US20150211160A1 - High loft, nonwoven web exhibiting excellent recovery - Google Patents

High loft, nonwoven web exhibiting excellent recovery Download PDF

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Publication number
US20150211160A1
US20150211160A1 US14/167,366 US201414167366A US2015211160A1 US 20150211160 A1 US20150211160 A1 US 20150211160A1 US 201414167366 A US201414167366 A US 201414167366A US 2015211160 A1 US2015211160 A1 US 2015211160A1
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US
United States
Prior art keywords
web
high loft
nonwoven web
agents
nonwoven
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US14/167,366
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English (en)
Inventor
Mohammad A. Hassan
Douglas B. Brown
Jeffrey D. Stark
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Biax Fiberfilm Corp
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Biax Fiberfilm Corp
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Filing date
Publication date
Application filed by Biax Fiberfilm Corp filed Critical Biax Fiberfilm Corp
Priority to US14/167,366 priority Critical patent/US20150211160A1/en
Assigned to BIAX-FIBERFILM reassignment BIAX-FIBERFILM ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BROWN, DOUGLAS B., HASSAN, MOHAMMAD A., STARK, JEFFREY D.
Priority to PCT/US2015/013429 priority patent/WO2015116766A1/en
Priority to JP2016567456A priority patent/JP2017505390A/ja
Priority to DE112015000561.7T priority patent/DE112015000561T8/de
Publication of US20150211160A1 publication Critical patent/US20150211160A1/en
Priority to US15/412,670 priority patent/US10961644B2/en
Priority to JP2019184292A priority patent/JP7032365B2/ja
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • 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
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • 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
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/07—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments otherwise than in a plane, e.g. in a tubular way
    • 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
    • D04H3/14—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 yarns or filaments produced by welding
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Definitions

  • This invention relates to a high loft, nonwoven web exhibiting excellent recovery.
  • polymeric fibers formed by spunbonding, meltblowing or by some other extrusion process are collected downstream from an emitter, such as a die with a plurality of nozzles, on a horizontal oriented conveyor belt.
  • an emitter such as a die with a plurality of nozzles
  • Such processes tends to produce two-dimensional web where the fibers are oriented in the x and y directions since they are laid down in a horizontal plane.
  • the webs are compacted or compressed during shipment, they lack the ability to recovery to their original thickness. In addition, once compacted or compressed, such webs tend to become hard and/or stiff and their pore structure may become less open. Furthermore, the drapeability of such webs can be diminished. Functionally, if a compacted or compressed web cannot recover to approximately its initial loft thickness after shipment, it can lose some of its thermal and/or acoustical insulation properties, thereby rendering the material less than desirable for this purpose.
  • this invention relates to a high loft, nonwoven web exhibiting excellent recovery.
  • the high loft, nonwoven web is a three dimensional structure with fibers oriented in the x, y and z directions.
  • the web can be constructed as a single layer or be formed with two or more layers.
  • the web has a thickness of less than about 250 millimeters and a basis weight of from between about 50 g/m 2 to about 3,000 g/m 2 .
  • the web can be bonded using a thermal bonder, a chemical bonder, a hydro-mechanical bonder, a mechanical bonder, or be left unbonded.
  • a vertical cross-section of the web when taken parallel to its machine direction, exhibits a plurality of snugly stacked, approximately V, U, or C-shaped structures, with each approximately V, U, or C-shaped shaped structure having an apex facing in the machine direction.
  • the web has a recovery value of from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes according to the guidelines of the IST 120.2 (01).
  • the apparatus includes a die having a plurality of nozzles each emitting a filament, and each of the plurality of nozzles having a distal end.
  • a pair of moving surfaces is located from between about 10 cm to about 150 cm of the distal end of each of the plurality of nozzles.
  • the pair of moving surfaces forms a convergent passage having an entry and an exit.
  • the apparatus also includes a mechanism for depositing the plurality of filaments onto and between the pair of moving surfaces. The plurality of filaments is routed through the convergent passage in descending travel from the entry to the exit to form a 3-dimensional structure.
  • the apparatus further includes a bonder located downstream of it and in vertically alignment with the pair of moving surfaces for bonding the 3-dimensional structure to create a high loft, nonwoven web with the filaments transformed into fibers oriented in the x, y and z directions.
  • the web has a thickness of less than about 250 mm and a basis weight ranging from between about 50 g/m 2 to about 3,000 g/m 2 .
  • a vertical cross-section of the high loft, nonwoven web when taken parallel to its machine direction, exhibits a plurality of snugly stacked, approximately V, U, or C-shaped structures, with each approximately V, U, or C-shaped structure having an apex facing in the machine direction.
  • the approximately V or U shaped structure is rotated 90 degrees to a horizontal orientation with the apex of each facing to the right.
  • the C-shaped structure is reversed in position so that the apex of each faces to the right.
  • the high loft, nonwoven web has a recovery value ranging from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.
  • a process for forming a high loft, nonwoven web includes the steps of introducing a molten polymer to a die having a plurality of nozzles. Emitting, ejecting or extruding the molten polymer through the plurality of nozzles to form a plurality of filaments. Air or gas streams are then used to facilitate movement and drawing/accelerating of the plurality of filaments.
  • the filaments are directed towards a pair of moving surfaces located at a distance of from between about 10 cm to about 150 cm from the plurality of nozzles.
  • the pair of moving surfaces forms a convergent passage having an entry and an exit.
  • the plurality of filaments is deposited into the entry of the convergent passage.
  • the plurality of filaments is then routed through the convergent passage in descending travel from the entry to the exit and between the pair of moving surfaces in a machine direction to form a 3-dimensional structure with the filaments transformed into fibers which are oriented in the x, y and z directions.
  • the 3-dimensional structure is bonded to form a high loft, nonwoven web having a thickness of less than about 250 millimeters and a basis weight ranging from between about 50 g/m 2 to about 3,000 g/m 2 .
  • a vertical cross-section of the high loft, nonwoven web when taken parallel to its machine direction, exhibits a plurality of snugly stacked, approximately V, U, or C-shaped structures, with each approximately V, U, or C-shaped structure having an apex facing in the machine direction.
  • the high loft, nonwoven web has a recovery value ranging from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.
  • the general object of this invention is to provide high loft, nonwoven web exhibiting excellent recovery such that it can be compactly shipped without losing any material properties.
  • a more specific object of this invention is to provide high loft, nonwoven web with good thermal insulation and/or acoustical insulation values.
  • Another object of this invention is to provide high loft, nonwoven web which can be used in the bedding, upholstery, filtration, foam replacement materials, and products utilizing cushioning materials.
  • a further object of this invention is to provide a high loft, nonwoven web exhibiting from between about 20% to about 99% recovery after compression, and such web exhibits a high porosity.
  • Still another object of this invention is to provide a high loft, nonwoven web exhibiting from between about 30% to about 95% recovery after compression.
  • an object of this invention is to provide a high loft, nonwoven web exhibiting from between about 40% to about 90% recovery after compression.
  • FIG. 1 is a perspective view of a high loft, nonwoven web of this invention showing a plurality of snugly stacked, approximate V, U or C-shaped structures, with each uniquely shaped structure having an apex facing in the machine direction of the web.
  • FIG. 2 is a schematic of a vertical cross-section of a section of a high loft, nonwoven web showing a plurality of snugly stacked, approximate V, U or C-shaped structures, with each uniquely shaped structure having an apex facing in the machine direction of the web.
  • FIG. 3 is a cross-sectional view of a two layer web.
  • FIG. 4 is a cross-sectional view of a multi-layer web.
  • FIG. 5 is a perspective view of an alternative embodiment of a high loft, nonwoven web depicting textured upper and lower surfaces
  • FIG. 6 is a schematic of the textured upper surface of the high loft, nonwoven web shown in FIG. 4 .
  • FIG. 7 is a schematic of an apparatus utilizing a pair of rotatable drums located immediately downstream of a die.
  • FIG. 8 is a schematic of an alternative apparatus utilizing a pair of angled conveyors located immediately downstream of a die.
  • FIG. 9 is a schematic of still another apparatus using a combination of a spunbond die positioned between first and second meltblown dies.
  • the high loft, nonwoven web 10 is a 3-dimensional structure with a plurality of fibers 12 oriented in the x, y and z directions.
  • X-X represents the longitudinal central axis
  • Y-Y represents the vertical central axis
  • Z-Z represents the transverse central axis.
  • web it is meant a fabric or material manufactured in sheet form.
  • high loft it is meant a low density, fibrous web characterized by a high ratio of thickness to weight per unit area.
  • the fibers in the web 10 may be continuous or discontinuous, bonded or unbounded.
  • the fibers 12 are continuous and some of the fibers 12 are bonded.
  • a high loft web has from between about 5% to about 60% solids by volume.
  • nonwoven it is meant a web, sheet or batt of natural and/or man-made fibers or filaments (excluding paper) that have not been converted into yarns, and that are bonded to each other by thermal, chemical, mechanical, hydro-mechanical, or by some other means known to those skilled in the art.
  • the high loft, nonwoven web 10 can be formed from a variety of materials.
  • the high loft, nonwoven web 10 can be formed from man-made fibers.
  • the fibers can be staple fibers.
  • the high loft, nonwoven web 10 is formed from a polymer.
  • the polymer can be selected from the group consisting of: polyolefins, polyesters, polyethylene terephthalates, polybutylene terephthalates, polycyclohexylene dimethylene terephthalates, polytrimethylene terephthalates, polymethyl methacrylates, polyamides, nylons, polyacrylics, polystyrenes, polyvinyls, polytetrafluoroethylenes, ultrahigh molecular weight polyethylenes, very high molecular weight polyethylenes, high molecular weight polyethylenes, polyether ether ketones, non-fibrous plasticized celluloses, polyethylenes, polypropylenes, polybutylenes, polymethylpentenes, low-density polyethylenes, linear low-density polyethylenes, high-density polyethylenes, polystyrenes, acrylonitrile-butadiene-styrenes, styrene-acrylonitriles, styrene-butadienes,
  • the high loft, nonwoven web 10 can be formed or manufactured using many different kinds and types of equipment and processes. Some commonly known technology which can be used to form the high loft, nonwoven web 10 include, but are not limited to: spinning processes such as meltblowing, spunbond, spunmelt, solution blowing, electrospinning. In addition, the high loft, nonwoven web 10 can be manufactured by a dry-laid process such as an air-lay process, a carding process or any combination of any two or more such processes where fibers are laid down at a nip between two moving surfaces. The manufactured high loft, nonwoven web 10 can be bonded or be unbounded. A bonding step adds strength and integrity to the finished web 10 .
  • spinning processes such as meltblowing, spunbond, spunmelt, solution blowing, electrospinning.
  • the high loft, nonwoven web 10 can be manufactured by a dry-laid process such as an air-lay process, a carding process or any combination of any two or more such processes where fibers are laid down at a ni
  • spunbond it is meant a process for producing strong fibrous nonwovens webs directly from thermoplastic polymers by attenuating the spun filaments using low temperature, high speed air while quenching the fibers near the spinnerette face. Individual fibers are then laid down randomly on a collection belt and are then conveyed to a bonder. The bonder gives the web strength and integrity. Fiber size is usually below 250 ⁇ m, the average fiber size is in the range of from between about 10 microns to about 50 microns and the fibers are very strong compared to meltblown fibers because of the molecular chain alignment that is achieved during the attenuating of the crystallized (solidified) filaments.
  • a typical spunbond die has multiple rows of polymer nozzle holes.
  • a typical melt flow rate is below about 500 grams/10 minutes.
  • spunmelt it is meant a process where fibers are spun from molten polymers through a plurality of nozzles located in a die head connected to one or more extruders.
  • a spunmelt process may include meltblowing and/or spunbonding.
  • meltblowing it is meant a process where a plurality of molten polymer streams are attenuated using an elevated temperature, high speed gas stream.
  • the gas can be air or other gases known to those skilled in the art.
  • the attenuated fibers are then collected on a moving belt, conveyor or a dual drum collector.
  • a meltblowing die has around 35 nozzles per inch, a row of spinnerettes and two inclined air or gas jets for attenuating the fiber streams.
  • U.S. Pat. No. 4,380,570 and WO 2005/106,085 A1 teach meltblowing processes where multiple rows of polymer nozzles are surrounded by air nozzles and the streams flowing therefrom are aligned parallel to one another.
  • the high loft, nonwoven web 10 can be constructed as a single layer 14 of material.
  • the high loft, nonwoven web 10 can be formed using equipment where air or gas is used to facilitate movement and drawing of the molten polymer through a plurality of nozzles into a plurality of filaments. Each of the plurality of filaments is emitted through a single nozzle.
  • the high loft, nonwoven web 10 ′ can also be formed of two separate and distinct layers, 14 and 16 , see FIG. 3 , or the web 10 ′′ can have multiple layers, see FIG. 4 .
  • multiple layers it is meant 3, 4, 5, 6, 7 or more separate and distinct layers.
  • Some of the layers can be similar and/or identical in composition and characteristics to another layer, while one or more layers can vary in composition and/or characteristics from one or more of the remaining layers.
  • three separate and distinct layers 18 , 20 and 22 are present.
  • the web 10 consisting of a single layer 14 , the web 10 ′, consisting of two layers 14 and 16 , or the web 10 ′′, consisting of three layers 18 , 20 and 22 , can be bonded to provide strength and integrity.
  • the web 10 ′ is a two layer embodiment having an upper layer 14 and a lower layer 16 .
  • the web 10 ′′ is a three layer embodiment having an upper layer 18 , a middle layer 20 and a lower layer 22 .
  • each layer can vary in the type of polymer it is made from.
  • the characteristics of a given layer can vary. For example, the characteristics of one layer can be different from another layer.
  • the thickness of each layer in the web 10 ′′ can vary or be the same.
  • the density of each layer in the web 10 ′′ can also vary or be the same.
  • the basis weight of each layer in the web 10 ′′ can also vary or be the same.
  • the high loft, nonwoven web 10 is depicted as a single layer structure.
  • the high loft, nonwoven web 10 has a thickness t which can vary in dimensions.
  • the thickness t of the high loft, nonwoven web 10 can range from between about 5 millimeters (mm) to about 300 mm.
  • the thickness t of the high loft, nonwoven web is less than about 250 millimeters. More desirably, the thickness t of the high loft, nonwoven web 10 is less than about 200 mm. Even more desirably, the thickness t of the high loft, nonwoven web 10 is less than about 100 mm.
  • the thickness t of the high loft, nonwoven web 10 is less than about 50 mm.
  • the overall thickness of the web 10 ′ or 10 ′′ can double, triple, etc. depending upon how many layers are present.
  • the high loft, nonwoven web 10 can be formed with different basis weights. Generally, the basis weight of the high loft, nonwoven web 10 ranges from between about 50 grams per square meter (g/m 2 ) to about 3,000 g/m 2 . Desirably, the basis weight of the high loft, nonwoven web 10 ranges from between about 750 grams per square meter (g/m 2 ) to about 2,500 g/m 2 . More desirably, the basis weight of the high loft, nonwoven web 10 ranges from between about 100 grams per square meter (g/m 2 ) to about 1,000 g/m 2 . Even more desirably, the basis weight of the high loft, nonwoven web 10 is less than about 600 g/m 2 .
  • the high loft, nonwoven web 10 can also vary in density. Generally, the high loft, nonwoven web 10 has a density ranging from between about 10 kilograms per cubic meters (Kg/m 3 ) to about 250 Kg/m 3 . Desirably, the high loft, nonwoven web 10 has a density ranging from between about 20 Kg/m 3 to about 200 Kg/m 3 . More desirably, the high loft, nonwoven web 10 has a density ranging from between about 30 Kg/m 3 to about 150 Kg/m 3 . Even more desirably, the high loft, nonwoven web 10 has a density ranging from between about 40 Kg/m 3 to about 100 Kg/m 3 .
  • the high loft, nonwoven web 10 can be bonded or unbounded. Desirably, the high loft, nonwoven web 10 is bonded. Bonding generally imparts strength and integrity to the web 10 . Bonding can be performed using different type of equipment and processes known to those skilled in the art. Various bonders include: mechanical bonders such as needle bonding, hydro-mechanical bonders, also known as wet bonding, thermal bonders, which include through air bonding and oven thermal bonding and chemical bonding. Whichever type of bonder is utilized, some of the fibers 12 , 14 , 16 , 18 , 20 and 22 are bonded together to make the high loft, nonwoven web 10 , 10 ′ and 10 ′′ stronger.
  • the high loft, nonwoven web 10 can be formed from polypropylene having a melt flow rate ranging from between about 4 g/10 min. to about 6,000 g/10 min at a temperature of 230° C. and at a pressure of 2.16 kg according to the teachings of ASTM D 1238 testing method.
  • the high loft, nonwoven web 10 can be formed from polypropylene having a melt flow rate ranging from between about 35 g/10 min. to about 2,500 g/10 min at a temperature of 230° C. and at a pressure of 2.16 kg.
  • the high loft, nonwoven web 10 can be formed from polypropylene having a melt flow rate ranging from between about 500 g/10 min.
  • the high loft, nonwoven web 10 can be formed from polypropylene having a melt flow rate ranging from between about 500 g/10 min. to about 1,500 g/10 min at a temperature of 230° C. and at a pressure of 2.16 kg.
  • the schematic clearly shows a vertical cross-section of the high loft, nonwoven web 10 taken parallel to the machine direction (MD).
  • the material advances from left to right.
  • the leading edge of the high loft, nonwoven web 10 is to the right.
  • the high loft, nonwoven web 10 exhibits a plurality of snugly stacked, approximately V, U or C-shaped structures 24 .
  • These V, U or C-shaped structures 24 are also depicted in FIG. 1 .
  • Each of the approximately V, U or C-shaped structures 24 has an apex 26 which faces in the machine direction (MD).
  • the approximately V or U shaped structure is rotated 90 degrees to a horizontal orientation with the apex of each facing to the right.
  • the C-shaped structure is reversed in position so that the apex of each faces to the right.
  • This unique structure occurs because of the way the fibers 12 are laid down during formation.
  • This unique structure is important for it gives the high loft, nonwoven web 10 a very high recovery value.
  • the high loft, nonwoven web has a recovery value ranging from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes, according to the guidelines of the INDA Standard Test Method (IST 120.2 (01)).
  • the high loft, nonwoven web 10 has a recovery value ranging from between about 30% to about 95% according to the guidelines of the IST 120.2 (01). More desirably, the high loft, nonwoven web 10 has a recovery value ranging from between about 40% to about 90% according to the guidelines of the IST 120.2 (01). Even more desirably, the high loft, nonwoven web 10 has a recovery value ranging from between about 50% to about 80% according to the guidelines of the IST 120.2 (01).
  • each layer of the two layer web 10 ′, shown in FIG. 3 , and each layer of the three layered web 10 ′′, shown in FIG. 4 also exhibits this plurality of snugly stacked, approximately V, U or C-shaped structures 24 if they are laminated offline, but they will show one snugly stacked structured, approximately V, U or C shaped structured, if they are comingled simultaneously from different spinning heads as shown in FIG. 9 .
  • This kind of comingled high loft structure could have different fiber size, different polymeric materials, and/or different fiber cross-section.
  • the two layered web 10 ′ has a three dimensional structure with fibers oriented in the x, y and z directions.
  • This two layer web 10 ′ has a thickness t 1 of from between about 5 millimeters to about 500 millimeters and a basis weight of from between about 50 g/m 2 to about 2,000 g/m 2 ′
  • the two layered web 10 ′ does not have to be bonded but desirably is thermally or chemically bonded. Alternatively, the web 10 ′ could be mechanically or hydro-mechanically bonded.
  • Each of the two layers, 14 and 16 , of the web 10 ′ exhibits a vertical cross-section, when taken parallel to the machine direction (MD) during manufacture of the two layered web 10 ′, which exhibits a plurality of snugly stacked, approximately V, U or C-shaped structures 24 .
  • Each of the approximately V, U or C-shaped structures 24 has an apex 26 facing in the machine direction (MD).
  • MD machine direction
  • the approximately V or U shaped structure is rotated 90 degrees to a horizontal orientation with the apex of each facing to the right.
  • the C-shaped structure is reversed in position so that the apex of each faces to the right.
  • the two layered web 10 ′ has a recovery value of from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes according to the guidelines of the IST 120.2 (01). Desirably, the two layered web 10 ′ has a recovery value ranging from between about 30% to about 95% according to the guidelines of the IST 120.2 (01). More desirably, the two layered web 10 ′ has a recovery value ranging from between about 40% to about 90% according to the guidelines of the IST 120.2 (01). Even more desirably, the two layered web 10 ′ has a recovery value ranging from between about 50% to about 80% according to the guidelines of the IST 120.2 (01).
  • the two layer web 10 ′ can be formed as two separate layers 14 and 16 from comingled fibrous materials where each layer has a different fiber size, is formed from a different material, has different fiber cross-sections, etc.
  • the two layered web 10 ′ could be laminated to one or more layers.
  • the additional layers could be a thermoplastic film, a film, another nonwoven material, paper, cardboard, etc.
  • the three layered web 10 ′′ has a three dimensional structure with fibers oriented in the x, y and z directions.
  • This three layer web 10 ′′ has a thickness t 2 of from between about 5 millimeters to about 750 millimeters and a basis weight of from between about 50 g/m 2 to about 2,000 g/m 2
  • the three layered web 10 ′′ does not have to be bonded but desirably is thermally or chemically bonded. Alternatively, the web 10 ′′ could be mechanically or hydro-mechanically bonded.
  • Each of the three layers, 18 , 20 and 22 , of the web 10 ′′ exhibits a vertical cross-section, when taken parallel to the machine direction (MD) during manufacture of the web 10 ′′, which exhibits a plurality of snugly stacked, approximately V, U or C-shaped structures 24 .
  • Each of the approximately V, U or C-shaped structures 24 has an apex 26 facing in the machine direction (MD).
  • MD machine direction
  • the approximately V or U shaped structure is rotated 90 degrees to a horizontal orientation with the apex of each facing to the right.
  • the C-shaped structure is reversed in position so that the apex of each faces to the right.
  • the three layered web 10 ′′ has a recovery value of from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes according to IST 120.2 (01). Desirably, the three layered web 10 has a recovery value ranging from between about 30% to about 95% according to IST 120.2 (01). More desirably, the three layered web 10 has a recovery value ranging from between about 40% to about 90% according to IST 120.2 (01). Even more desirably, the three layered web 10 has a recovery value ranging from between about 50% to about 80% according to IST 120.2 (01).
  • an additive can be incorporated into the high loft, nonwoven web 10 , 10 ′ or 10 ′.
  • the additive (not shown) can be applied to the high loft, nonwoven web 10 , 10 ′ or 10 ′′ during manufacture.
  • the additive can be applied in various ways, including but not limited to: being sprayed on, being sprinkled on, being extruded, being combined with, being painted on, being immersed, etc.
  • the additive can be a gas, a liquid, a solid or a semi-solid.
  • the additive can be selected from the group consisting of: a superabsorbent, absorbent particles, pulp fibers, polymers, nanoparticles, abrasive particulars, active particles, active compounds, ion exchange resins, zeolites, softening agents, plasticizers, ceramic particles pigments, dyes, flavorants, aromas, controlled release vesicles, binders, adhesives, tackifiers, surface modification agents, lubricating agents, emulsifiers, vitamins, peroxides, antimicrobials, deodorizers, fire retardants, flame retardants, antifoaming agents, anti-static agents, biocides, antifungals, degradation agents, stabilizing agents, conductivity modifying agents, or any combination thereof.
  • FIGS. 5 and 6 an alternative embodiment of high loft, nonwoven web 11 is shown having been formed as a single layer 14 with two major surfaces 28 and 30 .
  • the two major surfaces 28 and 30 are aligned opposite to one another.
  • the two major surfaces include the upper surface 28 and the lower surface 30 .
  • two major surfaces it is meant the two surfaces of the web 11 which have the greatest surface area.
  • the web 11 has two major surfaces, 28 and 30 , and both of these major surfaces 28 and 30 are textured.
  • textured it is meant a rough or grainy surface quality, as opposed to being smooth. The texture can be formed various ways during processing of the web 11 .
  • a plurality of protuberances 32 extends upward from the upper surface 28 and downward from the lower surface 30 .
  • protuberance it is meant a bulge, knob or swelling that protrudes outward.
  • indentations, cavities or depressions could be formed in the upper and/or lower surfaces, 28 and 30 respectively, to obtain a similar textured effect.
  • at least one of the two major surfaces, 28 and 30 of the web 11 is textured. More desirably, both of the two major surfaces, 28 and 30 of a web 11 are textured.
  • an apparatus 34 is shown for producing a high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 .
  • the apparatus 34 is shown being oriented in a horizontal configuration, although it could be arranged vertically or at some other angle relative to the vertical axis.
  • the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 has a three dimensional structure with fibers oriented in the x, y and z directions.
  • the apparatus 34 includes a die 36 having a plurality of nozzles 38 each emitting, ejecting or extruding a filament 40 .
  • Each of the plurality of nozzles 38 has a distal end 42 .
  • the apparatus 34 can use air or gas to facilitate movement and drawing of the molten polymer from the plurality of nozzles 38 into a plurality of filaments.
  • a pair of moving surfaces, 44 and 46 is located from between about 10 centimeters (cm) to about 150 cm of the distal end 42 of each of the plurality of nozzles 38 .
  • the pair of moving surfaces, 44 and 46 can be a first rotatable drum 48 and a second rotatable drum 50 , as is shown in FIG. 7 .
  • the pair of moving surfaces, 44 and 46 can be a first conveyor belt 52 and a second conveyor belt 54 , as is shown in FIG. 8 .
  • Other forms of moving surfaces, 44 and 46 known to those skilled in the art can also be employed.
  • the first rotatable drum 48 will have a diameter d 1 and the second rotatable drum 50 will have a diameter d 2 Desirably, the diameter d 1 is approximately equal to the diameter d 2 . More desirably, the diameters d 1 and d 2 are identical.
  • the first and second rotatable drums, 48 and 50 respectively will be aligned parallel to one another on the same plane X 1 -X 1 . It should be understood that the apparatus 34 is horizontally oriented so that the filaments 40 will move from left to right in a machine direction (MD) between the first and second rotatable drums, 48 and 50 respectively.
  • MD machine direction
  • first drum 48 rotates counterclockwise while the second drum 50 rotates clockwise. This specific rotation will cause the plurality of continuous filaments 40 to move in the machine direction (MD) away from the plurality of nozzles 38 .
  • the speed of the first and second rotatable drums, 48 and 50 respectively can vary. Desirably, each of the first and second rotatable drums, 48 and 50 respectively, will rotate at the same speed. Alternatively, one of the first and second rotatable drums, 48 and 50 respectively, could rotate at a different speed than the other drum and therefore a different cross-sectional structure may be produced in the machine direction such as S or S-like shape.
  • the speed of the first and second rotatable drums, 48 and 50 respectively, should be adjusted according to the basis weight of the material that is being produced, the thickness of the desired web 10 , the kind of polymer being extruded, the polymer throughput through the plurality of nozzles 38 , etc.
  • the first and second rotatable drums, 48 and 50 respectively can be operated at room temperature.
  • the first and second rotatable drums, 48 and 50 respectively could be operated at an elevated temperature or at a temperature below room temperature.
  • the first and second rotatable drums, 48 and 50 respectively are operated at room temperature.
  • the first and second rotatable drums, 48 and 50 respectively can be hollow cylinders with their outer peripheries covered with a forming wire or screen.
  • the forming wire or screen can be produced from a variety of different materials known to those skilled in the art.
  • the forming wire or screen could be made from a synthetic material, such as polyethylene terephthalate (PET).
  • PET polyethylene terephthalate
  • the forming wire or screen could be made from: metal, steel, aluminum, a plastic, a thermoplastics, etc.
  • the first and second rotatable drums, 48 and 50 respectively could also be constructed out of various materials, such as wood, steel, cast iron, aluminum, etc.
  • the metal belts could be ferrous or non-ferrous.
  • the metal belts could contain a plurality of apertures, openings or holes arranged in a predetermined pattern or could be randomly arranged. The size and shape of the apertures, openings or holes can vary.
  • each of the first and second rotatable drums, 48 and 50 respectively can be equipped with adjustable vacuum chamber, if desired.
  • the open mesh design of a wire, screen or a metal belt containing apertures, openings or holes can form a specific texture or pattern onto the outer surfaces of the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 that is being produced.
  • Such texture or pattern may enhance the sound insulation and/or thermal absorption properties of the finished web 10 , 10 ′, 10 ′′ or 11 .
  • each of the first and second rotatable drums, 48 and 50 respectively has a central axis 56 and 58 , respectively.
  • each of the central axes 56 and 58 are aligned on a common vertical plane, designated X 1 -X 1 .
  • a horizontal distance measured from the distal end 42 of each nozzle 38 perpendicular to the vertical plane X 1 -X 1 established a Die-to-Collector Distance (DCD).
  • This DCD distance can range from between about 10 cm to about 150 cm. Desirably, the DCD distance is less than about 100 cm. More desirably, the DCD distance is less than about 90 cm.
  • the DCD distance is less than about 80 cm. Most desirably, the DCD distance is less than about 60 cm.
  • the exact DCD distance is dependent upon a number of factors including but not limited to: the melt temperature of the polymer being extruded, the polymer throughput through the plurality of nozzles 38 , etc. However, it has been found through experimentation, that the closer the moving surfaces 44 and 46 are located from the distal end 42 of each of the plurality of nozzles 38 , the better the recovery value of the manufactured high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 is after compression. When the DCD distance ranges from between about 45 cm to about 75 cm, a high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 can be manufactured with a good recovery value after compression.
  • the outer peripheries of the first and second rotatable drums, 48 and 50 respectively, are spaced apart from one another thereby creating a convergence passage 60 .
  • convergent passage it is meant a point of converging, to approach a point.
  • This converging passage 60 narrows down to a dimension equal to a nip 62 established between the first and second rotatable drums, 48 and 50 respectively.
  • the nip 62 can vary in dimension.
  • the first and second rotating drums, 48 and 50 respectively, should be mounted such that the dimension of the nip 62 established therebetween can be easily adjusted. Generally, the nip 62 can range from between about 0.5 cm to about 25 cm.
  • the nip 62 is greater than about 0.5 cm. More desirably, the nip 62 ranges from between about 0.5 cm to about 10 cm. Even more desirably, the nip 62 ranges from between about 0.5 cm to about 8 cm. Most desirably, the nip 62 is less than about 5 cm.
  • the convergent passage 60 has an entry 64 and an exit 66 established by the circumference of the first and second rotatable drums, 48 and 50 respectively.
  • the plurality of filaments 40 are deposited at the entry 64 of the convergent passage 60 they are directed and routed onto and between the pair of moving surfaces 44 and 46 .
  • the routing is facilitated by the rotation of the first and second rotatable drums, 48 and 50 respectively.
  • the routing causes the plurality of filaments 40 to pass through the convergent passage 60 in descending travel from the entry 64 to the exit 66 .
  • the rotational movement of the first and second rotatable drums, 48 and 50 respectively, will cause some of the plurality of filaments 40 to temporarily contact the outer peripheries of the first and second rotatable drums, 48 and 50 respectively.
  • These filaments 40 will be compressed against the remaining filaments 40 passing through the nip 62 to create a 3-dimensional structure 68 .
  • the plurality of filaments 40 will be compressed at the nip 62 and this confined space helps the filaments 40 , which are transformed into fibers 12 as they cool, to be aligned in the x, y and z directions.
  • Transformed it is meant to change markedly the appearance or form of; to change the nature, function, or condition of; convert.
  • a 3-dimensional structure 68 is produced instead of a 2-dimensional structure.
  • the 3-dimensional structure 68 usually will not have a very good recovery value unless fiber-to-fiber bonds are created using some known bonding process to stabilize the formed 3-dimensional structure 68 .
  • the 3-dimensional structure 68 is advanced in the machine direction (MD) in a horizontal direction.
  • a conveyor belt 70 can be utilized.
  • the conveyor belt 70 can be constructed with a screen having a porous or open pattern to allow heat to pass therethrough freely.
  • the conveyor belt 70 can move in a given direction over a plurality of rollers 72 .
  • Four rollers 72 are depicted in FIG. 7 , although any number of rollers 72 can be utilized.
  • One of the rollers 72 is the drive roller and the remaining rollers 72 , 72 and 72 are idler or follower rollers.
  • the conveyor belt 70 makes a continuous loop and is illustrated moving in a clockwise direction so as to advance the 3-dimensional structure 68 in the downward machine direction (MD).
  • high loft, nonwoven webs 10 can be formed from certain materials and for certain uses, wherein bonding is not necessary. However, for most high loft, nonwoven webs 10 , it is advantageous to subject the 3-dimensional structure 68 to a bonding process. Bonding generally imparts strength and integrity into the finished web 10 . Various bonding techniques can be utilized. A single bonder or a pair of oppositely aligned bonders can be utilized.
  • a bonder 74 is shown located downstream of and in vertically alignment with the pair of moving surfaces 44 and 46 for bonding the 3-dimensional structure 68 .
  • the bonder 74 is located such that the 3-dimensional structure 68 passes therethrough.
  • the bonder 74 can be a thermal bonder, such as: a through air bonder or an oven bonder.
  • a thermal bonder can function by creating heat.
  • the heat can be created by a heated fluid, such as gases or liquid, burning a solid, such as coal, heating inert gases, using steam, using secondary radiation from nanoparticles, using infra-red heat, etc.
  • the bonder 74 itself can include a furnace, an oven, thermoelectric elements, etc., or any combination thereof.
  • the bonder 74 can be a chemical bonder, a mechanical bonder, a hydro-mechanical bonder, needle bonder, a wet bonder, etc.
  • the heat from a thermal bonder will lock some of the fibers 12 to one another in the x, y and z directions. All the fibers 12 do not have to be bonded together, just enough to create the high loft, nonwoven web 10 .
  • the fibers 12 are created as the plurality of filaments 40 solidify in the 3-dimensional structure 68 .
  • a high loft, nonwoven web 10 is create having a thickness of less than about 250 mm, desirably, less than about 200 mm, and more desirably, less than about 100 mm.
  • the high loft, nonwoven web 10 also has a basis weight ranging from between about 50 g/m 2 to about 3,000 g/m 2 , desirably, from between about 100 g/m 2 to about 2,000 g/m 2 , and more desirably, from between about 100 g/m 2 to about 600 g/m 2 . Furthermore, a vertical cross-section of the web 10 , when taken parallel to its machine direction, exhibits a plurality of snugly stacked, approximately V, U, or C-shaped structures 24 .
  • Each of the approximately V, U or C-shaped structures 24 has an apex 26 facing in the machine direction, in other words, the approximately V or U shaped structure is rotated 90 degrees to a horizontal orientation with the apex of each facing to the right.
  • the C-shaped structure is reversed in position so that the apex of each faces to the right.
  • This high loft, nonwoven web 10 has a recovery value ranging from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes, according to IST 120.2 (01).
  • the IST 120.2 (01) test requires the material to be compressed under a pressure of 0.25 psi for a time period of 30 minutes.
  • the high loft, nonwoven web 10 has a recovery value ranging from between about 30% to about 95% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes, according to IST 120.2 (01). More desirably, the high loft, nonwoven web 10 has a recovery value ranging from between about 40% to about 90% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes, according to IST 120.2 (01). Most desirably, the high loft, nonwoven web 10 has a recovery value ranging from between about 50% to about 80% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes, according to IST 120.2 (01).
  • the apparatus 34 may further include one or more dispensing mechanisms 76 and 78 for adding chemical binders, or dispensing one or more additives 80 to the high loft, nonwoven web 10 .
  • Two dispensing mechanisms 76 and 78 are illustrated in FIG. 7 .
  • Chemical bonding system can be utilized instead of the thermal bonding systems. Chemical binders may impart some new features to the web such as different surface chemistry, more stiffness or roughness. The exact number of dispensing mechanisms can vary.
  • one or two dispensing mechanisms 76 or 78 are utilized to add one or more additives to the high loft, nonwoven web 10 .
  • the additive 80 can be any of those described above, as well as others known to those skilled in the art.
  • the high loft, nonwoven web 10 could also be partially or fully immersed in a liquid solution containing an additive 80 .
  • the liquid solution could be chemically or electrically charged so as to cause the additive 80 to better adhere to the high loft, nonwoven web 10 .
  • the apparatus 34 may also include a conditioning unit 82 situated downstream from the last dispensing mechanism 76 or 78 .
  • the conditioning unit 82 can vary in design and function.
  • the conditioning unit 82 could be a dryer that can remove moisture from the web 10 by utilizing heat or some other process when the high loft, nonwoven web 10 has to be dried.
  • the conditioning unit 82 could be a cooler that could blow cool air onto the high loft, nonwoven web 10 and reduce its temperature.
  • the conditioning unit 82 could perform some other function, for example embossing the web 10 , printing the web 10 , combining the high loft, nonwoven web 10 with another layer, etc. Dryers and coolers are appliances well known to those skilled in the art.
  • FIG. 8 another embodiment of an apparatus 34 ′ is depicted wherein the pair of moving surfaces 44 and 46 is shown as a first conveyor belt 52 and a second conveyor belt 54 .
  • the orientation of the apparatus 34 ′ is vertical although other orientations could also be employed.
  • the first conveyor belt 52 moves in a counterclockwise direction while the second conveyor belt 54 moves in a clockwise direction.
  • This arrangement causes the plurality of filaments 40 emitted, ejected or extruded from the plurality of nozzles 38 to move vertically downward in a machine direction (MD).
  • the first and second conveyor belts, 52 and 54 respectively can run at various speeds. Desirably, the first and second conveyor belts, 52 and 54 respectively, will run at the same speed.
  • the first and second conveyor belts, 52 and 54 respectively, converge toward one another at a point located farthest away from the distal end 42 of each of said plurality of nozzles 38 .
  • An opening 55 equivalent to the nip 62 , is present between the first and second conveyor belts 52 and 54 respectively.
  • the opening 55 occurs and is situated at a plane X 2 -X 2 .
  • the plane X 2 -X 2 is equivalent to the plane X 1 -X 1 , shown in FIG. 7 .
  • a vertical distance measured from the distal end 42 of each nozzle 38 perpendicular to the plane X 2 -X 2 established a Die-to-Collector Distance (DCD). This DCD distance can range from between about 10 cm to about 150 cm.
  • DCD Die-to-Collector Distance
  • the DCD distance is less than about 100 cm. More desirably, the DCD distance is less than about 90 cm. Even more desirably, the DCD distance is less than about 80 cm. Most desirably, the DCD distance is less than about 60 cm.
  • the exact DCD distance is dependent upon a number of factors including but not limited to: the melting temperature of the polymer being extruded, the basis weight of the material being produced, the polymer throughput through the plurality of nozzles 38 , and the inside diameter of each of the nozzles, etc.
  • the first and second conveyor belts, 52 and 54 respectively are aligned at an angle alpha ( ⁇ ) to one another.
  • the angle ⁇ can vary. Desirably, the angle ⁇ is less than about 90 degrees. More desirably, the angle ⁇ is less than about 60 degrees. Even more desirably, the angle ⁇ is less than about 50 degrees. Most desirably, the angle ⁇ is less than about 45 degrees. An angle ⁇ of from between about 15 degrees to about 45 degrees works well. This orientation creates a convergent passage 60 and a nip 62 .
  • the plurality of filaments 40 are deposited at the entry 64 of the convergent passage 60 as they are directed and routed onto and between the first and second conveyor belts, 52 and 54 respectively.
  • the routing is facilitates by the movement of the first and second conveyor belts, 52 and 54 respectively.
  • the routing causes the plurality of filaments 40 to pass through the convergent passage 60 in descending travel from the entry 64 to the exit 66 .
  • the movement of the first and second conveyor belts, 52 and 54 respectively will cause some of the plurality of filaments 40 to temporarily contact the outer peripheries of the first and second conveyor belts, 52 and 54 respectively.
  • These filaments 40 will be compressed against the remaining filaments 40 passing through the nip 62 to create a 3-dimensional structure 68 .
  • the plurality of filaments 40 will be compressed at the nip 62 and this confined space helps the filaments 40 , which are transformed into fibers 12 as they cool, to be aligned in the x, y and z directions.
  • transformed it is meant to change markedly the appearance or form of; to change the nature, function, or condition of; convert.
  • a 3-dimensional structure 68 is produced instead of a 2-dimensional structure.
  • the 3-dimensional structure 68 usually will not have a very good recovery value unless fiber-to-fiber bonds are created using some known bonding process to stabilize the formed 3-dimensional structure 68 .
  • the apparatus 34 ′ also differs from the apparatus 34 , shown in FIG. 7 , in that the 3-dimensional structure 68 is advanced in a vertical, downward direction until it contacts a conveyor belt 84 .
  • the conveyor belt 84 is positioned perpendicular to the downward direction of the 3-dimensional structure 68 .
  • the conveyor belt 84 moves through a continuous loop in a clockwise direction.
  • the conveyor belt 84 causes the 3-dimensional structure 68 to make a 90 degree turn to the right. This new horizontal, rightward movement is referred to as machine direction (MD′).
  • the conveyor belt 84 is mounted on a plurality of rollers 86 .
  • rollers 86 are depicted in FIG. 8 although any number of rollers 86 can be utilized.
  • One of the rollers 86 is the drive roller and the remaining rollers 86 , 86 and 86 are idler or follower rollers.
  • high loft, nonwoven webs 10 can be formed from certain materials and for certain uses, wherein bonding is not necessary. However, it is advantageous when producing most nonwoven webs 10 to subject the 3-dimensional structure 68 to a bonding process. Bonding generally imparts strength and integrity into the finished web 10 . Various bonding techniques can be utilized. In FIG. 8 , a single bonder 74 is utilized. Upon exiting the bonder 74 , a high loft, nonwoven web 10 will be formed. The high loft, nonwoven web 10 has a thickness t.
  • FIG. 9 still another apparatus 34 ′′ is shown which utilized a combination of a first meltblown die 88 , a spunbond die 90 and a second meltblown die 92 .
  • the apparatus 34 ′′ is shown being oriented in a vertical configuration, although other configurations are possible.
  • the spunbond die 90 is positioned between the first and second meltblown dies, 88 and 92 respectively. This die arrangement produces a comingled, high loft hybrid nonwoven web that may have different fiber size, different polymeric materials, and/or different fiber cross-section.
  • the Die-to-Collector Distance is calculated by the distance from the middle spunbond die 90 to the plane X 1 -X 1 .
  • this DCD distance can range from between about 10 cm to about 150 cm. Desirably, the DCD distance is less than about 100 cm. More desirably, the DCD distance is less than about 90 cm. Even more desirably, the DCD distance is less than about 80 cm. Most desirably, the DCD distance is less than about 60 cm.
  • the exact DCD distance is dependent upon a number of factors including but not limited to: the melt temperature of the polymer being extruded, the polymer throughput through the plurality of nozzles 38 , etc.
  • a 3-dimensional structure 68 emerges from the exit 66 of the convergent passage 60 .
  • a bonder 74 is positioned downstream of the first and second rotatable drums 48 and 50 respectively.
  • the bonder 74 can be any of the various kinds of bonders explained above. Desirably, the bonder 74 is a thermal or chemical bonder.
  • any of the three apparatuses 34 , 34 ′ or 34 ′′ described above that one could add one or more features to them.
  • non-thermoplastic materials could also be added to the webs 10 , 10 ′, 10 ′′ or 11 during manufacture.
  • meltblown spunbond, spunmelt, etc.
  • the filaments may be attenuated at different temperatures, pressures, flow rates, etc.
  • the process air could be colder or hotter than the polymer melt.
  • the process of forming the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 will be explains with reference to FIGS. 7-9 .
  • the process includes introducing a molten polymer to a die 36 .
  • the die 36 has a plurality of nozzles 38 each having a distal end 42 .
  • the molten polymer is emitted through the plurality of nozzles 38 to form a plurality of filaments 40 .
  • emitting it is meant extruding, ejecting, spinning, forcing or discharging the molten polymer under pressure, in any of the known processes described above and/or known to those skilled in the art.
  • the process also includes using air or gas streams to facilitate movement and drawing of the plurality of filaments 30 .
  • the filaments 40 are directed towards a pair of moving surfaces 44 and 46 , located at a distance of from between about 10 cm to about 150 cm from the plurality of nozzles 38 .
  • the pair of moving surfaces 44 and 46 can be first and second rotatable drums, 48 and 50 respectively, or can be first and second conveyor belts, 52 and 54 respectively.
  • the pair of moving surfaces 44 and 46 forms a convergent passage 60 having an entry 64 and an exit 66 .
  • the plurality of filaments 40 are deposited into the entry 64 of the convergent passage 60 .
  • the plurality of filaments 40 are then routed through the convergent passage 60 in descending travel from the entry 64 to the exit 66 and between the pair of moving surfaces 44 and 46 in a machine direction to form a 3-dimensional structure 68 .
  • the filaments 40 are transformed upon cooling into fibers 12 oriented in the x, y and z directions.
  • the process further includes bonding the 3-dimensional structure 68 to form a high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 having a thickness t, t or t 2 of less than about 250 millimeters and a basis weight ranging from between about 50 g/m 2 to about 3,000 g/m 2 .
  • the 3-dimensional structure 68 can be bonded using a variety of different bonders. Some bonders which can be used include but are not limited to: thermal bonding, through air bonding, oven bonding, chemical bonding, wet bonding, mechanical bonding or hydro-mechanical bonding.
  • a vertical cross-section of the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 when taken parallel to the machine direction (MD), exhibits a plurality of snugly stacked, approximately V, U or C-shaped structures 24 .
  • Each of the approximately V, U or C-shaped structure 24 has an apex 26 facing in the machine direction (MD), in other words, the approximately V or U shaped structure is rotated 90 degrees to a horizontal orientation with the apex of each facing to the right.
  • the C-shaped structure is reversed in position so that the apex of each faces to the right.
  • the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 has a recovery value ranging from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.
  • an additive 80 can be added to the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 downstream of the bonder 74 .
  • the additive 80 can be any of those mentioned above.
  • the additive 80 can be deposited onto the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 , or it could be sprayed thereon.
  • the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 could be immersed in a liquid solution containing an additive 80 .
  • the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 can be dried downstream of the bonder 74 .
  • the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 could be cooled downstream of the bonder 74 . Such cooling could reduce the temperature of the high loft, nonwoven web 10 , 10 ′, 10 ′′ or 11 to room temperature or thereabout.
  • a number of high loft, nonwovens sample webs were produced using a meltblowing pilot line that had a 381 mm meltblowing die with multi-row spinnerettes known as the Biax meltblowing (MB) die.
  • MB Biax meltblowing
  • the meltblowing spinnerettes had 242 polymer nozzles.
  • the inside diameter of each spinnerette was 0.508 millimeters (mm) while the outside diameter of each spinnerette was 0.711 mm.
  • Each polymer nozzle was surrounded by an air nozzle where the blowing air was coming from the annular space between the polymer nozzle and the air nozzle.
  • the diameter of each of the air nozzles was 1.4 mm.
  • the Biax meltblowing (MB) die design is taught in U.S. Pat. No. 5,476,616 and U.S. Patent Publication 2005/0056956 A1.
  • Typical commercial Biax meltblowing (MB) dies have from between about 6,000 to about 11,000 nozzles per meter.
  • the first seven (7) nonwoven web samples were made of polypropylene that was provided by Exxon-Mobil under the trade name: ACHIEVE 6936G1. This polypropylene had a typical melt flow rate of 1,550 grams per 10 minutes (according to ASTM test D 1238, 230° C., 2.16 kg).
  • the last two (2) nonwoven web samples were made of polylactic acid that was provided by Natureworks under the trade name: INGEO PLA 6202D.
  • the polylactic acid had a melt flow rate of 15 grams (g) to 30 g per 10 minutes (according to ASTM test D 1238, 210° C., 2.16 kg).
  • Polymer melt temperature 190° C.
  • Air temperature 170° C.
  • the basis weight of these samples varied from between about 150 g/m 2 to 500 g/m 2 by varying the speed of the first and second rotatable drums or by varying the speed of the first and second conveyor belts.
  • the Die to Collector Distance (DCD) varied between about 30 centimeters (cm) to about 45 cm.
  • Polymer melt temperature 260° C.
  • Air temperature 260° C.
  • the basis weight was around 500 g/m 2 and the Die-to-Collector Distance (DCD) was around 75 cm.
  • Some of the samples were thermally bonded using an infra-red oven at a temperature of 120° C. and the dwell time (contact time) was about 3 seconds to about 5 seconds.
  • Basis weight is defined as the mass per unit area and it can be measured in grams per meter squared (g/m 2 ).
  • the basis weight test is done according the INDA standard IST 130.1 which is equivalent to the ASTM standard ASTM D3776.
  • Ten (10) different samples were die cut from different locations in a larger sample web and each one had an individual area equal to 100 cm 2 .
  • the weight of each replicate was measured using a sensitive balance within ⁇ 0.1% of weight on the balance.
  • the basis weight in grams/m 2 was measured by multiplying the average weight by 100.
  • Thickness is defined as the distance between one surface and an opposite surface of a single web measured under a specified pressure. For high loft, nonwoven webs, the thickness was measured according the INDA standard IST 120.2 (01).
  • the apparatus include a thickness testing instrument that had: an anvil, a presser foot, and a scale indicating the distance between these two parallel plates.
  • the foot presser was 305 mm ⁇ 305 mm (12 inches ⁇ 12 inches) in size and had a weight of 288 grams.
  • Five representative specimens of the fabric were die cut and tested in the standard atmosphere for testing as prescribed in ASTM D1776. Samples were handled carefully to avoid altering the natural state of the fabric. Each specimen was placed on the bottom plate and the presser foot was placed with care on the top of the sample. The average thickness of these specimens is reported along with a standard deviation.
  • the presser foot with the new weight was placed on top of the high loft, nonwoven webs samples for 30 minutes and then the compressed thickness T 2 was measured. Finally, the presser foot was raised and replaced by the 36 pound weight with the 288 gram weight. After five (5) minutes, the presser foot was lowered to measure the thickness recovered, T 3 .
  • Sample 1 and 2 showed a big difference in thickness or caliper of the nonwoven web.
  • the big difference is mainly due to collecting the spun fibers on a flat belt versus collecting them between two rotating drums having a nip gap of 2.5 cm.
  • the dual drum collection system increased the thickness by 1,500% although both samples have the same mass per unit area.
  • Sample 3 showed that by thermally bonding the high loft, nonwoven sample #2, one could enhance the recovery properties by 26%. Such enhancement will greatly increase the thermal insulation and acoustical properties of a web. With the proper tuning of the fiber formation conditions and the bonding conditions, the compression and recovery properties can be greatly enhanced, see Table 1 below.
  • sample 8 and 9 were produced using polylactic acid resin. Despite the spinning difficulty of such polymer and the shrinkage effect that accompanied the web formation, two high loft, nonwoven samples were collected. As shown in Table 4, sample 8, which was not thermally bonded, had higher compressibility but lower recovery properties than sample 9 which was thermally bonded using the infra-red thermal oven. Sample 9 was also stronger than sample 8 during handling and had a better structure integrity as sample 9 was not falling apart because of the fiber-to-fiber bonds that were created during the post heat treatment. It is well known that structural integrity of the loose fibers can be enhanced by using other bonding techniques, such as through air bonding or chemical bonding.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Artificial Filaments (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Cleaning Implements For Floors, Carpets, Furniture, Walls, And The Like (AREA)
US14/167,366 2014-01-29 2014-01-29 High loft, nonwoven web exhibiting excellent recovery Abandoned US20150211160A1 (en)

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US14/167,366 US20150211160A1 (en) 2014-01-29 2014-01-29 High loft, nonwoven web exhibiting excellent recovery
PCT/US2015/013429 WO2015116766A1 (en) 2014-01-29 2015-01-29 A high loft, nonwoven web exhibiting excellent recovery
JP2016567456A JP2017505390A (ja) 2014-01-29 2015-01-29 優れた回復を示す高ロフトの不織ウェブ
DE112015000561.7T DE112015000561T8 (de) 2014-01-29 2015-01-29 Hochbauschige Vliesstoffbahn, welche ausgezeichnete Rückstellung zeigt
US15/412,670 US10961644B2 (en) 2014-01-29 2017-01-23 High loft, nonwoven web exhibiting excellent recovery
JP2019184292A JP7032365B2 (ja) 2014-01-29 2019-10-07 優れた回復を示す高ロフトの不織ウェブ

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EP3511461A1 (en) 2018-01-11 2019-07-17 Carl Freudenberg KG Nonwoven sterile packaging
US10961644B2 (en) 2014-01-29 2021-03-30 Biax-Fiberfilm Corporation High loft, nonwoven web exhibiting excellent recovery
US11192327B2 (en) * 2017-07-03 2021-12-07 Axel Nickel Voluminous meltblown nonwoven fabric with improved stackability and storability
CN114388981A (zh) * 2021-12-10 2022-04-22 苏州大学 高抗拉强度和高离子电导率的电纺锂电池隔膜及其制法
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US11419970B2 (en) 2016-12-22 2022-08-23 Daicel Corporation Blood filter
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Publication number Priority date Publication date Assignee Title
US10961644B2 (en) 2014-01-29 2021-03-30 Biax-Fiberfilm Corporation High loft, nonwoven web exhibiting excellent recovery
US11344653B2 (en) * 2016-12-22 2022-05-31 Daicel Corporation Bone fixing material
US11419970B2 (en) 2016-12-22 2022-08-23 Daicel Corporation Blood filter
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CN114388981A (zh) * 2021-12-10 2022-04-22 苏州大学 高抗拉强度和高离子电导率的电纺锂电池隔膜及其制法

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JP2017505390A (ja) 2017-02-16
JP2020020088A (ja) 2020-02-06
DE112015000561T5 (de) 2016-12-01
DE112015000561T8 (de) 2017-01-12
JP7032365B2 (ja) 2022-03-08

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