US20070033779A1 - Non-woven based on exploded or splittable multicomponent fibers - Google Patents

Non-woven based on exploded or splittable multicomponent fibers Download PDF

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US20070033779A1
US20070033779A1 US10/552,163 US55216304A US2007033779A1 US 20070033779 A1 US20070033779 A1 US 20070033779A1 US 55216304 A US55216304 A US 55216304A US 2007033779 A1 US2007033779 A1 US 2007033779A1
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fibers
layer
woven
process according
hydro
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Vittorio Orlandi
Roberto Pedoja
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Ahlstrom Corp
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Orlandi SpA
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Publication of US20070033779A1 publication Critical patent/US20070033779A1/en
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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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266—Natural fibres not provided for in group D04H1/425
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43838—Ultrafine fibres, e.g. microfibres
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/49—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation entanglement by fluid jet in combination with another consolidation means
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • 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
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • 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]
    • Y10T442/689—Hydroentangled nonwoven fabric

Definitions

  • the present invention relates to the field of multi-layer non-wovens, which can be used as an absorbent material, particularly in the field of surface cleaning, personal hygiene or for the formation of garments.
  • a non-woven is widely used as a replacement for traditional textile products in a number of sectors, for example in the field of cleaning and protection of surfaces, or in the production of garments.
  • the non-woven have the advantage of lower production costs, outstanding mechanical properties and a high biocompatibility with skin.
  • Non-wovens are formed by synthetic, natural or naturally-derived material fibers, which are arranged on a mat in a molten state and left to solidify in the form of a layer; the thus obtained structure can be consolidated by dynamic treatments such as point-bonding or calendering or by water jets (hydro-entangling); other prior art bonding processes are mechanic needling, thermobonding, chemical bonding, etc.
  • Non-woven fibers generally consist of a single component; however for particular applications they may also be produced in a multi-component form, through the joint extrusion of different polymers.
  • the non-woven fibers are used in the form of single-ply or in the form of multi-layer composites; of the multi-layer composites those containing one or more layers of non-woven, associated to a layer of cellulose fibers are known: in these cases the final composite advantageously combines the non-woven mechanical properties to the absorbent properties of cellulose fibers.
  • the manufacture of these composites entails particular problems: in fact, the cellulose layer (that is typically formed by short fibers and is poorly reactive to the entangling processes), is very mobile and poorly cohesive with the other layers; therefore problems of cellulose material loss during the formation of the multi-layer composite are frequent, thus requiring to increase the amount of cellulose fibers used to compensate the losses; besides in the final composite one encounters problems of migration of the cellulose fibers thus creating areas that are richer and areas that are poorer in pulp inside the multi-layer non-woven and excessive pulp loss during hydro-entangling. In addition the cases of composite delamination due to insufficient entangling between the different layers and between the continuous thread fibers on the outer surfaces are frequent.
  • the continuous thread fibers of each of the outer layers of non-woven do not entangle suitably either with one another or with the fibers of different layers but rather they protrude from the respective outer surfaces in the form of tiny slots.
  • the non-woven tends to stick in a bothersome way to the rough surface due to miniscule contacts between said slots and the ribs of the rough surface.
  • U.S. Pat. No. 5,587,225 discloses a composite formed by a cellulose layer interposed between two outer non-woven layers, in which the non-woven fibers are not smooth, but have a series of creases or “crimps” per unit length of the fiber.
  • the outer layers are then made integral with the cellulose layer by hydro-entangling, and final fixing of the 3 layers made adhesively or thermally (calendering).
  • the crimping and creasing processes make the composite preparation process longer and more expensive, and they considerably reduce the softness of the product.
  • WO-A-01/63032 discloses a multi-layer cellulose/non-woven composite wherein the layer of non-woven is carded and pre-consolidated separately by means of calendering. The different layers of the composite are thus overlapped and entangled by means of hydro-entangling. Also in this case it is necessary to resort to additional processes of non-woven calendering and pre-consolidation in order to obtain a multi-layer composite with acceptable performance, and limit the loss of pulp during hydro-entangling.
  • the object of the present invention is therefore to overcome all the inconveniences mentioned with reference to the multi-layer non-wovens obtained according to the state of the art and particularly according to the processes described above.
  • the single- or multi-layer non-woven fabric is of a hydro-entangled type based on exploded continuous thread or splittable multi-component continuous thread fibers.
  • the thus obtained fabric has for example high characteristics of softness and resilience.
  • continuous thread fibers is meant herein a single continuous fiber composed of one or more synthetic or natural polymer components that may be decomposed into single micro-fibers, or filaments, according to the type of fiber used. Accordingly, both the splittable multi-component polymer fibers and the exploded polymer fibers give origin to micro-fibers, which are thinner than the fibers from which they derive.
  • FIG. 1A represents a schematic view of the production line and of the manufacturing steps of the single-layer non-woven
  • FIG. 1B represents a schematic view of the production line and the manufacturing steps of three-layer non-woven composite according to the present invention
  • FIG. 1C represents a schematic view of the production line and the manufacturing steps of a three-layer non-woven composite with pre-hydro-entangling of one layer according to the present invention
  • FIG. 2 represents a perspective view of two embodiments of the mat on which the fibers according to the present invention are arranged;
  • FIG. 3 represents a microscope image of a polymer fiber before ( 3 a ) and after ( 3 b ) the treatment according to the process described in patent application WO 00/20178 in the name of Hills, Inc and Fiber Innovation Technology, Inc.;
  • FIG. 4A represents a microscope image of the polymer fiber obtained with Nanoval technology comprising polypropylene and Fluff Pulp described in patent application WO 02/052070;
  • FIG. 4B represents a microscope image of the spun-bond type polymer fiber with a diameter of 2.2 dtex of the continuous thread type and 80 g/mt 2 PES weight;
  • FIG. 4C represents a microscope image of the polypropylene polymer fiber obtained with Nanoval technology according to the patent application WO 02/052070;
  • FIG. 4D represents a microscope image of the polymer fiber obtained with Nanoval technology according to patent application WO 02/052070 with different process parameters that determine a different “explosion” effect, according to one variant of the present invention.
  • a first object of the present invention is therefore to provide a process for the production of a single- or multi-layer hydro-entangled non-woven comprising exploded fibers or splittable multi-component fibers.
  • a second object of the present invention is a hydro-entangled single- or multi-layer non-woven, based on exploded fibers or based on splittable multi-component fibers.
  • the fiber forming the non-wovens of the present invention is a continuous fiber and is generally produced by three technologies:
  • the manufacturing steps generally comprise the supply of the non-woven layer T 1 in the form of fibers by means of a spinneret 1 (extruder) coupled up to a conventional suction fan A, a hydro-entangling station 2 , a drying station 3 and a rewinding station 4 of the hydro-entangled layer into a roll.
  • a spinneret 1 extruder
  • FIGS. 1B and 1C the steps with similar names are identical to those outlined above.
  • the process for the production of a non-woven comprises the following manufacturing steps;
  • step a) comprises:
  • FIG. 1B The production of a multi-layer composite in accordance with the present invention ( FIG. 1B ) generally provides, on the other hand, the supplying of the first layer of non-woven T 1 by means of a special spinneret 5 , one or more stations 6 for the laying of cellulose pulp 60 , the laying of a second layer of non-woven fabric T 2 by means of a special spinneret 7 , hydro-entangling 8 , drying 9 and rewinding 10 .
  • splittable multi-component fibers may be produced through extrusion by spinnerets of polymer materials such as to form continuous fibers, in accordance with the technology a. identified above. These fibers when exiting from the spinnerets are hit by a jet of compressed air that causes the elongation and the electrostatic charging thereof such to cause a mutual repulsion causing them to fall randomly onto a conveyor belt.
  • the subject process comprises the following manufacturing steps:
  • splittable multi-component synthetic fibers may be formed for the separate extrusion of the individual polymers in a molten state in the form of threads 50 , 70 that protrude from orifices, of capillary dimensions, of a spinneret 5 , 7 and the union thereof below the spinneret.
  • the polymers at the molten state are linked in a single fiber combined by extrusion of the individual polymer threads in directions such as to cause the contact thereof and the adhesion thereof, as described in patent U.S. Pat. No. 6,627,025.
  • a suction fan A positioned below the spinneret has the function of sucking and conveying the individual threads of extruded polymer in order to favour the bonding thereof into a single fiber.
  • the synthetic fibers may be composed of at least two threads of a single polymer up to 16 threads of different polymers, be they homopolymers, copolymers or mixtures thereof.
  • the polymers may be selected from polyesters, polyamides, polyolefins, polyurethane, polyester modified with additives, polypropylene, polyethylene, polypropylene terephthalate, polybutylene terephthalate.
  • such polymers may be selected such that in the fibers adjacent polymers cannot mix or in any case have poor affinity in order to favour the subsequent separation thereof.
  • the polymers may be additized with lubricants that prevent the adhesion thereof.
  • the longitudinal, axial portion of the fiber usually has a greater force of cohesion than the peripheral portion, it may be advantageous to spin multi-component fibers such as to leave an axial hole or in any case a weakened axial portion.
  • a second layer T 2 of non-woven fabric substantially identical to that prepared previously is laid on the layer of cellulose pulp T 3 , as represented in FIG. 1B by the station identified with reference number 7 .
  • the fibers are subject to hydro-entangling at the hydro-entangling station 8 .
  • This treatment advantageously enables to split the polymer fibers that compose the outer layers of non-woven in micro-fibers and to entangle them with one another and with the cellulose pulp fibers.
  • the hydro-entangling is made not only on side S 1 of the support S on which the fibers are laid but also on side S 2 , opposite side S 1 , through special through holes (not shown in the figures) and suitable equipment positioned on said side S 2 (not shown).
  • FIGS. 1B and 1C also schematically represent a conventional filtering device 20 for the water originating from the hydro-entangling machines positioned after the cellulose pulp laying step. Said device has the function of recovering the water of the hydro-entangling machine and filtering it of any cellulose pulp fibers.
  • FIG. 3 shows the splittable multi-component polymer fiber before ( 3 a ) and after( 3 b ) the hydro-entangling treatment.
  • splittable multi-component fibers are described in patent applications U.S. Pat. No. 5,970,583, DE-A-19846857 and WO 00/20178, incorporated herein for reference.
  • the process for the production of non-woven based on exploded polymer fibers comprises the following manufacturing steps:
  • the step i) comprises:
  • step i) comprises:
  • Nanoval technology consists in producing molten polymer threads protruding from spinning holes arranged in one or more rows placed in a chamber with a given pressure value separated from the outside environment and filled with gas, generally air. Said threads come to an area of rapid acceleration of this gas when exiting from the camera, the outlet being made in the form of a Laval nozzle.
  • the raw materials that can be spun are both of natural origin, such as cellulose Lyocell, PLA, and synthetic or such as polypropylene, polyethylene, polyamide, polyester.
  • the spinning mass is forced through a elongated nozzle in the form of a slit into a chamber separated from the environment with a given pressure, as above, into which gas, for example air, is introduced.
  • the film that is released from said nozzle reaches an area of rapid acceleration of the gas released from said camera. Below the acceleration area, i.e. in the stress release area, the film explodes and substantially endless micro-fibers or filaments are obtained.
  • the film unlike those formed by single threads, they have very different diameters and thickenings in the shape of knots.
  • the Laval nozzle is cylindrical and elongated with a convergent edge so that the transversal section thereof is narrow upstream and then rapidly widens downstream.
  • the pressure value in the chamber in the case of air about twice environmental pressure
  • flow speeds near to those of sound are obtained whereas in the wider part of the Laval nozzle speeds are higher than those of sound.
  • FIGS. 1A, 1B and 1 C With regards to the laying of the exploded fibers to form a first layer and the further manufacturing steps, the same references are valid as made to FIGS. 1A, 1B and 1 C in which the suction fan A is eliminated and the spinnerets 5 , 7 , 11 , 15 are each fitted with the abovementioned Laval nozzle (not shown) in order to obtain the explosion effect.
  • Nanoval technology lies in the possibility of producing very fine micro-fibers with diameters of less than 10 ⁇ m, for example between 2 and 5 ⁇ m in a simple and cost effective way without the aid of jets of gas (air) heated beyond the polymer's melting point, as occurs for example with meltblown technology.
  • the micro-fibers are not damaged in their molecular structure by the use of high temperatures. Accordingly, the end product has greater resistance and therefore shows slower wear over time.
  • a further advantage also in relation to the technology that employs splittable polymer fibers lies in the fact that a greater density of individual micro-fibers per each fiber is obtained.
  • the fiber divides into a number of components with equal initial diameters, i.e. the micro-fibers (filaments) that are obtained are at least 10 times finer, preferably up to 100 times finer.
  • the steps are as follows: laying the first layer T 1 by means of the spinneret 11 , pre-hydro-entangling through equipment 12 , drying through equipment 13 , laying cellulose pulp T 3 through equipment 14 , laying the second layer T 2 through spinneret 15 , hydro-entangling with hydro-entangling machine 16 , drying through equipment 17 and rewinding onto a roller 18 .
  • the production process and system may also provide a dewatering step or station 19 associated to the drying step or station.
  • the advantage of a pre-hydro-entangling step is that it allows to create a first layer of split or exploded polymer fibers that, thanks to the greater density of the entangling of the micro-fibers of said fiber, helps to lay fibers of absorbent material and prevents the partial loss thereof through spaces too wide, which are left by prior art technologies.
  • the step of laying fibers of absorbent material is preferably made with cellulose pulp fibers having a length that may vary from 0, i.e. cellulose powder, to 2.5 mm, preferably from 1 to 2 mm.
  • the process according to the invention may provide a drying step after the hydro-entangling step and, preferably also after the pre-hydro-entangling step.
  • a further step may consist in the elimination of the water contained in the fibers by means of a dewatering step.
  • said step consists in arranging a condenser 19 below support S for the non-woven fibers to which a completely conventional suction fan (not shown) is usually coupled up. The air sucked through the holes made on said support is conveyed into said condenser where it releases the water contained therein.
  • Equipment of this type is described for example in patent application PCT/IT2004/000127 of the same applicant.
  • the process may also comprise an embossing step of the multi-layer non-woven.
  • the embossing may consist in a calendering treatment made by making the non-woven being heated and pass under pressure between a pair of engraved rollers, in accordance with conventional techniques, or through a further step in a hydro-entangling machine.
  • embossing step does not mean a consolidation of the non-woven as occurs according to the prior art mentioned previously but simply constitutes a step enabling to make captions and/or three dimensional drawings in order to personalize or decorate the non-woven through a “thermoembossing” or “hydroembossing” calender.
  • the process comprises sucking the air at room temperature through the abovementioned through holes (non shown in the drawings) made in the support S for the fibers.
  • the splittable or exploded polymer fibers, laid at the molten state are cooled and cured.
  • a humidifier (not shown) can be arranged, which humidifies the exploded fibers immediately before laying them on the support S either to help or improve the softness of the end product.
  • said process may comprise one or more of the following final steps, known per se, in order to increase or add additional characteristics to the end product: coloring or finishing of a chemical nature as the anti-pilling treatment and the hydrophile treatment, antistatic treatment, improvement of flame proof properties, substantially mechanical treatments such as napping, sanforizing, emerizing.
  • non-woven may be subject to a further process of multicolor printing using the equipment described in patent application PCT/IT2004/000127 of the same applicant.
  • a sheet of non-woven at the end of the process described above may be printed directly in-line following the steps of:
  • command and control unit performing the printing on said non-woven under the command and control of a command and control unit, in which said command and control unit is operatively connected with said support and at least one printing organ in order to detect electrical signals originating from said support and at least one print organ, transforming said signals into numerical values representative of the state of their angular speed and torsional moment, comparing said numerical values with ratios of preset numerical values of said angular speeds and torsional moments and sending signals to said support and at least one print organ in order to correct any variation of said values that fall outside said ratios.
  • the process in accordance with the present invention may comprise a step of winding the non-woven on to a roller 18 .
  • a “crimp” effect can be advantageously obtained avoiding the use of engraved calenders or machines for mechanical “crimping”, by simply laying all the fibers that compose the multilayer non-woven on a support ( FIG. 2A and 2B ) having a surface comprising at least one section with a substantially perpendicular profile to the vertical flow of laying of said fibers interspaced by at least one section with an inclined profile of 10°-50° in relation to said vertical flow.
  • the profile of the support may be modified such as to create geometrical forms or figures and captions in relief as desired.
  • the process of the present invention enables to obtain different types of product:
  • the manufacturing process is such as illustrated in FIG. 1A .
  • the fiber used may be either a synthetic fiber with explosion effect, as described above and obtained according to the Nanoval technology, or it may be a bi-component (multisegments) synthetic fiber, splittable with a hydro-entangling machine, or a natural fiber with explosion (for example, Lyocell, PLA, etc.), also produced with “Nanoval”.
  • the product may for example be a three-layer multi-layer one, of which has one central cellulose pulp layer and the outer layers have different combinations of the technologies illustrated above.
  • the splittable multi-component polymer fibers are composed of micro-fibers or filaments of polymer such as those described above with reference to the manufacturing process.
  • the micro-fibers may have a diameter of between 0.1 dTex and 0.9 dTex and the corresponding fibers may vary according to the number of micro-fibers composing it but generally their size ranges between 1.7 dTex and 2.2 dTex.
  • the number of micro-fibers in said fibers generally ranges between 2 and 16.
  • the micro-fibers have a diameter ranging between 1 micron and 5 micron, preferably between 2 and 4 micron. Obviously said values may vary according to the type of preset characteristics for the end product and will depend on the production parameters selected, as described above, and in any case known to a man skilled in the art.
  • the final thickness of the multi-layer non-woven advantageously reaches values of up to 0.65 mm and a tensile strength of 27 N/5 cm.
  • non-wovens that are obtained by employing the technology relating to the exploded fibers advantageously enable to make a product that is softer and has a better appearance with regards to the compactness and evenness compared to a product obtained with split fibers, albeit of good quality.
  • filtering of the water originating from hydro-entangling is also improved, i.e. it contains fewer cellulose pulp fibers.
  • the products obtained according to the present invention have a plus of resistance, softness and have a better appearance. Besides the thickness is increased either by the explosion effect (Nanoval technology), or (splittable fibers) by the split effect, and by a technology of laying continuous thread fibers on the mat: the type of the mat (not smooth) may be as illustrated in FIG. 2 .
  • the abovementioned characteristics result from the combination of the use of splittable multi-component polymer fibers or of exploded polymer fibers in a process of hydro-entangling to obtain a multi-layer non-woven.
  • the weave of the micro-fibers or the individual filaments of the polymer fibers allows to withhold a greater amount of cellulose pulp fibers thus increasing both the thickness of the end product and the absorbent capacity thereof. Besides it is understood that at the same time, during the hydro-entangling process the loss of cellulose pulp is generally reduced by 50% compared to the usual technologies and, in the case of process according to the technology described in patent application WO-A-01/63032, the loss is substantially identical to the advantage of a product considerably better from the point of view of the softness, thickness and homogeneity.
  • the weave of said micro-fibers also considerably increases the bonding points per surface unit so that the resistance is far greater than single- or multi-layer products in which whole fibers are hydro-entangled.
  • the process of the present invention advantageously allows to eliminate the lengthy and costly steps of adhesion and/or pre-treatment of the fibers according to the prior art in order to obtain a sufficiently cohesive multi-layer product.
  • a 13% cellulose solution is placed in an NMMO (N-methylmorpholin-N-oxide) aqueous solution of 75% and 12% of water in a spinning device consisting of a spinneret with a hole and a round Laval nozzle, in which the single spinning hole has a diameter of 0.5 mm.
  • the solution was introduced directly through pumps in a dosed way in a spinning device.
  • the temperature of the Lyocell spinning mass exiting the extruder was set at 94° C. On the lower part of the tip of the nozzle and electrical resistance was applied.
  • the elongation of the fiber filaments of the exiting fibers the nozzle was made with air at room temperature of approximately 22° C.
  • the spinning speed is about 500 m/min.
  • the fibers exiting the spinneret undergo an explosion effect, caused by the difference of temperature and pressure between the process of extrusion and spinning and room temperature, thus opening into numerous threads that are hit by humidified air by means of a humidifier that causes moist air containing about 5% of water to pass through the extruded threads.
  • a humidifier that causes moist air containing about 5% of water to pass through the extruded threads.
  • the threads of the exploded polypropylene fibers are sucked onto a conveyor belt which is perforated and has its surface covered with cubical shaped ribs.
  • the suction takes place through a fan positioned below said conveyor belt and in correspondence with the spinneret.
  • the exploded fibers are arranged on said support in the form of a first continuous layer in amount of 11.5 g/m 2 .
  • said layer is subject to hydro-entangling by means of a device sold by FLEISSNER and equipped with five sequential injectors mounted on special rollers on both surfaces of said support. Said injectors work at respective pressures of 15, 50-100-100-100-150 bar and have a diameter of the injection hole from 100 to 140 microns.
  • said pre-water-entangled layer passes under a cellulose pulp fiber laying station.
  • the laying of the cellulose fibers takes place through a device sold by FLEISSNER of the “air-laid” type in which the fibers laid are fibers with a diameter of 3 micron and laid in amounts of 37.25 g/m 2 . Subsequently, a further layer of exploded polypropylene fibers is laid on said layer of cellulose pulp fibers in the same way as described with reference to the first layer of exploded fibers. At this point, the three layers are interconnected through hydro-entangling by means of a device identical to that described previously and at the same conditions.
  • the thus formed three-layer non-woven passes inside a drying station in which a perforated drum receives and transports the non-woven being hit by a hot air flow of approximately 120° C.
  • a perforated drum receives and transports the non-woven being hit by a hot air flow of approximately 120° C.
  • the non-woven is wound on a winding roller.
  • the feeding speed of the conveyor belt along the whole non-woven manufacturing steps is maintained at approximately 500 m/min.
  • the end product obtained has the following physical characteristics: Total Weight of Pulp Weight of MD Tensile CD Tensile weight upper layer weight lower layer strength strength Thickness (grams) (g/m 2 ) (g/m 2 ) (g/m 2 ) (N/5 cm) (N/5 cm) (cm) 60.25 11.50 37.25 11.50 21.93 8.01 0.58
  • the present patent application provides a process for the production of a multi-layer non-woven and a non-woven obtainable with said process that allows to overcome the drawbacks mentioned in the introductory part with reference to the prior art.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
US10/552,163 2003-04-17 2004-04-16 Non-woven based on exploded or splittable multicomponent fibers Abandoned US20070033779A1 (en)

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ITMI20030805 ITMI20030805A1 (it) 2003-04-17 2003-04-17 Non-tessuto a base di fibre esplose o fibre multicomponenti splittabili.
ITMI2003A00805 2003-04-17
PCT/IT2004/000220 WO2004092472A2 (fr) 2003-04-17 2004-04-16 Non-tisse a base de fibres a composants multiples, eclatees ou susceptibles d'etre divisees

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CN111501208A (zh) * 2019-01-30 2020-08-07 俊富非织造材料有限公司 一种高阻隔纺粘型透气新材料、制备方法及其应用
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CN104264365A (zh) * 2014-08-01 2015-01-07 李晔 可降解环保型絮片材料及其制备方法
US12043022B2 (en) 2018-02-02 2024-07-23 Essity Hygiene And Health Aktiebolag Composite nonwoven sheet material
CN111501208A (zh) * 2019-01-30 2020-08-07 俊富非织造材料有限公司 一种高阻隔纺粘型透气新材料、制备方法及其应用
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