MXPA04009751A

MXPA04009751A - Renewable imaged nonwoven fabric comprising reconstituted fibers.

Info

Publication number: MXPA04009751A
Application number: MXPA04009751A
Authority: MX
Inventors: Joy Nunn Kayren
Original assignee: Polymer Group Inc
Priority date: 2002-04-08
Filing date: 2003-04-07
Publication date: 2004-12-13
Also published as: EP1492913A4; CA2481419A1; AU2003221681A1; US20040248493A1; WO2003087457A1; EP1492913A1

Abstract

The present invention is directed to a nonwoven fabric comprising reconstituted or regenerated fibers, wherein the nonwoven fabric exhibits improved aesthetic and physical performance, thus permitting use of the fabric in a wide variety of consumer applications. The nonwoven fabric exhibits a three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a precursor web (P) comprising at least one reconstituted fiber, which when subjected to hydroentanglement on a moveable imaging surface of a three-dimensional image transfer device (24), an enhanced product is achieved.

Description

NON-WOVEN GENRE, WITH DESIGN, RENEWABLE, COMPOSED OF RECONSTITUTE FIBERS TECHNICAL FIELD The present invention relates, in general, to non-woven fabrics, and more specifically, to a non-woven fabric composed of reconstituted or regenerated fibers, the non-woven fabric exhibits better aesthetic and physical performance, allowing the use of the genre in a wide variety of consumer applications. The non-woven fabric with images is constructed so that durability is imparted by the regulated distribution and variation in fiber density and / or localized basis weight, and can be disassembled into its component fiber composition and this fibrous component can be used for manufacture new non-woven fabrics with images that have aesthetic and / or physical equivalent performance.

BACKGROUND OF THE INVENTION Non-woven fabrics are suitable for use in a wide variety of applications where the efficiency with which fabrics can be manufactured provides an important economic advantage for these fabrics against traditional textiles. However, non-woven fabrics usually have disadvantages when the properties of the fabric are compared with traditional textiles, in particular in terms of resistance to elongation, resistance when wetted and resistant to abrasion. Hydroentangled genera have been developed with better properties by forming complex composite structures to provide a necessary level of gender integrity. After entangling, the durability of the fabric has been further improved by the application of binder compositions and / or by thermal stabilization of the matted fibrous matrix.

Recently, hydroentanglement techniques have been developed that impart designs or images to the entangled genus by performing hydroentanglement in three-dimensional image transfer devices. These three-dimensional devices for image transfer are described in US Patent No. 5,098,764, which is incorporated herein by reference; with the use of these convenient image transfer devices to obtain a genre with better physical properties as well as a pleasant aesthetic appearance.

The selection of fibers to form hydroentangled non-woven fabrics is an important factor when evaluating potential end-use applications. It has usually been found that simple, inexpensive fibers are undesirable for semi-durable or durable end-use articles. To improve the convenience of these fibers, exogenous binder fibers or other adhesive agents that are applied topically have been incorporated. Although a non-woven fabric that incorporates performance-enhancing media can be used for semi-durable and durable applications, due to the inherent heterogeneity of the resulting fibrous constructions, these materials can not be easily reused or recovered in articles of equivalent type.

Notwithstanding the various attempts in the prior art to develop an acceptable nonwoven fabric for domestic, medical and hygiene applications, a nonwoven fabric containing simple and basic fibers, which provides an evident three-dimensional image, as well as the characteristics necessary mechanics. In addition, a nonwoven fabric that can be used in semi-durable or durable applications and that can be reformed in a newly manufactured nonwoven fabric from waste or used articles containing simple or basic fibers such as these, without degradation in the aesthetic and / or physical performance of the genre.

SUMMARY OF THE INVENTION The present invention is directed to a nonwoven fabric containing reconstituted or regenerated fibers (hereinafter referred to as a reconstituted fiber or reconstituted fibers), the non-woven fabric shows better aesthetic and physical performance, thus allowing the use of the genre in a wide variety of consumer applications. The non-woven fabric shows a three-dimensional image that is durable for conversion and application in the final use. In particular, the present invention contemplates that a fabric is formed from a precursor web containing at least one reconstituted fiber, which when subjected to hydroentanglement on a mobile imaging surface of a three-dimensional image transfer device is get an improved product. By specific control of fiber distribution and variation in localized density of the fibers and / or basis weight, an elongation-resistant non-woven fabric is formed, with wet resistance to failure and degradation due to abrasion, and which does not require another inclusion or application of exogenous binder agents.

In accordance with the present invention, a method for manufacturing a non-woven fabric incorporating the present invention includes the steps of: providing a precursor web consisting of a fibrous matrix of at least one type of reconstituted fiber. Although it is possible to use natural fibers of finite length, such as reconstituted cotton, the fibrous matrix may also include, in part or all, fibers of finite length of synthetic composition. In a particularly preferred form, the fibrous matrix consists of fibers of finite length which are loaded to form a precursor web. As an option, the carded precursor veil can be subjected to retraction, such as by random placement in air or cross-lapping. In a preferred embodiment of the present invention, the precursor web is subjected to pre-entanglement on a foraminous forming surface. Otherwise, one or more layers of the fibrous matrix, consisting of reconstituted fibers, virgin fibers or mixtures thereof, are superposed with a first layer of reconstituted fibers, the layered construction is then pre-tanned on a foraminous surface to form a precursor web .

The present method further contemplates the arrangement of a three-dimensional image transfer device having a mobile image forming surface. In a common configuration, the image transfer device may consist of a drum-like apparatus that can rotate with respect to one or more manifolds for hydroentanglement.

The precursor web of reconstituted fibers is advanced on the image forming surface of the image transmitting device. The hydroentanglement of the precursor web is effected to form a fabric with three-dimensional images. It is important to note that the interaction of a reconstituted fiber that has a prevalence equal to or less than 10% by weight of aberrant particles as harmful fibers, these fibrous artifacts include very short fibers ("fines") or fibrous components that are excessively nodular or non-processable ("thick"), and a three-dimensional image transfer device allows the regulated distribution and variation in zonal density and / or basis weight of the fibers to impart important and useful durability, without necessarily incorporating exogenous adhesive agents.

After hydroentanglement, the reconstituted, imaged genus may be subjected to one or more of the different treatments subsequent to entanglement, these treatments may include the application of dyes, printing of designs or logos, mechanical compaction, application of surfactant or electrostatic compositions, and similar processes.

Other features and advantages of the present invention will be apparent from the following detailed description, the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic drawing of a process by which an image transfer is employed in the manufacture of a nonwoven fabric in accordance with the present invention, and Figure 2 is a top plan view of a topography of the three-dimensional surface representative of an image transfer device, referred to as a "small box".

DETAILED DESCRIPTION Although the present invention allows incorporation in different forms, a currently preferred embodiment of the invention is shown in the drawings, and will be described below, with the understanding that the present description should be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment shown.

The present invention is directed to a nonwoven fabric consisting of reconstituted fibers, the nonwoven fabric shows better aesthetic and physical performance, allowing the use of the genre in a wide variety of consumer applications. The non-woven fabric shows a three-dimensional image that is durable for conversion and end-use applications. In particular, the present invention consists of a fabric that is formed from a precursor web containing at least one reconstituted fiber, which when subjected to hydroentanglement on a mobile, imaging surface of a three-dimensional image transfer device, you get an improved product. By means of the specific control of the distribution of the fibers and the variation in the density and / or localized or zonal basis weight of the fibers, a non-woven fabric resistant to elongation is formed, with wet resistance to the failure and degradation due to the abrasion and that does not need another inclusion or application of binders or exogenous adhesives.

One method of manufacturing a non-woven fabric incorporating the present invention is the steps of providing a precursor web containing a fibrous matrix of at least one type of reconstituted fiber. Although it is possible to use natural fibers of finite length, as shown by reconstituted cotton, the fibrous matrix may also include, in part or in total, finite length fibers of synthetic composition. In a particularly preferred form, the fibrous matrix contains fibers of finite length, which are carded to form a precursor web. As an option, the carded precursor veil can be subjected to reorientation, such as by random placement in air or cross-lapping. In one embodiment of the present invention, the precursor web is subjected to pre-tanning on a foraminous forming surface. Otherwise, one or more layers of the fibrous matrix, consisting of reconstituted fibers, virgin fibers, or combinations thereof, are superposed with a first layer of reconstituted fibers, the layered construction is then pre-tanned on a foraminous surface to form a precursor veil.

It has been found that the interaction of a reconstituted fiber having a prevalence equal to or less than 10% by weight is harmful fibrous artifacts and a three-dimensional image transfer device allows the controlled distribution and variation in zonal density and / or base weight of the fibers to impart important and useful durability without necessarily incorporating binders or exogenous adhesives. The formation of suitable and convenient reconstituted fiber that meets this rate or prevalence is best taught in pending application serial No. 09 / 755,523, assigned to Enviromental Textiles Incorporated, of Oklahoma, and is incorporated herein by reference.

The method for reconstituting fibers, as taught by pending application serial No. 09 / 755,523, is directed to a sequential process by which specific mechanisms are employed to "deconstruct" a preexisting fibrous fabric in a state of free fibers. In general, pre-existing or preformed fibrous genera are initially subjected to different media with which the genus is reduced to pieces of considerably smaller size and volume. These pieces are then transported through, and in them act, devices that convert them into fibrous components. The fibrous components are further treated with steam at elevated temperature and incubation with reducing enzymes, thereby eliminating the finishes of the fibers and other topical additives of the released fibers. The fibers are then re-treated, as an option, with a new fiber finish, such as an agent to improve the property to carve this fiber, and re-form into bales.

The reconstituted fibers are selected from a combined natural, synthetic or natural / synthetic composition, of homogeneous or mixed fibers of finite length. Suitable natural fibers include, but are not limited to, cotton, wool pulp and viscose rayon. Synthetic fibers, which may be combined in whole or in part, include thermoplastic and thermoset polymers. Suitable thermoplastic polymers for use as reconstituted fibers include polyolefins, polyamides and polyesters. The thermoplastic polymers may furthermore be selected from: homopolymers, copolymers, conjugates and other derivatives including those thermoplastic polymers having incorporated molten additives or surface active agents. The finite lengths of the reconstituted fibers are chosen in the range of about 0.13 inches to 1.0 inches, with the range of 0.25 to 0.75 inches being preferred and the denier of the fibers being chosen in the range of 1.0 to 22.0, the range of 1.2 to 6.0 denier is preferred for general applications. The profile of the cross section of the fiber does not limit the applicability of the present invention.

With reference to Figure 1, there is shown an apparatus for forming a non-woven fabric according to the present invention. The genus is formed from a fibrous matrix that usually contains fibers of finite length, of natural or synthetic composition, or combinations of these. The fibrous matrix is preferably carded and, as an option, folded or flapped to form a fibrous fluff, designated F. In a presently preferred embodiment, the fibrous fluff contains 100% overlapping fibers, ie, all fibers of the veil have formed by overlapping a carded veil, so that the reconstituted fibers are oriented at an angle in relation to the machine direction of the resulting veil. US Patent No. 5,475,903, hereby incorporated by reference, shows an apparatus for drafting the web.

The apparatus of Figure 1 includes a foraminous forming surface in the form of a belt 10 in which the precursor web P of the reconstituted fibers is placed for pre-entanglement with the entanglement collector 12 to impart an initial level of structural working integrity to the precursor web . The pre-entanglement of the precursor web is subsequently effected by the movement of the web P in sequence on a drum 14 having a foraminous forming surface, in which the entanglement collector 16 effects the entanglement of the web. Further entanglement of the web is effected on the foraminous forming surface of a cylinder 18 by the entanglement collector 20, the web subsequently passing over successive foraminous drums 20 for the treatment of successive entanglement by the entanglements 24 ', 24'.

The entanglement apparatus of Figure 1 further includes a three-dimensional image forming drum 24 consisting of a three-dimensional image transfer device for affecting the distribution of the fibers and localized or zonal variations in the density and / or basis weight of the fibers. The image transfer device includes a moving image forming surface that moves in relation to a plurality of tangle collectors 26 which act in cooperation with the three-dimensional elements defined by the topography of the image forming surface of the image transfer device to effect the formation of the images and the functional decoration of the genre that is being formed. Convenient finishing compositions or the like can be applied at 30, with the dry fabric in convenient drying cylinders 32.

The non-woven fabrics that are formed in accordance with the present invention have been shown to exhibit sufficient elongation resistance, resistance when wetted and abrasion resistance to ensure use in multiple end-use applications. Of particular importance, the absorbency of the non-woven fabric consisting of reconstituted cotton fibers has been sufficiently conserved to be useful in products and garments for personal hygiene, such as pads for removing make-up, laundry and clothes for the bathroom.

From the foregoing it will be noted that it is possible to effect numerous modifications and variations without departing from the true spirit and scope of the novel concept of the present invention. It should be understood that no limitation is intended or should be inferred with respect to the specific modalities shown herein. The description is intended to cover, through the appended claims, all such modifications falling within the scope of the claims.

Claims

1. A non-woven fabric composed of at least one type of reconstituted fiber of finite length, wherein the reconstituted fiber shows a prevalence of fibrous artifacts of equal to or less than 10% by weight, the reconstituted fibers having been integrated into a non-woven fabric , wherein the non-woven fabric has areas of different density and / or basis weight of the fibers, the non-woven fabric shows sufficient resistance to elongation, resistance when wetted and abrasion resistance to be useful in end-use applications Durable and semi-durable.

2. The non-woven genre in accordance with. claim 1, characterized in that the type of reconstituted fiber, of finite length, is selected from the group consisting of natural fibers, synthetic fibers and mixtures thereof.

3. The non-woven fabric according to claim 2, characterized in that the natural fibers are cotton fibers.

. The non-woven fabric according to claim 2, characterized in that the synthetic fibers are polyester fibers.

5. The non-woven fabric according to claim 1, characterized in that the length of the reconstituted fiber is between about 0.13 inches and 1.0 inches.

6. The non-woven fabric according to claim 5, characterized in that the length of the reconstituted fiber is between about 0.25 inches and 0.75 inches.

7. The non-woven fabric according to claim 1, characterized in that the prevalence of fibrous artifacts is equal to or less than 5% by weight.

8. The non-woven fabric according to claim 5, characterized in that the prevalence of the fibrous artifacts is equal to or less than 1% by weight.

9. The non-woven fabric according to claim 1, characterized in that the nonwoven fabric is integrated by the use of hydroentangling.

10. A nonwoven fabric composed of at least one type of reconstituted fiber of finite length, characterized in that the reconstituted fiber shows a prevalence of fibrous artifacts of equal to or less than 10% by weight, the reconstituted fiber has been integrated into a non-woven fabric , wherein the nonwoven fabric has imparted thereon regions of different density and / or basis weight of the fiber, the non-woven fabric shows sufficient resistance to elongation, resistance when wetted and abrasion resistance to be useful in applications end-use and semi-durable, and where the non-woven fabric can be deconstructed into its fibrous components and reformed to manufacture a new non-woven fabric of equivalent aesthetic and / or physical performance.

11. The non-woven fabric according to claim 10, characterized in that the same fibrous components can be formed in a non-woven fabric and subsequently deconstructed for at least 5 cycles.