US3644251A - Nonwoven fabrics and binders therefor - Google Patents

Nonwoven fabrics and binders therefor Download PDF

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Publication number
US3644251A
US3644251A US3644251DA US3644251A US 3644251 A US3644251 A US 3644251A US 3644251D A US3644251D A US 3644251DA US 3644251 A US3644251 A US 3644251A
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United States
Prior art keywords
rosin
percent
weight
binder
mixture
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English (en)
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Werner Alfred Wilhelmi
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Nederlandsche Bewoid Nv Mij
NL BEWOID MIJ NV
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NL BEWOID MIJ NV
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
    • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
    • C11D15/00—Manufacture of resin soap or soaps derived from naphthenic acids; Compositions
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/603—Including strand or fiber material precoated with other than free metal or alloy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/69—Autogenously bonded nonwoven fabric

Definitions

  • This invention relates to nonwoven fabrics and to a method for their production. It further relates to adhesive binders that are used in the production of nonwoven fabrics.
  • Nonwoven fabrics are composed of loosely assembled webs of natural and/or synthetic fibers that are bound together with an adhesive binder.
  • Two general procedures are used commercially for the production of nonwoven fabrics.
  • a web of fibers which is formed, for example, by carding or garnetting, is impregnated with a binder, and the treated web is then dried.
  • an aqueous suspension of the fibers is formed, a binder is added to the aqueous suspension and precipitated on the fibers, and the treated fibers are formed into a mat using papermaking equipment, such as fourdriniers or Rotoformers.
  • the wet process of producing nonwoven fabrics is preferred over the dry process because it yields superior products and because it permits higher production rates.
  • the products of the wet process have equal strength in all directions, whereas in the products of the dry process the fibers are ordinarily oriented parallel to the machine direction.
  • the products of the wet process are stronger and more uniform throughout the fiber mat because the binder is applied uniformly to the fibers in the aqueous suspension.
  • a number of polymers have been proposed as binding agents for nonwoven fabrics.
  • acrylic resins styrene-butadiene, copolymers, polyurethane, polyesters, polyamides, polyvinyl acetate, polyvinyl chloride, chlorinated polypropylene, and synthetic and natural rubber. None of these binders has given entirely satisfactory results when used in the production of nonwoven fabrics by the wet process because the polymers are not adequately retained on the fibers and the products produced do not have the desired combination of properties, and particularly good wet strength and dry strength.
  • nonwoven fabrics that are characterized by excellent tensile strength, softness, flexibility, and other valuable properties result when the binder used in the aforementioned wet process comprises a polymer latex and a mixture of alkali metal salts of disproportionated rosin and fortified rosin.
  • the properties of nonwoven fabrics prepared using the novel binders of this invention are in many ways superior to those of nonwoven fabrics prepared from binders that do not contain the mixture of modified rosin salts. Of particular importance is the higher tensile strength of the products ofthis invention.
  • Nonwoven fabrics are prepared in accordance with the process of this invention by forming a dilute aqueous suspension of fibers, adding to the suspension and precipitating on the fibers in the suspension a binder comprising a polymer and a mixture of alkali metal salts of disproportionated rosin and fortified rosin, forming the treated fibers into a nonwoven fabric, and drying the fabric.
  • any of the natural fibers and synthetic fibers that are commonly used in the production of nonwoven fabrics can be used in the practice of this invention. These include, for example, cotton, hemp, rayon, regenerated cellulose, cellulose acetate, wool, jute, polyamides, polyesters, acrylics, polyolefins, polyvinyl chloride, and polyurethane as well as mixtures of these fibers. It is generally preferred that the length of the fibers used in the present process be in the range of about to mm.
  • the binders that are applied to the fibers comprise an anionic polymer latex and about 3 to 50 percent, and preferably 5 to 20 percent, based on the weight of polymer in said latex, of a mixture of alkali metal salts of disproportionated rosin and fortified rosin.
  • the polymer latexes that may be present in the novel binders include solutions, emulsions, and dispersions of such polymers as acrylic resins, styrene-butadiene copolymers, polyurethanes, polyesters, polyamides, chlorinated polypropylene, polyvinyl acetate, and mixtures thereof. Particularly satisfactory results have been obtained using a binder in which the anionic polymer latex is an emulsion of an acrylic resin.
  • acrylic resin includes a number of polymers prepared by the polymerization of an acrylic monomer, such as acrylic acid, methacrylic acid, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, methyl methacrylate, butyl methacrylate, 2-ethylhexyl methacrylate, acrylonitrile, methacrylonitrile acrylamide, methacrylamide, N-methylolacrylamide, N-methylolmethacrylamide, and mixtures thereof alone or in combination with such comonomers as styrene, ethylene, propylene, butadiene, isoprene, chloroprene, itaconic acid and the like.
  • an acrylic monomer such as acrylic acid, methacrylic acid, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, methyl methacrylate, butyl methacrylate, 2-ethylhexyl methacryl
  • the anionic polymer latexes may be formed by any suitable and convenient procedure. For example, they may be formed by preparing a polymerization mixture containing water, the appropriate monomers, a free-radical polymerization initiator, and an anionic emulsifying agent and heating the mixture at a temperature in the range of about to C. until the polymerization has been completed.
  • anionic emulsifying agents that can be used are glycerol monostearate, sodium oleate, potassium oleate, triethanolamine oleate, sodium lauryl sulfate, and alkyl aryl sulfonates.
  • the anionic polymer latex generally contains about 10 to 70 percent by weight of the polymer. Latexes having a solids content of about 35 to 50 percent are ordinarily preferred.
  • the anionic polymer latex may also contain defoaming agents, wetting agents, dyes, fillers, and the like in the amounts usually used for these purposes.
  • the mixture of rosin salts that is present in the binders of this invention contains about 50 to 90 percent by weight of an alkali metal salt of disproportionated rosin and about l0 to 50 percent by weight of an alkali metal salt of fortified rosin.
  • Binders that have excellent retention characteristics and that form the most satisfactory products contain a mixture of salts that consists of 70 to 80 percent by weight of sodium, potassium, and/or lithium salts of disproportionated rosin and 20 to 30 percent by weight of sodium, potassium, and/or lithium salts of fortified rosin, with optimum results being obtained when the mixture contains about 75 percent by weight of the potassium salt of disproportionated rosin and about 25 percent by weight of the potassium salt of fortified rosin.
  • the mixture of modified rosin salts may be prepared, for example, by mixing together the appropriate amounts of the individual salts.
  • a mixture of disproportionated rosin and fortified rosin may be saponified by heating it with an aqueous solution of an alkali metal hydroxide, oxide, or carbonate, and preferably with an aqueous solution of potassium hydroxide.
  • the alkali metal salt of disproportionated rosin and the alkali metal salt of fortified rosin may be added separately to the polymer latex to form the binding agents of this invention.
  • the mixture of modified rosin salts or the individual salts are preferably added as a dilute aqueous dispersion or solution to the other components to form the binders.
  • the disproportionated rosin from which the alkali metal salt is formed may be prepared by known procedures from wood rosin, gum rosin, or tall oil rosin.
  • the rosin may be disproportionated by heating it at a temperature between and 300 C. in the presence of a catalyst, such as palladium, platinum, nickel, iodine, sulfur, or sulfur dioxide.
  • a catalyst such as palladium, platinum, nickel, iodine, sulfur, or sulfur dioxide.
  • the fortified rosin that is used in the practice of this invention may be prepared by heating rosin with about 1.9 to about 7.5 percent of its weight of formaldehyde or a formaldehydeyielding compound, such 'as paraformaldehyde or trioxane, at a temperature between 125 and 200 C. in the presence of an acid catalyst, such as sulfuric acid or p-toluenesulfonic acid, to form formaldehyde-rnodified rosin.
  • formaldehyde or a formaldehydeyielding compound such 'as paraformaldehyde or trioxane
  • the formaldehydemodified rosin is then heated at a temperature between 160 and 220 C., and preferably between 175 and 195 C., with about 4 to 12 percent, and preferably 5 to 7 percent, by weight of an alpha, beta-unsaturated carboxylic acid component, such as maleic, fumaric, erotonic, acrylic, methacrylic, itaconic, citraconic, and aconitic acids, their anhydrides, their esters, and mixtures thereof.
  • an alpha, beta-unsaturated carboxylic acid component such as maleic, fumaric, erotonic, acrylic, methacrylic, itaconic, citraconic, and aconitic acids, their anhydrides, their esters, and mixtures thereof.
  • the fortified rosin can be prepared by heating rosin with the appropriate amounts of an alpha, beta-unsaturated carboxylic acid component at a temperature between 160 and 220 C. without the formaldehyde treatment until a product having
  • Nonwoven fabrics may be prepared from fibers and the novel binders by procedures that are well known in the art.
  • the procedure is usually carried out in a papermaking machine or fiber mat machine that comprises a headbox, dc watering boxes, a suction box, and a wire on which the fabric is formed.
  • the headbox is equipped with an agitator that keeps the fibers in suspension and that assists in the uniform distribution of the binder and fixing agent throughout the suspension.
  • the fibers are added to water in the headbox to form an aqueous suspension containing about 0.005 to 0.10 percent by weight of the fiber.
  • a dilute aqueous solution of a cationic fixing agent such as a cationic ureaformaldehyde resin, melamine-formaldehyde resin, dicyandiamide-formaldehyde resin, guanidine-formaldehyde resin, polyethylenimine, polyamide, or polyamidoamine resin.
  • a cationic fixing agent such as a cationic ureaformaldehyde resin, melamine-formaldehyde resin, dicyandiamide-formaldehyde resin, guanidine-formaldehyde resin, polyethylenimine, polyamide, or polyamidoamine resin.
  • the amount of fixing agent that is used is not critical provided that it is sufficient to precipitate substantially all of the binder that is subsequently added.
  • a dilute aqueous solution of the binder or, if desired, separate dilute solutions of the anionic polymer and the salts of modified rosin.
  • a dilute aqueous solution of the binder or, if desired, separate dilute solutions of the anionic polymer and the salts of modified rosin.
  • about 50 to 200 parts by weight of the binder is added per 100 parts by weight of dry fibers, with about 60 to 110 parts by weight of binder per 100 parts by weight of dry fibers preferred.
  • a few minutes after the addition of the binder the filtrate becomes clear, which indicates that substantially all of the binder has been fixed on the fibers.
  • the amount of water added with the binder is such that the suspension contains about 0.05 to 1.0 gram of treated fibers per liter.
  • the treated fibers are formed into a sheet and dried.
  • the resulting nonwoven fabrics are soft and flexible and have excellent tensile strength.
  • the dilute aqueous binder solution is added to the aqueous suspension of fibers prior to the addition of the cationic fixing agent.
  • rosin was prepared by heating a mixture of 90 parts of rosin, 9 parts of maleic anhydride, and 1.7 parts of paraformaldehyde at l 75-180 C. for 90 minutes.
  • Disproportionated rosin was prepared by heating rosin at 250-310 C. for about 5 hours in the presence ofa 5 per cent palladium-on-carbon catalyst.
  • EXAMPLE 2 A suspension of parts (dry weight) of polyester fibers in about 500,000 parts of water was prepared. To this suspension which was vigorously agitated was added a dilute aqueous solution that contained 4.8 parts of at cationic urea-formaldehyde resin. To the resulting suspension was slowly added a dilute aqueous dispersion that contained (a) 60 parts of an anionic polymer latex that was an anionic emulsion that contained 50 percent of poly (ethyl acrylate) and (b) 3 parts of the product of Example 1. About 10 minutes after the dispersion had been added, the filtrate was clear. The treated fibers were formed into a sheet and dried. The resulting nonwoven fabric, which was soft and resilient, had a tensile strength of 210 kg.
  • Example 2 In a comparative experiment, the above procedure was followed except that the product of Example 1 was not added to the dispersion that contained the poly (ethyl acrylate). The resulting nonwoven fabric had a tensile strength of 40 kg.
  • EXAMPLE 3 To dilute aqueous suspension containing 100 parts (dry weight) of polyamide fibers was added a dilute aqueous solution that contained 4.8 parts of a cationic urea-formaldehyde resin. To the resulting suspension was slowly added a dilute aqueous dispersion that contained (a) 100 parts of an anionic polymer latex that contained 50 percent of a polymer of 94 percent of n-butyl acrylate, 5 percent of N-methylolacrylamide, and 1 percent of vinyl acrylate and (b) 5 parts of the product of Example 1. About 10 minutes after the dispersion had been added, the filtrate was clear. The treated fibers were formed into a sheet and dried. The resulting nonwoven fabric was soft and had excellent wet strength and dry strength.
  • EXAMPLE 4 To a dilute aqueous suspension containing 100 parts (dry weight) of polyurethane fibers was added a dilute aqueous dispersion that contained (a) 80 parts of an anionic polymer latex that contained 35 percent of poly (propyl acrylate) and (b) 2 parts of the product of Example 1 To the resulting slurry was added a dilute aqueous solution containing 5 parts ofa cationic polyamidoamine resin. The treated fibers were formed into a sheet and dried. The resulting nonwoven fabric was soft and resilient, and it had excellent wet strength and dry strength.
  • a nonwoven fabric comprising a web of fibers bonded with a binder that comprises (a) a polymer latex, said latex containing about 10 to 70 percent by weight of a polymer selected from the group consisting of acrylic resins, styrenebutadiene polymers, polyurethanes, polyesters, polyamides, chlorinated polypropylenes, polyvinyl acetate, and mixtures thereof and (b) 3 to 50 percent, based on the weight of polymer in said latex, of a mixture of rosin salts, said mixture containing about 50 to 90 percent by weight of an alkali metal salt of disproportionated rosin and about 10 to 50 percent by weight of an alkali metal salt of fortified rosin, said fortified rosin being the product obtained by heating rosin or formaldehyde-modified rosin and about 4 to 12 percent by weight of an alpha, beta-unsaturated carboxylic acid component at a temperature in the range of to 220 C.
  • a binder for nonwoven fabrics comprising (a) a polymer latex, said latex containing about 10 to 70 percent by weight of a polymer selected from the group consisting of acrylic resins, styrene-butadiene polymers, polyurethanes, polyesters, polyamides, chlorinated polypropylenes, polyvinyl acetate, and mixtures thereof and (b) 3 to 50 percent, based on the weight of polymer in said latex, of a mixture of rosin salts, said mixture containing about 50 to 90 percent by weight of an alkali metal salt of disproportionated rosin and about 10 to 50 percent by weight of an alkali metal salt of fortified rosin, said fortified rosin being the product obtained by heating rosin or formaldehyde-modified rosin and about 4 to 12 percent by weight of an alpha, beta-unsaturated carboxylic acid component at a temperature in the range of 160 to 220 C.
  • a polymer latex said latex
  • a binder for nonwoven fabrics as set forth in claim 6 that contains 5 to 20 percent, based on the weight of polymer in the binder, of said mixture of rosin salts.
  • a binder comprising a polymer is added to said suspension.
  • the polymer is precipitated onto said fibers, and the treated fibers are formed into a sheet and dried
  • the improvement that comprises incorporating in said binder 3 to 50 percent, based on the weight of polymer in said binder, of a mixture of rosin salts containing about 50 to percent by weight of an alkali metal salt of disproportionated rosin and about 10 to 50 percent by weight of an alkali metal salt of fortified rosin, said fortified rosin being the product obtained by heating rosin or formaldehyde-modified rosin and about 4 to 12 percent by weight of an alpha, beta-unsaturated carboxylic acid component at a temperature in the range of to 220 C.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Nonwoven Fabrics (AREA)
US3644251D 1969-04-08 1969-04-08 Nonwoven fabrics and binders therefor Expired - Lifetime US3644251A (en)

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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4179415A (en) * 1977-08-08 1979-12-18 Johnson & Johnson Pressure sensitive adhesive and process
US4278727A (en) * 1977-10-20 1981-07-14 Wacker-Chemie Gmbh Alkai-soluble, water-resistant binders for non-woven materials
US4510019A (en) * 1981-05-12 1985-04-09 Papeteries De Jeand'heurs Latex containing papers
US4521493A (en) * 1984-01-12 1985-06-04 Hercules Incorporated Fiber filter and stabilizer formulation
US4615689A (en) * 1984-12-31 1986-10-07 Mobil Oil Corporation Method for preparing paperlike products from fibers threaded with polymer
US5466526A (en) * 1992-07-16 1995-11-14 Magata; Katsumi Far infrared radiant composite fiber containing metal
US6048439A (en) * 1996-04-29 2000-04-11 International Paper Company Modified rosin emulsion
WO2001027368A1 (en) * 1999-10-08 2001-04-19 The University Of Akron Insoluble nanofibers of linear poly(ethylenimine) and uses therefor
US6349826B1 (en) 1997-06-30 2002-02-26 Kimberly-Clark Worldwide, Inc. Medical packaging fabric with improved bacteria barrier
US20030138563A1 (en) * 2000-10-19 2003-07-24 Mann Nick R. Ion processing element with composite media
US20040122141A1 (en) * 2000-10-19 2004-06-24 Todd Terry A Composite media for ion processing and a method for making the composite media
US20060041043A1 (en) * 2000-10-19 2006-02-23 Mann Nick R Composite media for ion processing
US11192986B2 (en) 2016-06-06 2021-12-07 Owens Corning Intellectual Capital, Llc Binder system

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3405019A1 (de) * 1984-02-13 1985-08-14 Chemische Fabrik Stockhausen GmbH, 4150 Krefeld Mischungen von wasserloeslichen synthetischen organischen polymeren mit naturharzleimen und ihre verwendung als leimungsmittel
JPS61108796A (ja) * 1984-10-26 1986-05-27 ディック・ハーキュレス株式会社 ロジン系エマルジョンサイズ剤

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3380851A (en) * 1965-03-31 1968-04-30 Air Reduction Nonwoven fabric with vinyl acetateethylene-n-methylol acrylamide interpolymer as binder
US3419465A (en) * 1965-04-05 1968-12-31 Kao Corp Saponified rosin solution of a vinyl polymer and method of sizing paper therewith
US3451890A (en) * 1966-01-19 1969-06-24 Tenneco Chem Rosin size compositions
US3490937A (en) * 1964-09-10 1970-01-20 Helmut A Pietsch Process for providing an article with a porous resinous coating and the coating composition
US3510344A (en) * 1966-07-11 1970-05-05 Ici Ltd Vapour permeable sheet materials

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3490937A (en) * 1964-09-10 1970-01-20 Helmut A Pietsch Process for providing an article with a porous resinous coating and the coating composition
US3380851A (en) * 1965-03-31 1968-04-30 Air Reduction Nonwoven fabric with vinyl acetateethylene-n-methylol acrylamide interpolymer as binder
US3419465A (en) * 1965-04-05 1968-12-31 Kao Corp Saponified rosin solution of a vinyl polymer and method of sizing paper therewith
US3451890A (en) * 1966-01-19 1969-06-24 Tenneco Chem Rosin size compositions
US3510344A (en) * 1966-07-11 1970-05-05 Ici Ltd Vapour permeable sheet materials

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4179415A (en) * 1977-08-08 1979-12-18 Johnson & Johnson Pressure sensitive adhesive and process
US4278727A (en) * 1977-10-20 1981-07-14 Wacker-Chemie Gmbh Alkai-soluble, water-resistant binders for non-woven materials
US4510019A (en) * 1981-05-12 1985-04-09 Papeteries De Jeand'heurs Latex containing papers
US4521493A (en) * 1984-01-12 1985-06-04 Hercules Incorporated Fiber filter and stabilizer formulation
US4615689A (en) * 1984-12-31 1986-10-07 Mobil Oil Corporation Method for preparing paperlike products from fibers threaded with polymer
US5466526A (en) * 1992-07-16 1995-11-14 Magata; Katsumi Far infrared radiant composite fiber containing metal
US6048439A (en) * 1996-04-29 2000-04-11 International Paper Company Modified rosin emulsion
US6349826B1 (en) 1997-06-30 2002-02-26 Kimberly-Clark Worldwide, Inc. Medical packaging fabric with improved bacteria barrier
WO2001027368A1 (en) * 1999-10-08 2001-04-19 The University Of Akron Insoluble nanofibers of linear poly(ethylenimine) and uses therefor
US20030138563A1 (en) * 2000-10-19 2003-07-24 Mann Nick R. Ion processing element with composite media
US20040122141A1 (en) * 2000-10-19 2004-06-24 Todd Terry A Composite media for ion processing and a method for making the composite media
US20060041043A1 (en) * 2000-10-19 2006-02-23 Mann Nick R Composite media for ion processing
US7507340B2 (en) * 2000-10-19 2009-03-24 Battelle Energy Alliance, Llc Ion processing element with composite media
US7629292B2 (en) 2000-10-19 2009-12-08 Battelle Energy Alliance, Llc Composite media for ion processing
US11192986B2 (en) 2016-06-06 2021-12-07 Owens Corning Intellectual Capital, Llc Binder system

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Publication number Publication date
DE2016792A1 (de) 1970-11-12
NL7004904A (de) 1970-10-12

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