KR20160146958A - Nonwoven fibrous structures including ionic reinforcement material, and methods - Google Patents

Abstract

Non-woven fibrous structures with ionic reinforcing materials and related media, and methods of forming the same, include bonding together at least a portion of the population of fibers using an ionic reinforcing material. The nonwoven fibrous structure may be used as a mat, a web, a sheet, a scrim, or a combination thereof. Non-woven fibrous structures with ionic reinforcing materials and methods of making such non-woven fibrous structures and associated media made according to the methods of making related media are also disclosed.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-woven fibrous structure including an ionic reinforcing material,

The present invention relates to a nonwoven fibrous structure having an ionic reinforcing material and related media and a method for forming the same.

Nonwoven fibrous webs have been used, for example, to produce a variety of absorbent articles useful as absorbent wipes for surface cleaning, wound dressings, as gas and liquid absorbent or filtration media, and as a barrier material for sound absorption come.

Although some methods of forming nonwoven fibrous webs are known, the art has recognized that nonwoven webs, particularly those having specific properties due to relatively high cross direction (CD) tensile strength and relatively high machine direction (MD) tensile strength We continue to explore new methods of forming and / or bonding air-laid nonwoven fibrous webs.

Accordingly, in one aspect, the present invention relates to a method of making a nonwoven fibrous structure (e.g., a nonwoven fibrous web), the method comprising: introducing a plurality of fibers into a forming chamber; Dispersing the fibers in a forming chamber to form a population of individual fibers suspended in the gas; Collecting a population of fibers as a nonwoven fibrous structure on a collector; And bonding at least a portion of the population of fibers together using an ionic reinforcing material. In some exemplary embodiments, the method comprises applying an ionic liquid material to a population of fibers. In certain exemplary embodiments, the method includes bonding at least a portion of a population of fibers together, wherein the bonding step comprises curing the applied ionic liquid material to form an ionic reinforcement material.

In some exemplary embodiments, the applied ionic liquid material further comprises water and removes at least a portion of the water from the ionic liquid material to which the curing step is applied, resulting in bonding of the ionic reinforcement material between the population of fibers. In certain exemplary embodiments, the applied ionic liquid material further comprises at least one binder resin, and optionally, the ionic liquid material applied serves as a plasticizer for the at least one binder resin. In some exemplary embodiments, the at least one binder resin is selected from the group consisting of a phenolic resin, a bio-based resin, a thermoplastic (meth) acrylic (co) polymer resin, an epoxy resin, or combinations thereof. In certain exemplary embodiments, the method is bonded using a binder resin mixture and an ionic liquid material to provide a greater tensile strength than a bonded nonwoven fibrous structure using a binder resin mixture in the absence of an ionic liquid material RTI ID = 0.0 > fibrous < / RTI >

In some exemplary embodiments, the ionic liquid material comprises at least one cation and at least one anion. In certain exemplary embodiments, at least one cation is selected from the group consisting of nitrogen containing heterocyclic cations, ammonium, phosphonium, or sulfonium; Also, at least one anion is selected from the group consisting of a halogen anion, a fluorine containing anion, an alkyl sulfate anion, an alkyl phosphate anion, acetate, dicyanamide (N (CN) ₂ ), or thiocyanate (SCN). In some exemplary embodiments, the method includes spraying an ionic liquid material, rolling the ionic liquid material, dip coating the ionic liquid material, or a combination thereof . In certain exemplary embodiments, the ionic liquid material is an ionic liquid solution in a solvent, and optionally the solvent is aqueous.

In some exemplary embodiments, bonding together at least a portion of the population of fibers comprises applying a thermosetting binder to the population of fibers. In certain exemplary embodiments, bonding at least a portion of the population of fibers comprises heating a portion of the population of fibers. In some exemplary embodiments, the ionic reinforcing material is at least one distinct characteristic selected from the group consisting of fire retardant, antistatic, antimicrobial, antimicrobial, antifungal, or combinations thereof To the nonwoven fibrous structure. In certain exemplary embodiments, the population of fibers includes fibers selected from the group consisting of staple fibers, melt-blown fibers, natural fibers, bio-based fibers, or combinations thereof.

In certain exemplary embodiments, the non-woven fibrous structure comprises a population of microparticles bonded to a non-woven fibrous structure, and the microparticles may also be a group of abrasive grains, detergent microparticles, antimicrobial microparticles, adsorptive microparticles, absorbent microparticles, . In some exemplary embodiments, the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.

The present invention also relates to non-woven fibrous webs made according to the methods described herein. In addition, the present invention relates to a nonwoven fibrous structure comprising a population of randomly oriented fibers bonded together at a plurality of intersections using an ionic reinforcing material. In some exemplary embodiments, the ionic reinforcing material is comprised of an ionic plasticizer (e.g., an ionic liquid that acts as a plasticizer). In certain exemplary embodiments, the ionic reinforcement material comprises an ionic liquid and a bond selected from the group consisting of (meth) acrylic (co) polymeric binders, styrene-butadiene latex binders, bio-based binders, Lt; / RTI > In some exemplary embodiments, the nonwoven fibrous structure comprises from 1 to 40% by weight of an ionic liquid. In a further embodiment, the ionic liquid comprises water, at least one cation, and at least one anion.

In some exemplary embodiments, the nonwoven fibrous structure exhibits at least one distinct characteristic selected from the group consisting of refractory, antistatic, antimicrobial, antimicrobial, antifungal, or combinations thereof. In certain exemplary embodiments, the ionic reinforcement material provides at least one distinct characteristic. In some exemplary embodiments, the ionic reinforcement material provides at least two of the distinct properties. In certain exemplary embodiments, the population of fibers is selected from the group consisting of poly (propylene), poly (ethylene), poly (butane), poly (ethylene) terephthalate, poly (butylene) terephthalate, Poly (ethylene) -co-poly (vinyl) acetate, poly (vinyl alcohol), poly (phenylene) sulfide, poly Thermoplastic (co) polymer fibers further comprising a (co) polymer selected from the group consisting of poly (ethylene terephthalate), poly (acrylonitrile), cyclic poly (olefin), poly (oxymethylene), poly (olefinic) thermoplastic elastomer, Recycled fibers containing any of the polymers, or combinations thereof.

In some exemplary embodiments, the population of fibers includes natural fibers selected from cotton, wool, jute, agave, sisal, coconut, soy, hemp, viscose, bamboo, or combinations thereof . In certain exemplary embodiments, the non-woven fibrous structure comprises a population of microparticles bonded to a non-woven fibrous structure, and the microparticles may also be a group of abrasive grains, detergent microparticles, antimicrobial microparticles, adsorptive microparticles, absorbent microparticles, . In some exemplary embodiments, the population of particles represents a median particle diameter of from 0.1 micrometer to 1,000 micrometers. In certain exemplary embodiments, the population of fibers exhibits a median fiber diameter of from 1 micrometer to 50 micrometers. In some exemplary embodiments, the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.

Various exemplary embodiments of the present invention are further illustrated by the following list of exemplary embodiments, which should not be construed as unduly limiting the present invention:

List of exemplary embodiments:

A. a. Introducing a plurality of fibers into the forming chamber;

b. Dispersing the fibers in a forming chamber to form a population of individual fibers suspended in the gas;

c. Collecting a population of fibers as a nonwoven fibrous structure on a collector; And

d. And bonding at least a portion of the population of fibers together using an ionic reinforcing material.

B. In Embodiment A, the method further comprises applying an ionic liquid material to the population of fibers.

C. In Embodiment B, the step of bonding together at least a portion of the population of fibers comprises curing the applied ionic liquid material to form an ionic reinforcement material.

D. In Embodiment C, the applied ionic liquid material further comprises water, and also removes at least a portion of the water from the ionic liquid material to which the curing step is applied, resulting in bonding of the ionic reinforcement material between the population of fibers. Way.

E. In any one of embodiments B through D, the ionic liquid material applied further comprises at least one binder resin, and optionally the ionic liquid material applied comprises at least one binder resin ≪ / RTI >

F. In Embodiment E, the at least one binder resin is selected from the group consisting of a phenolic resin, a bio-based resin, a thermoplastic (meth) acrylic (co) polymer resin, an epoxy resin, or a combination thereof.

G. In any one of Embodiments B to F, the bonding step may be performed by bonding using a binder resin mixture and an ionic liquid material to form a nonwoven fabric bonded using a binder resin mixture in the absence of an ionic liquid material, Providing a nonwoven fibrous structure having a tensile strength greater than that of the fibrous structure.

H. The method of any of embodiments B through G, wherein the ionic liquid material comprises at least one cation and at least one anion.

I. In any of embodiments B through H, at least one cation is selected from the group consisting of nitrogen containing heterocyclic cations, ammonium, phosphonium, or sulfonium; Wherein the at least one anion is selected from the group consisting of a halogen anion, a fluorine containing anion, an alkylsulfate anion, an alkyl phosphate anion, acetate, dicyanamide (N (CN) ₂ ), or thiocyanate (SCN).

J. In any of embodiments B through I, applying the ionic liquid material includes spraying the ionic liquid material, roll coating the ionic liquid material, dipping the ionic liquid material Coating, or a combination thereof.

K. The method of any of embodiments B through J wherein the ionic liquid material is an ionic liquid solution in a solvent and optionally the solvent is aqueous.

L. [0064] In any of embodiments A through K, bonding together at least a portion of the population of fibers comprises applying a thermosetting binder to the population of fibers.

M. [0041] In any of embodiments A through L, bonding at least a portion of the population of fibers comprises heating a portion of the population of fibers.

N. In any one of Embodiments A to M, the ionic reinforcing material may be at least one selected from the group consisting of refractory characteristics, antistatic characteristics, antibacterial characteristics, antimicrobial properties, antifungal properties, Providing one distinctive characteristic to the nonwoven fibrous structure.

O. In any of embodiments A through N, the population of fibers comprises fibers selected from the group consisting of monocomponent fibers, multicomponent fibers, crimped fibers, or combinations thereof.

P. In any of embodiments A through O, the population of fibers includes fibers selected from the group consisting of staple fibers, melt-blown fibers, natural fibers, bio-based fibers, or combinations thereof How to.

Q. In any one of Embodiments A to P, the nonwoven fibrous structure includes a group of fine particles bonded to the nonwoven fibrous structure, and the fine particles include abrasive fine particles, detergent fine particles, antibacterial fine particles, adsorptive fine particles, , Or a combination thereof.

R. The method of any of embodiments A-Q wherein the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.

S. A nonwoven fibrous structure produced according to the method of any one of embodiments A-R.

T. a. A nonwoven fibrous structure comprising a population of randomly oriented fibers bonded together at a plurality of intersections using an ionic reinforcing material.

U. The non-woven fibrous structure according to Embodiment T, wherein the ionic reinforcing material is composed of an ionic plasticizer.

V. In Embodiment T or Embodiment U, the ionic reinforcing material is selected from the group consisting of an ionic liquid and a (meth) acrylic (co) polymeric binder, a styrene-butadiene latex binder, a bio-based binder, ≪ / RTI > of a non-woven fibrous structure.

W. The non-woven fibrous structure of embodiment V, comprising 1 to 40% by weight of the ionic liquid.

X. The non-woven fibrous structure of Embodiment V or Embodiment W, wherein the ionic liquid comprises water, at least one cation, and at least one anion.

Y. In any one of Embodiments T through X, at least one distinct characteristic selected from the group consisting of refractory characteristics, antistatic characteristics, anti-bacterial characteristics, antimicrobial properties, antifungal properties, ≪ / RTI >

Z. In Embodiment Y, the ionic reinforcing material provides at least one distinct characteristic.

AA. In any of embodiments < RTI ID = 0.0 > T < / RTI > through Z, the population of fibers is a nonwoven fibrous structure, including fibers selected from the group consisting of monocomponent fibers, multicomponent fibers, crimped fibers, .

BB. In any of embodiments < RTI ID = 0.0 > T-A < / RTI > AA, the population of fibers comprises a fiber selected from the group consisting of staple fibers, melt-blown fibers, natural fibers, .

CC. In any of embodiments T through B, the population of fibers is selected from the group consisting of poly (propylene), poly (ethylene), poly (butane), poly (ethylene) terephthalate, poly (butylene) Poly (ethylene) naphthalate, poly (ethylene) naphthalate, poly (amide), poly (urethane), poly (lactic acid) A thermoplastic (co) polymer further comprising a (co) polymer selected from poly (vinyl) acetate, poly (acrylonitrile), cyclic poly (olefin), poly (oxymethylene), poly (olefinic) thermoplastic elastomer Fibers, recycled fibers containing any of the foregoing thermoplastic (co) polymers, or combinations thereof.

DD. In any of embodiments T through CC, the population of fibers is a natural fiber selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, ≪ / RTI >

EE. In any one of embodiments T through DD, the nonwoven fibrous structure comprises a population of microparticles bonded to a nonwoven fibrous structure, and the microparticles include abrasive particles, detergent particles, antibacterial particles, adsorptive particles, ≪ / RTI > or a combination thereof.

FF. [0061] In any one of embodiments T through EE, the population of microparticles exhibits a median particle diameter of from 0.1 micrometer to 1,000 micrometers.

GG. [0063] In any of embodiments T through FF, the population of fibers exhibits a median fiber diameter of from 1 micrometer to 50 micrometers.

HH. [0042] In any of embodiments T through GG, the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.

Various aspects and advantages of the presently disclosed embodiments of the present invention are summarized. The above summary is not intended to describe each illustrated embodiment or every implementation of the presently disclosed invention. The following drawings and detailed description more particularly illustrate certain preferred embodiments that use the principles disclosed herein.

Exemplary embodiments of the present invention are further described with reference to the accompanying drawings.
Figure 1 is a perspective view of an exemplary nonwoven fibrous structure of the present invention.
Figure 2 is an exploded view of a portion of the exemplary non-woven fibrous structure of Figure 1 showing one exemplary embodiment of the present invention.

As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a microfiber containing a "compound" includes a mixture of two or more compounds. As used in this specification and the appended embodiments, the term "or" is generally used to mean "and / or" unless the content clearly dictates otherwise.

As used herein, reference to a numerical range by an endpoint includes all numbers contained within that range (e.g., 1 to 5 are 1, 1.5, 2, 2.75, 3, 3.8, 4 and 5).

Unless otherwise indicated, all numbers expressing quantities of ingredients, measurements of properties, etc. used in the specification and in the specification are to be understood as being modified in all instances by the term "about ". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and in the accompanying list of embodiments may vary depending upon the desired properties sought to be obtained by those skilled in the art using the teachings herein. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claimed embodiments, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

In the following glossary terms for defined terms, such definitions shall apply to the entire application unless a different definition is provided in the claims or elsewhere in this specification.

Term Description

"Nonwoven fibrous web" or "nonwoven fibrous structure" means an article or sheet having a structure of fibers or individual fibers, but not put in an identifiable manner, such as in an interlaid knit. Nonwoven fabrics or webs have been formed from many processes, such as, for example, meltblowing processes, air-laying processes, and bonded carded web processes.

"Die" means a fabricated assembly for use in polymer melt processing and fiber extrusion processes, including but not limited to melt blowing and spun-bonding.

&Quot; Melting blowing "and" meltblowing "are the processes by which molten fiber-forming material is extruded through a plurality of orifices in a die to form fibers while contacting the fibers with air or other attenuating fluid Means a method for forming a nonwoven fibrous web by attenuating the fibers into fibers, and then collecting the attenuated fibers. An exemplary meltblowing process is taught, for example, in U.S. Patent No. 6,607,624 (Berrigan et al.).

"Meltblown fiber" means a fiber produced by a meltblowing or meltblown process.

"Spunbonding" and "spunbonding" are the processes of extruding a molten fiber-forming material from a plurality of microcapillaries of a spinneret as continuous or semi-continuous fibers, Means a method for forming a structure. An exemplary spun-bonding process is disclosed, for example, in U.S. Patent No. 3,802,817 to Matsuki et al.

"Spunbond fibers" and "spunbonded fibers" refer to fibers made using a spun-bonded or spunbond process. Such fibers are generally continuous fibers and are sufficiently entangled or point-bonded to form a coherent nonwoven fibrous web so that it is not usually possible to remove one finished spunbond fiber from the mass of such fibers. The fibers may also have the shape, for example, as described in U.S. Patent No. 5,277,976 to Hogle et al., Which describes fibers having a unique shape.

By " carding "and" carding process "are the steps of processing staple fibers through a combing or carding unit, which separates or fits and aligns staple fibers in the machine direction to form a fibrous nonwoven web oriented generally in the machine direction Means a method of forming a fibrous web. An exemplary carding process is taught, for example, in U.S. Patent No. 5,114,787 to Chaplin et al.

"Bonded carded web" refers to a web of fibers, for example, by methods including thermal point bonding, self-bonding, hot air bonding, ultrasonic bonding, needle punching, calendering, Refers to a nonwoven fibrous web formed by a carding process, at least a portion of which is bonded together.

"Calendering" refers to the process of passing a nonwoven fibrous web through a roller while applying pressure to obtain a compressed and bonded fibrous nonwoven web. The rollers can be selectively heated.

"Densification" refers to any process in which fibers deposited directly or indirectly on a filter winding arbor or mandrel are compressed before or after deposition, By design, or by artificial construction, it means a process of forming a region having a lower porosity as a whole or locally. Densification also includes calendering the web.

"Non-hollow ", particularly with reference to the protrusions extending from the major surface of the nonwoven fibrous structure, refers to an internal cavity or void, other than a microscopic void (i.e., void volume) between randomly oriented individual fibers It means that the region does not include the projection.

"Randomly oriented ", in particular with respect to a group of fibers, means that the fiber bodies are not substantially aligned in a single direction.

"Air-laying" is a process by which a nonwoven fibrous web layer can be formed. In the air-laying process, bundles of tiny fibers having a typical length in the range of about 3 to about 52 millimeters (mm) are separated and entrained in an air feeder, and then deposited on a forming screen, usually with the aid of a vacuum feeder. The randomly oriented fibers can then be bonded together using, for example, thermal point bonding, self-bonding, hot air bonding, needle punching, calendering, spray adhesives, and the like. An exemplary air-raining process is taught, for example, in U.S. Patent No. 4,640,810 to Laursen et al.

"Particle loading" or "particle loading process" refers to a process wherein particulates are added to a fiber stream or web while it is being formed. Exemplary particulate loading processes are taught, for example, in U.S. Patent No. 4,818,464 to Lau and in U.S. 4,100,324 to Anderson et al.

The terms "particulate" and "particle" are used interchangeably. In general, the fine particles or particles mean small separate pieces or individual portions of finely divided shaped material. However, the microparticles may also comprise a collection of individual particles that are associated or grouped together in finely divided form. Thus, the individual microparticles used in certain exemplary embodiments of the present invention may form lumps, physically engage with each other, electrostatically associate, or otherwise associate to form microparticles. In some cases, microparticles in the form of agglomerates of individual microparticles, such as those described in U.S. Patent No. 5,332,426 (Tang et al.), Can be intentionally formed.

"Layer" means a single stratum formed between two major surfaces. The layer may be internally present in a single web, for example, a single layer formed in multiple layers within a single web having a first major surface and a second major surface defining a thickness of the web. The layer may also be present in a composite article comprising a plurality of webs, for example, a first web having a first major surface defining a thickness of the web and a second major surface defining a thickness of the second web, And may be a single layer within the first web when it overlies or lies underneath the second web having the first major surface and the second major surface, in which case the first web and the second web each form at least one layer do. Also, in a single web, and between the web and one or more other webs, layers may be present at the same time, and each web forms a layer.

&Quot; Particle Density Gradient ", "sorbent density gradient," and "fiber population density gradient" refer to the amount of particulate, sorbent or fibrous material in a particular population of fibers (e.g., The number, weight or volume of a given material) does not need to be uniform throughout the nonwoven fibrous web and can be varied to provide more material at a given area of the web and less material at other areas .

Various exemplary embodiments of the present invention will now be described with specific reference to the drawings. The exemplary embodiments of the present invention may have various modifications and changes without departing from the spirit and scope of the invention. It is, therefore, to be understood that the embodiments of the present invention should not be limited to the exemplary embodiments described below, but should be dependent upon the limitations set forth in the claims and any equivalents thereof.

Non-woven fibrous structures (e.g., non-woven fibrous webs) have multiple applications (e.g., applications), particularly including cleaning applications, filtration applications, and / or textile applications. The nonwoven fibrous structure may be better suited for a particular application if the nonwoven fibrous structure exhibits certain properties (e.g., refractory, antistatic, antimicrobial, antimicrobial, antifungal, etc.). The present invention describes a nonwoven fibrous structure comprising a portion of a group of fibers bonded together using an ionic reinforcing material, and a method of making the same. The ionic reinforcing material not only provides an increase in the tensile strength of the nonwoven fibrous structure but also provides a number of properties. In some exemplary embodiments, the ionic reinforcing material provides a plurality of properties as described herein.

As further described herein, ionic reinforcing materials can be applied to non-woven fibrous structures using the application of ionic liquid materials. The ionic liquid material may comprise an ionic liquid (e.g., a liquid comprising at least one cation and at least one anion). The ionic liquid material applied to the nonwoven fibrous structure can be cured to bind a portion of the population of fibers of the nonwoven fibrous structure with the ionic reinforcing material.

Figure 1 is a cross-sectional view of a nonwoven fibrous structure 234 (e.g., air-laid nonwoven fibrous web, melt-spun nonwoven fibrous web, carded nonwoven fibrous web, etc.) comprising a plurality of randomly oriented fibers in accordance with the present invention 1 is a perspective view of one exemplary embodiment. In some exemplary embodiments, the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.

In some alternative embodiments, the present invention describes a non-woven fibrous structure comprising a plurality of randomly oriented fibers (2), the non-woven fibrous structure comprising a plurality of randomly oriented fibers (2) A plurality of optional non-beveled projections 200 extending from the major surface 204 and a plurality of substantially planar projections 200 formed between each adjacent projections 200 in a plane defined by, and substantially parallel to, And further includes an inland area 202.

In some exemplary embodiments, the randomly oriented individual fibers 2 may comprise fibers 120 selected from the group consisting of single component fibers, multicomponent fibers, crimped fibers, or combinations thereof. In certain exemplary embodiments, the randomly oriented individual fibers 2 may comprise fibers selected from the group consisting of staple fibers, melt-blown fibers, natural fibers, or combinations thereof. In some exemplary embodiments, the randomly oriented individual fibers 2 comprise natural fibers selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, or combinations thereof . In certain exemplary embodiments, the randomly oriented individual fibers 2 may comprise fibers that exhibit a median fiber diameter of from 1 micrometer to 50 micrometers.

In some exemplary embodiments, the randomly oriented individual fibers 2 may be selected from the group consisting of poly (propylene), poly (ethylene), poly (butane), poly (ethylene) terephthalate, poly (butylene) (Vinyl) alcohol, poly (phenylene) sulfide, poly (sulfone), liquid crystal polymer, poly (ethylene) -co-poly Thermoplastic (co) polymer fibers further comprising (co) polymer selected from poly (ethylene oxide) acetate, poly (acrylonitrile), cyclic poly (olefin), poly (oxymethylene), poly (olefinic) thermoplastic elastomer, Recycled fibers containing any of the polymerized thermoplastic (co) polymers, or combinations thereof.

In some exemplary embodiments, the randomly oriented individual fibers 2 may optionally include a filling fiber 110. The filled fibers 110 are any fibers other than multicomponent fibers. The optional fill fibers 110 are preferably single component fibers, which may be thermoplastic or "melty" fibers. In certain exemplary embodiments, the filled fibers may comprise bio-based fibers. The bio-based fibers may comprise natural fibers and / or biodegradable fibers. In some exemplary embodiments, for example, optional fill fibers 110 may comprise natural fibers, more preferably natural fibers derived from a renewable source and / or containing recycled materials. Non-limiting examples of suitable natural fibers include bamboo, cotton, wool, jute, agave, sisal, coconut, sawgrass, soybean, hemp, and the like. Cellulosic fibers (e. G., Cellulose, cellulose acetate, cellulose triacetate, rayon, etc.) may be particularly suitable natural fibers. The fiber component used may be recycled fibers recycled from virgin fibers or recycled waste fibers, such as clothing cuts, carpet making, textile making, textile processing, paper, recycled wood, and the like. In another example, the optional filled fibers 110 are biodegradable fibers. The biodegradable fibers include fibers that contain significant amounts of aliphatic polyester (co) polymers derived from poly (lactic acid), poly (glycolic acid), poly (lactic acid-co-glycolic acid) blends, and / But are not limited to these. In some presently preferred embodiments, at least some of the filled fibers 110 may be bonded to at least a portion of the individual fibers 2 at a plurality of intersections with the first region 112 of the multicomponent fibers 120.

In some exemplary embodiments of the non-woven fibrous structures described above, the non-woven fibrous structures 234 may optionally include a plurality of particulates 130, as shown in Fig. FIG. 2 illustrates an exploded view of region 2 of the nonwoven fibrous structure 234 of FIG. 1, including randomly oriented individual fibers 2 and a plurality of optional particulates 130.

In some exemplary embodiments, the optional particulate 130 may be particulate selected from the group consisting of abrasive particulates, detergent particulates, antibacterial particulates, adsorptive particulates, absorbent particulates, or combinations thereof. In certain exemplary embodiments, the population of selective microparticles 130 may exhibit a median particle diameter of from 0.1 micrometer to 1,000 micrometers. The optional particulate 130 may be applied at various stages of the forming process for the nonwoven fibrous structure 234. [ In one example, selective particulates can be applied by a particulate loading process. Exemplary particulate loading processes are taught, for example, in U.S. Patent Nos. 4,818,464 and 4,100,324.

Additionally, in some specific exemplary embodiments, the input stream may advantageously be positioned to introduce the particulates 130 in a manner that allows the particulates 130 to be substantially uniformly distributed throughout the non-woven fibrous structures 234 . Alternatively, in some specific exemplary embodiments, the input stream advantageously allows the particulate 130 to be deposited on the substantially major surface of the non-woven fibrous structure 234, for example, on the lower main surface side of the non-woven fibrous structure 234 Or in the vicinity of the upper major surface of the non-woven fibrous structure 234, as shown in FIG.

In certain exemplary embodiments, the binder may be applied to the non-woven fibrous structure 234 to provide additional strength to the non-woven fibrous structure 234 and / And / or may provide additional stiffness to a polishing or scouring article. The binder coating may be applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques. The binder coating may include additional fine particles 130 in the binder or additional fine particles 130 may be included and fixed in the binder.

In an exemplary embodiment, an ionic liquid material (e.g., an ionic liquid mixture) may be coated on the nonwoven fibrous structure 234. The ionic liquid material may comprise an ionic liquid (e.g., an aqueous solution comprising a liquid comprising at least one cation and at least one anion, at least one cation and at least one anion). That is, the ionic liquid material is an ionic liquid solution in a solvent, and optionally the solvent is aqueous. In some exemplary embodiments, the ionic liquid may comprise at least one cation selected from the group comprising a heterocyclic cation, ammonium, phosphonium, or sulfonium. In addition, in certain exemplary embodiments, the ionic liquid may be a halide anion, a fluorine containing anion, an alkyl sulfate anion, an alkyl phosphate anion, acetate, dicyanamide (N (CN) ₂ ), or thiocyanate (SCN) And at least one anion selected from the group consisting of The ionic liquid may be composed of a salt dissolved in a liquid. For example, the ionic liquid material may comprise a salt dissolved in water to produce an ionic liquid comprising at least one cation and at least one anion in the aqueous solution. For example, the ionic liquid material may comprise a salt dissolved in water to produce an ionic liquid comprising at least one cation and at least one anion in the aqueous solution. In some exemplary embodiments, the ionic liquid is selected from the group consisting of sodium chloride (NaCl), choline dihydrogenphosphate, 1-ethyl-3-methylimidazolium ethyl phosphate, Ethyl-3-methylimidazolium acetate, 1-ethyl-3-methylimidazolium triflate, or 1-ethyl-3-methylimidazolium dicyanamide. can do.

The ionic liquid material may be applied by known processing means such as roll coating, spray coating, and dip coating and combinations of these coating techniques. In some exemplary embodiments, the ionic liquid material is introduced mist from the atomizer in the forming chamber. In certain exemplary embodiments, the ionic liquid material moistens the fibers such that the particulates are suspended on the surface of the fibers.

In some exemplary embodiments, the ionic liquid material may also include a binder. The binder may comprise a resin. Suitable resins include phenolic resins, bio-based resins, thermoplastic (meth) acryl (co) polymer resins, epoxy resins, polyurethane resins, polyureas, styrene- butadiene rubbers, nitrile rubbers, epoxies, acrylics, and polyisoprenes do. The binder may be water-soluble. Examples of the water-soluble binder include surfactants, polyethylene glycol, polyvinylpyrrolidone, polylactic acid (PLA), polyvinylpyrrolidone / vinyl acetate copolymer, polyvinyl alcohol, carboxymethylcellulose, hydroxypropylcellulose starch, polyethylene oxide , Polyacrylic acid, polyacrylic acid, cellulose ether polymers, polyethyloxazolines, esters of polyethylene oxide, esters of polyethylene oxide and polypropylene oxide copolymers, urethanes of polyethylene oxide, and urethanes of polyethylene oxide and polypropylene oxide copolymers. .

In embodiments where the ionic liquid material comprises a binder, the ionic liquid material may comprise from 1 to 40 weight percent (wt%) of an ionic liquid and a binder in a liquid mixture (e.g., a liquid solution, aqueous solution, etc.) . In certain exemplary embodiments, the ionic liquid material may comprise from 1 to 10% by weight of the ionic liquid and the binder in the liquid mixture. That is, the ionic liquid material may comprise a specific weight percent of an ionic liquid, a binder as described herein, and / or a percentage of water. Thus, the ionic liquid material may include ionic liquids and binders as a mixture and / or solution and may be applied by known processing means such as roll coating, spray coating, and dip coating and combinations of these coating techniques.

In embodiments where the ionic liquid material comprises a binder, the ionic liquid may act as a plasticizer for the binder in the ionic liquid material. That is, the ionic liquid can increase the elongation (e. G., Plasticity, fluidity) of the resulting non-woven fibrous structure 234. In some exemplary embodiments, the increase in elongation of the nonwoven fibrous structure 234 occurs in the machine direction (MD). In certain exemplary embodiments, the increase in elongation of the nonwoven fibrous structure 234 occurs in the transverse direction (TD). In some exemplary embodiments, the increase in elongation of the air-laid nonwoven fibrous structure occurs in both the machine direction (MD) and the transverse direction (TD).

In certain exemplary embodiments, the ionic liquid material is selected from the group consisting of an ionic liquid and a bond selected from the group consisting of (meth) acrylic (co) polymeric binders, styrene-butadiene latex binders, bio-based binders, Lt; / RTI > In a specific embodiment, a liquid mixture of ionic liquid choline dihydrogenphosphate (e.g., a liquid solution) is mixed with a binder from the group as described herein (e.g., a thermosetting binder, from BASF Chemical Company Of the Acrodur thermosetting binder). In this specific embodiment, the thermosetting binder can be a binder that is relatively brittle when cured (e.g., when heat is applied to the binder, etc.). As described herein, the addition of the ionic liquid choline dihydrogenphosphate has a plasticizing effect on the thermosetting binder (e. G., Acts as a plasticizer). That is, the nonwoven fibrous structure 234 is less brittle due to the addition of the ionic liquid choline dihydrogenphosphate and the thermosetting binder, as compared to the nonwoven fibrous structure with the thermosetting binder added without ionic liquid addition.

A number of devices can be used to remove excess liquid (e. G., Water) from the non-woven fibrous structure 234. In some exemplary embodiments, calendering may be used to remove liquid from non-woven fibrous structures 234. [ "Calendering" may include passing a nonwoven fibrous web through a roller while applying pressure to obtain a compressed and bonded fibrous nonwoven web. In some exemplary embodiments, a plurality of devices may include a plurality of squeegees capable of compressing the non-woven fibrous structure 234 to remove a portion of the liquid (e. G., Water) applied to the non-woven fibrous structure 234 . In some exemplary embodiments, a plurality of squeegees may be used before the non-woven fibrous structure 234 is moved to a heating unit (e.g., an oven, etc.), wherein moving to the heating unit may be effected by a plurality of squeegees Unremoved liquid is removed. In other embodiments, multiple devices may be located at various points in the process of forming the non-woven fibrous structures 234.

The heating unit can also be used to cure the ionic liquid material applied to the nonwoven fibrous structure 234. [ In some exemplary embodiments, the binder in the ionic liquid material is a thermosetting binder (e.g., a binder resin that is hardened under heated conditions), wherein the binder of the ionic liquid material and the ionic liquid are Cured. In addition, the heating unit can be used to remove liquid (e.g., water) present on and / or within the non-woven fibrous structure 234. As described herein, the heating unit can remove remaining liquid after removing the liquid using a plurality of apparatuses. By removing the liquid, an ionic liquid material can be created at the location where the ionic liquid material is applied to the non-woven fibrous structure 234.

The ionic liquid material may bond a portion of the population of fibers with the ionic reinforcement material. In some exemplary embodiments, the ionic reinforcement material is a residual material of the ionic liquid material (e.g., a material that remains after the liquid is removed from the ionic liquid material). That is, in some exemplary embodiments, the ionic reinforcement material is a residue of the ionic liquid material after the liquid (e.g., water, excess water) has been removed from the non-woven fibrous structure 234. The ionic reinforcement material may provide an adhesive bond between portions of the population of fibers when the binder is included in the ionic liquid material as described herein.

The ionic reinforcing material may provide a number of characteristics to the nonwoven fibrous structure 234. [ An ionic reinforcement material may provide a number of properties when the ionic reinforcement material comprises an ionic liquid or an ionic liquid and a binder mixture, as described herein. In some exemplary embodiments, the plurality of properties may include a refractory characteristic, an anti-static characteristic, an anti-bacterial characteristic, an anti-microbial characteristic, an anti-fungal characteristic, or a combination thereof. In certain exemplary embodiments, the ionic reinforcement material provides at least one of a plurality of properties. In some exemplary embodiments, the ionic reinforcement material provides a plurality of a plurality of properties as described herein. In some exemplary embodiments, the ionic reinforcement material may provide at least two of the many properties listed herein.

In one exemplary embodiment, the ionic reinforcing material is applied to the nonwoven fibrous structure 234 with an ionic liquid material comprising an ionic liquid choline dihydrogen phosphate and a thermosetting binder. In this exemplary embodiment, the non-woven fibrous structure 234 is less brittle due to the addition of the ionic liquid choline dihydrogen phosphate and the thermosetting binder, as compared to the non-woven fibrous structure 234 with only the thermosetting binder added. In addition, the nonwoven fibrous structure 234 comprises an antistatic feature from an ionic reinforcing material. The addition of the ionic liquid choline dihydrogenphosphate and the thermosetting binder to the non-woven fibrous structure 234 may provide additional refractory (e.g., flame retardant) properties to the non-woven fibrous structure 234, as described further herein Can be provided. The ionic reinforcing material may also add additional properties that may include refractory, antistatic, antimicrobial, antimicrobial, antifungal, or combinations thereof.

As described herein, the ionic reinforcing material can increase the elongation (e.g., plasticity or fluidity) of the nonwoven fibrous structure 234. The ionic reinforcing material may also provide an increase in the tensile strength of the nonwoven fibrous structure 234. [ In some exemplary embodiments, the ionic reinforcement material may provide an increase in the tensile strength of the non-woven fibrous structure 234 and an increase in the elongation of the non-woven fibrous structure 234. In some exemplary embodiments, an increase in tensile strength and an increase in elongation are made in the machine direction (MD) of the nonwoven fibrous structure 234.

The nonwoven fibrous structures 234 (e.g., fibrous webs, air-laid nonwoven fibrous webs, etc.) according to the present invention may be formed by a number of methods of formation (e. G., Melt-spinning, air-laying, spun- ). ≪ / RTI > In an exemplary embodiment, the nonwoven fibrous structure 234 is formed by air-laying fiber processing equipment as shown and described in U.S. Patent Nos. 7,491,354 and 6,808,664.

In some exemplary embodiments, the air-laying fiber processing facility may use air flow to mix and interweave fibers to form an air-laid nonwoven fibrous structure. That is, an air-laid nonwoven fibrous structure is formed by introducing a plurality of fibers into a forming chamber and dispersing the fibers in a forming chamber to form a population of individual fibers suspended in the gas, wherein the fibers fall to the collector.

In a particular embodiment, a strong air flow is used (e.g., using a "RandoWebber" web forming machine available from Rando Machine Corporation, Macedon, Instead of mixing and intermeshing fibers to form air-laid nonwoven fibrous structures, the forming chambers have spike rollers, which blend and mix the fibers so that gravity causes the fibers to fall down through the endless belt screen, Lt; RTI ID = 0.0 > fibrous < / RTI > Utilizing this structure of the air-laying facility, in some exemplary embodiments, the fibers and the microparticles are dropped together at the bottom of the forming chamber to form an air-laid nonwoven fibrous structure. In one exemplary embodiment, a vacuum may be included below the region where the air-laid nonwoven fibrous structure is formed in the forming chamber.

In some exemplary embodiments, the nonwoven fibrous structure 234 is formed using a carding process. An exemplary carding process is taught, for example, in U.S. Patent No. 5,114,787. In some exemplary embodiments, the nonwoven fibrous structure 234 is formed by a melt blowing process. The melt blowing process involves extruding molten fiber-forming material through a plurality of orifices in a die to form fibers, contacting the fibers with air or other attenuating fluids to attenuate the fibers into fibers, Is a method for forming a nonwoven fibrous structure by collecting fibers. An exemplary meltblowing process is taught, for example, in U.S. Patent No. 6,607,624.

The ionic liquid material may be applied to the nonwoven fibrous structure 234 at different stages of each of the forming methods. In some exemplary embodiments, as described herein, an ionic liquid material is formed by spraying fibers and / or filaments using a foaming process to form fibers and / or filaments (e.g., in a forming chamber, etc.) While they are being collected on the collector, they can be applied to fibers and / or filaments. In some exemplary embodiments, as described herein, the ionic liquid material can be applied to the non-woven fibrous structure 234 once the fibers and / or filaments have been collected on the collector. In such embodiments, the ionic liquid material may be applied by known processing means such as roll coating, spray coating, and dip coating and combinations of these coating techniques.

In some exemplary embodiments, the nonwoven fibrous structure of the present invention and the filter media comprising it may advantageously comprise a biodegradable material, a particulate material, a frame material, or a combination thereof. Some filter media, including biodegradable materials (e.g., polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), etc.) are advantageously used at the end of their useful life, advantageously as municipal waste landfill or industrial compost By being discarded at the manufacturing site, the need to return or otherwise recycle the used filter media can be eliminated.

The practice of various embodiments of the present invention will be further described with reference to the following detailed examples.

Example

These embodiments are for illustrative purposes only and are not intended to unduly limit the scope of the appended claims. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are recorded as precisely as possible. However, any numerical value inherently includes certain errors necessarily resulting from the standard deviation found in the respective test measurements. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Test Methods

Testing of the formed nonwoven fibrous web was carried out using the test apparatus listed in Table I according to the method described further below. In all test procedures, a standard reference sample labeled "Std." (I.e., a comparative sample) was measured for comparison. The standard reference sample (i.e., the comparative example) consisted of a corresponding web coated with only the binder, without the ionic liquid additive.

[Table I]

Basis weight

The basis weight of the nonwoven web was measured using a METTLER TOLEDO XS4002S electronic balance.

Tensile Strength and Percent Elongation

Tensile strength and percent (%) elongation measurements were performed on non-woven samples (15 x 2.5 cm) on an Instron 5965 machine with a maximum load of 100 N. For each non-woven sample, three samples were measured and averaged.

Raw material

Unless otherwise noted, all parts, percentages, ratios, etc. in the examples and the remainder of the specification are by weight. The solvents and other reagents used are available from Sigma-Aldrich Chemical Company (Milwaukee, Wis.) Unless otherwise stated. In addition, Table II provides abbreviations and sources for all materials used in the following examples.

[Table II]

In the following examples, "IL" denotes an ionic liquid, "PET" denotes a polyester, "MD" denotes a machine direction, "TD" denotes a transverse direction (relative to MD) "TS" represents the tensile strength, "elong" represents the percentage elongation, "PEG" refers to polyethylene glycol, and "Std." Refers to the reference standard (ie, Comparative Example).

Binder

Acrodur 3530 (approximately 50% solids):

A, by 2 using the binder H ₂ O unless otherwise stated: 1 ratio of pre-by roll coating in a diluted form (approximately 33% solids) was coated onto a nonwoven web. The binder was then cured in an air-passing oven at 140 占 폚 for approximately 4 minutes.

OC BioBinder (approximately 15% solids):

One, the binding agent 2 by using H ₂ O unless otherwise stated: 1 ratio of pre-by roll coating in a diluted state was coated onto a nonwoven web. The binder was then cured in an air-passing oven at 130 DEG C for approximately 4 minutes.

Ionic liquid

The ionic liquids (IL) listed in Table III were added to the aqueous binder solution at 10% w / v. The ionic liquid was added all at once to the aqueous binder solution and stirred until completely dissolved.

[Table III]

fiber

A blend of fibers (i.e., viscose, PET, nylon) and low melting point fibers as listed in Table IV was formed with a fiber: low melting point fiber ratio of 80:20 ratio and fibers Processing of the mixture was carried out.

[Table IV]

[Table V]

Web formation

A fiber pre-bonded web was formed prior to coating the resin. The required ratio of fiber to meltable fibers was weighed and mixed by passing through a fiber opener. Air-laid pre-bonded webs were formed on a LAND WEBER forming machine. After formation of the web, it was passed through an air-passing oven at 130 캜 to produce a lightly bonded web suitable for coating attempts.

Web consolidation

The prebonded web was coated in a reservoir by passing it through a roll coating cylinder containing the binder / ionic liquid mixture.

Example 1

Tables 1 to 4 show the tensile test results for non-woven viscose pre-bonded webs having acrodel binder and various ionic liquids.

[Table 1]

[Table 2]

[Table 3]

[Table 4]

Tables 5 to 8 show tensile test results for non-woven viscose pre-bonded webs with OC biobinder binder and various ionic liquids.

[Table 5]

[Table 6]

[Table 7]

[Table 8]

Example 2

Tables 9 to 12 show tensile test results for nonwoven viscose pre-bonded webs with acrodel binder and various ionic liquids.

[Table 9]

[Table 10]

[Table 11]

[Table 12]

Tables 13 to 16 show the tensile test results for non-woven viscose pre-bonded webs with OC biobinder binder and various ionic liquids.

[Table 13]

[Table 14]

[Table 15]

[Table 16]

Example 3

Tables 17 and 18 show tensile test results for non-woven viscose pre-bonded webs with Primal B15 binder and various ionic liquids.

[Table 17]

[Table 18]

Example 4

The nonwoven sample tested consisted of a viscous pre-bonded web. Tables 19 to 22 show the tensile test results for Example 4 having various ionic liquids.

[Table 19]

[Table 20]

[Table 21]

[Table 22]

Example 5

The nonwoven sample tested consisted of a viscous pre-bonded web. Tables 23 and 24 show the tensile test results for Example 5 with various ionic liquids.

[Table 23]

[Table 24]

Surface resistivity test result

The surface resistivity of the nonwoven coated samples was determined according to VDE 0303 part 30. The test setup consisted of a terahome meter (PM 126 567), an electrode (20 cm 2) and an Ø electrode (5 cm). The following terms are defined for the surface resistivity test:

Example 1

Tables 25 to 32 show the results of surface resistivity test for Example 1 having various ionic liquids.

[Table 25]

[Table 26]

[Table 27]

[Table 28]

[Table 29]

[Table 30]

[Table 31]

[Table 32]

Example 2

Tables 33 to 43 show the results of surface resistivity test for Example 2 with various ionic liquids.

[Table 33]

[Table 34]

[Table 35]

[Table 36]

[Table 37]

[Table 38]

[Table 39]

[Table 40]

[Table 41]

[Table 42]

[Table 43]

Example 3

Tables 44 to 51 show the results of surface resistivity test for Example 3 with various ionic liquids.

[Table 44]

[Table 45]

[Table 46]

[Table 47]

[Table 48]

[Table 49]

[Table 50]

[Table 51]

Flammability test result

Test method The UL94 vertical burner test procedure was slightly modified and the flame resistance test was performed accordingly. Methane gas at a pressure of 17 pounds (2.5 psi) was used in the Bunsen burner. The flame cone height measurements were as follows: 1 cm inside and 2 cm outside. The distance between the spray tip and the end of the sample was 1 cm. The sample size was 15 x 2.5 cm. The measured samples consisted of a web of viscose fibers with the requisite binder containing 10% ionic liquid unless otherwise stated. Three samples were measured for each binder / IL combination. When all three samples provide the same results, only one synthetic result is given.

T1: duration (seconds) after flame generation after ignited powder is applied to the sample for 10 seconds

T2: after application of Bunsen for an additional 10 seconds after flame

T3: After the application of Bunsen for an additional 10 seconds after the flame

B: Burned sample

Note: When the result is 0 after flame exposure, the sample is resistant to ignition.

Table 52 shows the flame retardance test results for Example 2 with various binders and ionic liquids.

[Table 52]

Table 53 summarizes the overall performance characteristics in terms of tensile strength, antistatic properties and flame retardancy.

[Table 53]

Reference throughout this specification to "one embodiment", "any given embodiment", "one or more embodiments" or "an embodiment" means that the term "exemplary" Means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one of the exemplary exemplary embodiments of the present invention, whether or not including the feature. Thus, the appearances of the phrases "in one or more embodiments," in certain embodiments, "in an embodiment," or "in an embodiment," ≪ / RTI > of the present invention. Furthermore, a particular feature, structure, material, or characteristic may be combined in any suitable manner in one or more embodiments.

While the specification has described in detail certain illustrative embodiments, those skilled in the art will readily appreciate that many modifications, variations, and equivalents may be devised to those skilled in the art in light of the foregoing description. Accordingly, it is to be understood that the specification should not be unduly limited to the exemplary embodiments described above.

All publications and patents referred to in this specification are herein incorporated by reference to the same extent as if each individual publication or patent was specifically and individually indicated to be incorporated by reference. Various illustrative embodiments are described. These and other embodiments are within the scope of the following claims.

Claims (35)

Introducing a plurality of fibers into a forming chamber;
Dispersing the fibers in the forming chamber to form a population of individual fibers suspended in the gas;
Collecting the population of fibers as a nonwoven fibrous structure on a collector; And
Bonding at least a portion of said population of fibers together using an ionic reinforcing material
Lt; RTI ID = 0.0 > fibrous < / RTI > structure. 7. The method of claim 1, further comprising applying an ionic liquid material to the population of fibers. 3. The method of claim 2, wherein bonding at least a portion of the population of fibers comprises curing the applied ionic liquid material to form the ionic reinforcement material. 4. The method of claim 3, wherein the applied ionic liquid material further comprises water, and wherein a curing step removes at least a portion of the water from the applied ionic liquid material to form a layer of the ionic reinforcing material Thereby causing bonding. 5. A method according to any one of claims 2 to 4, wherein the applied ionic liquid material further comprises at least one binder resin, and optionally wherein the applied ionic liquid material has a melting point for the at least one binder resin ≪ / RTI > 6. The method of claim 5, wherein the at least one binder resin is selected from the group consisting of a phenolic resin, a bio-based resin, a thermoplastic (meth) acrylic (co) polymer resin, an epoxy resin, or combinations thereof. 7. A method according to any one of claims 2 to 6, wherein the bonding step comprises bonding with a binder resin mixture and the ionic liquid material to form a bondable resin mixture using the binder resin mixture in the absence of the ionic liquid material Providing a nonwoven fibrous structure having a tensile strength greater than that of the nonwoven fibrous structure. 8. A method according to any one of claims 2 to 7, wherein the ionic liquid material comprises at least one cation and at least one anion. 9. A compound according to any one of claims 2 to 8, wherein said at least one cation is selected from the group consisting of nitrogen containing heterocyclic cations, ammonium, phosphonium, or sulfonium; Wherein said at least one anion is selected from the group consisting of a halogen anion, a fluorine containing anion, an alkylsulfate anion, an alkyl phosphate anion, acetate, dicyanamide (N (CN) ₂ ), or thiocyanate (SCN) . 10. The method of any one of claims 2 to 9, wherein applying the ionic liquid material comprises spraying the ionic liquid material, roll coating the ionic liquid material, Or a combination thereof. ≪ Desc / Clms Page number 14 > 11. A method according to any one of claims 2 to 10, wherein the ionic liquid material is an ionic liquid solution in a solvent, optionally the solvent is aqueous. 12. The method of any one of claims 1 to 11, wherein bonding together at least a portion of the population of fibers comprises applying a thermosetting binder to the population of fibers. 13. The method according to any one of claims 1 to 12, wherein bonding at least a portion of the population of fibers comprises heating a portion of the population of fibers. 14. The method of any one of claims 1 to 13, wherein the ionic reinforcing material is selected from the group consisting of fire retardant, antistatic, antimicrobial, antimicrobial, antifungal, And providing at least one distinct characteristic to the non-woven fibrous structure to be selected. 15. The method according to any one of claims 1 to 14, wherein the population of fibers comprises fibers selected from the group consisting of single component fibers, multicomponent fibers, crimped fibers, or combinations thereof. 16. The method according to any one of claims 1 to 15, wherein the population of fibers is selected from the group consisting of staple fibers, melt-blown fibers, natural fibers, bio-based fibers, ≪ / RTI > 17. The non-woven fibrous structure of any one of claims 1 to 16, wherein the non-woven fibrous structure comprises a population of microparticles bonded to the non-woven fibrous structure, wherein the microparticles are abrasive particles, detergent particles, antibacterial microparticles, Particulate, or a combination thereof. 18. The method of any one of claims 1 to 17, wherein the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof. 18. A nonwoven fibrous structure produced according to the method of any one of claims 1 to 18. A nonwoven fibrous structure comprising a population of randomly oriented fibers bonded together at a plurality of intersections using an ionic reinforcing material. 21. The non-woven fibrous structure of claim 20, wherein the ionic reinforcing material is comprised of an ionic plasticizer. 22. The method of claim 20 or 21, wherein the ionic reinforcing material is selected from the group consisting of an ionic liquid and a (meth) acrylic (co) polymer binder, a styrene-butadiene latex binder, a bio-based binder, ≪ / RTI > wherein the non-woven fibrous structure is comprised of a binder selected. 23. The non-woven fibrous structure of claim 22 comprising from 1 to 40% by weight of the ionic liquid. 24. The non-woven fibrous structure of claim 22 or 23, wherein the ionic liquid comprises water, at least one cation, and at least one anion. 25. A method according to any one of claims 20 to 24, wherein at least one distinct characteristic selected from the group consisting of refractory properties, antistatic properties, anti-bacterial properties, antimicrobial properties, antifungal properties, Nonwoven fibrous structures. 26. The non-woven fibrous structure of claim 25, wherein the ionic reinforcement material provides the at least one distinctive property. 27. The non-woven fibrous structure of claim 26, wherein the ionic reinforcement material provides at least two of the distinct properties. 28. The non-woven fibrous structure of any one of claims 20 to 27, wherein the population of fibers comprises fibers selected from the group consisting of monocomponent fibers, multicomponent fibers, crimped fibers, or combinations thereof. 29. A nonwoven fibrous structure according to any of claims 20 to 28, wherein the population of fibers comprises fibers selected from the group consisting of staple fibers, melt-blown fibers, natural fibers, or combinations thereof. 31. The method of any of claims 20 to 29, wherein the population of fibers is selected from the group consisting of poly (propylene), poly (ethylene), poly (butane), poly (ethylene) terephthalate, poly (butylene) (Ethylene) naphthalate, poly (amide), poly (urethane), poly (lactic acid), poly (vinyl alcohol), poly (phenylene) sulfide, (Co) polymer fibers further comprising a (co) polymer selected from poly (vinyl) acetate, poly (acrylonitrile), cyclic poly (olefin), poly (oxymethylene), poly (olefinic) thermoplastic elastomer , Recycled fibers containing any of the aforementioned thermoplastic (co) polymers, or combinations thereof. 32. A method according to any one of claims 20 to 30, wherein the group of fibers is selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, ≪ RTI ID = 0.0 & 32. The method of any one of claims 20 to 31, wherein the non-woven fibrous structure comprises a population of microparticles bonded to the non-woven fibrous structure and wherein the microparticles are abrasive particles, detergent particles, antibacterial microparticles, Particulate, or a combination thereof. ≪ Desc / Clms Page number 13 > 32. The non-woven fibrous structure of any one of claims 20 to 32, wherein the population of particles represents a median particle diameter of from 0.1 micrometer to 1,000 micrometers. 34. The non-woven fibrous structure of any one of claims 20 to 33, wherein the population of fibers exhibits a median fiber diameter of from 1 micrometer to 50 micrometers. 35. The non-woven fibrous structure of any one of claims 20 to 34, wherein the non-woven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.

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