US20150017865A1 - Bi-component fiber for the production of spunbonded fabric - Google Patents

Bi-component fiber for the production of spunbonded fabric Download PDF

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Publication number
US20150017865A1
US20150017865A1 US14/331,644 US201414331644A US2015017865A1 US 20150017865 A1 US20150017865 A1 US 20150017865A1 US 201414331644 A US201414331644 A US 201414331644A US 2015017865 A1 US2015017865 A1 US 2015017865A1
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Prior art keywords
component
bicomponent fiber
fibers
fiber
fiber according
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US14/331,644
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English (en)
Inventor
Jörn Schröer
Daniel Placke
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Ewald Doerken AG
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Ewald Doerken AG
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Assigned to EWALD DOERKEN AG reassignment EWALD DOERKEN AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SCHROEER, JOERN, PLACKE, DANIEL
Publication of US20150017865A1 publication Critical patent/US20150017865A1/en
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    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00General methods for the manufacture of artificial filaments or the like
    • D01F1/02Addition of substances to the spinning solution or to the melt
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/18Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from other substances
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005Synthetic yarns or filaments
    • D04H3/007Addition polymers
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14Non-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 yarns or filaments produced by welding
    • D04H3/147Composite yarns or filaments
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16Non-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
    • DTEXTILES; PAPER
    • D10INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10BINDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913Rod, strand, filament or fiber
    • Y10T428/2929Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material

Definitions

  • the invention relates to a bi-component fiber, in particular for the production of spunbond fabric, with a first component and a second component, whereby as integral parts, the first component has a first polymer and the second component has a second polymer.
  • the invention relates to a spunbond fabric with at least one bi-component fiber of the above-mentioned type.
  • Bi-component fibers of the type in question usually have a first component that is formed of a first polymer and a second component that is formed of a second polymer.
  • different types of bi-component fibers can be distinguished, which in each case have different characteristic distributions of the components in the fiber cross-section.
  • Bi-component fibers, in which the first component surrounds and thus encompasses the second component in the cross-section of the fiber are referred to as core-sheath fibers.
  • Bi-component fibers, in which both the first component and the second component form a portion of the fiber surface in the cross-section of the fiber are referred to as side-by-side fibers.
  • Fibers with structures in which several strands of a component are embedded in a strand of the other component, so that an image is produced in the cross-section that resembles a large number of islands formed from a component, are referred to as island-in-the-sea fibers.
  • Bi-component fibers in which in the cross-section, in each case, a large number of areas of the respective components are present and form the outer fiber surface, are referred to as segmented-pie fibers, since the areas of the individual components in the cross-section routinely have a pie-wedge-like division.
  • segmented-pie fibers since the areas of the individual components in the cross-section routinely have a pie-wedge-like division.
  • bi-component fibers in terms of this application are in this case also expressly those fibers that have more than 2 components.
  • the purpose of the bi-component fibers is to improve the properties of the fibers or the properties of the spunbond fabric produced from the fibers.
  • the properties of a spunbond fabric in this case depend on a host of factors. Some of these factors in the properties of a spunbond fabric are in this case properties of the fibers that are used in each case, such as, e.g., their strength. It is a theory that is widely available and acknowledged at least in its basic idea that the properties of the resulting bi-component fiber then represent a combination of the properties of the individual components of the bi-component fiber, in which the properties of the individual components complement each other to the greatest extent possible so that the advantages of the properties of the two components are combined in the bi-component fiber. If, for example, a fiber is desired that both has high strength and shows advantageous behavior when interconnecting the fibers among themselves in the production of non-woven fabric, it is thus reasonable to combine a first component with high strength with a second component that has good connectivity.
  • additives are frequently added to the polymers.
  • the additives can be a wide variety of substances.
  • the latter can be used, for example, for coloring, for thermostabilization, for flame retardance, for hydrophilization or for hydrophobization or for UV stabilization.
  • the additives are routinely distributed uniformly in the phase.
  • additives can disrupt the production process, in particular when they exceed certain overall concentration limits.
  • the additives can be associated with high costs.
  • additives can be a health or environmental risk, in particular when they exceed overall concentrations in the fibers.
  • the invention is now based on the object of providing a bi-component fiber, in particular for the production of a spunbond fabric, as well as a spunbond fabric with at least one bi-component fiber, in which the negative effects of the addition of additives do not occur or occur at least to a reduced extent.
  • the first component has an additive for influencing or improving properties.
  • the proportion by weight of the additive of the first component in the second component is preferably at most 66.6%, more preferably at most 50%, and in particular at most 33.3% of the proportion by weight of the additive in the first component.
  • the additive in the second component is quite especially preferably not present.
  • the proportion by weight of the first component in the bi-component fiber is at most 50%, preferably 25%, especially preferably 10%, and quite especially preferably 5%.
  • the bi-component fiber is especially preferably a core-sheath fiber, whereby the first component forms the sheath.
  • the advantage of the concentration of the additives in the first component surrounding the second component lies in the fact that it has been shown that the amount of the required additive in the second component can be less than in the usual equal distribution of the additive in the two components, when the same or an improved action of the additive is to be produced.
  • Additives in this sense are defined as admixtures that are added to the polymer in the respective component in order to modify and thus to improve the properties of the resulting fiber or of the spunbond fabric obtained from the fiber.
  • the additives that are added at low concentrations to the polymers in principle represent a contamination of the polymer with respect to the fiber production.
  • contaminations in principle there is always the risk that because of these contaminations, the behavior of the components in the production of fibers changes. Therefore, an unequal distribution of the additives in the components of the bi-component fiber first involves the risk, from the standpoint of one skilled in the art, that the quality of the bi-component fiber or the stability of the production process deteriorates.
  • the point is not usually that an additive is concentrated in a specific zone of the fiber. This is due to the small thickness of the fibers in question.
  • the additive is a primary or secondary antioxidant, a UV absorber, a UV stabilizer, a flame retardant, an antistatic agent, a lubricating agent, a metal deactivator, a hydrophilizing agent, a hydrophobizing agent, an anti-fogging additive, and/or a biocide.
  • a UV absorber e.g., a UV absorber
  • a UV stabilizer e.g., a flame retardant
  • an antistatic agent e.g., a lubricating agent
  • a metal deactivator e.g., a hydrophilizing agent, a hydrophobizing agent, an anti-fogging additive, and/or a biocide.
  • the difference between the melting points of the first component and the second component is less than or equal to 8° C. It is pointed out that any individual intervals or individual values are contained in the indicated intervals and are to be considered disclosed as essential to the invention, even if they are not mentioned in detail.
  • the positive effects of this invention also include the fact that the proportion of recycled materials, which can be added to one of the components in the production of the bi-component fiber, increases relative to conventional fibers. It has been shown that when components with combined melting points according to the invention are used, the change in the properties of a component, which is caused by the addition of recycled material, turns out to be far less than in conventional fibers.
  • the component with the lower melting point preferably forms the outer surface of the fiber in the cross-section of the fiber.
  • the component with the lower melting point preferably surrounds the component with the higher melting point.
  • the difference between the melting points of the first component and the second component is at most 6° C. or between 1° C. to 8° C., and preferably between 1° C. to 6° C.
  • the positive effects of this invention come significantly strongly to the fore.
  • the proportion by weight of the component with the lower melting point in the bi-component fiber is at most 50%, more preferably at most 25%, even more preferably at most 10%, and in particular at most 5%.
  • the bi-component fiber is especially preferably a core-sheath fiber, whereby the component with the lower melting point forms the sheath.
  • the difference between the melt-flow indices of the first component and the second component is less than or equal to 25 g/10 minutes, whereby the melt-flow indices (MFI below) of the first component and the second component in each case are less than or equal to 50 g/10 minutes.
  • the difference between the melt-flow indices of the first component and the second component is preferably less than or equal to 20 g/10 minutes, especially preferably 15 g/10 minutes, and/or the MFIs of the first component and the second component are in each case less than or equal to 40 g/10 minutes.
  • the MFI is measured according to ISO 1133 with a test load of 2.16 kg and a test temperature of 230° C.
  • the MFI in this case is also referred to as a melt-flow index or else as a melt-mass-flow rate (MFR).
  • MFR melt-mass-flow rate
  • the determination is made according to ISO 1133 by the material being melted in a heating cylinder and being pressed by means of the test load through a defined die.
  • the MFI is a measurement of the viscosity of the melts of the respective polymer-containing components. The viscosity in turn is associated with the degree of polymerization, which corresponds to the mean number of monomer units in each molecule of a polymer.
  • the positive influence of the advantageous differences between the MFIs essentially relates to the specific tearing force and the specific nail tear resistance.
  • These two characteristic values of a spunbond fabric produced from the fibers can be improved by the advantageously selected MFIs.
  • the specific tearing force can be increased without softness and the so-called “textile grip” being negatively influenced.
  • textile grip is defined as a pleasant feeling upon contact.
  • the proportion by weight of the component with the higher MFI in the bi-component fiber is at most 50%, more preferably at most 25%, even more preferably at most 10%, and in particular at most 5%.
  • the bi-component fiber especially preferably forms a core-sheath fiber, whereby the component with the higher NMI forms the sheath.
  • the polymer of one of the two components has been polymerized with a metallocene catalyst, and the polymer of the other component has been polymerized with a Ziegler-Natta catalyst and subjected to a subsequent visbreaking treatment.
  • the polymer is preferably a polyolefin, in particular polypropylene, polyethylene or their copolymers or a mixture thereof.
  • the other polymer is preferably also polyolefin or a polyolefin-copolymer. In this case, it is especially advantageous when both polymers are composed of the same monomer or are at least predominantly composed of the same monomer.
  • Metallocene catalysts are structurally uniform catalysts, which contain transition metals coordinated by cyclopentadiene ligands. Such catalysts are described in detail in U.S. Pat. Nos. 5,374,696 and 5,064,802. Reference is made expressly to their disclosures which are hereby incorporated by reference.
  • the advantage of these catalysts is that the polymers that are produced with these catalysts have a narrow molecular weight distribution.
  • the narrow molecular weight distribution results in non-woven fabrics with high elongation at break. In this case, the elongation at break is the expansion of fibers that occurs at the peak tearing force, which is applied when tearing a strip of non-woven fabric.
  • metallocene catalysts or the polymers produced by means of metallocene catalysts is that the residual content of the catalyst in the polymer is very low.
  • the residual content of the catalyst in the polymer represents a contamination of the polymer and can result in the properties of the polymer being changed in an undesirable way. Thus, for example, staining can occur during the processing of the polymer.
  • metallocene catalysts are their slightly higher price in comparison to the Ziegler-Natta catalysts.
  • thermal solidification of the fibers in the production of non-woven fabric can be impeded when metallocene catalysts are used. This may be the case if the possibility opened up by the use of metallocene catalysts to increase the crystallinity and the strength of the individual fibers by their higher level of stretchability is used to a large extent.
  • Ziegler-Natta catalysts are heterogeneous mixed catalysts, which contain organometallic compounds of main group elements and transition metal compounds. As main group elements, in particular elements of the first to third main groups are used. The transition metal compounds contain in particular metals of the titanium group. A host of variants of these catalysts exist. In terms of this invention, the Ziegler-Natta catalysts are essentially defined by their distinction compared to the metallocene catalysts.
  • the Ziegler-Natta catalysts are more economical than the metallocene catalysts, however, polymers produced with the Ziegler-Natta catalysts have a considerably broader molecular weight distribution than polymers produced with metallocene catalysts.
  • the polymers produced with Ziegler-Natta catalysts are therefore usually after-treated. This after-treatment is referred to as “visbreaking.” In the visbreaking treatment, polymer chains are cleaved, by which the molecular weight of the individual molecules is reduced, and the number of molecules is increased. In this case, the width of the molecular weight distribution is also reduced.
  • the cleavage of the polymer chains is brought about by heat, irradiation, the addition of peroxide, or by similar measures. Examples of such visbreaking treatments are described in, i.a., U.S. Pat. Nos. 4,282,076 and 5,723,217.
  • the proportion by weight of the components, whose polymer has been polymerized with a metallocene catalyst is at most 50% in the bi-component fiber, more preferably at most 25%, even more preferably at most 10%, and in particular at most 5%.
  • the bi-component fiber especially preferably is a core-sheath fiber, whereby the component whose polymer has been polymerized with a metallocene catalyst forms the sheath.
  • the first polymer and/or the second polymer is/are a polyolefin or a polyolefin-copolymer, preferably a polymer and/or copolymer of ethylene, propylene, butylene, hexene or octene, and/or a mixture and/or a blend thereof It has been shown that these polymers are especially well suited to produce therefrom the bi-component fibers according to the invention.
  • a copolymer is defined as a polymer that was produced from at least two different types of monomers, whereby the proportion by weight of the monomer, which is decisive for the naming of the copolymer, is at least 50%.
  • the bi-component fiber is a core-sheath fiber, whereby the proportion by weight of the core is 50% to 98%, preferably 60% to 95%, especially preferably 70% to 95%, and quite especially preferably 80% to 90%. It has been shown that the advantages of the bi-component fiber according to the invention, when the latter is a core-sheath fiber, occur particularly in the case of these advantageous proportions by weight of the core.
  • the mass ratio of the two components lies in the range of 10:90 up to 90:10, preferably in the range of 70:30 up to 30:70, and especially preferably in the range of 60:40 up to 40:60.
  • these fiber types it has been shown that the advantages of the bi-component fibers according to the invention can be achieved especially readily for the cited component ratios.
  • the bi-component fiber is a multilobal fiber, in particular a tetralobal or trilobal fiber.
  • these fibers offer a higher specific surface area than comparable fibers with circular cross-sections.
  • the advantages of the fibers according to the invention can be used especially efficiently, in particular when the different properties of the components, which are to be optimized by the bi-component fibers according to the invention, are properties that relate to the surface area of the fibers.
  • the diameter of the bi-component fiber is between 1 ⁇ m and 50 ⁇ m, preferably between 5 ⁇ m and 30 ⁇ m, and especially preferably between 8 ⁇ m and 20 ⁇ m. It has been shown that especially in the case of fiber diameters that lie in these advantageous ranges, the combination of two components in a bi-component fiber results particularly in synergistic effects.
  • the invention relates to a spunbond fabric with bi-component fibers according to the invention.
  • Two properties that play a special role in spunbond fabrics are the specific tearing force of the spunbond fabric as well as the specific nail tear resistance of the spunbond fabric. In this case, a desirable high specific tearing force is achieved by fibers with high strength.
  • good connectivity is defined as the movability of the fibers in the spunbond fabric being able to be set defined as much as possible in the connecting of the fibers during the production of a spunbond fabric.
  • the targeted setting of the movability of fibers in the non-woven fabric which depends on the strength of the connecting of the fibers among themselves, is the requirement for the production of a spunbond fabric with high specific tensile strength and at the same time high specific nail tear resistance.
  • the problem may exist that suitable fibers with high strength have a poor connectivity and fibers with a good connectivity have only a low level of strength. Therefore, especially in the case of the production of a spunbond fabric, which is to have both a high specific tearing force and a high specific nail tear resistance, the use of a bi-component fiber is useful.
  • the bi-component fibers according to the invention are particularly suitable to make possible a high specific tearing force and a high specific nail tear resistance of a spunbond fabric, since especially the bi-component fibers according to the invention can be optimized with respect to a combination of good connectivity and high strength.
  • Such a non-woven fabric produced from the fibers according to the invention is suitable for numerous applications, for example in medicine, in the field of hygiene, in the automobile industry, in the field of clothing, in home and industrial textiles, as well as in particular in the construction industry and in agriculture.
  • possible applications comprise the use in filters and membranes, battery separators and as support non-woven fabrics for laminates and as carriers for coatings of all types.
  • the weight per unit of area of the spunbond fabric is between 1 g/m 2 and 300 g/m 2 , preferably between 5 g/m 2 and 200 g/m 2 , and especially preferably between 8 g/m 2 and 200 g/m 2 . It has been shown that in the case of weights per unit of area, which lie in these advantageous ranges, the use of a bi-component fiber with high strength and at the same time good connectivity according to the invention particularly results in a combination that is formed of high specific tearing force and at the same time high specific nail tear resistance of the non-woven fabric produced from these fibers.
  • the specific tearing force of the spunbond fabric is at least 1.8 N/g ⁇ 5 cm in the machine direction and/or at least 1.3 N/g ⁇ 5 cm in the transverse direction, preferably 2.0 N/g ⁇ 5 cm in the machine direction and/or at least 1.5 N/g ⁇ 5 cm in the transverse direction, preferably at least 2.2 N/g ⁇ 5 cm in the machine direction, and/or at least 2.0 N/g ⁇ 5 cm in the transverse direction, and especially preferably at least 2.4 N/g ⁇ 5 cm in the machine direction, and/or at least 1.9 N/g ⁇ 5 cm in the transverse direction.
  • machine direction refers to the direction in which the spunbond fabric has been transported during its production in the machine, i.e., routinely the longitudinal direction of a spunbond fabric web.
  • Transverse direction refers to the direction that lies at a right angle to the latter, in which the spunbond fabric expands in a flat manner, i.e., routinely the width of a spunbond fabric web.
  • the specific tearing force is measured according to EN 12311-1.
  • the specific nail tear resistance of the spunbond fabric is at least 1.0 N/g in the machine direction and/or at least 1.2 N/g in the transverse direction, preferably at least 1.4 N/g in the machine direction and/or at least 1.5 N/g in the transverse direction, preferably at least 1.6 N/g in the machine direction, and/or at least 2.16 N/g ⁇ cm in the transverse direction, and especially preferably at least 1.8 N/g in the machine direction, and/or at least 2.1 N/g in the transverse direction.
  • the specific nail tear resistance is in this case the maximum force that occurs when tearing a strip of non-woven fabric when the strip of non-woven fabric already has given damage, namely a nail thrust through the non-woven fabric.
  • the specific nail tear resistance is measured according to EN 12310-1. It has been shown that the above-mentioned minimum values for the specific nail tear resistance of the spunbond fabric can be sought without the specific tearing force of the spunbond fabric dropping disproportionately, when bi-component fibers according to the invention are optimized accordingly with respect to their connectivity and strength. In particular, in this case, it is also possible to produce a combination of the above-mentioned specific advantageous nail tear resistance and the previously-mentioned, advantageous specific minimum tearing forces.
  • spunbond fabric which is suitable for a host of applications with respect to its mechanical properties.
  • a spunbond fabric can be readily used, for example, in the construction field, where frequently a fastening of the spunbond fabric webs by nailing, stapling, or screwing must be possible. In this case, the spunbond fabric must not tear away or tear off when it is fastened to, for example, a roof.
  • use of these advantageous spunbond fabrics as geotextiles is readily possible. Geotextiles must in any case have a high tolerance for selective damage, as can be caused by, for example, sharp stones.
  • the invention is also extended to threads or objects produced therefrom, which have one or a large number of bi-component fibers of the above-mentioned type.
  • the invention also relates to a spunbond fabric that is produced from bi-component fibers according to the invention.
  • a spunbond fabric according to the invention is a structure, in particular a textile pattern, made from bi-component fibers according to the invention, in particular continuous fibers that have been joined in any way to form a non-woven fabric and have been connected with one another in any way.
  • the invention also relates to a method for the production of bi-component fibers according to the invention and a method for the production of a spunbond fabric from the bi-component fibers according to the invention.
  • the two components of the bi-component fiber are melted separately.
  • the polymer melts thus produced form the starting material for the fibers. It is advantageous to combine the melt flows thus produced only once they are in a spinning plate. In such a spinning plate, the melt flows are extruded by spinning nozzles to form bi-component fibers.
  • the spinning nozzles have a hole diameter of 0.1 mm to 10 mm, preferably a hole diameter of 0.2 mm to 5 mm, and especially preferably a hole diameter of 0.5 mm to 3 mm.
  • Spinning nozzles whose hole diameter lies in the above-mentioned preferred ranges, have proven especially suitable for the production of bi-component fibers.
  • the fibers are drawn off over galettes.
  • Galettes are special rollers that are used in the production of synthetic threads and fibers and serve in the transporting and/or stretching and/or heat treatment of the fibers or threads.
  • the cooling rate of the fibers can be regulated by the temperature of the galettes.
  • the defined cooling rate in particular during the stretching of the fibers, their mechanical properties can be further improved.
  • the cooling rate of the fibers is regulated by the temperature of the air flow and/or the amount of air.
  • the fibers which in this connection are also referred to as filaments, after they are cooled and stretched.
  • the fibers thus acquire a random arrangement.
  • parts of the fibers are reoriented from the machine direction into the transverse direction, so that an overall more isotropic non-woven fabric can be obtained.
  • the fibers can be placed on a filter belt.
  • the layer of fibers thus produced can then be preferably thermally solidified.
  • the individual fibers are connected to one another, by which the actual non-woven fabric is produced.
  • the thermal solidification can in this case be carried out by flowing through with hot air or water vapor; in an especially advantageous way, it is carried out by calendering.
  • Calendering is defined as solidification with use of hot or heated rollers. In an advantageous way, the calendering can be carried out with a smooth roller and a sculptured roller.
  • the sculptured roller is preferably configured in such a way that a proportional pressing surface of at least 5% and at most 25%, preferably at least 8% and at most 20%, and especially preferably at least 12% and at most 20%, is produced because of the engraving of the rollers.
  • the temperature of the rollers in this case is preferably at most 70° C., preferably at most 50° C. less than the temperature of the melting point of the component with the lower melting point. A good connecting of the fibers is ensured by these minimum temperatures of the rollers.
  • the pressing pressure of the rollers in the roll gap is advantageously 10 N/mm to 250 N/mm, preferably 25 N/mm to 200 N/mm, and especially preferably 50 N/mm to 150 N/mm.
  • the solidification of the fiber layer can also be carried out mechanically.
  • the non-woven fabric for example, can be needled or solidified by means of water jets.
  • Another possible advantageous alternative is the chemical solidification of the fiber layer.
  • a binder is applied to the fiber layer, for example by impregnation or spraying. This binder is hardened, by which the fibers are connected to the spunbond fabric. The hardening of the binder can take place by, for example, tempering, photo-induced or moisture-induced cross-linking, cooling, evaporation of a solvent, or similar measures.
  • FIG. 1 is a cross-sectional view of an embodiment of a bi-component fiber according to the invention as a core-sheath fiber,
  • FIG. 2 is a cross-sectional view of an embodiment of a bi-component fiber according to the invention as a core-sheath fiber with a thin sheath,
  • FIG. 3 is a cross-sectional view of another embodiment of a bi-component fiber according to the invention as a core-sheath fiber with an eccentrically arranged core,
  • FIG. 4 is a cross-sectional view of another embodiment of a trilobal bi-component fiber according to the invention as a core-sheath fiber,
  • FIG. 5 is a cross-sectional view of another embodiment of a bi-component fiber according to the invention as a side-by-side fiber,
  • FIG. 6 is a cross-sectional view of another embodiment of a bi-component fiber according to the invention as a side-by-side fiber with a small proportion of the second component,
  • FIG. 7 is cross-sectional views at various spots along another embodiment of a bi-component fiber as a mixed type that is formed of core-sheath fibers and side-by-side fibers,
  • FIG. 8 is a cross-sectional view of another embodiment of a bi-component fiber according to the invention as a side-by-side fiber,
  • FIG. 9 shows cross-sections at various spots along another embodiment of a bi-component fiber according to the invention as a mixed type of a side-by-side fiber and a core-sheath fiber,
  • FIG. 10 is a cross-sectional view of another embodiment of a trilobal bi-component fiber according to the invention as a side-by-side fiber,
  • FIG. 11 is a cross-sectional view of another embodiment of a trilobal bi-component fiber according to the invention as a side-by-side fiber,
  • FIG. 12 is a cross-sectional view of another embodiment of a trilobal bi-component fiber according to the invention as a side-by-side fiber with an alternative arrangement of the components,
  • FIG. 13 is a cross-sectional view of another embodiment of a tetralobal bi-component fiber according to the invention as a side-by-side fiber with a component arrangement similar to the fiber depicted in FIG. 12 ,
  • FIG. 14 is a cross-sectional view of another embodiment of a bi-component fiber according to the invention as a segmented-pie fiber,
  • FIG. 15 is a cross-sectional view of another embodiment of a bi-component fiber according to the invention as an island-in-the-sea fiber,
  • FIG. 16 is a cross-sectional view of another embodiment of a bi-component fiber according to the invention with a strip-like arrangement of the components, and
  • FIG. 17 shows a portion of a spunbond fabric according to the invention by way of example.
  • FIGS. 1 to 16 show cross-sectional views of bi-component fibers 1 according to the invention by way of example.
  • the depicted bi-component fibers 1 in each case, have a first component 2 and a second component 3 .
  • the first component 2 surrounds the second component 3 and thus forms the outer surface of the fiber.
  • the bi-component fibers 1 depicted in FIGS. 1 to 3 have an at least approximately circular or round geometry in cross-section.
  • the bi-component fiber depicted in FIG. 4 shows, however, a trilobal cross-section.
  • Such trilobal cross-sections like other multilobal cross-sections as well, have the effect that the fiber has a larger outer surface in relation to its mass than is the case with fibers with a circular cross section.
  • core-sheath fibers in which the proportion of the components forming the sheath is very small, for example approximately 2%, but certainly even in “core-sheath fibers” with a higher sheath proportion, it may occur that the sheath has defects. This means that the sheath does not completely surround the core but rather is broken at several spots, so that the core at these spots also forms the outer surface of the fiber.
  • such fibers are “core-sheath fibers.”
  • the component that forms the broken sheath constitutes the outer surface of the fiber in terms of this invention.
  • FIGS. 5 , 6 , 8 and 10 to 13 show bi-component fibers that are embodied as side-by-side fibers. These side-by-side fibers are characterized in that both the first component 2 and the second component 3 form a portion of the outer surface of the bi-component fiber 1 . Also, in the case of side-by-side fibers, circular or at least approximately circular cross-sections, as they are depicted in FIGS. 5 , 6 and 8 , are also possible, such as multilobal cross sections, as they are depicted in FIGS. 10 to 13 . Depending on which fiber properties or nonwoven fabric properties are to be achieved, the first component 2 and the second component 3 can be combined with one another in different ratios and in different spatial arrangements.
  • a component the second component 3 in the example that is shown—can be arranged so that it forms only a small proportion of the outer surface of the bi-component fiber 1 relative to its proportion by weight.
  • a component, the first component 2 in the examples shown can be arranged at especially exposed spots of the bi-component fiber 1 in the case of a multilobal bi-component fiber 1 .
  • the first component 2 is arranged at the tips of the multilobal cross-section of the bi-component fiber 1 .
  • this fiber structure is embodied as a segmented-pie fiber.
  • this fiber structure exhibits a similarity to the side-by- side fiber structures to the extent that both the first component 2 and the second component 3 form a portion of the outer surface of the bi-component fiber 1 .
  • the structures shown in FIGS. 14 and 16 have in common the fact, however, that in each case they have a host of areas that are formed from the first component 2 or the second component 3 .
  • the bi-component fiber 1 shown in FIG. 15 with its islands-in-the-sea structure can be regarded as a variation on a core-sheath fiber, in which a host of cores from the second component 3 are present.
  • the individual cores from the second component 3 are surrounded by a common sheath that is formed of the first component 2 .
  • the bi-component fiber 1 depicted in FIG. 7 has partial cross-sections along the fibers in which the first component 2 surrounds the second component 3 similar to a core-sheath fiber and forms by itself the outer surface of the bi-component fiber 1 .
  • the second component 3 also forms a portion of the outer surface of the bi-component fiber 1 .
  • the first component 2 does not completely surround the second component 3 in cross-section. This also applies for the bi-component fiber 1 depicted in FIG.
  • FIG. 17 it is shown how a host of bi-component fibers 1 , by way of example, form a spunbond fabric 4 .
  • the spunbond fabric forms a web with a transverse direction X, a thickness direction Y, and a longitudinal direction Z, which is also referred to as the machine direction.
  • a spunbond fabric 4 was produced from bi-component fibers 1 , which were thermally solidified by means of a calender.
  • the bi-component fibers 1 are core-sheath fibers, with a sheath that is formed of the first component 2 with polypropylene as a first polymer and a core that is formed of the second component 3 with polypropylene as a second polymer.
  • the weight per unit of area of the spunbond fabric 4 is 70 g/m 2 .
  • the proportion by weight of the second component 3 in the bi-component fiber 1 is 80%.
  • the MFI of the first component 2 in the sheath is 30 g/10 minutes
  • the MFI of the second component 3 in the core is 25 g/10 minutes.
  • the bi-component fibers 1 have a flame retardant agent (NOR-HALS).
  • the additive concentration is 1.5% in the first component and 0.5% in the second component.
  • the burning behavior of the spunbond fabric 4 in a small flame test according to EN 13501-1 leads to the classification in Class E.
  • Another spunbond fabric 4 was produced from bi-component fibers 1 , which were thermally solidified by means of a calender.
  • the bi-component fibers 1 are core-sheath fibers, with a sheath that is formed of the first component 2 with polypropylene as a first polymer and a core that is formed of the second component 3 with polypropylene as a second polymer.
  • the weight per unit of area of the spunbond fabric 4 is 70 g/m 2 .
  • the proportion by weight of the second component 3 in the bi-component fiber 1 is 80%.
  • the MFI of the first component in the sheath is 30 g/10 minutes
  • the MFI of the second component in the core is 25 g/10 minutes.
  • the bi-component fibers 1 have a flame retardant agent (NOR-HALS).
  • the additive concentration is 3% in the first component 2 and 0% in the second component 3 .
  • the burning behavior of the spunbond fabric 4 in a small flame test according to EN 13501-1 leads to the classification in Class E.
  • Another spunbond fabric 4 was produced from bi-component fibers 1 , which were thermally solidified by means of a calender.
  • the bi-component fibers 1 are core-sheath fibers, with a sheath that is formed of the first component 2 with PET as a first polymer and a core that is formed of the second component 3 with PET as a second polymer.
  • the weight per unit of area of the spunbond fabric 4 is 70 g/m 2 .
  • the proportion by weight of the second component 3 in the bi-component fiber 1 is 70%.
  • the bi-component fibers 1 have an antioxidant (trade name Irganox 1010, manufacturer BASF).
  • the additive concentration is 0.15% in the first component 2 and 0.04% in the second component 3 .
  • the specific tearing force of the spunbond fabric 4 still reaches 54% of the starting value after 3 weeks of storage at 150° C.
  • Another spunbond fabric 4 was produced from bi-component fibers 1 , which were thermally solidified by means of a calender.
  • the bi-component fibers 1 are core-sheath fibers, with a sheath that is formed of the first component 2 with PET as a first polymer and a core that is formed of the second component 3 with PET as a second polymer.
  • the weight per unit of area of the spunbond fabric 4 is 70 g/m 2 .
  • the proportion by weight of the second component 3 in the bi-component fiber 1 is 70%.
  • the bi-component fibers 1 have an antioxidant (trade name Irganox 1010, manufacturer BASF).
  • the additive concentration is 0.25% in the first component 2 and 0% in the second component 3 .
  • the specific tearing force of the spunbond fabric 4 still reaches 61% of the starting value after 3 weeks of storage at 150° C.
  • Another spunbond fabric 4 by way of example was produced from bi-component fibers 1 , which were thermally solidified by means of a calender.
  • the bi-component fibers 1 are core-sheath fibers, with a sheath that is formed of the first component 2 with polyethylene as a first polymer and a core that is formed of the second component 3 with polypropylene as a second polymer.
  • the weight per unit of area of the spunbond fabric 4 is 70 g/m 2 .
  • the proportion by weight of the second component 3 in the bi-component fiber 1 is 90%.
  • the bi-component fibers 1 have a UV stabilizer (trade name Uvinul 5050, manufacturer BASF).
  • the additive concentration is 0.4% in the first component 2 and 0.23% in the second component 3 .
  • the specific tearing force still reaches 59% of its starting value after 16 weeks of outdoor exposure.
  • Another spunbond fabric 4 was produced from bi-component fibers 1 , which were thermally solidified by means of a calender.
  • the bi-component fibers 1 are core-sheath fibers, with a sheath that is formed of the first component 2 with polyethylene as a first polymer and a core that is formed of the second component 3 with polypropylene as a second polymer.
  • the weight per unit of area of the spunbond fabric 4 is 70 g/m 2 .
  • the proportion by weight of the second component 3 in the bi-component fiber 1 is 90%.
  • the bi-component fibers 1 have a UV stabilizer (Uvinul® 5050, manufacturer BASF).
  • the additive concentration is 0.7% in the first component 2 and 0.1% in the second component 3 .
  • the specific tearing force still reaches 72% of its starting value after 16 weeks of outdoor exposure.
US14/331,644 2013-07-15 2014-07-15 Bi-component fiber for the production of spunbonded fabric Abandoned US20150017865A1 (en)

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WO2022140104A1 (en) * 2020-12-21 2022-06-30 O&M Halyard, Inc. Higher strength calcium carbonate filled fiber spunbond and sms nonwoven material
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US11745480B2 (en) 2018-10-31 2023-09-05 Ewald Dörken Ag Composite film
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ES2742406T3 (es) 2016-10-06 2020-02-14 Eurofilters Nv Bolsas filtro para aspiradora con materiales textiles reciclados y/o línters de algodón
CN109576814B (zh) * 2018-05-21 2021-02-05 山东第一医科大学(山东省医学科学院) 一种帕金森病患者的复合鞋
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EP2826895B1 (de) 2018-08-29

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