US20150354139A1 - Wet laid non-woven substrate containing polymeric nanofibers - Google Patents

Wet laid non-woven substrate containing polymeric nanofibers Download PDF

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Publication number
US20150354139A1
US20150354139A1 US14/762,758 US201414762758A US2015354139A1 US 20150354139 A1 US20150354139 A1 US 20150354139A1 US 201414762758 A US201414762758 A US 201414762758A US 2015354139 A1 US2015354139 A1 US 2015354139A1
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United States
Prior art keywords
substrate
nanofibers
polymeric
wet laid
wet
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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US14/762,758
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English (en)
Inventor
Peter Geisen
Sumit Gangwal
Miles C. Wright
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.)
XANOFI Inc
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XANOFI Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by XANOFI Inc filed Critical XANOFI Inc
Priority to US14/762,758 priority Critical patent/US20150354139A1/en
Publication of US20150354139A1 publication Critical patent/US20150354139A1/en
Abandoned legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/02—Synthetic cellulose fibres
    • D21H13/06—Cellulose esters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0654—Support layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2201/00—Cellulose-based fibres, e.g. vegetable fibres
    • D10B2201/20—Cellulose-derived artificial fibres
    • D10B2201/28—Cellulose esters or ethers, e.g. cellulose acetate
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2501/00—Wearing apparel
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/04—Filters
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2509/00—Medical; Hygiene

Definitions

  • the present invention relates generally to forming wet laid substrates that contain polymeric nanofibers. More specifically, the invention relates to forming a substrate with wet laid staple polymeric nanofibers of short lengths.
  • the polymeric nanofibers can be surface coated on a non-woven or woven substrates, wet laid with other fiber types to create a nonwoven substrate or wet laid onto themselves to form a nanofiber-only mat.
  • Fibers form, in part or in whole, a large variety of both consumer and industrial materials such as, for example, clothing and other textile materials, medical prostheses, construction materials and reinforcement materials, and barrier, filtration and absorbent materials.
  • materials such as, for example, clothing and other textile materials, medical prostheses, construction materials and reinforcement materials, and barrier, filtration and absorbent materials.
  • Wet lay technology is essentially a paper machine process to form nonwoven substrates.
  • fibers are suspended in liquids and specialized paper machines are used to separate the water from the fibers to form a uniform sheet of material, which is then bonded and dried.
  • Nanofibers are increasingly being investigated for use in various applications. Nanofibers may attain a high surface area comparable with the finest nanoparticle powders, yet are fairly flexible, and retain one macroscopic dimension which makes them easy to handle, orient and organize
  • the present invention comprises a fabric substrate of cotton, synthetic or blend fibers containing wet laid polymeric, staple nanofibers of short cut lengths ( FIG. 1 ).
  • the staple polymeric nanofibers can be wet laid onto a fabric substrate of natural, synthetic or blend fibers or the nanofibers can be wet laid with other fibers to form a nonwoven mat or the nanofibers can be wet laid onto themselves to form a nonwoven containing only nanofibers.
  • fabric substrates of natural, synthetic or blend fibers may be utilized as starting materials, examples of which are given below.
  • FIG. 1 is a schematic of nanofibers and microfibers wet-laid into a composite substrate.
  • FIG. 2 is a scanning electron micrograph of the cross-section of a wet-laid substrate consisting of 70% by weight PET microfibers ( ⁇ 10 micron diameter) and 30% cellulose acetate nanofibers ( ⁇ 500 nm diameter).
  • FIG. 3 is a scanning electron micrograph of the surface of a PET microfiber substrate coated on the top with cellulose acetate nanofibers.
  • FIG. 4 is a scanning electron micrograph of the cross-section of a PET microfiber substrate coated on the top with cellulose acetate nanofibers.
  • the term nanofiber refers generally to an elongated fiber structure having an average diameter ranging from less than 50 nm-2 ⁇ m.
  • the “average” diameter may take into account not only that the diameters of individual nanofibers making up a plurality of nanofibers formed by implementing the presently disclosed method may vary somewhat, but also that the diameter of an individual nanofiber may not be perfectly uniform over its length in some implementations of the method.
  • the average length of the nanofibers may range from 10 micros or greater. In other examples, the average length may range from 110 microns to over 25 centimeters.
  • the aspect ratio (length/diameter) of the nanofibers may range from 10:1 or greater.
  • nanofibers according to the invention have aspect ratios of at least 10,000:1.
  • the diameter of the nanofiber may be on the order of two microns or less, for convenience the term “nanofiber” as used herein encompasses both nano-scale fibers and extremely small micro-scale fibers (microfibers).
  • fibril refers generally to a fine, filamentous non-uniform structure in animals or plants having an average diameter ranging from about 1 nm-1,000 nm in some examples, in other examples ranging from about 1 nm-500 nm, and in other examples ranging from about 25 nm-250 nm.
  • fibrils are formed by phase separation from nanofibers.
  • a fibril may be composed of an inorganic precursor or an inorganic compound.
  • the term “fibrils” distinguishes these structures from the polymer nanofibers utilized to form the inorganic fibrils.
  • the length of the fibrils may be about same as the polymer nanofibers or may be shorter.
  • Polymers encompassed by the present disclosure generally may be any naturally-occurring or synthetic polymers capable of being fabricated into nanofibers.
  • examples of polymers include many high molecular weight (MW) solution-processable polymers such as polyethylene (more generally, various polyolefins), polystyrene, cellulose, cellulose acetate, poly(L-lactic acid) (PLA), polyacrylonitrile (PAN), polyvinylidene difluoride (PVDF), conjugated organic semiconducting and conducting polymers, biopolymers such as polynucleotides (DNA) and polypeptides, etc.
  • MW high molecular weight
  • solution-processable polymers such as polyethylene (more generally, various polyolefins), polystyrene, cellulose, cellulose acetate, poly(L-lactic acid) (PLA), polyacrylonitrile (PAN), polyvinylidene difluoride (PVDF), conjugated organic semiconducting and conducting polymers, bio
  • suitable polymers to form nanofibers include vinyl polymers such as, but not limited to, cellulose acetate propionate, cellulose acetate butyrate, polyethylene, polypropylene, poly(vinyl chloride), polystyrene, polytetrafluoroethylene, poly( ⁇ -methylstyrene), poly(acrylic acid), poly(isobutylene), poly(acrylonitrile), poly(methacrylic acid), poly(methyl methacrylate), poly(1-pentene), poly(1,3-butadiene), poly(vinyl acetate), poly(2-vinyl pyridine), 1,4-polyisoprene, and 3,4-polychloroprene.
  • vinyl polymers such as, but not limited to, cellulose acetate propionate, cellulose acetate butyrate, polyethylene, polypropylene, poly(vinyl chloride), polystyrene, polytetrafluoroethylene, poly( ⁇ -methylstyrene), poly(
  • nonvinyl polymers such as, but not limited to, poly(ethylene oxide), polyformaldehyde, polyacetaldehyde, poly(3-propionate), poly(10-decanoate), poly(ethylene terephthalate), polycaprolactam, poly(11-undecanoamide), poly(hexamethylene sebacamide), poly(m-phenylene terephthalate), poly(tetramethylene-m-benzenesulfonamide).
  • nonvinyl polymers such as, but not limited to, poly(ethylene oxide), polyformaldehyde, polyacetaldehyde, poly(3-propionate), poly(10-decanoate), poly(ethylene terephthalate), polycaprolactam, poly(11-undecanoamide), poly(hexamethylene sebacamide), poly(m-phenylene terephthalate), poly(tetramethylene-m-benzenesulfonamide).
  • Additional polymers include those falling within one of the following polymer classes: polyolefin, polyether (including all epoxy resins, polyacetal, polyetheretherketone, polyetherimide, and poly(phenylene oxide)), polyamide (including polyureas), polyamideimide, polyarylate, polybenzimidazole, polyester (including polycarbonates), polyurethane, polyimide, polyhydrazide, phenolic resins, polysilane, polysiloxane, polycarbodiimide, polyimine, azo polymers, polysulfide, and polysulfone.
  • polyolefin polyether (including all epoxy resins, polyacetal, polyetheretherketone, polyetherimide, and poly(phenylene oxide))
  • polyamide including polyureas
  • polyamideimide polyarylate
  • polybenzimidazole polyester (including polycarbonates)
  • polyester including polycarbonates
  • polyurethane polyimide
  • polyhydrazide phenolic resins
  • the polymer used to form nanofibers can be synthetic or naturally-occurring.
  • natural polymers include, but are not limited to, polysaccharides and derivatives thereof such as cellulosic polymers (e.g., cellulose and derivatives thereof as well as cellulose production byproducts such as lignin) and starch polymers (as well as other branched or non-linear polymers, either naturally occurring or synthetic).
  • exemplary derivatives of starch and cellulose include various esters, ethers, and graft copolymers.
  • the polymer may be crosslinkable in the presence of a multifunctional crosslinking agent or crosslinkable upon exposure to actinic radiation or other type of radiation.
  • the polymer may be homopolymers of any of the foregoing polymers, random copolymers, block copolymers, alternating copolymers, random tripolymers, block tripolymers, alternating tripolymers, derivatives thereof (e.g., graft copolymers, esters, or ethers thereof), and the like.
  • web is meant a fibrous material capable of being wound into a roll.
  • nonwoven web is meant a web of individual fibers or filaments which are interlaid and positioned in a random manner to form a planar material without identifiable pattern, as opposed to a knitted or woven fabric.
  • Nonwoven webs have been in the past formed by a variety of processes known to those skilled in the art such as, for example, meltblown, spunbound, wet-laid, dry-laid, and bonded carded web processes.
  • a nonwoven or woven fabric substrate or web can be made from natural or synthetic fabrics and may be composed of fibers of cotton, cellulose, Lyocell, acetate, cellulose acetate, rayon, silk, wool, hemp, spandex (including LYCRA), polyolefins (polypropylene, polyethylene, etc.), polyamide (nylon 6, nylon 6-6, etc.), aramids (e.g. Kevlar®, Twaron®, Nomex, etc.), acrylic, or polyester (polyethylene teraphthalate, trimethylene terephthalate), polyurethane, glass microfibers, fiberglass, etc.
  • fabric blends is meant fabrics of two or more types of fibers. Typically these blends are a combination of a natural fiber and a synthetic fiber, but can also include a blend of two natural fibers or two synthetic fibers.
  • Nanofibers can be wet laid deposited onto a non-woven or woven substrate, which is placed on a filter mesh of 27-200 microns pore size as per the following example:
  • Nanofibers can also be deposited onto themselves without a substrate with basis weights ranging from 4 to 800 GSM or higher. In this case the length is important as longer length fibers provide mat integrity and strength.
  • Polymeric nanofibers can also be wet laid together with other nano- or microfibers to form a nonwoven substrate containing many types of fibers.
  • nanofibers are typically produced as long (>20 cm) dry fibers by electrospinning and meltblowing technologies.
  • the nanofibers used here are produced by the XanoShear process. This method allows production of polymeric nanofibers in a liquid based process.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonwoven Fabrics (AREA)
US14/762,758 2013-01-25 2014-01-24 Wet laid non-woven substrate containing polymeric nanofibers Abandoned US20150354139A1 (en)

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US201361756949P 2013-01-25 2013-01-25
US14/762,758 US20150354139A1 (en) 2013-01-25 2014-01-24 Wet laid non-woven substrate containing polymeric nanofibers
PCT/US2014/012946 WO2014116946A1 (fr) 2013-01-25 2014-01-24 Substrat non-tissé par voie humide ayant des nanofibres polymères

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US10160833B2 (en) 2012-04-26 2018-12-25 The Regents Of The University Of Michigan Synthesis and use of aramid nanofibers
US10214859B2 (en) 2016-04-05 2019-02-26 Fiberlean Technologies Limited Paper and paperboard products
US10801162B2 (en) 2016-04-05 2020-10-13 Fiberlean Technologies Limited Paper and paperboard products
US11846072B2 (en) 2016-04-05 2023-12-19 Fiberlean Technologies Limited Process of making paper and paperboard products
US11274399B2 (en) 2016-04-05 2022-03-15 Fiberlean Technologies Limited Paper and paperboard products
US11732421B2 (en) 2016-04-05 2023-08-22 Fiberlean Technologies Limited Method of making paper or board products
WO2017184725A1 (fr) 2016-04-20 2017-10-26 Clarcor Inc. Pâte de fibre fine de filage, et support de filtre déposé par voie humide
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