US20040110443A1 - Abrasive webs and methods of making the same - Google Patents

Abrasive webs and methods of making the same Download PDF

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Publication number
US20040110443A1
US20040110443A1 US10/310,245 US31024502A US2004110443A1 US 20040110443 A1 US20040110443 A1 US 20040110443A1 US 31024502 A US31024502 A US 31024502A US 2004110443 A1 US2004110443 A1 US 2004110443A1
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United States
Prior art keywords
composite material
fabric
meltblown
wipe
plane
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Abandoned
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US10/310,245
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English (en)
Inventor
Matthew Pelham
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JENTEX Corp
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JENTEX Corp
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Publication date
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Priority to US10/310,245 priority Critical patent/US20040110443A1/en
Assigned to JENTEX CORPORATION reassignment JENTEX CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PELHAM, MATTHEW C.
Priority to PCT/US2003/038726 priority patent/WO2004053219A2/fr
Priority to AU2003297681A priority patent/AU2003297681A1/en
Publication of US20040110443A1 publication Critical patent/US20040110443A1/en
Priority to US11/487,195 priority patent/US7253137B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B32B37/0084—Point bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • B32B2038/0028—Stretching, elongating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2432/00—Cleaning articles, e.g. mops, wipes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24612—Composite web or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/671—Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/673—Including particulate material other than fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/68—Melt-blown nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/699—Including particulate material other than strand or fiber material

Definitions

  • the present invention relates to abrasive webs, composite materials, and methods of making such webs and composite materials.
  • the present invention is directed to abrasive webs and nonwoven composite materials.
  • the abrasive webs and nonwoven composite materials may comprise one or more layers, wherein each layer provides desired properties to the web or composite material.
  • the abrasive web comprises a first meltblown nonwoven web bonded to a second fabric, wherein the meltblown nonwoven web/fabric composite is differentially microstretched in its cross direction to produce a composite material having greater bulk, softness and drapeability relative to the pre-stretched composite material.
  • the present invention is further directed to methods of making abrasive webs and nonwoven composite materials having desired properties, and various uses for the abrasive webs and nonwoven composite materials.
  • FIG. 1 depicts exemplary components for abrasive webs and nonwoven composite materials of the present invention
  • FIG. 2 depicts an exemplary bonded composite of the present invention
  • FIG. 3 depicts an exemplary cross-sectional configuration of the bonded composite of FIG. 2 as viewed along line A-A;
  • FIG. 4 depicts an exemplary process for making a meltblown web for use in the abrasive webs and nonwoven composite materials of the present invention
  • FIG. 5 depicts a variation of the exemplary process shown in FIG. 4, wherein a second layer is joined to the meltblown web layer;
  • FIG. 6 depicts another exemplary process for making abrasive webs and nonwoven composite materials of the present invention
  • FIG. 7A depicts an exemplary stretching process for stretching a nonwoven composite material or one or more layers of the nonwoven composite material
  • FIG. 7B depicts a cross-sectional view of the apparatus used in the stretching process of FIG. 7A.
  • FIGS. 8A and 8B depict exemplary cross-sectional configurations for composite materials of the present invention.
  • the present invention is directed to abrasive webs and nonwoven composite materials having desired properties.
  • the abrasive webs and nonwoven composite materials possess one or more of the following properties: (1) desired abrasiveness; (2) desired absorbency; (3) desired bulkiness; (4) desired softness; (5) desired scent or aroma; and (6) the ability to be manufactured in a cost-effective manner.
  • the present invention is also directed to methods of making abrasive webs and nonwoven composite materials and various uses for the abrasive webs and nonwoven composite materials.
  • the abrasive webs and nonwoven composite materials of the present invention comprise a variety of materials, which provide one or more of the above-mentioned desired properties.
  • a description of suitable materials for forming the abrasive webs and nonwoven composite materials of the present invention is given below.
  • the abrasive webs and nonwoven composite materials of the present invention may comprise one or more layers of material, wherein each layer contributes at least one desired property to the resulting abrasive web or nonwoven composite material. Suitable layers and layer components for forming the abrasive webs and nonwoven composite materials of the present invention are described below.
  • the abrasive webs and nonwoven composite materials of the present invention desirably comprise at least one abrasive layer of meltblown fibers.
  • the abrasive web comprises a single layer of meltblown fibers.
  • the layer of meltblown fibers is a nonwoven fabric.
  • the single layer of meltblown fibers possesses enough structural integrity to form a nonwoven fabric, which may exist as a nonwoven fabric without the need for a supporting substrate.
  • the meltblown fibers may be (1) autogenously bonded to one another, (2) bonded to one another using an external source of heat and/or pressure, or (3) both (1) and (2).
  • autogenously bonded is used to describe fibers, which bond to one another as the fibers come into contact with one another after leaving an extrusion die.
  • the fibers of the abrasive meltblown fabric layer may be made from a variety of materials depending on a number of factors including, but not limited to, processability of the fiber-forming material, desired properties of the individual web and the resulting composite material, and manufacturing costs. Suitable fiber-forming materials include, but are not limited to, polypropylene, polybutylene, polyethylene terephthalate, polyamide, and combinations thereof. Desirably, the fibers of the abrasive meltblown fabric layer comprise polypropylene. Commercially available polypropylenes suitable for use in the present invention include, but are not limited to, polypropylene available from Basell Polyolefins (Wilmington, Del.) under the trade designation Basell.
  • the fibers of the abrasive meltblown fabric layer comprise polypropylene fibers formed from polypropylene available from Basell Polyolefins (Wilmington, Del.) under the trade designation Basell, and having a melt flow index of about 800 g/10 min as measured according to ASTM D-1238.
  • the fibers of the abrasive meltblown fabric layer have an average fiber diameter of less than about 100 microns. More desirably, the fibers have an average fiber diameter of from about 0.5 micron to about 40 microns. Even more desirably, the fibers have an average fiber diameter of from about 10 micron to about 35 microns.
  • the abrasive meltblown fabric layer may have a basis weight, which varies depending upon the particular end use of the individual web and the resulting composite material. Desirably, the abrasive meltblown fabric layer has a basis weight of less than about 500 grams per square meter (gsm) prior to stretching. More desirably, the abrasive meltblown fabric layer has a basis weight of from about 2.5 gsm to about 500 gsm prior to stretching. Even more desirably, the abrasive meltblown fabric layer has a basis weight of from about 8 gsm to about 100 gsm prior to stretching, even more desirably from about 28 gsm to about 60 gsm prior to stretching.
  • gsm grams per square meter
  • the abrasive meltblown web may have a thickness, which varies depending upon the particular end use of the individual web and the resulting composite material. Desirably, the abrasive meltblown web has a thickness of less than about 1000 microns ( ⁇ m) prior to stretching. More desirably, the abrasive meltblown web has a thickness of from about 10 ⁇ m to about 500 ⁇ m prior to stretching. Even more desirably, the abrasive meltblown web has a thickness of from about 20 ⁇ m to about 100 ⁇ m prior to stretching.
  • the fibers within the abrasive meltblown web are uniformly distributed within the web. However, there may be some embodiments wherein it is desirable to have a non-uniform distribution of fibers within the abrasive meltblown web.
  • the composite materials of the present invention may further comprise an absorbent layer in the form of an additional nonwoven fabric.
  • Suitable nonwoven fabric layers include, but are not limited to, a meltblown fabric layer, a spunbonded fabric layer, a spunlaced fabric layer, a carded thermally-bonded (or ‘point-bonded’) nonwoven containing a percentage of viscose fibers or other hydrophilic fiber, or a combination thereof.
  • the absorbent layer comprises a meltblown fabric layer or a spunbonded fabric layer.
  • the fibers of the absorbent nonwoven fabric layer may be made from a variety of materials depending on a number of factors including, but not limited to, processability of the fiber-forming material, desired properties of the individual web and the resulting composite material, and manufacturing costs. Desirably, the fibers of the absorbent nonwoven fabric layer any of the above-mentioned fiber-forming materials.
  • the fibers of the absorbent meltblown fabric layer desirably have an average fiber diameter of less than about 100 microns. More desirably, the fibers of the absorbent meltblown fabric layer have an average fiber diameter of from about 0.5 micron to about 40 microns. Even more desirably, the fibers have an average fiber diameter of from about 1 micron to about 30 microns.
  • the meltblown fabric layer desirably has a basis weight of less than about 1000 grams per square meter (gsm) prior to stretching. More desirably, the absorbent meltblown fabric layer has a basis weight of from about 25 gsm to about 500 gsm prior to stretching. Even more desirably, the absorbent meltblown fabric layer has a basis weight of from about 30 gsm to about 100 gsm prior to stretching.
  • the absorbent meltblown fabric layer may have a thickness, which varies depending upon the particular end use of the composite material. Desirably, the absorbent meltblown fabric layer has a thickness of less than about 1000 microns ( ⁇ m) prior to stretching. More desirably, the absorbent meltblown fabric layer has a thickness of from about 10 ⁇ m to about 500 ⁇ m prior to stretching. Even more desirably, the absorbent meltblown fabric layer has a thickness of from about 20 ⁇ m to about 100 ⁇ m prior to stretching.
  • the absorbent nonwoven fabric layer may comprise nonwoven fabric layers other than a meltblown fabric layer.
  • the absorbent nonwoven fabric layer comprises a spunbonded fabric layer having fiber dimensions, fabric basis weight, and fabric thickness values similar to the values given above with regard to the absorbent meltblown fabric layer.
  • the composite materials of the present invention may comprise an absorbent layer in the form of a woven fabric.
  • Suitable woven fabric layers include, but are not limited to, woven fabrics formed from absorbent fibers, hydrophilic fibers, or a combination thereof.
  • the fibers of the absorbent woven fabric layer may be made from any of the above-described materials.
  • the absorbent woven fabric layer may include cellulosic fibers, cotton fibers, viscose fibers, or any other absorbent or hydrophilic fiber.
  • the absorbent layer comprises a woven fabric layer
  • the woven fabric layer desirably has a basis weight of less than about 1000 grams per square meter (gsm) prior to stretching. More desirably, the absorbent woven fabric layer has a basis weight of from about 25 gsm to about 500 gsm prior to stretching. Even more desirably, the absorbent woven fabric layer has a basis weight of from about 30 gsm to about 100 gsm prior to stretching.
  • the absorbent woven fabric layer may have a thickness, which varies depending upon the particular end use of the composite material. Desirably, the absorbent woven fabric layer has a thickness of less than about 1000 microns ( ⁇ m) prior to stretching. More desirably, the absorbent woven fabric layer has a thickness of from about 10 ⁇ m to about 500 ⁇ m prior to stretching. Even more desirably, the absorbent woven fabric layer has a thickness of from about 20 ⁇ m to about 100 ⁇ m prior to stretching.
  • additives may be added to the fiber melt and extruded to incorporate the additive into the fiber.
  • one or more additives may be coated onto the fiber during or after the fabric forming process.
  • Suitable additives include, but are not limited to, fillers, stabilizers, plasticizers, tackifiers, flow control agents, cure rate retarders, adhesion promoters (for example, silanes and titanates), adjuvants, impact modifiers, expandable microspheres, thermally conductive particles, electrically conductive particles, and the like, such as silica, glass, clay, talc, pigments, colorants, scent-producing agents, surfactants, detergents, glass beads or bubbles, antioxidants, optical brighteners; antimicrobial agents; surfactants; fire retardants; and fluoropolymers.
  • the amount of one or more additives is less than about 25 weight percent, desirably, up to about 2.5 percent, based on the total weight of the fiber and/
  • One or more of the above-described additives may be used to reduce the weight and/or cost of the resulting fiber and/or web, adjust viscosity, or modify the thermal properties of the fiber or confer a range of physical properties derived from the physical property activity of the additive including: cleansing properties,antimicrobial properties, scent-producing properties, color-producing properties, etc.
  • At least one colorant and at least one scent-producing additive are added to or coated onto the fiber-forming materials of the abrasive meltblown layer and/or the at least one additional fabric layer.
  • the fiber-forming materials of the abrasive meltblown layer are substantially free of colorants and scent-producing additives, while the fiber-forming materials of the at least one additional fabric layer contains at least one colorant and at least one scent-producing additive.
  • the fiber-forming materials of the abrasive meltblown layer contain at least one colorant and/or at least one scent-producing additive, while the fiber-forming materials of the at least one additional fabric layer are substantially free of colorants and scent-producing additives.
  • the colorant when present, comprises a pigment or dye providing a desired color, such as yellow, orange, or any other desired color.
  • the scent-producing additive when present, provides a desired scent, such as a lemon scent, a pine scent, or any other desired scent.
  • a suitable scent-producing additive is Lemon Citrus #50-3264 commercially available from Cognis Corporation (Ambler, Pa.).
  • At least one layer of the composite material comprises a soap, surfactant or detergent.
  • soap surfactant
  • detergent detergent
  • materials for cleaning a surface such as cookware, utensils, countertop, or any other surface.
  • a surfactant may be added to the fiber-forming material of the abrasive layer and/or the additional fabric layer before the abrasive layer and/or the additional fabric layer is formed to make the abrasive layer and/or the additional fabric layer more hydrophilic.
  • a surfactant may be applied to the fiber-forming materials of the abrasive layer and/or the additional fabric layer after the abrasive layer and/or the additional fabric layer is formed.
  • one or more antimicrobial agents such as silver zeolite, may also be incorporated into the abrasive layer and/or the additional fabric layer.
  • hydrophilic additives soaps, surfactants and detergents
  • Suitable surfactants include, but are not limited to, nonionic surfactants, anionic surfactants, and a combination thereof.
  • a suitable hydrophilic additive is polyethylene glycol.
  • a suitable detergent is Detergent 0240-82 commercially available from Cognis Corporation (Ambler, Pa.).
  • exemplary composite material 10 comprises an abrasive web 11 including extruded polypropylene fibers 15 and an additional nonwoven material 12 comprising extruded polypropylene fibers 16.
  • FIG. 2 An exemplary bonded composite is shown in FIG. 2.
  • the exemplary bonded composite 10 of FIG. 2 comprises upper layer 11 bonded to lower layer 12.
  • upper layer 11 may be an abrasive meltblown nonwoven fabric of polypropylene fibers
  • lower layer 12 may be a second meltblown nonwoven fabric of polypropylene fibers.
  • upper layer 11 may be bonded to lower layer 12 using a variety of bonding processes as described below
  • exemplary bonded composite 10 of FIG. 2 comprises point bonds 13 uniformly distributed along an upper surface 110 of upper layer 11.
  • FIG. 3 depicts a cross-sectional view of exemplary bonded composite 10 of FIG. 2 along line A-A.
  • bonded composite 10 has an overall thickness, which is the combined thickness of upper layer 11 and lower layer 12 .
  • the term “overall thickness” when used to describe the thickness of bonded composite 10 describes the average thickness of the bonded composite 10 in areas other than point-bonded areas 13 .
  • bonded composite 10 has an overall thickness of from about 40 microns ( ⁇ m) to about 250 ⁇ m prior to stretching.
  • bonded composite 10 has an overall thickness of from about 60 ⁇ m to about 110 ⁇ m prior to stretching.
  • the bonded composite may be prepared in a number of ways.
  • One exemplary method of making a meltblown web for use in the bonded composite is depicted in FIG. 4.
  • molten polymer 300 is introduced into a die assembly 320 .
  • Die assembly 320 comprises a plurality of spinnerets (not shown) from which molten polymer 300 is extruded.
  • Molten polymer 300 exits die assembly 320 at location 325 and enters into a curtain of process air 330 .
  • the curtain of process air 330 attenuates extruded polymer fibers 350 as the fibers 350 travel a distance d from an exit of the plurality of spinnerets (not shown) to a collection surface at location 360 on an outer surface of drum 365 .
  • Drum 365 rotates at a desired speed to form a meltblown web 370 , which moves along an outer surface of drum 365 .
  • Meltblown web 370 moves along drum 365 to point 366 , wherein a nip roll 367 contacts the meltblown web 370 and guides the web off of drum 365 onto an outer surface of nip roll 367 .
  • Meltblown web 370 may proceed onto other processes along the process line, such as a calender assembly 380 .
  • Calender assembly 380 comprises a first roll 381 and a second roll 382 which nip the meltblown web 370 to further bond the fibers of the web to one another.
  • First roll 381 and second roll 382 may have a smooth surface to form bonding sites throughoutmeltblown web 370 .
  • at least one of first roll 381 and second roll 382 has raised portions along the roll surface, which results in a point-bonding pattern across meltblown web 370 (such as the point-bonding shown in FIGS. 2 - 3 ). Each point of the point-bonding pattern may have any shape and size desired.
  • the total bonded area of the meltblown web 370 may vary from about 5 to about 95 percent of the total surface area of the web, desirably, from about 8 to about 50 percent of the total surface area of the web, more desirably, from about 25 to about 40 percent of the total surface area of the web.
  • the resulting meltblown web 370 may be taken off the process line in the form of a roll, such as on a cardboard or plastic tube, and stored for later processing. Alternatively, resulting meltblown web 370 may be further processed by joining meltblown web 370 to another composite component layer, such as an additional nonwoven fabric layer, and then processed through a bonding process, such as the above-described calendering process.
  • a bonding process such as the above-described calendering process.
  • an additional composite component layer such as an additional nonwoven fabric layer, is joined to meltdown web 370 as shown in FIG. 5.
  • meltblown web 370 also referred to as meltblown layer 12
  • meltblown web 370 is brought into contact with a pre-manufactured abrasive meltblown fabric layer 11 .
  • the combined meltblown web 370 /abrasive meltblown fabric layer 11 assembly proceeds through calender assembly 380 to produce bonded composite material 10 .
  • the pre-manufactured abrasive meltblown fabric layer 11 may be prepared using a process as shown in FIG. 4.
  • a woven fabric (not shown) may be joined to a pre-manufactured abrasive meltblown fabric layer 11 and processed through calender assembly 380 to produce a bonded composite material.
  • the bonded pre-stretched composite material When a point-bonding process is used to join the meltblown web 370 (or a woven fabric) to an additional nonwoven fabric layer, it is desirable for the bonded pre-stretched composite material to have a bond cover area of less than about 50% based on a total surface area of the bonded pre-stretched composite material. More desirably, the bonded pre-stretched composite material has a bond cover area of from about 30% to about 40% based on a total surface area of the bonded pre-stretched composite material.
  • FIG. 6 One alternative method of forming a bonded composite material 10 is shown in FIG. 6.
  • a second substrate 12 e.g., a pre-manufactured absorbent nonwoven or woven fabric layer
  • Second substrate 12 can be stored in roll form 340 .
  • first roll 381 and second roll 382 bond the fibers of meltblown web 370 to one another and also bond meltblown web 370 to second substrate 12 to form bonded pre-stretched composite material 10 .
  • the degree of bonding within meltblown web 370 and to second substrate 12 may vary as described above.
  • the method of forming the meltblown web involves melt extruding a thermoformable material at a melt extrusion temperature of from about 130° C. to about 350° C.
  • the polypropylene is melt extruded at a melt extrusion temperature of about 270° C.
  • the die assembly comprises a plurality of spinnerets through which molten thermoformable material is extruded.
  • the die assembly comprises a plurality of spinnerets, wherein the number of spinneret holes through the die is at least 700 spinneret holes per linear meter.
  • the plurality of spinnerets has an average hole diameter of from about 0.25 to about 0.75 mm.
  • the method of making the meltblown web comprises melt extruding a thermoformable material, such as polypropylene, at a rate of at least 25 kilograms per hour per linear meter of extrusion width (k/hr/lm).
  • the weight of extruded polymer per orifice of die is from about 0.3 g of polymer per hole per minute to about 2.0 g of polymer per hole per minute.
  • the method of making the meltblown web comprises using a stream of air to attenuate the plurality of extruded fibers at a point below an exit of the plurality of spinnerets within the die assembly.
  • the exit of the plurality of spinnerets may be positioned a distance, d, above the collection surface.
  • the distance, d may be adjusted by moving the plurality of spinnerets up or down relative to the collection surface. This may be beneficial for control of fiber size, web pore size, fiber fusion, and web basis weight uniformity.
  • distanced may vary from about 100 mm to about 1500 mm.
  • the stream of air used to attenuate the plurality of extruded fibers desirably has an air speed of from about 5 meters per second (ms ⁇ 1 ) to about 300 ms ⁇ 1 .
  • the air stream volume typically ranges from about 550 cm 3 /sec per centimeter (cm) of die width (3 cfm per inch of die width) to about 1860 cm 3 /sec per centimeter (cm) of die width (10 cfm per inch of die width), desirably about 1100 cm 3 /sec per centimeter (cm) of die width (6 cfm per inch of die width).
  • the stream of air desirably has an air temperature of from about 150° C. to about 400° C., more desirably, from about 160° C. to about 240° C., and even more desirably about 200° C.
  • the method uses a die assembly comprising a plurality of spinnerets wherein the plurality of spinnerets are arranged along a die having a length,l, and a width, w, with an upper surface (i.e., die entrance), a lower surface (i.e., die exit), two side surfaces, and two end surfaces.
  • a die assembly comprising a plurality of spinnerets wherein the plurality of spinnerets are arranged along a die having a length,l, and a width, w, with an upper surface (i.e., die entrance), a lower surface (i.e., die exit), two side surfaces, and two end surfaces.
  • the die assembly has a length, 1, of from about 0.05 meters (m) to about 3 m extending in a first direction perpendicular to the web (i.e., the cross direction of the web); and a width, w, of from about 1 mm to about 100 mm extending in a second direction parallel to the web (i.e., the machine direction of the web).
  • a plurality of spinneret holes extends in a direction from the upper surface to the lower surface.
  • a stream of attenuating air may contact the plurality of fibers at a point below an exit of the plurality of spinnerets, wherein the stream of air flows through slots positioned along the two side surfaces (see FIGS. 4 - 6 ).
  • the collection surface may be in the form of a flat surface as oppose to a rotating drum (as shown in FIGS. 4 - 6 ).
  • the collection surface may comprise a drum supporting a carrier material; an endless belt, a horizontal table; a horizontal table supporting a carrier material; or a tenter frame supporting a carrier material.
  • the collection surface is a drum having a diameter of from about 0.3 m to about 2.0 m, and a width of from about 0.05 m to about 3 m.
  • the drum may have an outer surface comprising a smooth metal surface or a wire screen mesh.
  • the drum has an outer surface comprising a wire screen mesh.
  • the drum outer surface may be of any appropriate material, such as metal, polyester or teflon.
  • the drum outer surface is a wire screen mesh having an x-y matrix pattern with gaps in between the wire mesh material. Any gauge wire mesh material may be used as long as the meltblown web that is formed on the wire mesh material maintains a sufficient amount of integrity and strength after being removed from the wire mesh material.
  • the speed of the drum may vary depending on the throughput of the process line. Desirably, an outer surface of the drum has a linear speed of from about 0.1 ⁇ m/min to about 150 m/min.
  • the method of forming the bonded pre-stretched composite may include any of the above-described features.
  • the method of forming the bonded pre-stretched composite may include one or more of the following process steps:
  • the bonded composite may be further processed through a stretching apparatus, such as the exemplary stretching apparatus shown in FIG. 7A.
  • bonded composite 10 proceeds through stretching apparatus 60 and exits as stretched composite material 395 .
  • Stretching apparatus 60 comprises two interengaged drums, upper drum 61 and lower drum 62 , and a nip roller 63 . Each drum consists of alternating discs having different disc diameters. A cross-sectional view of upper drum 61 and lower drum 62 is given in FIG. 7B.
  • upper drum 61 consists of alternating discs 612 and 613 having a larger disc diameter, d 612 , and a smaller diameter, d 613 , respectively.
  • Lower drum 62 also consists of alternating discs 615 and 616 having a larger disc diameter, d 615 , and a smaller diameter, d 616 , respectively.
  • tension is exerted on bonded composite 10 by nip roller 63 to keep bonded composite 10 positioned next to lower drum 62 .
  • microstretched portions extend in the machine direction of the stretched composite material 395 , and are located substantially between adjacent peaks and valleys as described below.
  • discs 612 on upper drum 61 exert a stretching force on bonded composite 10 , forcing portions of bonded composite 10 into the gaps between discs 615 on lower drum 62 .
  • Peaks 82 and valleys 84 are formed in bonded composite 10 .
  • the areas between peaks 82 and valleys 84 are microstretched portions 86 . It is believed that a substantial amount of the total stretching of bonded composite 10 occurs in microstretched portions 86 .
  • the distance between peaks 82 and valleys 84 (and the length of microstretched portions 86 as measured in the cross direction of bonded compositely) may vary depending on the width and diameters of discs 612 , 613 , 615 and 616 . Further, it is believed that peaks 82 and valleys 84 have a higher concentration of bonds between the composite material layers (e.g., upper layer 11 and lower layer 12 ) compared to a bond concentration in the microstretched portions 86 .
  • discs 612 , 613 , 615 and 616 have a width ranging from about 0.5 mm (20 mil.) to about 3.0 mm (120 mil.), desirably, from about 1.0 mm (40 mil.) to about 1.5 mm (60 mil.). In one exemplary embodiment of the present invention, discs 612 , 613 , 615 and 616 have the following widths: disc 612 -1.27 mm (50 mil.); disc 613 -2.54 mm (100 mil.); disc 615 -1.27 mm (50 mil.); and disc 616-2.54 mm (100 mil.).
  • discs 612 , 613 , 615 and 616 have a diameter ranging from about 5.1 cm (2 inches (in.)) to about 61.0 cm (24 in.), desirably, from about 7.6 cm (3 in.) to about 30.5 cm (12 in.).
  • discs 612 , 613 , 615 and 616 have the following diameters: disc 612 -17.8 cm (7 in.); disc 613 -15.2 cm (6 in.); disc 615 -17.8 cm (7 in.); and disc 616 -15.2 cm (6 in.).
  • the bonded composite may be laterally stretched using the above-describe stretching apparatus to increase the width of the bonded composite up to about 30% (i.e., the final width is 1.3 times the original width).
  • the bonded composite is laterally stretched to a final width, which is from about 2% to about 25% greater than the original width of the bonded pre-stretched composite, more desirably, from about 10% to about 25% greater than the original width of the bonded pre-stretched composite.
  • any single layer of the composite material of the present invention may be laterally stretched using the above-describe stretching apparatus prior to being joined to one or more other layers of the composite material.
  • an absorbent layer may be stretched to increase the width of the absorbent layer up to about 30% (i.e., the final width is 1.3 times the original width) prior to joining the absorbent layer to an abrasive nonwoven layer.
  • the absorbent layer is calendered as described above, although calendering is an optional step. After stretching the absorbent layer, the stretched absorbent layer may be joined to the abrasive nonwoven layer to form the composite material.
  • the resulting composite material may be further processed as described below.
  • the composite material comprises (i) a calendered, stretched absorbent layer comprising a meltblown or spunbonded nonwoven fabric, and (ii) an abrasive nonwoven fabric layer bonded to the stretched absorbent layer.
  • the absorbent layer is desirably laterally stretched to a final width, which is from about 2% to about 25% greater than the original width of the absorbent layer, more desirably, from about 10% to about 25% greater than the original width of the absorbent layer.
  • the abrasive layer may be either (i) point-bonded to the stretched absorbent layer at a desired bond cover area of from about 30% to about 40% based on a total surface area of the bonded composite material, or (ii) overblown onto the stretched absorbent layer (using the meltblowing process described above and depicted in FIG. 6) to produce a composite material.
  • the abrasive layer is overblown onto the stretched absorbent layer to produce a composite material.
  • one or more additives may be incorporated into one or more layers of the composite material of the present invention.
  • the one or more additives may be incorporated into an individual layer of the composite material prior to being bonded to one or more additional layers of the composite material.
  • one or more additives may be incorporated into each of the individual layers of the composite material after being bonded to one another.
  • one or more additives such as a colorant, a scent-producing agent, and/or a surfactant
  • a colorant, a scent-producing agent, and/or a surfactant are sprayed onto the fibers as the fibers travel distanced, between (i) the exit of the plurality of spinnerets and (ii) the collection surface (see FIGS. 4 - 6 ).
  • one or more additives such as a colorant, a scent-producing agent, and/or a surfactant, are coated onto and/or impregnated into the composite material.
  • the coating process may be any known coating process, such as a spray coating, pad coating, dip coating, etc.
  • One method of impregnating one or more additives into the composite material is via an extrusion process, wherein the composite material is passed through an extrusion die having a width and height similar to or slightly larger than the dimensions of the composite material.
  • one or more additives are fed into the extruder as the composite material travels through the extruder, resulting in an impregnation of the composite material.
  • one or more additives may be incorporated into the polymer melt prior to fiber formation.
  • the one or more additives are typically in the form of finely divided solid particles, which may be blended with the polymer. The particle size is small relative to the die orifices used to extrude the fiber-forming material.
  • the stretched composite materials of the present invention may have a cross-sectional configuration along a cross direction of the composite, which varies depending on the stretching apparatus used.
  • the term “stretched composite materials” refers to composite materials of the present invention wherein (i) the entire composite material is stretched or (ii) at least one layer of the composite material (e.g., the absorbent layer) is stretched using the method as described above.
  • the stretched composite material has a wave-like cross-sectional configuration along a cross direction of the stretched composite material, wherein the wave-like cross-sectional configuration contains a plurality of alternating peaks and valleys. Exemplary wave-like cross-sectional configurations are shown in FIGS. 8A and 8B.
  • stretched composite material 395 may have a sine-wave shape (FIG. 8A) or a truncated cone-wave shape (FIG. 8B). It should be noted that stretched composite material 395 may have other cross-sectional configurations depending on the shape and dimensions of the alternating discs used to stretch the composite material.
  • stretched composite material 395 has peaks 82 , valleys 84 , and microstretched portions 86 positioned between peaks 82 and valleys 84 .
  • the microstretched portions 86 extend in the machine direction of stretched composite material 395 , and are located substantially between adjacent peaks 82 and valleys 84 .
  • stretched composite material 395 may have a cross-sectional configuration, wherein each peak 82 is separated from adjacent peaks as viewed along the cross direction of stretched composite material 395 and located substantially within a first plane.
  • each valley 84 may be separated from adjacent valleys as viewed along the cross direction of stretched composite material 395 and located substantially within a second plane parallel with and below the first plane.
  • the microstretched portions 86 are located substantially between the first plane and the second plane.
  • stretched composite material 395 have a cross-sectional configuration, wherein the average distance between adjacent peaks ranges from about 1.0 mm to about 10.0 mm, and the average distance between adjacent valleys ranges from about 1.0 mm to about 10.0 mm.
  • distance between adjacent peaks refers to the distance between the apex of one peak and the apex of an adjacent peak. Desirably, the average distance between adjacent peaks ranges from about 2.0 mm to about 6.0 mm, and the average distance between adjacent valleys also ranges from about 2.0 mm to about 6.0 mm.
  • stretched composite material 395 has a cross-sectional configuration, wherein the microstretched portions 86 have an average width as measured along the cross direction of stretched composite material 395 between the first plane and the second plane ranging from about 0.05 mm to about 8.0 mm, more desirably, from about 1.0 mm to about 3.0 mm.
  • the stretched composite material of the present invention comprises a stretched layer (e.g., a stretched absorbent layer) and an unstretched layer (e.g., an abrasive nonwoven layer)
  • the composite material may still have any of the above-described cross-sectional configurations having peaks and valleys as described above.
  • the above-described microstretched portions will only be present within the stretched layer of the composite material.
  • the stretched composite materials of the present invention may have a final width of at least 2% greater than the bonded pre-stretched composite. Further, the stretched composite materials of the present invention (or a stretched layer thereof) may have a final thickness of at least 20% greater than the pre-stretched composite material (or pre-stretched layer). Desirably, the stretched composite material (or a stretched layer thereof) has a final thickness of from about 30% to about 60% greater than the pre-stretched composite material (or pre-stretched layer), more desirably, from about 35% to about 50% greater than the pre-stretched composite material (or pre-stretched layer).
  • the stretched composite material (or a stretched layer of the composite material) has the following properties:
  • the stretched and pre-stretched composite materials of the present invention may be used in a variety of applications including residential, commercial (e.g., food service businesses), and industrial applications.
  • the stretched and pre-stretched composite materials of the present invention are particularly useful as materials for forming wipes.
  • the wipes may be used for cleaning pots and pans, as well as, surface cleaning for bathrooms, outdoor camping, recreational vehicles, etc.
  • the wipes may also be cut to a suitable dimension for use in gun cleaning applications.
  • the stretched composite material is formed into a wipe.
  • the wipe comprises an outer layer of an abrasive meltblown nonwoven fabric and at least one absorbent nonwoven fabric bonded to the abrasive meltblown nonwoven fabric.
  • the wipe may have any desired size and shape.
  • the wipes are available as separate individual sheets or as connected individual sheets in roll form, similar to a roll of paper towels, wherein the individual sheets have a width and/or length of up to about 50 cm. In one exemplary roll of wipes, each individual wipe has a width of about 28 cm and a length of about 22 cm.
  • the wipe comprises (a) an abrasive meltblown nonwoven fabric formed from polypropylene fibers having an average fiber diameter of less than about 100 microns and a fabric basis weight of from about 28 gsm to about 60 gsm; and (b) at least one additional meltblown nonwoven fabric formed from polypropylene fibers having an average fiber diameter of less than about 100 microns and a fabric basis weight of from about 44 gsm to about 100 gsm.
  • the wipe comprises (a) an abrasive meltblown fabric layer of extruded polypropylene fibers having a basis weight of about 34 gsm and an average fiber diameter ranging from about 10 ⁇ m to about 32 ⁇ m calendared to (b) an absorbent meltblown nonwoven fabric of extruded polypropylene fibers having an average fiber diameter of from about 2 ⁇ m to about 10 ⁇ m.
  • the wipe material is desirably calendered at a point-bonding density of about 33% (i.e., about 33% of the total surface area of an outer layer of the composite wipe material is bonded) to form pockets within the layers of the composite material (i.e., point bonds 13 as shown in FIG. 2).
  • the pockets allow the composite wipe material to collect dirt or other particles from a surface being wiped. As an abrasive force is applied to the surface, dirt or other particles are released from the surface. The capture of particles in the wipe pockets allows the particles to move away from the surface, which reduces scratching or damaging of the surface being wiped. Furthermore, it is believed that the pockets increase the durability and life-span of the composite wipe material.
  • each pocket desirably has a pocket lip and a pocket floor (see FIG. 3, which depicts pocket lip 131 and pocket floor 132 ).
  • the pocket lips are desirably positioned along an outer surface of the abrasive layer while the pocket floors are positioned within an interior of the composite material, desirably within the additional nonwoven fabric layer.
  • the plurality of pockets may be uniformly distributed in an amount depending on the size and shape of the pockets.
  • the plurality of pockets are uniformly distributed in an amount of about 25 pockets per square centimeter of outer surface of the abrasive layer, wherein each pocket has a substantially square or diamond shape having a pocket surface area of about 1 square millimeter.
  • each pocket has a substantially square or diamond shape having a pocket surface area of about 1 square millimeter.
  • the size, shape, and number of pockets per given area of composite material may vary as desired.
  • the wipe comprises at least one of (i) a colorant, (ii) a scent-producing additive, (iii) a surfactant, and (iv) an antimicrobial agent in (a) the abrasive layer, (b) the absorbent nonwoven and/or woven layer, or both.
  • the wipe comprises a colorant (e.g., yellow) in the abrasive layer, and both a scent-producing additive (e.g., lemon scent) and a surfactant in the absorbent meltblown nonwoven layer.
  • the wipe comprises an abrasive layer substantially free of additives, and an absorbent meltblown nonwoven layer comprising a colorant (e.g., yellow), a scent-producing additive (e.g., lemon scent), and a surfactant.
  • a colorant e.g., yellow
  • a scent-producing additive e.g., lemon scent
  • the wipe may be used in residential, commercial, or industrial applications.
  • a surfactant impregnated into the wipe enables the wipe to produce a cleaning foam composition once the wipe is exposed to water.
  • the wipe provides an abrasive cleaning surface and surfactant composition, which is safe to use on teflon-coated cookware, as well as, other scratch-sensitive surfaces, such as porcelain surfaces and painted surfaces.
  • the pre-stretched composite material (i.e., no layers in the composite material are stretched) is formed into a wipe.
  • the wipe comprises an outer layer of an abrasive meltblown nonwoven fabric and at least one absorbent nonwoven fabric bonded to the abrasive meltblown nonwoven fabric.
  • the pre-stretched composite wipe may have any desired size and shape, and may be available as separate individual sheets or as connected individual sheets in roll form, similar to a roll of paper towels.
  • the pre-stretched composite wipes are available as separate individual sheets, wherein each individual wipe has a width of about 33 cm and a length of about 29.7 cm.
  • Softness is determined using a drapeability test. Samples of fabric are cut into 2.54 cm (1 in.) ⁇ 12.7 cm (5 in.) strips. Samples are taped to the edge of a flat, level surface so that the sample hangs over the edge of the surface. The distance from the surface to the hanging edge of the strip is measured. A longer distance measurement indicates a softer and more drapeable fabric sample.
  • Samples are cut into 12.7 cm (5 in.) diameter circles. The dry samples are weighed. The dry weight is recorded. The samples are immersed in a water bath for 10 minutes. Samples are then allowed to drain on a rack for 10 minutes. The wet samples are weighed. The wet weight is recorded. The absorbency is expressed in percentage dry weight.
  • the hydrohead test method measures the resistance of a fabric to the penetration of water under low hydrostatic pressure.
  • the method is performed by applying a fabric sample to the top of a test head reservoir. Water pressure is increased at a constant rate until water leaks through the fabric sample. The water pressure is read at the first sign of leakage in three separate areas of the sample. Water pressure is reported in units of psi or mbar. Details of this test method are described in INDA test method, IST 80.6 (01)-Standard Test Method for Water Resistance, The Hydrostatic Pressure Test.
  • a fiber-producing melt was prepared by melting a fiber composition comprising polypropylene at a melt temperature of about 270° C.
  • the polymer melt was extruded a rate of 100 kilograms per hour per linear meter of extrusion width (kg/hr/lm) using an apparatus similar to the apparatus as shown in FIG. 4.
  • the molten polymer was introduced into a die assembly having a height of 0.13 m, a width of 0.15 m, and a length of 1 m, and comprising a plurality of spinnerets having a hole diameter of 0.305 mm, wherein the number of spinneret holes through the die was 1378 spinneret holes per linear meter.
  • the curtain of process air attenuated the extruded fibers as the fibers traveled a distance d (d 230 mm) from an exit of the plurality of spinnerets to a collection surface on an outer surface of a rotating drum having an outer diameter of 0.66 m.
  • the drum was rotating with a linear speed of 40 m/min.
  • the plurality of fibers moved along an outer surface of the rotating drum having a wire screen contact surface.
  • the formed web was removed from the drum by a nip roll assembly.
  • a fiber-producing melt was prepared by melting a fiber composition comprising polypropylene at a melt temperature of about 270° C.
  • the polymer melt was extruded a rate of 100 kilograms per hour per linear meter of extrusion width (kg/hr/lm) using an apparatus similar to the apparatus as shown in FIG. 4.
  • the molten polymer was introduced into a die assembly having a height of 0.13 m, a width of 0. 15 m, and a length of 1 m, and comprising a plurality of spinnerets having a hole diameter of 0.305 mm, wherein the number of spinneret holes through the die was 1378 spinneret holes per linear meter.
  • the curtain of process air attenuated the extruded fibers as the fibers traveled a distance d (d 230 mm) from an exit of the plurality of spinnerets to a collection surface on an outer surface of a rotating drum having an outer diameter of 0.66 m.
  • the drum was rotating with a linear speed of 40 m/min.
  • Example 1 The abrasive meltblown web formed in Example 1 was bonded to the absorbent meltblown web formed in Example 2 by passing both webs through a calendering process. The abrasive meltblown web/absorbent meltblown web was then point-bonded to produce a bonded pre-stretched composite having a bond cover area of about 33% based on a total surface area of the bonded pre-stretched composite.
  • Example 3 The pre-stretched composite material formed in Example 3 was laterally stretched in a stretching apparatus as shown in FIGS. 7 A- 7 B.
  • the final nonwoven composite material had a final width 20% greater than the width of the bonded pre-stretched composite.
  • the composite material had the following properties as shown in Table 1 below.
  • TABLE 1 Test Data for Pre-Stretched and Post-stretched Composites Pre-stretched Post-stretched % Change Basis Weight 110 99 ⁇ 10% (gsm) Thickness (mm) 0.439 0.642 46% Absorbency (% 322 402 25% dry weight) Drape Good drape in Slightly improved +Change machine direction direction, poor drape drape, greatly in cross improved cross direction. direction drape Hydro-head (psi) >3 psi 2.6 psi ⁇ 13%
  • microstretching provided the benefits of increased material thickness and bulk, increased absorbency, and also improved drape and softness.
  • Example 4 The stretched composite material formed in Example 4 was spray coated with a scent-producing agent, Lemon Citrus #50-3264, available from Cognis Corporation (Ambler, Pa.) and a detergent, Detergent 0240-82, also available from Cognis Corporation (Ambler, Pa.). The coated composite material was dried to form a coated, stretched wipe composite material having a desired scent and enhanced cleaning capabilities.
  • a scent-producing agent Lemon Citrus #50-3264
  • Detergent 0240-82 also available from Cognis Corporation
US10/310,245 2002-12-05 2002-12-05 Abrasive webs and methods of making the same Abandoned US20040110443A1 (en)

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AU2003297681A AU2003297681A1 (en) 2002-12-05 2003-12-04 Abrasive webs and methods of making the same
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AU2003297681A1 (en) 2004-06-30
AU2003297681A8 (en) 2004-06-30

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