US20170037564A1 - Nonwoven fibrous structures including ionic reinforcement material, and methods - Google Patents
Nonwoven fibrous structures including ionic reinforcement material, and methods Download PDFInfo
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- US20170037564A1 US20170037564A1 US15/304,117 US201515304117A US2017037564A1 US 20170037564 A1 US20170037564 A1 US 20170037564A1 US 201515304117 A US201515304117 A US 201515304117A US 2017037564 A1 US2017037564 A1 US 2017037564A1
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/01—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with hydrogen, water or heavy water; with hydrides of metals or complexes thereof; with boranes, diboranes, silanes, disilanes, phosphines, diphosphines, stibines, distibines, arsines, or diarsines or complexes thereof
- D06M11/05—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with hydrogen, water or heavy water; with hydrides of metals or complexes thereof; with boranes, diboranes, silanes, disilanes, phosphines, diphosphines, stibines, distibines, arsines, or diarsines or complexes thereof with water, e.g. steam; with heavy water
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
-
- 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
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- 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
- B01D39/18—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being cellulose or derivatives thereof
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
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- 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
- B01D2239/0266—Types of fibres, filaments or particles, self-supporting or supported materials comprising biodegradable or bio-soluble polymers
Definitions
- the present disclosure relates to nonwoven fibrous structures and related media with ionic reinforcement material and methods of forming the same.
- Nonwoven fibrous webs have been used to produce a variety of absorbent articles that are useful, for example, as absorbent wipes for surface cleaning, as wound dressings, as gas and liquid absorbent or filtration media, and as barrier materials for sound absorption.
- nonwoven fibrous webs Although some methods of forming nonwoven fibrous webs are known, the art continually seeks new methods of forming and/or bonding nonwoven webs, particularly air-laid nonwoven fibrous webs having particular characteristics with a relatively high cross direction (CD) tensile strength and a relatively high machine direction (MD) tensile strength.
- CD cross direction
- MD machine direction
- the present disclosure relates to a method of making a nonwoven fibrous structure (e.g., a nonwoven fibrous web), including: introducing a plurality of fibers into a forming chamber, dispersing the fibers within the forming chamber to form a population of individual fibers suspended in a gas, collecting the population of fibers as a nonwoven fibrous structure on a collector, and bonding at least a portion of the population of fibers together with an ionic reinforcement material.
- the method comprises applying an ionic liquid material to the population of fibers.
- the method includes bonding at least the portion of the population of fibers together comprises curing the applied ionic liquid material to form the ionic reinforcement material.
- the applied ionic liquid material further comprises water, and where curing removes at least a portion of the water from the applied ionic liquid material to cause bonding of the ionic reinforcement material between the population of fibers.
- the applied ionic liquid material further comprises at least one binder resin, optionally wherein the applied ionic liquid material acts as a plasticizer for the at least one binder resin.
- the at least one binder resin is selected from the group consisting of a phenolic resin, a bio-based resin, a thermoplastic (meth)acrylic (co)polymer resin, an epoxy resin, or a combination thereof.
- the method includes bonding with a binder resin mixture and the ionic liquid material to provide a nonwoven fibrous structure with a tensile strength that is greater than a nonwoven fibrous structure bonded with the binder resin mixture in the absence of the ionic liquid material.
- the ionic liquid material comprises at least one cation and at least one anion.
- the at least one cation is selected from the group consisting of nitrogen containing heterocyclic cations, ammonium, phosphonium, or sulfonium; and further wherein the at least one anion is selected from the group consisting of halogen anions, fluorine containing anions, alkyl sulfate anions, alkyl phosphate anions, acetate, dicyanamide (N(CN) 2 ), or thiocyanate (SCN).
- the method includes spraying the ionic liquid material, roll coating the ionic liquid material, dip coating the ionic liquid material, or a combination thereof.
- the ionic liquid material is an ionic liquid solution in a solvent, optionally wherein the solvent is aqueous.
- bonding at least the portion of the population of fibers together includes applying a thermosetting binder to the population fibers. In certain exemplary embodiments, bonding at least the portion of the population of fibers includes heating the portion of the population of fibers.
- the ionic reinforcement material provides at least one distinguishing characteristic to the nonwoven fibrous structure selected from the group consisting of a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof.
- the population of fibers includes fibers selected from the group consisting of staple fibers, melt blown fibers, natural fibers, bio-based fibers, or a combination thereof.
- the nonwoven fibrous structure includes a population of particulates bonded to the nonwoven fibrous structure, further wherein the particulates are selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates, or a combination thereof.
- the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.
- the disclosure also relates to a nonwoven fibrous web prepared according to the method described herein.
- the disclosure relates to a nonwoven fibrous structure comprising a population of randomly oriented fibers bonded together at a plurality of intersection points with an ionic reinforcement material.
- the ionic reinforcement material is comprised of an ionic plasticizer (e.g., ionic liquid acting as a plasticizer).
- the ionic reinforcement material is comprised of an ionic liquid and a binder selected from the group consisting of a (meth)acrylic (co)polymer binder, a styrene-butadiene latex binder, a bio-based binder, or a combination thereof.
- the nonwoven fibrous structure comprises from 1 to 40 wt. % of the ionic liquid.
- the ionic liquid comprises water, one or more cations, and one or more anions.
- the nonwoven fibrous structure exhibits at least one distinguishing characteristic selected from the group consisting of a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof.
- the ionic reinforcement material provides the at least one distinguishing characteristic. In some exemplary embodiments, the ionic reinforcement material provides at least two of the distinguishing characteristics.
- the population of fibers includes thermoplastic (co)polymer fibers further comprising a (co)polymer selected from poly(propylene), poly(ethylene), poly(butane), poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(ethylene) napthalate, poly(amide), poly(urethane), poly(lactic acid), poly(vinyl)alcohol, poly(phenylene) sulfide, poly(sulfone), liquid crystalline polymer, poly(ethylene)-co-poly(vinyl)acetate, poly(acrylonitrile), cyclic poly(olefin), poly(oxymethylene), poly(olefinic) thermoplastic elastomers, recycled fibers containing any of the preceding thermoplastic (co)polymers, or a combination thereof.
- a (co)polymer selected from poly(propylene), poly(ethylene), poly(butane), poly(ethylene) terephthalate, poly(butylene) terephthalate
- the population of fibers includes natural fibers selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, or a combination thereof.
- the nonwoven fibrous structure includes a population of particulates bonded to the nonwoven fibrous structure, further wherein the particulates are selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates; or a combination thereof.
- the population of particulates exhibits a median particle diameter of from 0.1 micrometer to 1,000 micrometers.
- the population of fibers exhibits a median fiber diameter of from 1 micrometer to 50 micrometers.
- the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.
- FIG. 1 is a perspective view of an exemplary nonwoven fibrous structure of the present disclosure.
- FIG. 2 is an exploded view of a portion of the exemplary nonwoven fibrous structure of FIG. 1 , illustrating one exemplary embodiment of the present disclosure.
- Nonwoven fibrous web or “nonwoven fibrous structure” means an article or sheet having a structure of individual fibers or fibers, which are interlaid, but not in an identifiable manner as in a knitted fabric.
- Nonwoven fabrics or webs have been formed from many processes such as for example, meltblowing processes, air-laying processes, and bonded carded web processes.
- Die means a processing assembly for use in polymer melt processing and fiber extrusion processes, including but not limited to meltblowing and spun-bonding.
- Meltblowing and “meltblown process” means a method for forming a nonwoven fibrous web by extruding a molten fiber-forming material through a plurality of orifices in a die to form fibers while contacting the fibers with air or other attenuating fluid to attenuate the fibers into fibers, and thereafter collecting the attenuated fibers.
- An exemplary meltblowing process is taught in, for example, U.S. Pat. No. 6,607,624 (Berrigan et al.).
- Meltblown fibers means fibers prepared by a meltblowing or meltblown process.
- spun-bonding and “spun bond process” mean a method for forming a nonwoven fibrous structure by extruding molten fiber-forming material as continuous or semi-continuous fibers from a plurality of fine capillaries of a spinneret, and thereafter collecting the attenuated fibers.
- An exemplary spun-bonding process is disclosed in, for example, U.S. Pat. No. 3,802,817 to Matsuki et al.
- spun bond fibers and “spun-bonded fibers” mean fibers made using spun-bonding or a spun bond process. Such fibers are generally continuous fibers and are entangled or point bonded sufficiently to form a cohesive nonwoven fibrous web such that it is usually not possible to remove one complete spun bond fiber from a mass of such fibers.
- the fibers may also have shapes such as those described, for example, in U.S. Pat. No. 5,277,976 to Hogle et al., which describes fibers with unconventional shapes.
- Carding and “carding process” mean a method of forming a nonwoven fibrous web webs by processing staple fibers through a combing or carding unit, which separates or breaks apart and aligns the staple fibers in the machine direction to form a generally machine direction oriented fibrous nonwoven web.
- An exemplary carding process is taught in, for example, U.S. Pat. No. 5,114,787 to Chaplin et al.
- “Bonded carded web” refers to nonwoven fibrous web formed by a carding process wherein at least a portion of the fibers are bonded together by methods that include for example, thermal point bonding, autogenous bonding, hot air bonding, ultrasonic bonding, needle punching, calendering, application of a spray adhesive, and the like.
- “Calendering” means a process of passing a nonwoven fibrous web through rollers with application of pressure to obtain a compressed and bonded fibrous nonwoven web.
- the rollers may optionally be heated.
- Densification means a process whereby fibers which have been deposited either directly or indirectly onto a filter winding arbor or mandrel are compressed, either before or after the deposition, and made to form an area, generally or locally, of lower porosity, whether by design or as an artifact of some process of handling the forming or formed filter. Densification also includes the process of calendering webs.
- Non-hollow with particular reference to projections extending from a major surface of a nonwoven fibrous structure means that the projections do not contain an internal cavity or void region other than the microscopic voids (i.e. void volume) between randomly oriented discrete fibers.
- Randomly oriented with particular reference to a population of fibers means that the fiber bodies are not substantially aligned in a single direction.
- Air-laying is a process by which a nonwoven fibrous web layer can be formed.
- bundles of small fibers having typical lengths ranging from about 3 to about 52 millimeters (mm) are separated and entrained in an air supply and then deposited onto a forming screen, usually with the assistance of a vacuum supply.
- the randomly oriented fibers may then be bonded to one another using, for example, thermal point bonding, autogenous bonding, hot air bonding, needle punching, calendering, a spray adhesive, and the like.
- An exemplary air-laying process is taught in, for example, U.S. Pat. No. 4,640,810 to Laursen et al.
- Porate loading or a “particle loading process” means a process in which particulates are added to a fiber stream or web while it is forming.
- Exemplary particulate loading processes are taught in, for example, U.S. Pat. No. 4,818,464 to Lau and U.S. Pat. No. 4,100,324 to Anderson et al.
- particulate and particle are used substantially interchangeably.
- a particulate or particle means a small distinct piece or individual part of a material in finely divided form.
- a particulate may also include a collection of individual particles associated or clustered together in finely divided form.
- individual particulates used in certain exemplary embodiments of the present disclosure may clump, physically intermesh, electro-statically associate, or otherwise associate to form particulates.
- particulates in the form of agglomerates of individual particulates may be intentionally formed such as those described in U.S. Pat. No. 5,332,426 (Tang et al.).
- Layer means a single stratum formed between two major surfaces.
- a layer may exist internally within a single web, e.g., a single stratum formed with multiple strata in a single web having first and second major surfaces defining the thickness of the web.
- a layer may also exist in a composite article comprising multiple webs, e.g., a single stratum in a first web having first and second major surfaces defining the thickness of the web, when that web is overlaid or underlaid by a second web having first and second major surfaces defining the thickness of the second web, in which case each of the first and second webs forms at least one layer.
- layers may simultaneously exist within a single web and between that web and one or more other webs, each web forming a layer.
- Porate density gradient mean that the amount of particulate, sorbent or fibrous material within a particular fiber population (e.g., the number, weight or volume of a given material per unit volume over a defined area of the web) need not be uniform throughout the nonwoven fibrous web, and that it can vary to provide more material in certain areas of the web and less in other areas.
- Nonwoven fibrous structures e.g., nonwoven fibrous webs, etc.
- applications e.g., uses
- Nonwoven fibrous structures can be better suited to particular applications when the nonwoven fibrous structure exhibits particular characteristics (e.g., fire retardant characteristics, antistatic characteristics, antibacterial characteristics, antimicrobial characteristics, antifungal characteristics, etc.).
- the present disclosure describes nonwoven fibrous structures that include a portion of a population of fibers that are bonded together with an ionic reinforcement material and methods of making the same.
- the ionic reinforcement material provides an increase in the tensile strength of the nonwoven fibrous structure as well as provides a number of characteristics.
- the ionic reinforcement material provides a plurality of characteristics as described herein.
- the ionic reinforcement material can be applied to the nonwoven fibrous structure utilizing an application of an ionic liquid material.
- the ionic liquid material can include an ionic liquid (e.g., liquid comprising at least one cation and at least one anion).
- the ionic liquid material applied to the nonwoven fibrous structure can be cured to bind a portion of the population of fibers of the nonwoven fibrous structure with an ionic reinforcement material.
- FIG. 1 is a perspective view of one exemplary embodiment of a nonwoven fibrous structure 234 (e.g., air-laid nonwoven fibrous web, melt-spun nonwoven fibrous web, carded nonwoven fibrous web, etc.) comprising a plurality of randomly oriented fibers according to the present disclosure.
- the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.
- the present disclosure describes a nonwoven fibrous structure comprising a plurality of randomly oriented fibers 2 , the nonwoven fibrous structure further comprising a plurality of optional non-hollow projections 200 extending from a major surface 204 of the nonwoven fibrous structure (as considered without the projections), and a plurality of substantially planar land areas 202 formed between each adjoining projection 200 in a plane defined by and substantially parallel with the major surface 204 .
- the randomly oriented discrete fibers 2 can include fibers 120 selected from the group consisting of mono-component fibers, multi-component fibers, crimped fibers, or a combination thereof.
- the randomly oriented discrete fibers 2 can include fibers selected from the group consisting of staple fibers, melt blown fibers, natural fibers, or a combination thereof.
- the randomly oriented discrete fibers 2 can include natural fibers selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, or a combination thereof.
- the randomly oriented discrete fibers 2 can include fibers that exhibit a median fiber diameter of from 1 micrometer to 50 micrometers.
- the randomly oriented discrete fibers 2 can include thermoplastic (co)polymer fibers further comprising a (co)polymer selected from poly(propylene), poly(ethylene), poly(butane), poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(ethylene) napthalate, poly(amide), poly(urethane), poly(lactic acid), poly(vinyl)alcohol, poly(phenylene) sulfide, poly(sulfone), liquid crystalline polymer, poly(ethylene)-co-poly(vinyl)acetate, poly(acrylonitrile), cyclic poly(olefin), poly(oxymethylene), poly(olefinic) thermoplastic elastomers, recycled fibers containing any of the preceding thermoplastic (co)polymers, or a combination thereof.
- a (co)polymer selected from poly(propylene), poly(ethylene), poly(butane), poly(ethylene) terephthalate, poly(butylene)
- the randomly oriented discrete fibers 2 may, in some exemplary embodiments, optionally include filling fibers 110 .
- the filling fibers 110 are any fiber other than a multi-component fiber.
- the optional filling fibers 110 are preferably mono-component fibers, which may be thermoplastic or “melty” fibers.
- the filling fibers can include bio-based fibers.
- Bio-based fibers can include natural fibers and/or biodegradable fibers.
- the optional filling fibers 110 may, in some exemplary embodiments, comprise natural fibers, more preferably natural fibers derived from renewable sources, and/or incorporating recycled materials.
- Non-limiting examples of suitable natural fibers include those of bamboo, cotton, wool, jute, agave, sisal, coconut, sawgrass, soybean, hemp, and the like.
- Cellulosic fibers e.g., cellulose, cellulose acetate, cellulose triacetate, rayon, and the like
- the fiber component used may be virgin fibers or recycled waste fibers, for example, recycled fibers reclaimed from garment cuttings, carpet manufacturing, fiber manufacturing, textile processing, paper, reclaimed wood, or the like.
- the optional filling fibers 110 are biodegradable fibers.
- the biodegradable fibers can include, but are not limited to fibers comprising a substantial amount of aliphatic polyester (co)polymer derived from poly(lactic acid), poly (glycolic acid), poly (lactic-co-glycolic acid) blends, and/or a combination thereof.
- at least some of the filling fibers 120 may be bonded to at least a portion of the discrete fibers 2 at a plurality of intersection points with the first region 112 of the multi-component fibers 110 .
- the nonwoven fibrous structure 234 may optionally include a plurality of particulates 130 as shown in FIG. 2 .
- FIG. 2 illustrates an exploded view of region 2 of the nonwoven fibrous structure 234 of FIG. 1 , shown comprising randomly oriented discrete fibers 2 and a plurality of optional particulates 130 .
- the optional particulates 130 can be particulates selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates, or a combination thereof.
- the optional population of particulates 130 can exhibit a median particle diameter of from 0.1 micrometer to 1,000 micrometers.
- the optional particulates 130 can be applied at various stages of the forming process for the nonwoven fibrous structure 234 .
- the optional particulates can be applied by a particulate loading process. Exemplary particulate loading processes are taught in, for example, U.S. Pat. Nos. 4,818,464 and 4,100,324.
- an input stream may advantageously be located to introduce particulates 130 in a manner such that the particulates 130 are distributed substantially uniformly throughout the nonwoven fibrous structure 234 .
- an input stream may advantageously be located to introduce particulates 130 in a manner such that the particulates 130 are distributed substantially at a major surface of the nonwoven fibrous structure 234 , for example, proximate a lower major surface of nonwoven fibrous structure 234 , or proximate the upper major surface of the nonwoven fibrous structure 234 .
- a binder can be applied to the nonwoven fibrous structure 234 and may provide further strength to the nonwoven fibrous structure 234 , may further secure the particulates 130 to the fibers of the nonwoven fibrous structure 234 , and/or may provide additional stiffness for an abrasive or scouring article.
- the binder coating may be applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques.
- the binder coating may include additional particulates 130 within the binder or additional particulates 130 may be incorporated and secured to the binder.
- an ionic liquid material (e.g., ionic liquid mixture) can be coated on the nonwoven fibrous structure 234 .
- the ionic liquid material can include an ionic liquid (e.g., liquid that comprises at least one cation and at least one anion, aqueous solution that comprises at least one cation and at least one anion). That is, the ionic liquid material is an ionic liquid solution in a solvent, optionally the solvent is aqueous.
- the ionic liquid can include at least one cation that is selected from the group containing heterocyclic cations, ammonium, phosphonium, or sulfonium.
- the ionic liquid can include at least one anion that is selected from the group consisting of halogen anions, fluorine containing anions, alkyl sulfate anions, alkyl phosphate anions, acetate, dicyanamide (N(CN) 2 ), or thiocyanate (SCN).
- the ionic liquid can be comprised of a salt dissolved in a liquid.
- the ionic liquid material can comprise a salt dissolved in water to produce an ionic liquid that comprises at least one cation and at least one anion in an aqueous solution.
- the ionic liquid material can comprise a salt dissolved in water to produce an ionic liquid that comprises at least one cation and at least one anion in an aqueous solution.
- the ionic liquid can include at least one of the ionic liquids from the group of: sodium chloride (NaCl), choline dihydrogen phosphate, 1-ethyl-3-methylimidazolium ethyl phosphate, 1-ethyl-3-methylimidazolium ethyl sulfate, 1-ethyl-3-methylimidazolium acetate, 1-ethyl-3-methylimidazolium triflate, or 1-ethyl-3-methylimidazolium dicyanamide.
- the ionic liquid material may be applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques.
- the ionic liquid material is introduced as a mist from an atomizer within a forming chamber.
- the ionic liquid material wets the fibers so that particulates cling to the surface of the fibers.
- the ionic liquid material can also include a binder.
- the binder may comprise a resin. Suitable resins include phenolic resins, a bio-based resin, a thermoplastic (meth)acrylic (co)polymer resin, an epoxy resin, polyurethane resins, polyureas, styrene-butadiene rubbers, nitrile rubbers, epoxies, acrylics, and polyisoprene.
- the binder may be water soluble.
- water soluble binders examples include surfactants, polyethylene glycol, polyvinylpyrrolidones, polylactic acid (PLA), polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohols, carboxymethyl celluloses, hydroxypropyl cellulose starches, polyethylene oxides, polyacrylamides, polyacrylic acids, cellulose ether polymers, polyethyl oxazolines, esters of polyethylene oxide, esters of polyethylene oxide and polypropylene oxide copolymers, urethanes of polyethylene oxide, and urethanes of polyethylene oxide and polypropylene oxide copolymers.
- surfactants polyethylene glycol, polyvinylpyrrolidones, polylactic acid (PLA), polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohols, carboxymethyl celluloses, hydroxypropyl cellulose starches, polyethylene oxides, polyacrylamides, polyacrylic
- the ionic liquid material can include from 1 to 40 weight percent (wt. %) of an ionic liquid and a binder in a liquid mixture (e.g., liquid solution, aqueous solution, etc.).
- the ionic liquid material can include from 1 to 10 wt. % of an ionic liquid and a binder in a liquid mixture. That is, the ionic liquid material can include a particular weight percent of ionic liquid, a binder as described herein, and/or a percentage of water.
- the ionic liquid material can include the ionic liquid and the binder as a mixture and/or solution and applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques.
- the ionic liquid can act as a plasticizer for the binder in the ionic liquid material. That is, the ionic liquid can increase the elongation (e.g., plasticity, fluidity) of the resulting nonwoven fibrous structure 234 .
- an increase in elongation of the nonwoven fibrous structure 234 occurs in the machine direction (MD).
- the increase in elongation of the nonwoven fibrous structure 234 occurs in the transverse direction (TD).
- the increase in elongation of the air laid nonwoven fibrous structure occurs in both the machine direction (MD) and the transverse direction (TD).
- the ionic liquid material is comprised of an ionic liquid and a binder selected from the group consisting of a (meth)acrylic (co)polymer binder, a styrene-butadiene latex binder, a bio-based binder, or a combination thereof.
- a liquid mixture e.g., liquid solution
- ionic liquid choline dihydrogen phosphate can be added to a binder from the group as described herein (e.g., thermosetting binder, Acrodur thermosetting binder from BASF chemical company).
- the thermosetting binder can be a binder that is relatively brittle when cured (e.g., heat is applied to the binder, etc.).
- the addition of the ionic liquid choline dihydrogen phosphate has a plasticizing effect (e.g., acts as a plasticizer) on the thermosetting binder. That is, the nonwoven fibrous structure 234 is less brittle with the addition of the ionic liquid choline dihydrogen phosphate and thermosetting binder compared to a nonwoven fibrous structure with the addition of the thermosetting binder and no ionic liquid.
- a number of devices can be utilized to remove excess liquid (e.g., water) from the nonwoven fibrous structure 234 .
- calendering can be utilized to remove liquid from the nonwoven fibrous structure 234 .
- Calendering can include a process of passing a nonwoven fibrous web through rollers with application of pressure to obtain a compressed and bonded fibrous nonwoven web.
- the number of devices can include a number of squeegees that can compress the nonwoven fibrous structure 234 and remove a portion of the liquid (e.g., water) that is applied to the nonwoven fibrous structure 234 .
- the number of squeegees can be utilized before the nonwoven fibrous structure 234 is moved to a heating unit (e.g., oven, etc.) to remove liquid that was not removed by the number of squeegees.
- the number of devices can be located at various points of the formation process of the nonwoven fibrous structure 234 .
- the heating unit can also be utilized for curing the ionic liquid material applied to the nonwoven fibrous structure 234 .
- the binder in the ionic liquid material is a thermosetting binder (e.g., a binder resin that hardens under heated conditions, etc.), wherein the binder and the ionic liquid of the ionic liquid material is cured with the heating unit.
- the heating unit can be utilized to remove liquid (e.g., water) that exists on and/or within the nonwoven fibrous structure 234 . As described herein, the heating unit can remove liquid that remains after a number of devices are utilized to remove liquid. Removing the liquid can produce an ionic reinforcement material at locations where the ionic liquid material was applied to the nonwoven fibrous structure 234 .
- the ionic liquid material can bond a portion of the population of fibers with an ionic reinforcement material.
- the ionic reinforcement material is a residual material of the ionic liquid material (e.g., material remaining after liquid is removed from the ionic liquid material). That is, in some exemplary embodiments, the ionic reinforcement material is the residual of the ionic liquid material after the liquid (e.g., water, excess water) is removed from the nonwoven fibrous structure 234 .
- the ionic reinforcement material can provide an adhesive bond between the portion of the population of fibers when a binder is included in the ionic liquid material, as described herein.
- the ionic reinforcement material can provide a number of characteristics to the nonwoven fibrous structure 234 .
- the ionic reinforcement material can provide the number of characteristics when the ionic reinforcement material includes the ionic liquid or the ionic liquid and binder mixture as described herein.
- the number of characteristics can include a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof.
- the ionic reinforcement material provides at least one of the number of characteristics.
- the ionic reinforcement material provides a plurality of the number of characteristics as described herein.
- the ionic reinforcement material can provide at least two of the number of characteristics listed herein.
- the ionic reinforcement material is applied to the nonwoven fibrous structure 234 with an ionic liquid material comprising the ionic liquid choline dihydrogen phosphate and a thermosetting binder.
- the nonwoven fibrous structure 234 is less brittle with the addition of the ionic liquid choline dihydrogen phosphate and thermosetting binder compared to a nonwoven fibrous structure 234 with only the addition of the thermosetting binder.
- the nonwoven fibrous structure 234 comprises antistatic characteristics from the ionic reinforcement material.
- the addition of the ionic liquid choline dihydrogen phosphate and thermosetting binder to the nonwoven fibrous structure 234 can provide additional fire retardant (e.g., flame retardant) characteristics to nonwoven fibrous structure 234 .
- the ionic reinforcement material can also add additional characteristics that can include: a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof.
- the ionic reinforcement material can increase the elongation (e.g., plasticity or fluidity) of the nonwoven fibrous structure 234 .
- the ionic reinforcement material can also provide an increase in a tensile strength of the nonwoven fibrous structure 234 .
- the ionic reinforcement material can provide an increase in a tensile strength of the nonwoven fibrous structure 234 and an increase in elongation of the nonwoven fibrous structure 234 .
- the increase in tensile strength and the increase in elongation are in the machine direction (MD) of the nonwoven fibrous structure 234 .
- a nonwoven fibrous structure 234 (e.g., fibrous web, air-laid nonwoven fibrous web, etc.) according to the present disclosure can be formed utilizing a number of forming methods (e.g., melt-spinning, air-laying, spun-bonding, carding, etc.).
- the nonwoven fibrous structure 234 is formed by air-laying fiber processing equipment, such as shown and described in U.S. Pat. Nos. 7,491,354 and 6,808,664.
- the air laying fiber processing equipment can use air flow to mix and inter-engage the fibers to form an air laid nonwoven fibrous structure. That is, the air laid nonwoven fibrous structure is formed by introducing a plurality of fibers into a forming chamber and dispersing the fibers within the forming chamber to form a population of individual fibers suspended in a gas, wherein the fibers are allowed to fall down to a collector.
- the forming chamber can have spike rollers to blend and mix the fibers while gravity allows the fibers to fall down through the endless belt screen and form an air-laid nonwoven fibrous structure of inter-engaged fibers.
- the fibers and the particulates are, in some exemplary embodiments, falling together to the bottom of the forming chamber to form the air-laid nonwoven fibrous structure.
- a vacuum can be included below the area where the air-laid nonwoven fibrous structure forms in the forming chamber.
- the nonwoven fibrous structure 234 is formed using a carding process.
- An exemplary carding process is taught in, for example, U.S. Pat. No. 5,114,787.
- the nonwoven fibrous structure 234 is formed by a meltblowing process.
- the meltblowing process is a method for forming a nonwoven fibrous structure by extruding a molten fiber-forming material through a plurality of orifices in a die to form fibers while contacting the fibers with air or other attenuating fluid to attenuate the fibers into fibers, and thereafter collecting the attenuated fibers.
- An exemplary meltblowing process is taught in, for example, U.S. Pat. No. 6,607,624.
- the ionic liquid material can be applied to the nonwoven fibrous structure 234 at different stages of each of the forming methods.
- the ionic liquid material can be applied to fibers and/or filaments during a formation (e.g., in a forming chamber, etc.) of the fibers and/or filaments utilizing a mist process to spray the fibers and/or filaments while they are being collected on a collector.
- the ionic liquid material can be applied to the nonwoven fibrous structure 234 once the fibers and/or filaments are collected on a collector.
- the ionic liquid material can be applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques.
- Nonwoven fibrous structures of the present disclosure and filter media including the same may, in some exemplary embodiments, advantageously incorporate a biodegradable material, a particulate material, a frame material, or a combination thereof.
- Some filter media incorporating biodegradable material e.g. polyhydroxy alkonates (PHA), polyhydroxybutyrates (PHB), and the like
- PHA polyhydroxy alkonates
- PHB polyhydroxybutyrates
- the basis weight of the nonwoven webs was measured with a Mettler Toledo XS4002S electronic balance.
- IL denotes ionic liquid
- PET denotes polyester
- MD denotes machine direction
- TD denotes transverse direction (relative to MD)
- TS tensile strength
- elong denotes percentage elongation
- PEG denotes polyethylene glycol
- Std denotes a reference standard (i.e., a comparative example).
- this binder was coated on the nonwoven web by roll coating pre-diluted in the ratio of 2:1 with H 2 O (33% solids approx.). The binder was then cured in a through air oven at 140° C. for approx. 4 minutes.
- this binder was coated on the nonwoven web by roll coating pre-diluted in the ratio of 2:1 with H 2 O. The binder was then cured in a through air oven at 130° C. for approx. 4 minutes.
- the ionic liquids (IL) listed in Table III were added at 10% w/v to the binder aqueous solutions.
- the ionic liquids were added in one part to the binder aqueous solution and stirred until fully dissolved.
- Ionic Liquids Ionic Liquid Reference Code Chemical Name
- IL A 1-ethyl-3-methylimidazolium diethyl phosphate
- IL B 1-ethyl-3-methylimidazolium ethyl sulfate
- C 1-ethyl-3-methylimidazolium acetate
- I 1-ethyl-3-methylimidazolium triflate
- L 1-ethyl-3-methylimidazolium dicyanamide
- O Trihexyltetradecylphosphonium chloride
- IL E1 Choline dihydrogen phosphate
- H1 1-ethyl-3-methylimidazolium chloride
- IL K1 Ethyltributylphosphonium diethyl phosphate
- M1 1,3-dimethylimidazolium dimethyl phosphate
- Fiber prebonded webs were formed prior to coating of the resins.
- the required ratio of fibers to melty fibers were weighed and mixed by passing through a fiber opener.
- the air-laid prebonded webs were formed on a Rando Webber forming machine. Following forming of the web, it was sent through a through-air oven at 130° C. to yield a lightly bonded web suitable for coating trials.
- the prebonded webs were coated by passing through roll coating cylinders containing the binder/ionic liquid mixture in the reservoir.
- Tables 1-4 show the Tensile Test results for nonwoven viscose prebond webs with Acrodur binder and with various ionic liquids.
- Tables 5-8 show the Tensile Test results for nonwoven viscose prebond webs with OC Biobinder binder and various ionic liquids.
- Tables 9-12 show the Tensile Test results for nonwoven viscose prebond webs with Acrodur binder and various ionic liquids.
- Tables 13-16 show the Tensile Test results for nonwoven viscose prebond webs with OC Biobinder binder and various ionic liquids.
- Tables 17-18 show the Tensile Test results for nonwoven viscose prebond webs with Primal B15 binder and various ionic liquids.
- the nonwoven samples tested consisted of viscose prebond webs. Tables 23-24 show the Tensile Test results for Example 5 with various ionic liquids.
- the surface resistivity of the nonwoven coated samples was carried out according to VDE 0303 part 30.
- the test equipment consisted of a Teraohmmeter (PM 126 567), electrode (20 cm 2 ) and ⁇ Electrode (5 cm). The following terms are defined for the Surface Resistivity Test:
- Tables 25-32 show the Surface Resistivity Test results for Example 1 with various ionic liquids.
- Tables 33-43 show the Surface Resistivity Test results for Example 2 with various ionic liquids.
- Tables 44-51 show the Surface Resistivity Test results for Example 3 with various ionic liquids.
- Flame retardancy testing was carried out according to test method UL94 vertical burner test procedure with minor modifications. Methane gas at a pressure of 2.5 psi was used for the Bunsen burner. The flame cone height measurements were as follows: 1 cm for the interior and 2 cm for the exterior. The distance between the Bunsen tip and the end of the sample was 1 cm. The sample size was 15 ⁇ 2.5 cm. The sample measured consisted of a web of viscose fibers with the requisite binder containing 10% ionic liquid unless otherwise stated. 3 samples were measured for each binder/IL combination. When all 3 samples gave the same results, only 1 overall result is noted.
- T1 Duration (seconds) of after flame after ignited Bunsen was applied to sample for 10 seconds
- T2 After flame following application of Bunsen for a further 10 seconds
- T3 After flame following application of Bunsen for a further 10 seconds
- B Sample burned Note: When after flame exposure result is equal to zero, this the sample resisted ignition.
- Table 52 shows the Flame Retardancy Test results for Example 2 with various binders and ionic liquids.
- Table 53 summarizes overall performance properties with respect to Tensile Strength, Anti-static properties, and Flame Retardancy.
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Abstract
Nonwoven fibrous structures and related media with ionic reinforcement material and methods of forming the same includes bonding at least a portion of the population of fibers together with an ionic reinforcement material. Nonwoven fibrous structures can be utilized as a mat, a web, a sheet, a scrim, or a combination thereof. Methods of making nonwoven fibrous structures and related media with ionic reinforcement material made according to the methods, are also disclosed.
Description
- The present disclosure relates to nonwoven fibrous structures and related media with ionic reinforcement material and methods of forming the same.
- Nonwoven fibrous webs have been used to produce a variety of absorbent articles that are useful, for example, as absorbent wipes for surface cleaning, as wound dressings, as gas and liquid absorbent or filtration media, and as barrier materials for sound absorption.
- Although some methods of forming nonwoven fibrous webs are known, the art continually seeks new methods of forming and/or bonding nonwoven webs, particularly air-laid nonwoven fibrous webs having particular characteristics with a relatively high cross direction (CD) tensile strength and a relatively high machine direction (MD) tensile strength.
- Thus, in one aspect, the present disclosure relates to a method of making a nonwoven fibrous structure (e.g., a nonwoven fibrous web), including: introducing a plurality of fibers into a forming chamber, dispersing the fibers within the forming chamber to form a population of individual fibers suspended in a gas, collecting the population of fibers as a nonwoven fibrous structure on a collector, and bonding at least a portion of the population of fibers together with an ionic reinforcement material. In some exemplary embodiments, the method comprises applying an ionic liquid material to the population of fibers. In certain exemplary embodiments, the method includes bonding at least the portion of the population of fibers together comprises curing the applied ionic liquid material to form the ionic reinforcement material.
- In some exemplary embodiments, the applied ionic liquid material further comprises water, and where curing removes at least a portion of the water from the applied ionic liquid material to cause bonding of the ionic reinforcement material between the population of fibers. In certain exemplary embodiments, the applied ionic liquid material further comprises at least one binder resin, optionally wherein the applied ionic liquid material acts as a plasticizer for the at least one binder resin. In some exemplary embodiments, the at least one binder resin is selected from the group consisting of a phenolic resin, a bio-based resin, a thermoplastic (meth)acrylic (co)polymer resin, an epoxy resin, or a combination thereof. In certain exemplary embodiments, the method includes bonding with a binder resin mixture and the ionic liquid material to provide a nonwoven fibrous structure with a tensile strength that is greater than a nonwoven fibrous structure bonded with the binder resin mixture in the absence of the ionic liquid material.
- In some exemplary embodiments, the ionic liquid material comprises at least one cation and at least one anion. In certain exemplary embodiments, the at least one cation is selected from the group consisting of nitrogen containing heterocyclic cations, ammonium, phosphonium, or sulfonium; and further wherein the at least one anion is selected from the group consisting of halogen anions, fluorine containing anions, alkyl sulfate anions, alkyl phosphate anions, acetate, dicyanamide (N(CN)2), or thiocyanate (SCN). In some exemplary embodiments, the method includes spraying the ionic liquid material, roll coating the ionic liquid material, dip coating the ionic liquid material, or a combination thereof. In certain exemplary embodiments, the ionic liquid material is an ionic liquid solution in a solvent, optionally wherein the solvent is aqueous.
- In some exemplary embodiments, bonding at least the portion of the population of fibers together includes applying a thermosetting binder to the population fibers. In certain exemplary embodiments, bonding at least the portion of the population of fibers includes heating the portion of the population of fibers. In some exemplary embodiments, the ionic reinforcement material provides at least one distinguishing characteristic to the nonwoven fibrous structure selected from the group consisting of a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof. In certain exemplary embodiments, the population of fibers includes fibers selected from the group consisting of staple fibers, melt blown fibers, natural fibers, bio-based fibers, or a combination thereof.
- In certain exemplary embodiments, the nonwoven fibrous structure includes a population of particulates bonded to the nonwoven fibrous structure, further wherein the particulates are selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates, or a combination thereof. In some exemplary embodiments, the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.
- The disclosure also relates to a nonwoven fibrous web prepared according to the method described herein. In addition, the disclosure relates to a nonwoven fibrous structure comprising a population of randomly oriented fibers bonded together at a plurality of intersection points with an ionic reinforcement material. In some exemplary embodiments, the ionic reinforcement material is comprised of an ionic plasticizer (e.g., ionic liquid acting as a plasticizer). In certain exemplary embodiments, the ionic reinforcement material is comprised of an ionic liquid and a binder selected from the group consisting of a (meth)acrylic (co)polymer binder, a styrene-butadiene latex binder, a bio-based binder, or a combination thereof. In some exemplary embodiments, the nonwoven fibrous structure comprises from 1 to 40 wt. % of the ionic liquid. In further embodiments, the ionic liquid comprises water, one or more cations, and one or more anions.
- In some exemplary embodiments, the nonwoven fibrous structure exhibits at least one distinguishing characteristic selected from the group consisting of a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof. In certain exemplary embodiments, the ionic reinforcement material provides the at least one distinguishing characteristic. In some exemplary embodiments, the ionic reinforcement material provides at least two of the distinguishing characteristics. In certain exemplary embodiments, the population of fibers includes thermoplastic (co)polymer fibers further comprising a (co)polymer selected from poly(propylene), poly(ethylene), poly(butane), poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(ethylene) napthalate, poly(amide), poly(urethane), poly(lactic acid), poly(vinyl)alcohol, poly(phenylene) sulfide, poly(sulfone), liquid crystalline polymer, poly(ethylene)-co-poly(vinyl)acetate, poly(acrylonitrile), cyclic poly(olefin), poly(oxymethylene), poly(olefinic) thermoplastic elastomers, recycled fibers containing any of the preceding thermoplastic (co)polymers, or a combination thereof.
- In some exemplary embodiments, the population of fibers includes natural fibers selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, or a combination thereof. In certain exemplary embodiments, the nonwoven fibrous structure includes a population of particulates bonded to the nonwoven fibrous structure, further wherein the particulates are selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates; or a combination thereof. In some exemplary embodiments, the population of particulates exhibits a median particle diameter of from 0.1 micrometer to 1,000 micrometers. In certain exemplary embodiments, the population of fibers exhibits a median fiber diameter of from 1 micrometer to 50 micrometers. In some exemplary embodiments, the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.
- Various exemplary embodiments of the present disclosure are further illustrated by the following listing of exemplary embodiments, which should not be construed to unduly limit the present disclosure:
-
-
- A. A method of making a nonwoven fibrous structure, comprising:
- a. introducing a plurality of fibers into a forming chamber;
- b. dispersing the fibers within the forming chamber to form a population of individual fibers suspended in a gas;
- c. collecting the population of fibers as a nonwoven fibrous structure on a collector; and
- d. bonding at least a portion of the population of fibers together with an ionic reinforcement material.
- B. The method of embodiment A, further comprising applying an ionic liquid material to the population of fibers.
- C. The method of embodiment B, wherein bonding at least the portion of the population of fibers together comprises curing the applied ionic liquid material to form the ionic reinforcement material.
- D. The method of embodiment C, wherein the applied ionic liquid material further comprises water, and further wherein curing removes at least a portion of the water from the applied ionic liquid material to cause bonding of the ionic reinforcement material between the population of fibers.
- E. The method of any one of embodiments B-D, wherein the applied ionic liquid material further comprises at least one binder resin, optionally wherein the applied ionic liquid material acts as a plasticizer for the at least one binder resin.
- F. The method of embodiment E, wherein the at least one binder resin is selected from the group consisting of a phenolic resin, a bio-based resin, a thermoplastic (meth)acrylic (co)polymer resin, an epoxy resin, or a combination thereof
- G. The method of any one of embodiments B-F, wherein bonding includes bonding with a binder resin mixture and the ionic liquid material to provide a nonwoven fibrous structure with a tensile strength that is greater than a nonwoven fibrous structure bonded with the binder resin mixture in the absence of the ionic liquid material.
- H. The method of any one of embodiments B-G, wherein the ionic liquid material comprises at least one cation and at least one anion.
- I. The method of any one of embodiments B-H, wherein the at least one cation is selected from the group consisting of nitrogen containing heterocyclic cations, ammonium, phosphonium, or sulfonium; and further wherein the at least one anion is selected from the group consisting of halogen anions, fluorine containing anions, alkyl sulfate anions, alkyl phosphate anions, acetate, dicyanamide (N(CN)2), or thiocyanate (SCN).
- J. The method of any one of embodiments B-I, wherein applying the ionic liquid material consists of spraying the ionic liquid material, roll coating the ionic liquid material, dip coating the ionic liquid material, or a combination thereof
- K. The method of any one of embodiments B-J, wherein the ionic liquid material is an ionic liquid solution in a solvent, optionally wherein the solvent is aqueous.
- L. The method of any one of embodiments A-K, wherein bonding at least the portion of the population of fibers together includes applying a thermosetting binder to the population fibers.
- M. The method of any one of embodiments A-L, wherein bonding at least the portion of the population of fibers includes heating the portion of the population of fibers.
- N. The method of any one of embodiments A-M, wherein the ionic reinforcement material provides at least one distinguishing characteristic to the nonwoven fibrous structure selected from the group consisting of a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof.
- O. The method of any one of embodiments A-N, wherein the population of fibers includes fibers selected from the group consisting of mono-component fibers, multi-component fibers, crimped fibers, or a combination thereof.
- P. The method of any one of embodiments A-O, wherein the population of fibers includes fibers selected from the group consisting of staple fibers, melt blown fibers, natural fibers, bio-based fibers, or a combination thereof
- Q. The method of any one of embodiments A-P, wherein the nonwoven fibrous structure includes a population of particulates bonded to the nonwoven fibrous structure, further wherein the particulates are selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates, or a combination thereof
- R. The method of any one of embodiments A-Q, wherein the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof
- S. A nonwoven fibrous structure prepared according to the method of any one of embodiments A-R.
- T. A nonwoven fibrous structure comprising:
- a. a population of randomly oriented fibers bonded together at a plurality of intersection points with an ionic reinforcement material.
- U. The nonwoven fibrous structure of embodiment T, wherein the ionic reinforcement material is comprised of an ionic plasticizer.
- V. The nonwoven fibrous structure of embodiment T or U, wherein the ionic reinforcement material is comprised of an ionic liquid and a binder selected from the group consisting of a (meth)acrylic (co)polymer binder, a styrene-butadiene latex binder, a bio-based binder, or a combination thereof.
- W. The nonwoven fibrous structure of embodiment V, comprising from 1 to 40 wt. % of the ionic liquid.
- X. The nonwoven fibrous structure of any one of embodiments V-W, wherein the ionic liquid comprises water, one or more cations, and one or more anions.
- Y. The nonwoven fibrous structure of any one of embodiments T-X, exhibiting at least one distinguishing characteristic selected from the group consisting of a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof.
- Z. The nonwoven fibrous structure of embodiment Y, wherein the ionic reinforcement material provides the at least one distinguishing characteristic.
- AA. The nonwoven fibrous structure of any one of embodiments T-Z, wherein the population of fibers includes fibers selected from the group consisting of mono-component fibers, multi-component fibers, crimped fibers, or a combination thereof
- BB. The nonwoven fibrous structure of any one of embodiments T-AA, wherein the population of fibers includes fibers selected from the group consisting of staple fibers, melt blown fibers, natural fibers, or a combination thereof
- CC. The nonwoven fibrous structure of any one of embodiments T-BB, wherein the population of fibers includes thermoplastic (co)polymer fibers further comprising a (co)polymer selected from poly(propylene), poly(ethylene), poly(butane), poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(ethylene) napthalate, poly(amide), poly(urethane), poly(lactic acid), poly(vinyl)alcohol, poly(phenylene) sulfide, poly(sulfone), liquid crystalline polymer, poly(ethylene)-co-poly(vinyl)acetate, poly(acrylonitrile), cyclic poly(olefin), poly(oxymethylene), poly(olefinic) thermoplastic elastomers, recycled fibers containing any of the preceding thermoplastic (co)polymers, or a combination thereof
- DD. The nonwoven fibrous structure of any one of embodiments T-CC, wherein the population of fibers includes natural fibers selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, or a combination thereof
- EE. The nonwoven fibrous structure of any one of embodiments T-DD, wherein the nonwoven fibrous structure includes a population of particulates bonded to the nonwoven fibrous structure, further wherein the particulates are selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates; or a combination thereof
- FF. The nonwoven fibrous structure of any one of embodiments T-EE, wherein the population of particulates exhibits a median particle diameter of from 0.1 micrometer to 1,000 micrometers.
- GG. The nonwoven fibrous structure of any one of embodiments T-FF, wherein the population of fibers exhibits a median fiber diameter of from 1 micrometer to 50 micrometers.
- HH. The nonwoven fibrous structure of any one of embodiments T-GG, wherein the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.
- A. A method of making a nonwoven fibrous structure, comprising:
- Various aspects and advantages of embodiments of the presently disclosed invention have been summarized. The above Summary is not intended to describe each illustrated embodiment or every implementation of the presently disclosed invention. The Drawings and the Detailed Description that follow more particularly exemplify certain preferred embodiments using the principles disclosed herein.
- Exemplary embodiments of the present disclosure are further described with reference to the appended figures, wherein:
-
FIG. 1 is a perspective view of an exemplary nonwoven fibrous structure of the present disclosure. -
FIG. 2 is an exploded view of a portion of the exemplary nonwoven fibrous structure ofFIG. 1 , illustrating one exemplary embodiment of the present disclosure. - As used in this specification and the appended embodiments, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to fine fibers containing “a compound” includes a mixture of two or more compounds. As used in this specification and the appended embodiments, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
- As used in this specification, the recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.8, 4, and 5).
- Unless otherwise indicated, all numbers expressing quantities or ingredients, measurement of properties and so forth used in the specification and embodiments are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached listing of embodiments can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings of the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claimed embodiments, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
- For the following Glossary of defined terms, these definitions shall be applied for the entire application, unless a different definition is provided in the claims or elsewhere in the specification.
- “Nonwoven fibrous web” or “nonwoven fibrous structure” means an article or sheet having a structure of individual fibers or fibers, which are interlaid, but not in an identifiable manner as in a knitted fabric. Nonwoven fabrics or webs have been formed from many processes such as for example, meltblowing processes, air-laying processes, and bonded carded web processes.
- “Die” means a processing assembly for use in polymer melt processing and fiber extrusion processes, including but not limited to meltblowing and spun-bonding.
- “Meltblowing” and “meltblown process” means a method for forming a nonwoven fibrous web by extruding a molten fiber-forming material through a plurality of orifices in a die to form fibers while contacting the fibers with air or other attenuating fluid to attenuate the fibers into fibers, and thereafter collecting the attenuated fibers. An exemplary meltblowing process is taught in, for example, U.S. Pat. No. 6,607,624 (Berrigan et al.).
- “Meltblown fibers” means fibers prepared by a meltblowing or meltblown process.
- “Spun-bonding” and “spun bond process” mean a method for forming a nonwoven fibrous structure by extruding molten fiber-forming material as continuous or semi-continuous fibers from a plurality of fine capillaries of a spinneret, and thereafter collecting the attenuated fibers. An exemplary spun-bonding process is disclosed in, for example, U.S. Pat. No. 3,802,817 to Matsuki et al.
- “Spun bond fibers” and “spun-bonded fibers” mean fibers made using spun-bonding or a spun bond process. Such fibers are generally continuous fibers and are entangled or point bonded sufficiently to form a cohesive nonwoven fibrous web such that it is usually not possible to remove one complete spun bond fiber from a mass of such fibers. The fibers may also have shapes such as those described, for example, in U.S. Pat. No. 5,277,976 to Hogle et al., which describes fibers with unconventional shapes.
- “Carding” and “carding process” mean a method of forming a nonwoven fibrous web webs by processing staple fibers through a combing or carding unit, which separates or breaks apart and aligns the staple fibers in the machine direction to form a generally machine direction oriented fibrous nonwoven web. An exemplary carding process is taught in, for example, U.S. Pat. No. 5,114,787 to Chaplin et al.
- “Bonded carded web” refers to nonwoven fibrous web formed by a carding process wherein at least a portion of the fibers are bonded together by methods that include for example, thermal point bonding, autogenous bonding, hot air bonding, ultrasonic bonding, needle punching, calendering, application of a spray adhesive, and the like.
- “Calendering” means a process of passing a nonwoven fibrous web through rollers with application of pressure to obtain a compressed and bonded fibrous nonwoven web. The rollers may optionally be heated.
- “Densification” means a process whereby fibers which have been deposited either directly or indirectly onto a filter winding arbor or mandrel are compressed, either before or after the deposition, and made to form an area, generally or locally, of lower porosity, whether by design or as an artifact of some process of handling the forming or formed filter. Densification also includes the process of calendering webs.
- “Non-hollow” with particular reference to projections extending from a major surface of a nonwoven fibrous structure means that the projections do not contain an internal cavity or void region other than the microscopic voids (i.e. void volume) between randomly oriented discrete fibers.
- “Randomly oriented” with particular reference to a population of fibers means that the fiber bodies are not substantially aligned in a single direction.
- “Air-laying” is a process by which a nonwoven fibrous web layer can be formed. In the air-laying process, bundles of small fibers having typical lengths ranging from about 3 to about 52 millimeters (mm) are separated and entrained in an air supply and then deposited onto a forming screen, usually with the assistance of a vacuum supply. The randomly oriented fibers may then be bonded to one another using, for example, thermal point bonding, autogenous bonding, hot air bonding, needle punching, calendering, a spray adhesive, and the like. An exemplary air-laying process is taught in, for example, U.S. Pat. No. 4,640,810 to Laursen et al.
- “Particulate loading” or a “particle loading process” means a process in which particulates are added to a fiber stream or web while it is forming. Exemplary particulate loading processes are taught in, for example, U.S. Pat. No. 4,818,464 to Lau and U.S. Pat. No. 4,100,324 to Anderson et al.
- “Particulate” and “particle” are used substantially interchangeably. Generally, a particulate or particle means a small distinct piece or individual part of a material in finely divided form. However, a particulate may also include a collection of individual particles associated or clustered together in finely divided form. Thus, individual particulates used in certain exemplary embodiments of the present disclosure may clump, physically intermesh, electro-statically associate, or otherwise associate to form particulates. In certain instances, particulates in the form of agglomerates of individual particulates may be intentionally formed such as those described in U.S. Pat. No. 5,332,426 (Tang et al.).
- “Layer” means a single stratum formed between two major surfaces. A layer may exist internally within a single web, e.g., a single stratum formed with multiple strata in a single web having first and second major surfaces defining the thickness of the web. A layer may also exist in a composite article comprising multiple webs, e.g., a single stratum in a first web having first and second major surfaces defining the thickness of the web, when that web is overlaid or underlaid by a second web having first and second major surfaces defining the thickness of the second web, in which case each of the first and second webs forms at least one layer. In addition, layers may simultaneously exist within a single web and between that web and one or more other webs, each web forming a layer.
- “Particulate density gradient,” “sorbent density gradient,” and “fiber population density gradient” mean that the amount of particulate, sorbent or fibrous material within a particular fiber population (e.g., the number, weight or volume of a given material per unit volume over a defined area of the web) need not be uniform throughout the nonwoven fibrous web, and that it can vary to provide more material in certain areas of the web and less in other areas.
- Various exemplary embodiments of the disclosure will now be described with particular reference to the Drawings. Exemplary embodiments of the invention may take on various modifications and alterations without departing from the spirit and scope of the disclosure. Accordingly, it is to be understood that the embodiments of the invention are not to be limited to the following described exemplary embodiments, but is to be controlled by the limitations set forth in the claims and any equivalents thereof.
- Nonwoven fibrous structures (e.g., nonwoven fibrous webs, etc.) have a plurality of applications (e.g., uses) including: cleaning applications, filtration applications, and/or textile applications, among others. Nonwoven fibrous structures can be better suited to particular applications when the nonwoven fibrous structure exhibits particular characteristics (e.g., fire retardant characteristics, antistatic characteristics, antibacterial characteristics, antimicrobial characteristics, antifungal characteristics, etc.). The present disclosure describes nonwoven fibrous structures that include a portion of a population of fibers that are bonded together with an ionic reinforcement material and methods of making the same. The ionic reinforcement material provides an increase in the tensile strength of the nonwoven fibrous structure as well as provides a number of characteristics. In some exemplary embodiments, the ionic reinforcement material provides a plurality of characteristics as described herein.
- As described further herein, the ionic reinforcement material can be applied to the nonwoven fibrous structure utilizing an application of an ionic liquid material. The ionic liquid material can include an ionic liquid (e.g., liquid comprising at least one cation and at least one anion). The ionic liquid material applied to the nonwoven fibrous structure can be cured to bind a portion of the population of fibers of the nonwoven fibrous structure with an ionic reinforcement material.
-
FIG. 1 is a perspective view of one exemplary embodiment of a nonwoven fibrous structure 234 (e.g., air-laid nonwoven fibrous web, melt-spun nonwoven fibrous web, carded nonwoven fibrous web, etc.) comprising a plurality of randomly oriented fibers according to the present disclosure. In some exemplary embodiments, the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof. - In some optional embodiments, the present disclosure describes a nonwoven fibrous structure comprising a plurality of randomly oriented
fibers 2, the nonwoven fibrous structure further comprising a plurality of optionalnon-hollow projections 200 extending from amajor surface 204 of the nonwoven fibrous structure (as considered without the projections), and a plurality of substantiallyplanar land areas 202 formed between each adjoiningprojection 200 in a plane defined by and substantially parallel with themajor surface 204. - In some exemplary embodiments, the randomly oriented
discrete fibers 2 can includefibers 120 selected from the group consisting of mono-component fibers, multi-component fibers, crimped fibers, or a combination thereof. In certain exemplary embodiments, the randomly orienteddiscrete fibers 2 can include fibers selected from the group consisting of staple fibers, melt blown fibers, natural fibers, or a combination thereof. In some exemplary embodiments, the randomly orienteddiscrete fibers 2 can include natural fibers selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, or a combination thereof. In certain exemplary embodiments, the randomly orienteddiscrete fibers 2 can include fibers that exhibit a median fiber diameter of from 1 micrometer to 50 micrometers. - In some exemplary embodiments, the randomly oriented
discrete fibers 2 can include thermoplastic (co)polymer fibers further comprising a (co)polymer selected from poly(propylene), poly(ethylene), poly(butane), poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(ethylene) napthalate, poly(amide), poly(urethane), poly(lactic acid), poly(vinyl)alcohol, poly(phenylene) sulfide, poly(sulfone), liquid crystalline polymer, poly(ethylene)-co-poly(vinyl)acetate, poly(acrylonitrile), cyclic poly(olefin), poly(oxymethylene), poly(olefinic) thermoplastic elastomers, recycled fibers containing any of the preceding thermoplastic (co)polymers, or a combination thereof. - The randomly oriented
discrete fibers 2 may, in some exemplary embodiments, optionally include fillingfibers 110. The fillingfibers 110 are any fiber other than a multi-component fiber. Theoptional filling fibers 110 are preferably mono-component fibers, which may be thermoplastic or “melty” fibers. In certain exemplary embodiments, the filling fibers can include bio-based fibers. Bio-based fibers can include natural fibers and/or biodegradable fibers. For example, theoptional filling fibers 110 may, in some exemplary embodiments, comprise natural fibers, more preferably natural fibers derived from renewable sources, and/or incorporating recycled materials. Non-limiting examples of suitable natural fibers include those of bamboo, cotton, wool, jute, agave, sisal, coconut, sawgrass, soybean, hemp, and the like. Cellulosic fibers (e.g., cellulose, cellulose acetate, cellulose triacetate, rayon, and the like) may be particularly well-suited natural fibers. The fiber component used may be virgin fibers or recycled waste fibers, for example, recycled fibers reclaimed from garment cuttings, carpet manufacturing, fiber manufacturing, textile processing, paper, reclaimed wood, or the like. In another example, theoptional filling fibers 110 are biodegradable fibers. The biodegradable fibers can include, but are not limited to fibers comprising a substantial amount of aliphatic polyester (co)polymer derived from poly(lactic acid), poly (glycolic acid), poly (lactic-co-glycolic acid) blends, and/or a combination thereof. In some presently preferred embodiments, at least some of the fillingfibers 120 may be bonded to at least a portion of thediscrete fibers 2 at a plurality of intersection points with thefirst region 112 of themulti-component fibers 110. - In some exemplary embodiments of the previously described nonwoven fibrous structure, the nonwoven
fibrous structure 234 may optionally include a plurality ofparticulates 130 as shown inFIG. 2 .FIG. 2 illustrates an exploded view ofregion 2 of the nonwovenfibrous structure 234 ofFIG. 1 , shown comprising randomly orienteddiscrete fibers 2 and a plurality ofoptional particulates 130. - In some exemplary embodiments, the
optional particulates 130 can be particulates selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates, or a combination thereof. In certain exemplary embodiments, the optional population ofparticulates 130 can exhibit a median particle diameter of from 0.1 micrometer to 1,000 micrometers. Theoptional particulates 130 can be applied at various stages of the forming process for the nonwovenfibrous structure 234. In one example, the optional particulates can be applied by a particulate loading process. Exemplary particulate loading processes are taught in, for example, U.S. Pat. Nos. 4,818,464 and 4,100,324. - Additionally, in some particular exemplary embodiments, an input stream may advantageously be located to introduce
particulates 130 in a manner such that theparticulates 130 are distributed substantially uniformly throughout the nonwovenfibrous structure 234. Alternatively, in some particular exemplary embodiments, an input stream may advantageously be located to introduceparticulates 130 in a manner such that theparticulates 130 are distributed substantially at a major surface of the nonwovenfibrous structure 234, for example, proximate a lower major surface of nonwovenfibrous structure 234, or proximate the upper major surface of the nonwovenfibrous structure 234. - In certain exemplary embodiments, a binder can be applied to the nonwoven
fibrous structure 234 and may provide further strength to the nonwovenfibrous structure 234, may further secure theparticulates 130 to the fibers of the nonwovenfibrous structure 234, and/or may provide additional stiffness for an abrasive or scouring article. The binder coating may be applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques. The binder coating may includeadditional particulates 130 within the binder oradditional particulates 130 may be incorporated and secured to the binder. - In exemplary embodiments, an ionic liquid material (e.g., ionic liquid mixture) can be coated on the nonwoven
fibrous structure 234. The ionic liquid material can include an ionic liquid (e.g., liquid that comprises at least one cation and at least one anion, aqueous solution that comprises at least one cation and at least one anion). That is, the ionic liquid material is an ionic liquid solution in a solvent, optionally the solvent is aqueous. In some exemplary embodiments, the ionic liquid can include at least one cation that is selected from the group containing heterocyclic cations, ammonium, phosphonium, or sulfonium. In addition, in certain exemplary embodiments, the ionic liquid can include at least one anion that is selected from the group consisting of halogen anions, fluorine containing anions, alkyl sulfate anions, alkyl phosphate anions, acetate, dicyanamide (N(CN)2), or thiocyanate (SCN). The ionic liquid can be comprised of a salt dissolved in a liquid. For example, the ionic liquid material can comprise a salt dissolved in water to produce an ionic liquid that comprises at least one cation and at least one anion in an aqueous solution. For example, the ionic liquid material can comprise a salt dissolved in water to produce an ionic liquid that comprises at least one cation and at least one anion in an aqueous solution. In some exemplary embodiments, the ionic liquid can include at least one of the ionic liquids from the group of: sodium chloride (NaCl), choline dihydrogen phosphate, 1-ethyl-3-methylimidazolium ethyl phosphate, 1-ethyl-3-methylimidazolium ethyl sulfate, 1-ethyl-3-methylimidazolium acetate, 1-ethyl-3-methylimidazolium triflate, or 1-ethyl-3-methylimidazolium dicyanamide. - The ionic liquid material may be applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques. In some exemplary embodiments, the ionic liquid material is introduced as a mist from an atomizer within a forming chamber. In certain exemplary embodiments, the ionic liquid material wets the fibers so that particulates cling to the surface of the fibers.
- In some exemplary embodiments, the ionic liquid material can also include a binder. The binder may comprise a resin. Suitable resins include phenolic resins, a bio-based resin, a thermoplastic (meth)acrylic (co)polymer resin, an epoxy resin, polyurethane resins, polyureas, styrene-butadiene rubbers, nitrile rubbers, epoxies, acrylics, and polyisoprene. The binder may be water soluble. Examples of water soluble binders include surfactants, polyethylene glycol, polyvinylpyrrolidones, polylactic acid (PLA), polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohols, carboxymethyl celluloses, hydroxypropyl cellulose starches, polyethylene oxides, polyacrylamides, polyacrylic acids, cellulose ether polymers, polyethyl oxazolines, esters of polyethylene oxide, esters of polyethylene oxide and polypropylene oxide copolymers, urethanes of polyethylene oxide, and urethanes of polyethylene oxide and polypropylene oxide copolymers.
- In embodiments where the ionic liquid material includes the binder, the ionic liquid material can include from 1 to 40 weight percent (wt. %) of an ionic liquid and a binder in a liquid mixture (e.g., liquid solution, aqueous solution, etc.). In certain exemplary embodiments, the ionic liquid material can include from 1 to 10 wt. % of an ionic liquid and a binder in a liquid mixture. That is, the ionic liquid material can include a particular weight percent of ionic liquid, a binder as described herein, and/or a percentage of water. Thus, the ionic liquid material can include the ionic liquid and the binder as a mixture and/or solution and applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques.
- In embodiments where the ionic liquid material includes the binder, the ionic liquid can act as a plasticizer for the binder in the ionic liquid material. That is, the ionic liquid can increase the elongation (e.g., plasticity, fluidity) of the resulting nonwoven
fibrous structure 234. In some exemplary embodiments, an increase in elongation of the nonwovenfibrous structure 234 occurs in the machine direction (MD). In certain exemplary embodiments, the increase in elongation of the nonwovenfibrous structure 234 occurs in the transverse direction (TD). In some exemplary embodiments, the increase in elongation of the air laid nonwoven fibrous structure occurs in both the machine direction (MD) and the transverse direction (TD). - In certain exemplary embodiments, the ionic liquid material is comprised of an ionic liquid and a binder selected from the group consisting of a (meth)acrylic (co)polymer binder, a styrene-butadiene latex binder, a bio-based binder, or a combination thereof. In a specific embodiment, a liquid mixture (e.g., liquid solution) of ionic liquid choline dihydrogen phosphate can be added to a binder from the group as described herein (e.g., thermosetting binder, Acrodur thermosetting binder from BASF chemical company). In this specific embodiment, the thermosetting binder can be a binder that is relatively brittle when cured (e.g., heat is applied to the binder, etc.). As described herein, the addition of the ionic liquid choline dihydrogen phosphate has a plasticizing effect (e.g., acts as a plasticizer) on the thermosetting binder. That is, the nonwoven
fibrous structure 234 is less brittle with the addition of the ionic liquid choline dihydrogen phosphate and thermosetting binder compared to a nonwoven fibrous structure with the addition of the thermosetting binder and no ionic liquid. - A number of devices can be utilized to remove excess liquid (e.g., water) from the nonwoven
fibrous structure 234. In some exemplary embodiments calendering can be utilized to remove liquid from the nonwovenfibrous structure 234. Calendering can include a process of passing a nonwoven fibrous web through rollers with application of pressure to obtain a compressed and bonded fibrous nonwoven web. In certain exemplary embodiments, the number of devices can include a number of squeegees that can compress the nonwovenfibrous structure 234 and remove a portion of the liquid (e.g., water) that is applied to the nonwovenfibrous structure 234. In certain exemplary embodiments, the number of squeegees can be utilized before the nonwovenfibrous structure 234 is moved to a heating unit (e.g., oven, etc.) to remove liquid that was not removed by the number of squeegees. In other embodiments, the number of devices can be located at various points of the formation process of the nonwovenfibrous structure 234. - The heating unit can also be utilized for curing the ionic liquid material applied to the nonwoven
fibrous structure 234. In some exemplary embodiments, the binder in the ionic liquid material is a thermosetting binder (e.g., a binder resin that hardens under heated conditions, etc.), wherein the binder and the ionic liquid of the ionic liquid material is cured with the heating unit. In addition, the heating unit can be utilized to remove liquid (e.g., water) that exists on and/or within the nonwovenfibrous structure 234. As described herein, the heating unit can remove liquid that remains after a number of devices are utilized to remove liquid. Removing the liquid can produce an ionic reinforcement material at locations where the ionic liquid material was applied to the nonwovenfibrous structure 234. - The ionic liquid material can bond a portion of the population of fibers with an ionic reinforcement material. In some exemplary embodiments, the ionic reinforcement material is a residual material of the ionic liquid material (e.g., material remaining after liquid is removed from the ionic liquid material). That is, in some exemplary embodiments, the ionic reinforcement material is the residual of the ionic liquid material after the liquid (e.g., water, excess water) is removed from the nonwoven
fibrous structure 234. The ionic reinforcement material can provide an adhesive bond between the portion of the population of fibers when a binder is included in the ionic liquid material, as described herein. - The ionic reinforcement material can provide a number of characteristics to the nonwoven
fibrous structure 234. The ionic reinforcement material can provide the number of characteristics when the ionic reinforcement material includes the ionic liquid or the ionic liquid and binder mixture as described herein. In some exemplary embodiments, the number of characteristics can include a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof. In certain exemplary embodiments, the ionic reinforcement material provides at least one of the number of characteristics. In some exemplary embodiments, the ionic reinforcement material provides a plurality of the number of characteristics as described herein. In some exemplary embodiments, the ionic reinforcement material can provide at least two of the number of characteristics listed herein. - In one exemplary embodiment, the ionic reinforcement material is applied to the nonwoven
fibrous structure 234 with an ionic liquid material comprising the ionic liquid choline dihydrogen phosphate and a thermosetting binder. In this exemplary embodiment, the nonwovenfibrous structure 234 is less brittle with the addition of the ionic liquid choline dihydrogen phosphate and thermosetting binder compared to a nonwovenfibrous structure 234 with only the addition of the thermosetting binder. In addition, the nonwovenfibrous structure 234 comprises antistatic characteristics from the ionic reinforcement material. As described further herein, the addition of the ionic liquid choline dihydrogen phosphate and thermosetting binder to the nonwovenfibrous structure 234 can provide additional fire retardant (e.g., flame retardant) characteristics to nonwovenfibrous structure 234. The ionic reinforcement material can also add additional characteristics that can include: a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof. - As described herein, the ionic reinforcement material can increase the elongation (e.g., plasticity or fluidity) of the nonwoven
fibrous structure 234. The ionic reinforcement material can also provide an increase in a tensile strength of the nonwovenfibrous structure 234. In some exemplary embodiments the ionic reinforcement material can provide an increase in a tensile strength of the nonwovenfibrous structure 234 and an increase in elongation of the nonwovenfibrous structure 234. In some exemplary embodiments, the increase in tensile strength and the increase in elongation are in the machine direction (MD) of the nonwovenfibrous structure 234. - A nonwoven fibrous structure 234 (e.g., fibrous web, air-laid nonwoven fibrous web, etc.) according to the present disclosure can be formed utilizing a number of forming methods (e.g., melt-spinning, air-laying, spun-bonding, carding, etc.). In exemplary embodiments, the nonwoven
fibrous structure 234 is formed by air-laying fiber processing equipment, such as shown and described in U.S. Pat. Nos. 7,491,354 and 6,808,664. - In some exemplary embodiments, the air laying fiber processing equipment can use air flow to mix and inter-engage the fibers to form an air laid nonwoven fibrous structure. That is, the air laid nonwoven fibrous structure is formed by introducing a plurality of fibers into a forming chamber and dispersing the fibers within the forming chamber to form a population of individual fibers suspended in a gas, wherein the fibers are allowed to fall down to a collector.
- In particular embodiments, instead of using strong air flow to mix and inter-engaged the fibers to form an air-laid nonwoven fibrous structure (such as with a “RandoWebber” web forming machine, available from Rando Machine Corporation, Macedon, N.Y.), the forming chamber can have spike rollers to blend and mix the fibers while gravity allows the fibers to fall down through the endless belt screen and form an air-laid nonwoven fibrous structure of inter-engaged fibers. With this construction of air-laying equipment, the fibers and the particulates are, in some exemplary embodiments, falling together to the bottom of the forming chamber to form the air-laid nonwoven fibrous structure. In one exemplary embodiment, a vacuum can be included below the area where the air-laid nonwoven fibrous structure forms in the forming chamber.
- In some exemplary embodiments, the nonwoven
fibrous structure 234 is formed using a carding process. An exemplary carding process is taught in, for example, U.S. Pat. No. 5,114,787. In some exemplary embodiments, the nonwovenfibrous structure 234 is formed by a meltblowing process. The meltblowing process is a method for forming a nonwoven fibrous structure by extruding a molten fiber-forming material through a plurality of orifices in a die to form fibers while contacting the fibers with air or other attenuating fluid to attenuate the fibers into fibers, and thereafter collecting the attenuated fibers. An exemplary meltblowing process is taught in, for example, U.S. Pat. No. 6,607,624. - The ionic liquid material can be applied to the nonwoven
fibrous structure 234 at different stages of each of the forming methods. In some exemplary embodiments, as described herein, the ionic liquid material can be applied to fibers and/or filaments during a formation (e.g., in a forming chamber, etc.) of the fibers and/or filaments utilizing a mist process to spray the fibers and/or filaments while they are being collected on a collector. In some exemplary embodiments, as described herein, the ionic liquid material can be applied to the nonwovenfibrous structure 234 once the fibers and/or filaments are collected on a collector. In this embodiment, the ionic liquid material can be applied by known processing means such as roll coating, spray coating, and immersion coating and combinations of these coating techniques. - Nonwoven fibrous structures of the present disclosure and filter media including the same may, in some exemplary embodiments, advantageously incorporate a biodegradable material, a particulate material, a frame material, or a combination thereof. Some filter media incorporating biodegradable material (e.g. polyhydroxy alkonates (PHA), polyhydroxybutyrates (PHB), and the like) may, at the end of their useful life, be disposed of advantageously in municipal land-fills or industrial composting sites, thereby eliminating the need to return or otherwise recycle the spent filter media.
- The operation of various embodiments of the present disclosure will be further described with regard to the following detailed Examples.
- These Examples are merely for illustrative purposes and are not meant to be overly limiting on the scope of the appended claims. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
- Testing of the formed nonwoven fibrous webs was carried out using the testing apparatus listed in Table I, according to the methods described further below. In all testing procedures, a standard reference sample (i.e., comparative example), denoted “Std.” was measured for comparison. The standard reference samples (i.e., comparative examples) consisted of the corresponding web coated with binder only and no ionic liquid additive.
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TABLE I Testing Apparatus Apparatus Supplier Balance Mettler Toledo, Inc. Instron 5965 Instron Instruments, Inc. - The basis weight of the nonwoven webs was measured with a Mettler Toledo XS4002S electronic balance.
- Tensile strength and percent (%) elongation measurements were carried out on nonwoven samples (15×2.5 cm) on an Instron 5965 machine with a maximum load of 100N. For each nonwoven sample, three samples were measured and the average obtained.
- Unless otherwise noted, all parts, percentages, ratios, etc. in the Examples and the rest of the specification are by weight. Solvents and other reagents used may be obtained from Sigma-Aldrich Chemical Company (Milwaukee, Wis.) unless otherwise noted. In addition, Table II provides abbreviations and a source for all materials used in the Examples below:
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TABLE II Raw Materials Raw Material Supplier Acrodur 3530 BASF France S.A.S. OC Biobinder Organoclick AB Sweden Rhoplex B-15RH Emulsion Rohm and Haas Europe Trading APS Latex Plextol SB310 Synthomer PEG 400 Dow Chemical Ionic liquids Iolitec GmbH Larostat HTS 905 BASF GmbH Viscose Fibers (40 mm, 1.7 dTex) Lenzing AG Polyester Fibers (20 denier) Palmetto Synthetics LLC Nylon Fibers (HT) EMS-GRILTECH Melty Fibers (20 denier) Huvis - In the following examples, “IL” denotes ionic liquid, “PET” denotes polyester, “MD” denotes machine direction, “TD” denotes transverse direction (relative to MD), “TS” denotes tensile strength, “elong” denotes percentage elongation, “PEG” denotes polyethylene glycol, “Std.” denotes a reference standard (i.e., a comparative example).
- Acrodur 3530 (50% Solids Approx.):
- Unless otherwise stated this binder was coated on the nonwoven web by roll coating pre-diluted in the ratio of 2:1 with H2O (33% solids approx.). The binder was then cured in a through air oven at 140° C. for approx. 4 minutes.
- OC Biobinder (15% Solids Approx.):
- Unless otherwise stated this binder was coated on the nonwoven web by roll coating pre-diluted in the ratio of 2:1 with H2O. The binder was then cured in a through air oven at 130° C. for approx. 4 minutes.
- The ionic liquids (IL) listed in Table III were added at 10% w/v to the binder aqueous solutions. The ionic liquids were added in one part to the binder aqueous solution and stirred until fully dissolved.
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TABLE III Ionic Liquids (IL) Ionic Liquid Reference Code Chemical Name IL A 1-ethyl-3-methylimidazolium diethyl phosphate IL B 1-ethyl-3-methylimidazolium ethyl sulfate IL C 1-ethyl-3-methylimidazolium acetate IL I 1-ethyl-3-methylimidazolium triflate IL L 1-ethyl-3-methylimidazolium dicyanamide IL O Trihexyltetradecylphosphonium chloride IL E1 Choline dihydrogen phosphate IL H1 1-ethyl-3-methylimidazolium chloride IL I1 Larostat HTS 905 IL J1 1-butyl-3-methylimidazolium chloride IL K1 Ethyltributylphosphonium diethyl phosphate IL M1 1,3-dimethylimidazolium dimethyl phosphate IL N1 1-ethyl-3-methylimidazolium dimethyl phosphate IL O1 1-butyl-3-methylimidazolium dimethyl phosphate IL P1 1,3-diethylimidazolium diethyl phosphate - Mixtures of fibers as listed in Table IV (i.e., viscose, PET, nylon) with low melting fibers were formed in a ratio of 80:20 fiber:low melting fiber ratio, and processing of the fiber mixtures was carried out using the nonwoven processing equipment listed in Table V.
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TABLE IV Fibers Prebond Web Basis Weight Fiber Prebond Web (g/m2) Viscose 80 PET 70 Nylon 95 -
TABLE V Nonwoven Processing Equipment Machine Supplier Fiber Opener Laroche Rando Webber Rando Machine Corporation Roll Coater Cavitec - Fiber prebonded webs were formed prior to coating of the resins. The required ratio of fibers to melty fibers were weighed and mixed by passing through a fiber opener. The air-laid prebonded webs were formed on a Rando Webber forming machine. Following forming of the web, it was sent through a through-air oven at 130° C. to yield a lightly bonded web suitable for coating trials.
- The prebonded webs were coated by passing through roll coating cylinders containing the binder/ionic liquid mixture in the reservoir.
- Tables 1-4 show the Tensile Test results for nonwoven viscose prebond webs with Acrodur binder and with various ionic liquids.
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TABLE 1 Tensile Acrodur Binder Strength (MD) with IL TS - MD TS - MD TS - MD Average IT1 Std. 3.44 3.59 3.44 3.49 IT2 PEG 400 3.81 3.71 3.5 3.67 IT3 ILA 4.28 4.01 3.93 4.07 IT4 ILB 2.71 2.56 2.56 2.61 IT5 ILC 4.2 3.25 3.88 3.78 IT6 ILI 3.62 2.89 3.27 3.26 IT7 ILL 4.25 2.58 4.08 3.64 -
TABLE 2 Acrodur Binder Elongation - Elongation - Elongation - Elongation - with IL MD MD MD MD Average IT1 Std. 2.92 1.82 2.65 2.46 IT2 PEG 400 9.25 10.9 11.17 10.44 IT3 ILA 6.73 6.77 7.87 7.12 IT4 ILB 6.22 6.5 6.77 6.50 IT5 ILC 4.57 2.65 4.3 3.84 IT6 ILI 4.85 3.47 3.75 4.02 IT7 ILL 2.64 1.27 1.82 1.91 -
TABLE 3 Acrodur Binder TS - TD with IL TS - TD TS - TD TS - TD Average IT1 Std. 2.66 2.78 2.63 2.69 IT2 PEG 400 2.69 2.7 3.39 2.93 IT3 ILA 2.19 2.61 1.47 2.09 IT4 ILB 2.55 2.76 2.54 2.62 IT5 ILC 1.67 1.96 1.8 1.81 IT6 ILI 1.92 1.82 1.71 1.82 IT7 ILL 2.5 2.17 2.93 2.53 -
TABLE 4 Acrodur Binder Elongation - Elongation - Elongation - Elongation - with IL TD TD TD TD Average IT1 Std. 2.37 2.65 2.37 2.46 IT2 PEG 400 11.72 12 14.75 12.82 IT3 ILA 3.2 4.02 2.65 3.29 IT4 ILB 12 13.92 11.17 12.36 IT5 ILC 4.02 4.85 4.85 4.57 IT6 ILI 4.57 5.12 4.3 4.66 IT7 ILL 1.82 1.55 2.1 1.82 - Tables 5-8 show the Tensile Test results for nonwoven viscose prebond webs with OC Biobinder binder and various ionic liquids.
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TABLE 5 OC Biobinder TS - MD Binder with IL TS - MD TS - MD TS - MD Average IT9 Std. 3.66 3.36 3.21 3.41 IT10 PEG 400 2.52 2.24 2.33 2.36 IT11 ILA 2 1.91 2 1.97 IT12 ILB 2.17 2.32 2.39 2.29 IT13 ILC 1.44 1.29 1.31 1.35 IT14 ILI 3.27 2.65 3.16 3.03 IT15 ILL 2.48 2.15 2.13 2.25 IT16 IL0 2.43 2.49 2.49 2.47 -
TABLE 6 OC Biobinder Elongation - Elongation - Elongation - Elongation - Binder with IL MD MD MD MD Average IT9 Std. 3.75 3.47 4.3 3.84 IT10 PEG 400 3.75 2.65 3.47 3.29 IT11 ILA 9.25 7.32 6.77 7.78 IT12 ILB 8.97 7.87 9.52 8.79 IT13 ILC 14.2 15.02 15.3 14.84 IT14 ILI 4.02 4.3 3.75 4.02 IT15 ILL 10.35 9.8 4.27 8.14 IT16 IL0 5.12 3.75 4.3 4.39 -
TABLE 7 OC Biobinder TS - TD Binder with IL TS - TD TS - TD TS - TD Average IT9 Std. 2.28 2.17 2.22 2.22 IT10 PEG 400 1.41 1.21 1.24 1.29 IT11 ILA 1.13 1.16 1.03 1.11 IT12 ILB 1.64 1.6 1.48 1.57 IT13 ILC 0.6 0.62 0.56 0.59 IT14 ILI 2.01 1.78 1.78 1.86 IT15 ILL 1.29 1.13 1.03 1.15 IT16 IL0 1.55 1.66 1.65 1.62 -
TABLE 8 OC Biobinder Elongation - Elongation - Elongation - Elongation - Binder with IL TD TD TD TD Average IT9 Std. 4.02 4.3 4.3 4.21 IT10 PEG 400 4.02 3.2 2.92 3.38 IT11 ILA 10.35 9.25 10.62 10.07 IT12 ILB 7.87 8.15 8.42 8.15 IT13 ILC 12 14.75 14.47 13.74 IT14 ILI 4.57 4.02 3.47 4.02 IT15 ILL 8.97 8.7 6.77 8.15 IT16 IL0 5.67 5.67 5.12 5.49 - Tables 9-12 show the Tensile Test results for nonwoven viscose prebond webs with Acrodur binder and various ionic liquids.
-
TABLE 9 Acrodur Binder TS - MD with IL TS - MD TS - MD TS - MD Average 1 Std. 3.11 3.12 2.71 2.98 2 PEG 5.16 4.43 4.45 4.68 3 ILE1 3.91 4.7 4.78 4.46 4 ILH1 3.86 3.55 3.64 3.68 5 IL I1 4.28 3.64 3.07 3.66 -
TABLE 10 Acrodur Elongation - Elongation - Elongation - Elongation - Binder with IL MD MD MD MD Average 1 Std. 1.55 1.55 1.27 1.46 2 PEG 4.02 5.67 3.75 4.48 3 ILE1 1.82 2.1 2.1 2.01 4 ILH1 8.42 6.77 4.85 6.68 5 IL I1 2.65 2.37 1.55 2.19 -
TABLE 11 Acrodur TS - TD Binder with IL TS - TD TS - TD TS - TD Average 1 Std. 2.6 2.78 2.53 2.64 2 PEG 3.54 3.75 3.57 3.62 3 ILE1 3.08 3.22 3.53 3.28 4 ILH1 2.58 2.11 3.2 2.63 5 IL I1 2.91 2.43 2.62 2.65 -
TABLE 12 Acrodur Elongation - Elongation - Elongation - Elongation - Binder with IL TD TD TD TD Average 1 Std. 1.27 1.27 1.27 1.27 2 PEG 8.42 8.15 8.7 8.42 3 ILE1 2.1 2.37 2.1 2.19 4 ILH1 4.57 3.47 8.15 5.40 5 IL I1 2.37 1.82 2.37 2.19 - Tables 13-16 show the Tensile Test results for nonwoven viscose prebond webs with OC Biobinder binder and various ionic liquids.
-
TABLE 13 OC Biobinder TS - MD Binder with IL TS - MD TS - MD Average 1 Std. 2.89 3.29 3.09 2 PEG 2.16 2.2 2.18 3 ILE1 2.86 2.47 2.67 4 ILH1 2.14 2.33 2.24 5 IL I1 2.4 2.43 2.42 -
TABLE 14 OC Biobinder Elongation - Elongation - Elongation - Binder with IL MD MD MD Average 1 Std. 1.82 2.37 2.10 2 PEG 3.47 4.3 3.89 3 ILE1 8.15 7.32 7.74 4 ILH1 12 12 12.00 5 IL I1 5.95 7.23 6.59 -
TABLE 15 OC Biobinder TS - TD Binder with IL TS - TD TS - TD Average 1 Std. 2.14 2.63 2.39 2 PEG 1.89 1.82 1.86 3 ILE1 2 2.28 2.14 4 ILH1 1.03 1.06 1.05 5 IL I1 1.85 1.75 1.80 -
TABLE 16 OC Biobinder Elongation - Elongation - Elongation - Binder with IL TD TD TD Average 1 Std. 2.1 2.92 2.51 2 PEG 3.75 4.3 4.03 3 ILE1 5.12 7.05 6.09 4 ILH1 11.45 18.32 14.89 5 IL I1 6.5 6.77 6.64 - Tables 17-18 show the Tensile Test results for nonwoven viscose prebond webs with Primal B15 binder and various ionic liquids.
-
TABLE 17 Primal B15 TS - MD Binder with IL TS - MD TS - MD TS - MD Average Std. 3.39 3.7 3.68 3.59 ILA 2.05 1.6 1.49 1.71 ILB 2.12 1.65 1.86 1.88 ILC 1.98 1.58 1.88 1.81 ILH1 2.07 1.57 1.73 1.79 ILI1 0.78 0.95 0.98 0.90 -
TABLE 18 Primal B15 Elongation - Elongation - Elongation - Elongation - Binder with IL MD MD MD MD Average Std. 23.55 27.95 25.75 25.75 ILA 32.35 32.07 32.62 32.35 ILB 27.95 26.57 27.67 27.40 ILC 32.62 27.67 32.9 31.06 ILH1 31.25 22.72 30.7 28.22 ILI1 41.7 37.3 43.07 40.69 - The nonwoven samples tested consisted of viscose prebond webs. Tables 19-22 show the Tensile Test results for Example 4 with various ionic liquids.
-
TABLE 19 Latex Plextol TS - MD Binder with IL TS - MD TS - MD TS - MD Average Std. 5.44 4.54 4.54 4.84 IL B 4.22 2.95 3.67 3.61 IL C 3.28 3.3 3.11 3.23 IL I 2.61 2.47 2.69 2.59 IL L 3.54 3.21 3.29 3.35 IL I1 0.97 0.92 0.78 0.89 IL H1 1.89 2.2 1.97 2.02 -
TABLE 20 Latex Plextol Elongation - Elongation - Elongation - Elongation - Binder with IL MD MD MD MD Average Std. 16.4 10.9 12.27 13.19 IL B 15.85 16.94 18.04 16.94 IL C 26.06 23.82 24.64 24.84 IL I 11.99 11.99 11.44 11.81 IL L 19.15 18.32 19.15 18.87 IL I1 7.32 7.59 6.77 7.23 IL H1 14.47 18.32 16.67 16.49 -
TABLE 21 Latex Plextol TS - TD Binder with IL TS - TD TS - TD TS - TD Average Std. 4.23 4.53 4.39 4.38 IL B 2.63 2.46 2.09 2.39 IL C 2.07 1.86 2.24 2.06 IL I 3.54 3.71 3.3 3.52 IL L 1.44 1.43 1.61 1.49 IL I1 0.74 0.84 0.77 0.78 IL H1 2.28 1.87 1.66 1.94 -
TABLE 22 Latex Plextol Elongation - Elongation - Elongation - Elongation - Binder with IL TD TD TD TD Average Std. 15.3 13.92 15.3 14.84 IL B 22.72 18.87 17.49 19.69 IL C 28.22 25.74 25.19 26.38 IL I 17.49 16.94 15.84 16.76 IL L 21.62 18.12 24.09 21.28 IL I1 6.22 6.49 6.77 6.49 IL H1 23.54 21.64 22.72 22.63 - The nonwoven samples tested consisted of viscose prebond webs. Tables 23-24 show the Tensile Test results for Example 5 with various ionic liquids.
-
TABLE 23 Acrodur TS - MD Binder with IL TS - MD TS - MD TS - MD Average Std. 3.1 3.05 2.97 3.04 IL J1 3.39 3.4 3.29 3.36 IL K1 3.2 2.63 2.95 2.93 IL M1 2.6 2.99 3.07 2.89 IL N1 3.39 2.65 3.42 3.15 IL O1 3.11 2.79 2.78 2.89 IL P1 3.25 3.21 3.78 3.41 -
TABLE 24 Primal B15 Elongation - Elongation - Elongation - Elongation - Binder with IL MD MD MD MD Average Std. 1.55 1.55 1.55 1.55 IL J1 4.85 4.02 3.75 4.21 IL K1 2.37 1.82 1.82 2.00 IL M1 2.92 2.92 2.92 2.92 IL N1 3.75 2.37 2.65 2.92 IL O1 2.92 2.65 2.1 2.56 IL P1 2.37 2.65 2.92 2.65 - The surface resistivity of the nonwoven coated samples was carried out according to VDE 0303 part 30. The test equipment consisted of a Teraohmmeter (PM 126 567), electrode (20 cm2) and Å Electrode (5 cm). The following terms are defined for the Surface Resistivity Test:
-
σ [Ω] surface resistivity Rx [Ω] measured surface resistivity p [cm] effective scope of the protected electrode g [cm] distance between the electrodes - Tables 25-32 show the Surface Resistivity Test results for Example 1 with various ionic liquids.
-
TABLE 25 Sample Ref. Rx Avg. Latex Plextol Std. 5 2.E+09 IL A 6 3.E+05 IL C 7 1.E+06 IL I 8 1.E+08 IL L 9 2.E+05 IL I1 10 2.E+05 IL H1 11 7.E+05 -
TABLE 26 Rx σ Voltage Sample [Ω] [Ω] [V] 5 1.35E+08 2.16E+10 500 4.47E+09 7.16E+11 500 2.48E+09 3.97E+11 500 -
TABLE 27 Rx σ Voltage Sample [Ω] [Ω] [V] 6 6.35E+05 1.02E+08 100 1.54E+05 2.47E+07 100 1.68E+05 2.70E+07 100 -
TABLE 28 Rx σ Voltage Sample [Ω] [Ω] [V] 7 9.96E+05 1.60E+08 100 1.65E+05 2.64E+07 100 2.03E+06 3.24E+08 100 -
TABLE 29 Rx σ Voltage Sample [Ω] [Ω] [U] 8 1.88E+08 3.01E+10 500 7.78E+07 1.25E+10 500 3.69E+07 5.91E+09 500 -
TABLE 30 Rx σ Voltage Sample [Ω] [Ω] [V] 9 2.59E+05 4.15E+07 100 1.84E+05 2.95E+07 100 2.55E+05 4.09E+07 100 -
TABLE 31 Rx σ Voltage Sample [Ω] [Ω] [V] 10 3.92E+05 6.28E+07 10 1.84E+05 2.95E+07 10 1.23E+05 1.96E+07 10 -
TABLE 32 Rx σ Voltage Sample [Ω] [Ω] [V] 11 2.00E+05 3.20E+07 100 1.13E+06 1.81E+08 100 7.06E+05 1.13E+08 100 - Tables 33-43 show the Surface Resistivity Test results for Example 2 with various ionic liquids.
-
TABLE 33 Sample Ref. Rx Avg. Acrodur Std. 12 4.E+09 PEG 13 3.E+08 E1 14 2.E+08 H1 15 2.E+07 I1 16 7.E+08 OC BioBinder Std. 17 7.E+08 PEG 18 6.E+06 E1 19 3.E+05 H1 20 2.E+04 I1 21 1.E+06 -
TABLE 34 Rx σ Voltage Sample [Ω] [Ω] [V] 12 4.22E+09 6.76E+11 500 3.92E+09 6.27E+11 500 2.91E+09 4.67E+11 500 -
TABLE 35 Rx σ Voltage Sample [Ω] [Ω] [V] 13 4.53E+08 7.25E+10 500 2.95E+08 4.72E+10 500 2.00E+08 3.21E+10 500 -
TABLE 36 Rx σ Voltage Sample [Ω] [Ω] [V] 14 2.11E+08 3.38E+10 500 1.38E+08 2.20E+10 500 1.28E+08 2.05E+10 500 -
TABLE 37 Rx σ Voltage Sample [Ω] [Ω] [V] 15 2.49E+07 3.99E+09 500 2.13E+07 3.42E+09 500 1.97E+07 3.16E+09 500 -
TABLE 38 Rx σ Voltage Sample [Ω] [Ω] [V] 16 1.13E+09 1.82E+11 500 5.18E+08 8.30E+10 500 5.10E+08 8.16E+10 500 -
TABLE 39 Rx σ Voltage Sample [Ω] [Ω] [V] 17 1.04E+09 1.66E+11 500 6.73E+08 1.08E+11 500 5.06E+08 8.11E+10 500 -
TABLE 40 Rx σ Voltage Sample [Ω] [Ω] [V] 18 4.84E+06 7.75E+08 500 4.90E+06 7.85E+08 500 7.02E+06 1.12E+09 500 -
TABLE 41 Rx σ Voltage Sample [Ω] [Ω] [V] 19 2.53E+05 4.05E+07 100 2.32E+05 3.71E+07 100 3.86E+05 6.18E+07 100 -
TABLE 42 Rx σ Voltage Sample [Ω] [Ω] [V] 20 1.73E+04 2.78E+06 10 2.27E+04 3.64E+06 10 8.08E+03 1.29E+06 10 -
TABLE 43 Rx σ Voltage Sample [Ω] [Ω] [V] 21 1.31E+06 2.10E+08 500 1.17E+06 1.87E+08 500 8.74E+05 1.40E+08 500 - Tables 44-51 show the Surface Resistivity Test results for Example 3 with various ionic liquids.
-
TABLE 44 Sample Ref. Rx Avg. Acrodur Std. 22 2.E+09 PEG 23 2.E+08 A 24 1.E+08 B 25 4.E+07 C 26 1.E+08 I 27 5.E+06 L 28 1.E+09 -
TABLE 45 Rx σ Voltage Sample [Ω] [Ω] [V] 22 1.51E+09 2.42E+11 500 1.67E+09 2.68E+11 500 1.62E+09 2.59E+11 500 -
TABLE 46 Rx σ Voltage Sample [Ω] [Ω] [V] 23 1.26E+08 2.02E+10 500 1.96E+08 3.14E+10 500 1.63E+08 2.61E+10 500 -
TABLE 47 Rx σ Voltage Sample [Ω] [Ω] [V] 24 1.47E+08 2.35E+10 500 1.73E+08 2.77E+10 500 1.23E+08 1.97E+10 500 -
TABLE 48 Rx σ Voltage Sample [Ω] [Ω] [V] 25 5.03E+07 8.05E+09 500 5.33E+07 8.54E+09 500 2.65E+07 4.24E+09 500 -
TABLE 49 Rx σ Voltage Sample [Ω] [Ω] [V] 26 1.17E+08 1.88E+10 500 1.50E+08 2.40E+10 500 1.24E+08 1.98E+10 500 -
TABLE 50 Rx σ Voltage Sample [Ω] [Ω] [V] 27 7.23E+06 1.16E+09 500 5.02E+06 8.05E+08 500 2.61E+06 4.18E+08 500 -
TABLE 51 Rx σ Voltage Sample [Ω] [Ω] [V] 28 1.63E+09 2.62E+11 500 1.22E+09 1.95E+11 500 1.06E+09 1.70E+11 500 - Flame retardancy testing was carried out according to test method UL94 vertical burner test procedure with minor modifications. Methane gas at a pressure of 2.5 psi was used for the Bunsen burner. The flame cone height measurements were as follows: 1 cm for the interior and 2 cm for the exterior. The distance between the Bunsen tip and the end of the sample was 1 cm. The sample size was 15×2.5 cm. The sample measured consisted of a web of viscose fibers with the requisite binder containing 10% ionic liquid unless otherwise stated. 3 samples were measured for each binder/IL combination. When all 3 samples gave the same results, only 1 overall result is noted.
- T1: Duration (seconds) of after flame after ignited Bunsen was applied to sample for 10 seconds
T2: After flame following application of Bunsen for a further 10 seconds
T3: After flame following application of Bunsen for a further 10 seconds B: Sample burned
Note: When after flame exposure result is equal to zero, this the sample resisted ignition. - Table 52 shows the Flame Retardancy Test results for Example 2 with various binders and ionic liquids.
-
TABLE 52 Binder IL T1 T2 T3 OC Biobinder No IL - Standard B — — OC Biobinder E1 0 0 0 OC Biobinder H1 B — — OC Biobinder I1 B — — OC Biobinder K1 0 B — B — — B — — OC Biobinder K1 30% 0 0 0 OC Biobinder M1 B — — OC Biobinder M1 30% 0 B — 0 B — 0 0 0 OC Biobinder N1 0 B — B — — B — — OC Biobinder N1 30% 0 B — B — — B — — OC Biobinder O1 0 B — 0 B — 0 0 0 OC Biobinder O1 30% 0 0 B B — — 0 — — OC Biobinder P1 0 B — B — — B — — OC Biobinder P1 30% 0 0 0 0 B — 0 0 0 Acrodur No IL - Standard B — — Acrodur E1 0 0 0 Acrodur H1 0 0 0 0 B — B — — Acrodur K1 0 0 0 0 B — 0 B — Acrodur M1 0 0 0 x — — x — — Acrodur N1 x — — 0 0 0 0 0 0 Acrodur O1 0 0 0 Acrodur P1 0 X — - Table 53 summarizes overall performance properties with respect to Tensile Strength, Anti-static properties, and Flame Retardancy.
-
TABLE 53 Multi-functional Ionic Liquids - Performance Summary Improvements Flame IL Binder TS Elongation Anti-static Retardancy A Acrodur + + + B Acrodur + + C Acrodur + + + I Acrodur + + L Acrodur + + E1 Acrodur + + + + H1 Acrodur + + + I1 Acrodur + + + J1 Acrodur + + K1 Acrodur + + M1 Acrodur + + N1 Acrodur + + + O1 Acrodur + + P1 Acrodur + + + A OC Biobinder + B OC Biobinder + C OC Biobinder + I OC Biobinder + L OC Biobinder + E1 OC Biobinder + + + H1 OC Biobinder + + I1 OC Biobinder + + J1 OC Biobinder + K1 OC Biobinder + + M1 OC Biobinder + + N1 OC Biobinder + O1 OC Biobinder + + P1 OC Biobinder + + Sample tested + Sample tested and demonstrated improvement in comparison to the control standard - Reference throughout this specification to “one embodiment,” “certain exemplary embodiments,” “one or more embodiments” or “an embodiment,” whether or not including the term “exemplary” preceding the term “embodiment,” means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the certain exemplary embodiments of the present disclosure. Thus, the appearances of the phrases such as “in one or more embodiments,” “in certain exemplary embodiments,” “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the certain exemplary embodiments of the present disclosure. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.
- While the specification has described in detail certain exemplary embodiments, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. Accordingly, it should be understood that this disclosure is not to be unduly limited to the illustrative embodiments set forth hereinabove.
- Furthermore, all publications and patents referenced herein are incorporated by reference in their entirety to the same extent as if each individual publication or patent was specifically and individually indicated to be incorporated by reference. Various exemplary embodiments have been described. These and other embodiments are within the scope of the following claims.
Claims (24)
1. A method of making a nonwoven fibrous structure, comprising:
introducing a plurality of fibers into a forming chamber;
dispersing the fibers within the forming chamber to form a population of individual fibers suspended in a gas;
collecting the population of fibers as a nonwoven fibrous structure on a collector; and
bonding at least a portion of the population of fibers together with an ionic reinforcement material.
2. The method of claim 1 , further comprising applying an ionic liquid material to the population of fibers, optionally wherein bonding at least the portion of the population of fibers together comprises curing the applied ionic liquid material to form the ionic reinforcement material.
3-4. (canceled)
5. The method of claim 2 , wherein the applied ionic liquid material further comprises at least one binder resin, optionally wherein the applied ionic liquid material acts as a plasticizer for the at least one binder resin, optionally wherein the at least one binder resin is selected from the group consisting of a phenolic resin, a bio-based resin, a thermoplastic (meth)acrylic (co)polymer resin, an epoxy resin, or a combination thereof.
6-7. (canceled)
8. The method of claim 2 , wherein the ionic liquid material comprises at least one cation and at least one anion.
9. The method of claim 2 , wherein the at least one cation is selected from the group consisting of nitrogen containing heterocyclic cations, ammonium, phosphonium, or sulfonium; and further wherein the at least one anion is selected from the group consisting of halogen anions, fluorine containing anions, alkyl sulfate anions, alkyl phosphate anions, acetate, dicyanamide (N(CN)2), or thiocyanate (SCN).
10. The method of claim 2 , wherein applying the ionic liquid material consists of spraying the ionic liquid material, roll coating the ionic liquid material, dip coating the ionic liquid material, or a combination thereof.
11-19. (canceled)
20. A nonwoven fibrous structure comprising:
a population of randomly oriented fibers bonded together at a plurality of intersection points with an ionic reinforcement material.
21. The nonwoven fibrous structure of claim 20 , wherein the ionic reinforcement material is comprised of an ionic plasticizer.
22. The nonwoven fibrous structure of claim 20 , wherein the ionic reinforcement material is comprised of an ionic liquid and a binder selected from the group consisting of a (meth)acrylic (co)polymer binder, a styrene-butadiene latex binder, a bio-based binder, or a combination thereof.
23. The nonwoven fibrous structure of claim 22 , comprising from 1 to 40 wt. % of the ionic liquid.
24. The nonwoven fibrous structure of claim 22 , wherein the ionic liquid comprises water, one or more cations, and one or more anions.
25. The nonwoven fibrous structure of claim 20 , exhibiting at least one distinguishing characteristic selected from the group consisting of a fire retardant characteristic, an antistatic characteristic, an antibacterial characteristic, an antimicrobial characteristic, an antifungal characteristic, or a combination thereof.
26-27. (canceled)
28. The nonwoven fibrous structure of claim 20 , wherein the population of fibers includes fibers selected from the group consisting of mono-component fibers, multi-component fibers, crimped fibers, or a combination thereof.
29. The nonwoven fibrous structure of claim 20 , wherein the population of fibers includes fibers selected from the group consisting of staple fibers, melt blown fibers, natural fibers, or a combination thereof.
30. The nonwoven fibrous structure of claim 20 , wherein the population of fibers includes thermoplastic (co)polymer fibers further comprising a (co)polymer selected from poly(propylene), poly(ethylene), poly(butane), poly(ethylene) terephthalate, poly(butylene) terephthalate, poly(ethylene) napthalate, poly(amide), poly(urethane), poly(lactic acid), poly(vinyl)alcohol, poly(phenylene) sulfide, poly(sulfone), liquid crystalline polymer, poly(ethylene)-co-poly(vinyl)acetate, poly(acrylonitrile), cyclic poly(olefin), poly(oxymethylene), poly(olefinic) thermoplastic elastomers, recycled fibers containing any of the preceding thermoplastic (co)polymers, or a combination thereof.
31. The nonwoven fibrous structure of claim 20 , wherein the population of fibers includes natural fibers selected from cotton, wool, jute, agave, sisal, coconut, soybean, hemp, viscose, bamboo, or a combination thereof.
32. The nonwoven fibrous structure of claim 20 , wherein the nonwoven fibrous structure includes a population of particulates bonded to the nonwoven fibrous structure, further wherein the particulates are selected from the group consisting of abrasive particulates, detergent particulates, anti-bacterial particulates, adsorbent particulates, absorbent particulates; or a combination thereof.
33. The nonwoven fibrous structure of claim 20 , wherein the population of particulates exhibits a median particle diameter of from 0.1 micrometer to 1,000 micrometers.
34. The nonwoven fibrous structure of claim 20 , wherein the population of fibers exhibits a median fiber diameter of from 1 micrometer to 50 micrometers.
35. The nonwoven fibrous structure of claim 20 , wherein the nonwoven fibrous structure is a structure selected from the group consisting of a mat, a web, a sheet, a scrim, or a combination thereof.
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US20180127906A1 (en) * | 2015-07-02 | 2018-05-10 | Sgl Carbon Se | Method for producing thin carbon fiber nonwovens by a horizontal splitting process |
DE102019108691A1 (en) * | 2019-04-03 | 2020-10-08 | Cerdia International GmbH | INSULATING MATERIAL, METHOD FOR MANUFACTURING SUCH INSULATING MATERIAL AND USE OF SUCH INSULATING MATERIAL |
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CN107903561B (en) * | 2017-07-24 | 2020-05-19 | 杭州师范大学 | Permanent antibacterial polymer composite material and preparation method thereof |
WO2020262231A1 (en) * | 2019-06-26 | 2020-12-30 | パナソニックIpマネジメント株式会社 | Water treatment filter material, water treatment filtration device using same, and water treatment filter material production method |
CN112176527A (en) * | 2020-09-30 | 2021-01-05 | 福州大学 | Antibacterial antistatic flame-retardant polyester fiber gradient structure sound-absorbing material and preparation method thereof |
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US5807364A (en) * | 1992-08-17 | 1998-09-15 | Weyerhaeuser Company | Binder treated fibrous webs and products |
US5445878A (en) * | 1993-09-20 | 1995-08-29 | Georgia-Pacific Resins, Inc. | High tear strength glass mat urea-formalehyde resins for hydroxyethyl cellulose white water |
US8193104B2 (en) * | 2001-11-30 | 2012-06-05 | Celanese International Corporation | Crosslinkable cationic emulsion binders and their use as a binder for nonwovens |
WO2007032022A2 (en) * | 2005-07-13 | 2007-03-22 | Lodha Preeti | Consolidation of non-woven textile fibres |
US8202379B1 (en) * | 2009-12-03 | 2012-06-19 | The United States Of America As Represented By The Secretary Of The Air Force | Natural fiber welding |
BR112013000281A2 (en) * | 2010-07-07 | 2016-05-24 | 3M Innovative Properties Co | non-woven airborne fibrous webs (airlaid) fitted with a standard and methods for the preparation and use thereof |
WO2013101615A1 (en) * | 2011-12-30 | 2013-07-04 | 3M Innovative Properties Company | Methods and apparatus for producing nonwoven fibrous webs |
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2015
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- 2015-04-28 CN CN201580021758.6A patent/CN106460271A/en active Pending
- 2015-04-28 WO PCT/US2015/027869 patent/WO2015168049A1/en active Application Filing
- 2015-04-28 JP JP2016564574A patent/JP2017514035A/en active Pending
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20180127906A1 (en) * | 2015-07-02 | 2018-05-10 | Sgl Carbon Se | Method for producing thin carbon fiber nonwovens by a horizontal splitting process |
US11208745B2 (en) * | 2015-07-02 | 2021-12-28 | Sgl Carbon Se | Method for producing thin carbon fiber nonwovens by a horizontal splitting process |
DE102019108691A1 (en) * | 2019-04-03 | 2020-10-08 | Cerdia International GmbH | INSULATING MATERIAL, METHOD FOR MANUFACTURING SUCH INSULATING MATERIAL AND USE OF SUCH INSULATING MATERIAL |
Also Published As
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EP3137667A4 (en) | 2018-01-10 |
EP3137667A1 (en) | 2017-03-08 |
KR20160146958A (en) | 2016-12-21 |
JP2017514035A (en) | 2017-06-01 |
WO2015168049A1 (en) | 2015-11-05 |
CN106460271A (en) | 2017-02-22 |
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