US20060185134A1 - Method of making a filamentary laminate and the products thereof - Google Patents

Method of making a filamentary laminate and the products thereof Download PDF

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Publication number
US20060185134A1
US20060185134A1 US11/290,234 US29023405A US2006185134A1 US 20060185134 A1 US20060185134 A1 US 20060185134A1 US 29023405 A US29023405 A US 29023405A US 2006185134 A1 US2006185134 A1 US 2006185134A1
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United States
Prior art keywords
web
laminate
nonwoven fabric
making
continuous filament
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Abandoned
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US11/290,234
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English (en)
Inventor
Nick Carter
Sergio Diaz deLeon
Ralph Moody
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PGI Polymer Inc
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PGI Polymer Inc
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Priority to US11/290,234 priority Critical patent/US20060185134A1/en
Assigned to PGI POLYMER, INC. reassignment PGI POLYMER, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CARTER, NICK M, DE LEON, SERGIO DIAZ, MOODY, III, RALPH A.
Publication of US20060185134A1 publication Critical patent/US20060185134A1/en
Assigned to CITICORP NORTH AMERICA, INC., AS COLLATERAL AGENT reassignment CITICORP NORTH AMERICA, INC., AS COLLATERAL AGENT NOTICE OF NEW COLLATERAL Assignors: CHICOPEE, INC., FIBERTECH GROUP, INC., PGI POLYMER INC., POLY-BOND INC., POLYMER GROUP, INC.
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • D04H5/03—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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 shape; Layered products comprising a layer 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 shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
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    • 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
    • B32B5/022—Non-woven fabric
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    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
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    • 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
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    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/689—Hydroentangled nonwoven fabric

Definitions

  • the present invention relates generally to hydroentangled (spunlaced) nonwoven fabrics, and more particularly to hydroentangled laminate nonwoven fabrics formed from a continuous filament web and a cellulosic fiber web, which are integrated so that the cellulosic fibers become integrated with the continuous filament structure.
  • the resultant fabric exhibits excellent strength and absorbency, and is particularly suited for use in hygiene, medical, and industrial applications.
  • Nonwoven fabrics have found widespread application by virtue of the versatility afforded by the manner in which the physical characteristics of such fabrics can be selectively engineered. Formation of nonwoven fabrics by hydroentanglement (spunlacing) is particularly advantageous in that the fibers or filaments from which the fabric is formed can be efficiently integrated and oriented as may be desired for a specific application. Blends of different types of fibers can be readily combined by hydroentanglement so that resultant fabrics exhibiting selected physical properties can be fabricated.
  • nonwoven fabrics formed from blends of synthetic and cellulosic fibers have been known, with such fabrics desirably exhibiting physical properties which are characteristic of the constituent synthetic and cellulosic fibers.
  • synthetic fibers can be formed into a fabric so that the characteristics such as good abrasion resistance and tensile strength can be provided in the resultant fabric.
  • cellulosic fibers provides such fabrics with desired absorbency and softness.
  • U.S. Pat. No. 5,459,912 to Oathout discloses patterned, spunlaced fabrics formed from synthetic fibers and wood pulp which are stated as exhibiting good absorbency, and low particle counts. The fabrics are thus suited for use where these characteristics are desirable, such as for use as wipes in clean rooms, wipes for food service, and like applications.
  • this patent contemplates integration of wood pulp fibers and synthetic fibers in a dry state, with subsequent hydroentanglement by treatment on one side only (prior to aperturing). It is believed that this results in significant loss of the wood pulp fibrous material through the loosely bonded synthetic fibers, thus detracting from the efficiency of the manufacturing process.
  • the present invention is directed to a method of making such a laminate nonwoven fabric which facilitates efficient fabric formation by abating loss of cellulosic fibers to the filtrate water during integration by hydroentanglement.
  • the present invention is directed to a method of making a laminate nonwoven fabric which entails integration of a continuous filament web with a web of cellulosic fiber material, typically wood pulp.
  • the present invention contemplates that the continuous filament web is first subjected to hydroentanglement, with the cellulosic fibrous material thereafter integrated, by hydroentangling, into the partially entangled continuous filament web.
  • This formation technique has been found to desirably abate the loss of the cellulosic fibers during the hydroentangling process into the filtrate water employed for hydroentanglement.
  • the resultant fabric exhibits the desired blend of characteristics achieved by use of continuous filaments and cellulosic fibers together, with the manufacturing technique of the present invention desirably facilitating efficient and cost-effective formation of the present fabric.
  • a method of making a laminate nonwoven fabric comprises the steps of providing a continuous filament web and further comprises hydroentangling the continuous filament web to form a partially entangled web.
  • This partial hydroentanglement desirably acts to integrate the filaments and improve web uniformity, prior to introduction of the associated cellulosic fibrous material.
  • the cellulosic fibrous material of the present fabric is introduced by juxtaposing a cellulosic fibrous web with the partially entangled continuous filament web.
  • the juxtaposed webs are then hydroentangled, and subsequently dried to form the present laminate nonwoven fabric.
  • the pre-entanglement of the continuous filament web prior to introduction of the cellulosic fibrous material, has been found to desirably minimize loss of the cellulosic material as the continuous filament and cellulosic webs are integrated by hydroentanglement.
  • the pre-entangled continuous filament web may desirably act to improve the uniformity of the filamentary web, as well as “filter” the cellulosic fibrous material, so as to minimize its loss to the filtrate water.
  • pre-entanglement of the continuous filament web desirably permits the use of reduced energy input for entangling the filamentary and cellulosic fiber webs, which is also believed to contribute to reduced loss of the cellulosic fibers. It is also believed that the ability to employ reduced energy input for entangling the component webs allows for maintaining the inherent bulk of the laminate nonwoven fabric, and thus allowing for improved absorbency with the increase in interstitial volume over a high-pressure hydroentangled nonwoven fabric.
  • FIG. 1 is a diagrammatic view of an apparatus for making a laminate nonwoven web embodying the principles of the present invention.
  • the present laminate fabric is preferably formed from juxtaposed continuous filament webs and cellulosic fiber webs, which are subjected to hydroentanglement by direction of high-pressure liquid streams thereagainst, preferably first against one expansive surface of the juxtaposed webs and thereafter against the opposite expansive surface of the webs. It is within the purview of the present invention that each of the continuous filament and cellulosic fiber webs may be provided in the form of more than one web, thereby permitting the integration of different types of filaments, and/or different types of cellulosic fibers.
  • each of the filamentary and cellulosic fibers webs may be comprised of a homogenous component composition within the web, or in the alternative, comprised of a blend of differing component compositions.
  • the laminate of the present invention may include one or more discontinuous filamentary layers or film layers, wherein breathable, apertured, imaged films, or a combination thereof may be employed.
  • the continuous filaments are provided in the form of self bonding spunbond web, while the cellulosic fibers are provided in the form of wood pulp fibers introduced in the form of a wetlaid web, commonly referred to a “tissue”, subsequently integrated by hydroentanglement with the spunbond web (alternately airlaid pulp could be introduced at this point).
  • the present invention contemplates that the spunbond web is subjected to hydroentanglement to form a partially entangled web prior to hydroentanglement of the cellulosic fiber web therewith. Formation in this fashion has been found to desirably abate loss of the cellulosic fibers during hydroentanglement with the spunbond web.
  • pre-entanglement of the spunbond web has been found to desirably enhance web uniformity, as well as permit the use of lower entangling pressures during integration of the cellulosic fiber web therewith, which is also believed to abate loss of the cellulosic fibers to the filtrate water employed during hydroentanglement.
  • the present invention contemplates the use of a spunbond web 6 for manufacture of the present laminate fabric.
  • a spunbond process involves supplying a molten polymer, which is then extruded under pressure through a large number of orifices in a plate known as a spinneret or die.
  • the resulting continuous filaments are quenched and drawn by any of a number of methods, such as slot draw systems, attenuator guns, or Godet rolls.
  • the continuous filaments are collected as a loose web upon a moving foraminous surface, such as a wire mesh conveyor belt.
  • the subsequent webs are collected upon the uppermost surface of the previously formed web.
  • a continuous filament fabric may include those fabrics formed from filaments having a nano-denier, as taught in U.S. Pat. No. 5,679,379 and U.S. Pat. No. 6,114,017, both incorporated herein by reference. Further still, the continuous filament fabric may be formed from an intermingling of conventional and nano-denier filaments.
  • thermoplastic polymers of the continuous filament web may be chosen from the group consisting of polyolefins, polyamides, and polyesters, wherein the polyolefins are chosen from the group consisting of polypropylene, polyethylene, and combinations thereof. It is within the purview of the present invention that the continuous filament web or webs may comprise either the same or different thermoplastic polymers. Further, the continuous filaments may comprise homogeneous, bi-component, and/or multi-component profiles, as well as, performance modifying additives, and the blends thereof.
  • the web is further integrated by the impingement of hydraulic energy at 15 by liquid streams 16 from manifold 14 , so as to partially entangle the web prior to receiving a layer of pulp 8 .
  • the continuous filament web 6 may be directly advanced onto an entangling belt 12 , wherein the process is completed in-line or alternately, the continuous filament web may be wound, transferred to an unwind station 4 , and unwound onto a separate entangling apparatus.
  • a cellulosic fiber web 8 is juxtaposed with the partially entangled continuous filament web for formation of the present laminate nonwoven fabric.
  • the cellulosic fiber web 8 is preferably provided in the form of a wetlaid web, but it is within the purview of the present invention to provide the cellulosic fibrous material in other forms.
  • the juxtaposed continuous filament and cellulosic fiber webs are subjected to hydroentanglement under the influence of reduced-pressure liquid streams generated by suitable manifolds positioned above an entangling belt.
  • reduced-pressure liquid streams from the manifolds 22 are directed against a first expansive surface of the juxtaposed webs which can be the surface comprising fiber web 8 as illustrated. Entanglement can be effected on a three-dimensional image transfer device 18 , or other suitable foraminous entangling device. Thereafter, the webs are directed about another entangling drum (not shown), with reduced-pressure liquid streams directed against the opposite expansive surface of the webs.
  • the now integrated webs can be transferred over a dewatering slot at 24 , then dried and wound for storage and shipment.
  • the laminate nonwoven fabric be treated with one or more mechanical or chemical post treatments.
  • the resultant fabric may be mechanically compacted and/or additives imparted to achieve a specific performance within the fabric.
  • additives may include pigments, thermochromics, fragrances, emollients, natural herbs and botanicals, UV chemistries, antimicrobials, and the combinations thereof, as well as various other performance or aesthetically modifying additives.
  • the laminate of the present invention is suitable for various hygiene, medical, and industrial end-uses, including but not limited to wipes, drapes, protective covers.
  • the entangled nonwoven laminate may be imparted with a three-dimensional image.
  • the entangling apparatus may further include an imaging foraminous surface, such as a three-dimensional imaging drum comprising a three-dimensional image transfer device for effecting imaging of the now-entangled laminate.
  • an imaging foraminous surface such as a three-dimensional imaging drum comprising a three-dimensional image transfer device for effecting imaging of the now-entangled laminate.
  • Such three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, which is hereby incorporated by reference.
  • the image transfer device includes a moveable imaging surface which moves relative to a plurality of entangling manifolds which act in cooperation with three-dimensional elements defined by the imaging surface of the image transfer device to affect additional imaging and patterning of the fabric being formed.
  • a fabric formed in accordance with the present invention need not be subjected to hydroentangling treatment by direction of hydraulic water jets against both expansive surfaces of the fabric as it is formed. Additionally, it will be recognized that the illustrated nip rolls can be utilized to improve fabric density, and reduce the moisture content of the web prior to drying.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
US11/290,234 2004-11-30 2005-11-30 Method of making a filamentary laminate and the products thereof Abandoned US20060185134A1 (en)

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US11/290,234 US20060185134A1 (en) 2004-11-30 2005-11-30 Method of making a filamentary laminate and the products thereof

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EP (1) EP1836338A4 (zh)
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US20100227138A1 (en) * 2009-03-03 2010-09-09 William Ouellette Multiple Layer Absorbent Substrate and Method of Formation
US8021996B2 (en) 2008-12-23 2011-09-20 Kimberly-Clark Worldwide, Inc. Nonwoven web and filter media containing partially split multicomponent fibers
US9394637B2 (en) 2012-12-13 2016-07-19 Jacob Holm & Sons Ag Method for production of a hydroentangled airlaid web and products obtained therefrom
WO2016115566A1 (en) * 2015-01-16 2016-07-21 Polymer Group, Inc. Absorbent composite comprising a hydroentangled nonwoven
US10219672B2 (en) 2015-12-15 2019-03-05 The Clorox Company Multilayer cleaning article with gripping layer and dry surface contact layer
JP2019127667A (ja) * 2018-01-24 2019-08-01 花王株式会社 ワイピングシートの製造方法

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DE102018123768B3 (de) 2018-09-26 2019-10-24 Sandler Ag Mehrschichtiges Abdeckvlies für eine Fahrzeug-Innenverkleidung, Innenverkleidung mit einem derartigen Abdeckvlies sowie Verfahren zur Herstellung eines derartigen Abdeckvlieses
CN114836904B (zh) * 2022-04-26 2023-11-03 大连华阳新材料科技股份有限公司 自动调整成网两边均匀性系统及其调整方法

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* Cited by examiner, † Cited by third party
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US8021996B2 (en) 2008-12-23 2011-09-20 Kimberly-Clark Worldwide, Inc. Nonwoven web and filter media containing partially split multicomponent fibers
US20100227138A1 (en) * 2009-03-03 2010-09-09 William Ouellette Multiple Layer Absorbent Substrate and Method of Formation
US8250719B2 (en) * 2009-03-03 2012-08-28 The Clorox Company Multiple layer absorbent substrate and method of formation
US9394637B2 (en) 2012-12-13 2016-07-19 Jacob Holm & Sons Ag Method for production of a hydroentangled airlaid web and products obtained therefrom
US11622919B2 (en) 2012-12-13 2023-04-11 Jacob Holm & Sons Ag Hydroentangled airlaid web and products obtained therefrom
WO2016115566A1 (en) * 2015-01-16 2016-07-21 Polymer Group, Inc. Absorbent composite comprising a hydroentangled nonwoven
US10219672B2 (en) 2015-12-15 2019-03-05 The Clorox Company Multilayer cleaning article with gripping layer and dry surface contact layer
US10881262B2 (en) 2015-12-15 2021-01-05 The Clorox Company Multilayer cleaning article with gripping layer and dry surface contact layer
US11439289B2 (en) 2015-12-15 2022-09-13 The Clorox Company Multilayer cleaning article with gripping layer and dry surface contact layer
US11730336B2 (en) 2015-12-15 2023-08-22 The Clorox Company Multilayer cleaning article with gripping layer and dry surface contact layer
JP2019127667A (ja) * 2018-01-24 2019-08-01 花王株式会社 ワイピングシートの製造方法
JP7097705B2 (ja) 2018-01-24 2022-07-08 花王株式会社 ワイピングシートの製造方法

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MX2007005567A (es) 2007-07-09
WO2006060403A3 (en) 2007-04-19
CA2583914A1 (en) 2006-06-08
WO2006060403A2 (en) 2006-06-08
EP1836338A4 (en) 2009-01-28
EP1836338A2 (en) 2007-09-26

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