dimensional range is particularly efficient.
  • FIG 9 illustrates an elementary cell of rutile-type titanium oxide 222 used as electromagnetic radiation diffusing particles 220 of nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention.
  • oxygen is indicated with reference numeral 224
  • titanium is indicated with reference numeral 226. Due to its pronounced scattering capability, stability and durability, rutile-type titanium oxide 222 is a particularly preferred material for the electromagnetic radiation diffusing particles 220.
  • FIG 10 illustrates an elementary cell of anatase-type titanium oxide 228 used as electromagnetic radiation diffusing particles 220 of nonwoven cellulose fiber fabric 102 according to another exemplary embodiment of the invention.
  • oxygen is indicated with reference numeral 224
  • titanium is indicated with reference numeral 226.
  • Anatase-type titanium oxide 228 is an appropriate alternative to the rutile-type titanium oxide 222, in particular when a pronounced photocatalytic activity of the fabric 102 is desired.
  • Figure 11 illustrates procedures carried out during executing a method of manufacturing nonwoven cellulose fiber fabric 102 with implemented electromagnetic radiation diffusing particles 220 according to exemplary embodiments of the invention.
  • the upper illustration in Figure 11 shows a mixture of cellulose-based lyocell spinning solution 104 with electromagnetic radiation diffusing particles 220 immediately after extrusion and hence directly downstream of the nozzle or orifice 126.
  • a further process flow indicated schematically with reference numeral 270 shows formation of fibers 108 by gas flow 146 (see Figure 1 and Figure 12 ) supported stretching only (see B).
  • Figure 12 illustrates a device 100 for manufacturing nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention which is specifically adapted for integrating electromagnetic radiation diffusing particles 220 in the nonwoven cellulose fiber fabric 102.
  • the device 100 is configured so that the gas flow 146 may be enriched with electromagnetic radiation diffusing particles 220 to thereby provide the fabric 102 with the electromagnetic radiation diffusing particles 220.
  • a metering valve 234 is provided which connects a particle container 232 (containing electromagnetic radiation diffusing particles 220 such as titanium dioxide spheres) with a flow generation unit for generating the gas flow 146.
  • the metering valve 234 is controlled by the control unit 140. Consequently, the gas flow 146 may be supplied with the added electromagnetic radiation diffusing particles 220 which come into interaction with strands of the lyocell spinning solution 104 extruded through the orifices 126.
  • the lyocell spinning solution 104 may be mixed in an adjustable way with the electromagnetic radiation diffusing particles 220, so that fibers 108 with attached and/or embedded particles 220 may be obtained.
  • the device 100 can be additionally or alternatively configured so that the lyocell spinning solution 104 itself is enriched with at least part of the electromagnetic radiation diffusing particles 220 prior to being supplied to the jets 122, i.e. upstream of the orifices 126.
  • the fabric 102 with the electromagnetic radiation diffusing particles 220 attached to and/or embedded in the fibers 108. This can be accomplished by providing a particle container 230 containing electromagnetic radiation diffusing particles 220 which can be mixed into the lyocell spinning solution 104 at the metering valve 119.
  • the coagulation fluid 106 may be enriched with electromagnetic radiation diffusing particles 220 stored in a further particle container 236 to thereby provide the fabric 102 with the electromagnetic radiation diffusing particles 220.
  • the control unit 140 controls an amount of particles 220 added to the coagulation fluid 106 so as to connect particles 220 to the fibers 108 during coagulation.
  • an exemplary embodiment of the invention provides an embedding of electromagnetic radiation diffusing particles 220 in a nonwoven cellulose fiber fabric 102. Since a nonwoven cellulose fiber fabric 102 may be optically transparent when wet, the embedding of electromagnetic radiation diffusing particles 220 may provide a fabric 102 being opaque in all humidity states. What concerns conventional staple fibers, the high amount of free fiber ends may here function as scattering centers so that a corresponding fabric can be more opaque in all humidity states. However, with a fabric 102 according to an exemplary embodiment of the invention composed of substantially endless fibers 108 with extremely small amount of free fiber ends, the opacity in the wet state of the fabric 102 requires the added particles 220.
  • Electromagnetic radiation diffusing particles 220 having a high efficiency of scattering optical light have in many cases dimensions which are in the range of respirable particles (which may enter, as such, into the alveoles of the human body) and/or particles having a tendency to enter the blood circuit (i.e. entering the human organism).
  • respirable particles which may enter, as such, into the alveoles of the human body
  • particles having a tendency to enter the blood circuit i.e. entering the human organism.
  • particles smaller than 2.5 ⁇ m may have a strong tendency of entering the alveoles, and particles smaller than 100 nm may have the tendency of intruding into the organism.
  • the electromagnetic radiation diffusing particles 220 when the dimensions of the electromagnetic radiation diffusing particles 220 are sufficiently small, they can be properly introduced in lyocell spinning solution 104 and can therefore be integrally embedded within the fibers 108 during the manufacturing process of the fabric 102 described above. At the same time, particles of such dimensions have strong diffusing properties in the optical regime (compare Figure 8 ). Too large particles 220 may also have the tendency of clogging the orifices 126 of the nozzles of device 100.
  • the particles 220 may also be added to the coagulation fluid 106 and may adhesively attach to the fibers 108, the percentage of the particles 220 being embedded in an interior of the fibers 108 (and being therefore less prone of being released from the fabric 102) is higher when the particles 220 are added to the lyocell spinning solution 104. In contrast to this, a relatively large percentage of the particles 220 adheres to an exterior surface of the fibers 108 when the particles 110 20 are added to the coagulation fluid 106 and/or to the gas flow 146. In view of these considerations, a dimensional range of the particles 220 between 70 nm and 3000 nm has turned out as preferred.
  • not more than 10% of the particles 220 has a diameter of smaller than 100 nm. It may also be advantageous that at least 90% of the particles 220 has a diameter of not more than 3000 nm, in particular not more than 1000 nm.
  • the diameter or diameter distribution of the implemented electromagnetic radiation diffusing particles 220 may be controlled as a process parameter by control unit 140 for adjusting the optical properties of the manufactured fabric 102 and the adhesion force between particles 220 and fibers 108.
  • control unit 140 for adjusting the optical properties of the manufactured fabric 102 and the adhesion force between particles 220 and fibers 108.
  • the addition of the particles 220 into one or both of the lyocell spinning solution 104 and the coagulation fluid 106 allows to obtain a fabric 102 with sufficiently strong adhesion of the particles 220 to the fibers 108 and with proper light diffusing properties.
  • the dimension of the particles 220 it is possible to control, by the dimension of the particles 220, the frequency selection of the filtered (since reflected) electromagnetic radiation.
  • small particles 220 may allow to manufacture a nonwoven cellulose fiber fabric 102 being still optically transparent in a wet state while showing a proper filter effect and protection function with regard to ultraviolet radiation.
  • the electromagnetic radiation diffusing particles 220 in fabric 102 it is also possible, with another configuration of the electromagnetic radiation diffusing particles 220 in fabric 102, to obtain an opacity over the entire visible range of light, which for instance may be advantageous for the example of wet T-shirts.
  • material and concentration of the electromagnetic radiation diffusing particles 220 may be adjusted for adjusting the properties of the fabric 102 in terms of interaction with electromagnetic radiation.
  • certain electromagnetic radiation diffusing particles 220 (such as barium sulfate) have not only a light diffusing function, but additionally have an electromagnetic radiation absorbing function (in the given example in particular in the X-ray range).
  • an exemplary embodiment of the invention may implement electromagnetic radiation diffusing particles 220 in nonwoven cellulose fiber fabric 102 to thereby provide an electromagnetic radiation diffusing function in a first wavelength range and an electromagnetic radiation absorbing function in a second wavelength range, wherein the first wavelength range and the second wavelength range may be identical, may be completely different, or may overlap.
  • the fiber formation process may not yet have already been completed. More specifically, this connection may be accomplished before completion coagulation and/or precipitation of the fibers 108 from the lyocell spinning solution 104.
  • the adhesive strength between the particles 220 and the fibers 108 may be further reinforced during a shrinkage process and a drying process of the fibers 108 after coagulation or precipitation. As a result of a corresponding control of the process parameters of the manufacturing method, it is therefore possible to obtain an intimately connected particle-fiber fabric 102 in which the fiber 108 and the particles 220 do not tend to be separated from one another.
  • Attaching and/or embedding the particles 222 on or in the fibers 108 during their formation allows a proper embedding and allows surrounding cellulose material to find a large number of adhesion points with regard to respective particles 220.
  • the amount of particles 220 to be added to the fabric 102 may be kept small, and at the same time an undesired release of the particles 220 from the fibers 108 may be efficiently prevented.
  • a further advantageous property of certain electromagnetic radiation diffusing particles 220 is their photocatalytic activity.
  • the latter can be further reinforced by the high surface/volume ratio of nanoparticles compared to microparticles.
  • the particles 220 may be configured as nanoparticles.
  • titanium dioxide may be more appropriate to be used for the electromagnetic radiation diffusing particles 221 in the anatase crystal state when strong photocatalytic properties are desired.
  • anatase type titanium dioxide can form radicals from water or air which are capable of (in particular oxidatively) decomposing (in particular organic) harmful substances.
  • Such an additional functionalization of nonwoven cellulose fiber fabric 102 with electromagnetic radiation diffusing particles 220 having a photocatalytic activity may be particularly advantageous according to an exemplary embodiment of the invention.
  • a washing procedure of washing the fiber fabric 102 with the attached and/or embedded electromagnetic radiation diffusing particles 220 in washing unit 180 may selectively remove weakly attached particles 220 from the fiber 108.
  • the readily manufactured fabric 102 comprises only particles 220 being strongly bonded to the fibers 108. This prevents an undesired release of particles 220 from the fibers 108 during use of the fabric 102 by a user.
  • the electromagnetic radiation diffusing particles 220 can be coated with an additional material, in order to provide a certain additional function.
  • Such an additional function may be an improved dispersion property and/or an improvement of the photostability.
  • the particles 220 may be coated so that they are not chemically attacked by the dope or lyocell spinning solution 104.
  • large electromagnetic radiation diffusing particles 220 may be embedded in the nonwoven cellulose fiber fabric 102. By taking this measure it can be ensured that sufficient particles 220 are also present at the surface of the fibers 108. As a result, the photocatalytic effect of titanium dioxide may be used particularly efficiently. For instance, this effect can be applied for antibacterial, taste neutralizing and/or cleaning functions.
  • the respective effect can be reinforced or even optimized by correspondingly adjusting an amount of the particles 220, a dimension of the particles 220, a surface positioning of the particles 220, etc.
  • the particles 220 are only active when they are present at the surface of the fibers 108, in particular for making use of the effects of such a functionalization, the addition of the particles 222 to the gas flow 146 and/or to the coagulation fluid 106 may be advantageous.
  • the manufactured fabric 102 with the surface attached and/or embedded electromagnetic radiation diffusing particles 220 may be used for providing an ultraviolet protection for products such as medical bandage or surgical dressing, or for smoke masks.
  • an optical diffusing function may be realized (so that a wound covered by the fabric 102 does not become visible in the wet state).
  • the manufactured fabric 108 may be used for an X-ray protection product, for instance for medical clothing or cloths with X-ray protection function.
  • the manufactured fabric 108 may be used for surgical pads or cloths which can be detected easily by X-ray analysis.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Materials For Medical Uses (AREA)
EP17164606.0A 2017-04-03 2017-04-03 Tissu de fibres de cellulose non tissé ayant des particules de diffusion de rayonnement connectés aux fibres Withdrawn EP3385429A1 (fr)

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EP17164606.0A EP3385429A1 (fr) 2017-04-03 2017-04-03 Tissu de fibres de cellulose non tissé ayant des particules de diffusion de rayonnement connectés aux fibres
PCT/EP2018/057862 WO2018184926A1 (fr) 2017-04-03 2018-03-28 Tissu de fibres de cellulose non tissées avec des particules de diffusion de rayonnement connectées par des fibres
TW107110759A TWI782966B (zh) 2017-04-03 2018-03-28 非織纖維素纖維織物，製造彼之方法和裝置，彼之用途，及包含彼之產品

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