US3753826A - Methods of making nonwoven textile fabrics - Google Patents

Methods of making nonwoven textile fabrics Download PDF

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US3753826A
US3753826A US00125239A US3753826DA US3753826A US 3753826 A US3753826 A US 3753826A US 00125239 A US00125239 A US 00125239A US 3753826D A US3753826D A US 3753826DA US 3753826 A US3753826 A US 3753826A
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weight
percent
fibers
fibrous structure
resin binder
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C Plummer
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Johnson and Johnson
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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
    • D21H25/04—Physical treatment, e.g. heating, irradiating
    • D21H25/06—Physical treatment, e.g. heating, irradiating of impregnated or coated paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H15/00—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
    • D21H15/02—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution characterised by configuration
    • D21H15/06—Long fibres, i.e. fibres exceeding the upper length limit of conventional paper-making fibres; Filaments
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24826—Spot bonds connect components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24893—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y10T428/2964—Artificial fiber or filament
    • Y10T428/2965—Cellulosic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/298—Physical dimension
    • 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.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2631—Coating or impregnation provides heat or fire protection
    • Y10T442/2713—Halogen containing
    • 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.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2631—Coating or impregnation provides heat or fire protection
    • Y10T442/2721—Nitrogen containing

Definitions

  • ABSTRACT A nonwoven textile fabric having excellent softness, drape, and hand, good long and cross tensile strength, good wet abrasion resistance and good washability, and good absorptive capacity and opacity comprising: a re1- atively flat, sheet-like fibrous structure of from about 30 percent by weight to about 90 percent by weight of overlapping and intersecting structural fibers having an average length of from about A inch to about 1% inches or more, and from about 70 percent by weight to about 10 percent by weight of relatively short fibers having an average length of from about 1/6 inch to about l/25 inch or less; said structural fibers being bonded together by a closely-spaced, non-migrating, intermittent print pattern of discrete synthetic resin binder areas, and said relatively short fibers being bonded together by a substantially uniform, overall application of a relatively soft, synthetic resin binder in an amount of from about 2 percent by weight to about 10 percent by weight, based on the total weight of the finished nonwoven textile fabric.
  • Such nonwoven textile fabrics have usually been manufactured by laying down one or more fibrous layers or webs of textile length fibers by dry textile carding techniques which normally align the majority of the individual fibers more or less generally lengthwise of the fibrous layer or web being prepared.
  • the individual textile length fibers of these carded fibrous webs are then bonded by conventional bonding techniques, such as, for example, by intermittent print pattern bonding, whereby a unitary, self-sustaining nonwoven textile fabric having excellent softness, drape, and hand is obtained.
  • Such manufacturing techniques are relatively slow and it has always been desired that manufacturing processes having greater production rates be devised.
  • nonwoven textile fabrics which have the necessary softness, drape, and hand, and esthetic qualities of nonwoven textile fabrics, along with the other qualities, properties, and characteristics required for nonwoven textile fabrics. This is particularly true when the nonwoven textile fabrics are to be used in the single-use or limited re-use disposable field, such as for disposable apparel, linens, cleaning and wiping cloths, bandages, dressings, pads, surgical drapes and gowns, diaper linings and facings, etc.
  • THE INVENTIVE CONCEPT pacity and opacity can be made by:
  • FIG. 1 is a schematic drawing showing a typical flow chart of a wet-forming manufacturing process, representing a preferred embodiment of the present inventive concept;
  • FIG. 2 is a schematic drawing showing in crosssection the idealized internal construction of the finished nonwoven textile fabric of the present invention.
  • the discharge portion 10 of a papermaking machine headbox associated with a conventional stock chest (not shown) wherein the fibers are formed into a substantially uniform aqueous slurry, preferably in the presence of discrete resin binder particles or like materials and a deposition aid, if required or desired.
  • the concentration of the fibers in the stock chest aqueous slurry is on the order of from about 1/20 percent by weight to about 1% percent by weight, on a dry fiber weight basis.
  • suclh range of fiber concentration in the aqueous slurry is from about I/ 10 percent by weight to about 1 percent by weight.
  • the concentration of the resin binder particles or like materials in the stock chest aqueous slurry depends on the amount of resin binder particles which are intended to be deposited on the individual fibers. The range extends from about 5 percent by weight to about percent by weight of dry resin solids, based on the total dry fiber weight in the stock chest, and preferably extends from about 15 percent by weight to about 40 percent by weight.
  • the concentration of the deposition aid in the stock chest slurry should be enough to bring about satisfactory deposition of the resin particles on the fibers in the aqueous slurry. Normally, such concentration is in the range of from about 1% percent by weight to about l /s percent by weight, based on the total dry resin solids in the stock chest.
  • the substantially uniformly dispersed fibers in the stock chest leading to the discharge portion comprise from about 30 percent by weight to about 90 percent by weight of structural textile length fibers ST having an average length of from about V4 inch to about 1% inches or more and from about 70 percent by weight to about 10 percent by weight of relatively short fibers W having an average length of from about 1/6 inch (0.167 inch) to about l/25 inch (0.040 inch) or less.
  • the structural textile length fibers ST may be selected from a large group of natural, synthetic or manmade fibers such as: the cellulosic fibers, notably cotton, regenerated cellulose (both viscose and cuprammonium processes), cellulose acetate, and cellulose triacetate; the non-cellulosic fibers such as: the polyamide fibers, notably nylon 6,6 and 6; the polyesters, notably Dacron, Fortrel and Kodel"; the acrylics, notably Creslan, Acrilan” and Orlon; the modacrylics, notably Dynel and Verel”; the polyolefins, especially polypropylene and polyethylene, notably Vectra and Herculon"; the spandexes, notably Lycra and Unel; the fluorocarbons, notably Teflon TFE and FEP; etc.
  • These fibers may be used by themselves, or in various combinations and blends of two or more species in varying percentages, as desired or
  • the denier of the synthetic or man-made structural fibers ST may be varied relatively widely, depending on the circumstances, and vary from about 1% denier to about 6 denier, with lower deniers to about $4 or less, and higher deniers to about 9, 15, or more, being of use in special circumstances.
  • the remaining fibers in the stock chest slurry are wood pulp fibers, or other short fibers W.
  • Unbeaten or unrefined wood pulp fibers, or at least relatively unbeaten or unrefined wood pulp fibers are preferably used inasmuch as beating and refining are rather severe mechanical treatments, and beat and macerate the fibers whereby enhanced hydration bonding is obtained which is not desired in the present inventive concept and which leads to a product which undesirably has increased stiffness, harshness, and a papery hand.
  • unbeaten hardwood sulfite pulp will be disclosed as the preferred type of wood pulp fiber used in the application of the present invention, substantially any type of wood pulp, either hardwood or softwood, is of use.
  • wood pulps in which the cooking liquor, calcium or magnesium bisulfite, is acid, or sodium sulfite which is neutral or slightly alkaline; soda pulps in which the cooking liquor, caustic soda, is alkaline; kraft or sulfate pulps in which the cooking liquor, sodium hydroxide and sodium sulfide, is alkaline, etc.
  • wood pulp fibers are preferred in the application of the present inventive concept, other short fibers or fibrous materials are of use.
  • Examples of such short fibers or fibrous materials having lengths of from about l/6 inch to about l/25 inch or less are: cotton linters, bagasse, flax, flax straw, jute, straw, bamboo,
  • Viscose rayon fibers are the preferred structural textile length fiber.
  • Othr structural textile length fibers may be included in amounts up to about 30 percent by weight of the total structural fiber weight.
  • the relatively short fibers which are usually wood pulp fibers may be included in amounts from about 10 percent by weight up to as high as about percent by weight of the total fiber weight and preferably from about 20 percent by weight to about 50 percent by weight.
  • Dispersion aids may be used to assist or promote such uniformity of dispersion.
  • the particular resin binder which is incorporated on the fibers is selected from a relatively large class of synthetic resins well known in the art for bonding or adhering fibers of fibrous materials together.
  • Such resins may be of the internal or self cross-linking type, the crosslinkable type which are cross-linked by added crosslinking agents, or the non-cross-linked or non-crosslinkable type.
  • Examples of such synthetic resins include: polymers and copolymers of vinyl ethers; vinyl halides such as plasticized and unplasticized polyvinyl chloride, polyvinyl chloride-polyvinyl acetate, ethylene-vinyl chloride, etc.; polymers and copolymers of vinyl esters such as plasticized and unplasticized polyvinyl acetate, ethylene-vinyl acetate, acrylic-vinyl acetate, etc.; polymers and copolymers of the polyacrylic resins such as ethyl acrylate, methyl acrylate, butyl acrylate, ethylbutyl acrylate, ethyl hexyl acrylate, hydroxyethyl acrylate, dimethyl amino ethyl acrylate, etc.; polymers and copolymers of the polymethacrylic resins such as methyl methacrylate, ethyl methacrylate, isopropyl methacrylate, butyl
  • synthetic rubbers such as l,2-butadiene, 1,3-butadiene, 2-ethyl-1,3-butadiene, high, medium and carboxylated butadiene-acrylonitrile, butadiene-styrene, chlorinated rubber, etc., natural latex; the polyurethanes, the polyamides; the polyesters; the polymers and copolymers of the styrenes including styrene, 2-methyl styrene, 3- methyl styrene, 4-methyl styrene, 4-ethyl styrene, 4- butyl styrene, natural latex; phenolic emulsions; etc.
  • These resins may be used either as homopolymers comprising a single repeating monomer unit, or they may be used as copolymers comprising two, three, or more different monomer units which are arranged in random fashion, or in a definite ordered alternating fashion, within the polymer chain.
  • block polymers comprising relatively long blocks of different monomer units in a polymer chain and graft polymers comprising chains of one monomer attached to the backbone of another polymer chain.
  • the deposition of the synthetic resin binder particles on the individual fibers may be accomplished in many ways at various points in the manufacturing process but, preferably, is accomplished by stock chest deposition techniques. Such techniques generally include (1) the formation of a substantially uniform, aqueous slurry of the fibers which will make up the fibrous structure or web and (2) the inclusion in the aqueous slurry of the synthetic resin binder particles which are to be deposited on and adhered to the individual fibers.
  • Deposition aids may be used, if necessary, to promote the deposition and adherence of the synthetic resin particles on the individual fibers. Examples of such deposition aids are Rohm & Haas Deposition Aid 8-243, polyethylene imine, alum, polymeric amines, polymeric amides, cationic starch, etc.
  • the aqueous slurry containing the structural fibers ST and the short fibers W which have incorpo rated therewith the discrete particles of resin binder B is discharged through discharge portion 10 onto the open screen-like surface of a moving forming surface which is provided with underlying conventional suction boxes (not shown) whereby a considerable part of the water is drained rapidly from the aqueous slurry to form a relatively flat, sheet-like fibrous structure S in the area 12 of the forming surface 20.
  • a rectilinearly moving forming surface 20 is disclosed herein but it is to be appreciated that this is merely illustrative of the present inventive concept, and that other forming surfaces such as Fourdrinier wires, inclined wires, screens, belts, rotating cylinders, etc., are of use. i
  • drying means 30 which preferably take the form of a series of heated rotatable drying cylinders.
  • Other drying means such as a single large drying drum, or a heated oven, or the like, are of use, if they are capable of providing an elevated drying, bonding and curing temperature in the range of from about 200 F. to about 350 F. or higher, if desired or required.
  • the drying at such an elevated temperature serves to activate the bonding characteristics of the resin binder particles, whereby the individual fibers become bonded to each other. This is particularly important in the case of the short fibers, such as wood pulp fibers, which are effectively bonded and locked in position.
  • the resin binder particles thus act as a prebonding agent and stabilize the fibrous structure so that it is selfsustaining and can be readily handled and easily manipulated during subsequent processing.
  • Other prebonding means may be employed, provided they are capable of supplying the necessary strength and coherency properties and characteristics required during subsequent processing.
  • the dried, pre-bonded fibrous structure is then passed through additional bonding apparatus 40 wherein there is applied an additional bonding agent 42 in the form of an intermittent print pattern of closelyspaced discrete binder areas 76.
  • the particular print pattern is selected from a large group of commercially known intermittent print patterns such as, for example, illustrated in U. S. Pat. Nos. 2,705,498, 2,705,687, 2,705,688, 2,880,111 and 3,009,822.
  • the synthetic resins which are used to additionally bond the individual structural fibers are selected from the groupof synthetic resins listed hereinbefore.
  • the amount of synthetic resin binder applied is in the range of from about I percent by weight to about 30 percent by weight, based on the weight of the nonwoven textile fabric being bonded.
  • the amount of the applied synthetic resin binder is in the range of from about 10 percent by weight to about 20 percent by weight, based on the weight of the nonwoven textile fabric being bonded.
  • the surface coverage of the binder areas varies widely, depending upon the requirements and needs of the particular circumstances. Normally, a surface cov' erage of from about 10 percent to about 35 percent of the nonwoven textile fabric is found satisfactory.
  • the closely-spaced intermittent print pattern bonding takes place on a dry fibrous substrate in order to limit or restrict the binder migration which would take place if the bonding were to take place on a wet fibrous substrate. Limitation or restriction of binder migration maintains the softness, drape and hand of the resulting nonwoven textile fabric which otherwise could be lost if the binder migration was uncontrolled.
  • a second dryer 46 is used to dry the fibrous structure subsequent to the intermittent print pattern bonding.
  • This dryer 46 may comprise a series of heated drying cylinders, or a single large heated. drying drum, or a heated oven, or the like, as described previously.
  • the dried, intermittently print pattern bonded fibrous structure is then forwarded to an overall or saturation bonding device or padder 50 whereat an additional binder 52 is applied in overall fashion.
  • Such overall bonding securely ties together the fibrous structure and particularly the relatively short fibers therein.
  • the amount of binder 52 applied in such treatment is in the range of from about 2 percent by weight to about 10 percent by weight, based on the total weight of the finished non-woven textile fabric.
  • the range of the weight of the applied overall binder is from about 2 percent by weight to about 5 percent by weight, based on the total weight of the finished nonwoven textile fabric.
  • the particular resin which is applied in overall fashion may be selected from the resins mentioned previously herein, with the condition, however, that the resin, when dried and cured, be relatively soft so as to provide the desired softness, drape and hand.
  • resins suitable for such purpose include acrylic means such as polyethylacrylate; methacrylic resins such as copolymers of methyl methacrylate and ethyl hexyl acrylate; polyolefin and vinyl resins such as copolymers of ethylene and vinyl acetate; carboxylated butadiene-styrene copolymers; etc.
  • the degree of softness is, of course, determined by the requirements and needs of the particular situation and the particular product.
  • Reactive type resins and particularly those of the thermosetting variety, which actually react with and heavily cross-link a cellulosic fibrous structure, to yield hard, crease resistant finishes of a permanent press type are to be avoided.
  • reactive type resins are ethylene urea formaldehyde, melamine formaldehyde, etc., which not only cross-link with themselves but additionally and undesirably cross-link with the cellulosic fibrous structure itself.
  • Another dryer 56 similar to any of the drying devices described previously, may be employed to dry the nonwoven textile fabric. Subsequent to drying, the nonwoven textile fabric is forwarded to and wound on a batcher 60 or other re-wind device.
  • additional treatments may be applied to the nonwoven textile fabric subsequent to the drying operation in dryer 56 in order to achieve specific purposes and particular properties.
  • An additional oversaturation in a second conventional padder or the like (not shown) with an additional binder or other additives or other treating agents may be resorted to, for example, in order to attain special properties.
  • Such other additives and treating agents include water-proofing agents, waterrepellent agents, flame-proofing agents, insect or vermin-proofing materials, dyes and pigments, and the like.
  • Such additional treatment may be used to apply the additional specialty treatment agent or other additive to the extent of from about 2 percent by weight to about 50 percent by weight, based on the weight of the nonwoven textile fabric being treated.
  • Another dryer (not shown), similar to any of the drying devices described previously, may be employed to dry the nonwoven textile fabric, prior to forwarding to the batcher or re-wind device.
  • FIG. 2 there is schematically shown in crosssection the idealized internal construction of a typical nonwoven textile fabric 70 of the present invention.
  • the structural textile length fibers ST and the relatively short fibers W are shown, bonded into a unitary structure by the binder B in the areas 76 and by the overall saturation bonding which substantially unifonnly impregnates the entire nonwoven textile fabric.
  • Nonwoven textile fabrics made by the techniques described herein are found to have excellent softness, drape, and hand, good long and cross tensile strength, good wet abrasion resistance and good washability, and good absorptive capacity and opacity. They are of excellent use as diaper and other facings, towels and wipes, operating room products such as drapes and gowns, and other uses mentioned herein.
  • weights of such finished nonwoven textile fabrics vary widely depending upon the particular uses and intended applications. Within the more commercial aspects of the present invention, finished fabric weights of from about 200 grains per square yard to about 1,200 grains per square yard are contemplated. Within the broader aspects of the present invention, however, heavier or lighter fabrics may be made for special uses and applications.
  • a wet-formed, nonwoven textile fabric is prepared as follows:
  • the fibrous structure comprises: percent by weight of rayon fibers having a denier of 1.5 and a length of% inch; and 25 percent by weight of unbeaten and unrefined hardwood sulfite wood pulp fibers. These fibers are slurried to a consistency of about 1 percent by weight in a stock chest containing about 50 percent by weight, based on the total dry fiber weight, of Rohm & Haas Resin Emulsion E-63l, a self crosslinking (methylol functionality) anionic ethyl acrylate acrylic binder, and about 1 percent by weight, based on the total dry resin solids, of Rohm & Haas Deposition Aid 8-243, a moderate molecular weight cationic polyelectrolyte (hydroxy group functionality) deposition aid.
  • the total weight of the fibrous structure is 230 grains per square yard, of which 184 grains is the fiber weight and 46 is the resin particle weight. This is equivalent to a 20% add-on of resin binder particles.
  • This fibrous structure is then dried by being passed over heated drying cylinders at a temperature of about 250 F.
  • the individual overlapping and intersecting fibers are bonded to each other.
  • the dried nonwoven textile fabric is then passed through an intermittent print pattern bonding apparatus of a conventional design.
  • the print pattern comprises a double-diagonal diamond pattern (see FIG. 3, U. S. Pat. No. 2,705,498) wherein there are five lines per inch, with each line 0.020 inch wide, as measured on the binder applying roll.
  • the binder is Rohm & Haas PIA-8, primarily a polyethyl acrylate. Lateral migration is minimal.
  • the total finished weight of the nonwoven textile fabric is 291 grains. This represents a print binder add-on of 60 grains per square yard, or about 26 percent by weight, based on the weight of the fabric being bonded.
  • the dried intermittently print pattern bonded nonwoven textile fabric is then passed through a saturation bonding device or padder and approximately 3 percent by weight on a dry solids basis of a soft acrylic resin Rohm & Haas I-IA-8 (primarily a polyethyl acrylate) is substantially uniformly applied thereto.
  • a saturation bonding device or padder approximately 3 percent by weight on a dry solids basis of a soft acrylic resin Rohm & Haas I-IA-8 (primarily a polyethyl acrylate) is substantially uniformly applied thereto.
  • Drying then takes place in a conventional dryer and the finished nonwoven fabric is wound on a take-up roll or batcher.
  • the nonwoven textile fabric has excellent softness, drape and hand, as well as good long and cross tensile stength, good wet abrasion resistance and good washability, and good absorptive capacity and opacity. It is suitable for use as a diaper facing.
  • Example II The procedures of Example I are followed substantially as set forth therein with the exception that the fiber blend is 40 percent rayon fibers and 60 percent wood pulp fibers.
  • Example III EXAMPLE IV
  • the procedures of Example I are followed substantially as set forth therein with the exception that the rayon fibers have an average length of 1% inch, instead of inch.
  • Example V The procedures of Example I are followed substantially as set forth therein with the exception that the rayon fibers have an average length of /4 inch, instead of inch.
  • Example VI The procedures of Example 1 are followed substantially as set forth therein with the exception that the resin formulation used for the overall bonding is a soft, carboxylated butadiene (54%)-styrene (43%) resin.
  • Example VII The procedures of Example I are followed substantially as set forth therein with the exception that the resin used for the overall bonding is a soft copolymer of ethylene (30%) and vinyl acetate The results are good and are generally comparable to those set forth in Example I. The resulting product is commercially acceptable.
  • Example VIII The procedures of Example I are followed substantially as set forth therein with the exception that the resin used for the overall bonding is a soft copolymer of methyl methacrylate (40%) and ethyl hexyl acrylate (60%).
  • Example IX The procedures of Example I are followed substantially as set forth therein with the exception that the print binder resin comprises National Starch 25-4260, primarily a soft self-reactive acrylic copolymer resin.
  • the saturation bath comprises the same resin formulation.
  • Example I The procedures of Example I are followed substantially as set forth therein with the exception that the intermittent print pattern binder is viscose instead of polyethyl acrylate.
  • the fiber weight is increased to 220 grains per square yard
  • the stock chest resin add-on is 56 grains per square yard
  • the binder add-on is reduced to 4 percent by weight, based on the weight of the nonwoven textile fabric being bonded, which reduces the finished product weight accordingly to about 295 grains per square yard.
  • Example XI The procedures of Example I are followed substantially as set forth therein with the exception that the closely-spaced intermittent print pattern comprises 12 lines per inch with each line 0.015 inch wide having an angle of 45 to the long axis.
  • Example XII The procedures of Example I are followed substantially as set forth therein with the exception that the closely-spaced intermittent print pattern comprises 10 lines per inch with each line 0.020 inch wide.
  • Example Xlll The procedures of Example I are followed substantially as set forth therein with the exception that the closely-spaced intermittent print pattern comprises miniature circular areas 0.015 inch in diameter spaced 0.015 inch from adjacent binder areas in a square pattern as described in Example 111 of U. S. Pat. 2,880,l 1 l.
  • Example XIV The procedures of Example I are followed substantially as set forth therein with the exception that the nonwoven textile fabric is given an additional special treatment in another padder containing a conventional flame-proofing agent.
  • the amount of add-on of the flame-proofing agent is 10 percent by weight.
  • a method of making a nonwoven textile fabric which comprises:
  • a substantially uniform aqueous slurry of from about 30 percent by weight to about 90 percent by weight of structural fibers having an average length of from about V4 inch to about 1% inches or more, and from about 70 percent by weight to about 10 percent by weight of relatively short fibers having an average length of from about 1/6 inch to about 1/25 inch or less, and from about 5 percent by weight to about 100 percent by weight of discrete particles of heat activatable resin binder solids, based on the total fiber weight in the aqueous slurry;
  • a method of making a nonwoven textile fabric having excellent softness, drape, and hand, good long and cross tensile strength, good wet abrasion resistance and good washability, and good absorptive capacity and opacity which comprises:
  • forming a relatively flat, sheet-like fibrous structure of from about 30 percent by weight to about percent by weight of structural fibers having an average length of from about /4 inch to about 1% inches or more and from about 70 percent by weight to about 10 percent by weight of relatively short fibers having an average length of from about 1/6 inch to about l/25 inch or less and from about 5 percent by weight to about percent by weight of discrete particles of resin binder solids, based on the total fiber weight in the aqueous slurry;
  • concentration of the fibers in the aqueous slurry ranges from about l/lO percent by weight to about 1 percent by weight.
  • concentration of the discrete particles of resin binder solids ranges from about 15 percent to about 40 percent by weight.
  • concentration of the resin deposition aid in the aqueous slurry ranges from about A percent by weight to about l'k percent by weight, based on the total dry resin solids in the aqueous slurry.
  • the structural fibers comprise a mixture of rayon fibers and polyamide nylon fibers and the relatively short fibers are wood pulp fibers.

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  • Nonwoven Fabrics (AREA)
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Cited By (48)

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US3908058A (en) * 1974-01-16 1975-09-23 Johnson & Johnson Spot-bonded nonwoven fabrics and methods of making the same
US3940535A (en) * 1972-11-23 1976-02-24 Basf Aktiengesellschaft Reversible moisture-vapor-absorptive sheet structures and process
US3976075A (en) * 1975-02-24 1976-08-24 Personal Products Company Tampon blank with reduced sloughing properties
US4002171A (en) * 1975-03-17 1977-01-11 Personal Products Company Water-dispersible ionic polyurethane binder for nonwoven fabrics
US4047991A (en) * 1975-09-12 1977-09-13 Fiberlok, Inc. Polyester batt and method for producing such
US4050977A (en) * 1974-09-19 1977-09-27 Fiberlok, Inc. Composite batt and method for producing same
US4051294A (en) * 1975-09-12 1977-09-27 Fiberlok, Inc. Fiberous batt and method for producing such
US4053674A (en) * 1975-09-12 1977-10-11 Fiberlok, Inc. Glow-resistant batt and process for producing such
US4053673A (en) * 1975-09-12 1977-10-11 Fiberlok, Inc. Glow-resistant batt and process for producing such
US4088726A (en) * 1974-04-26 1978-05-09 Imperial Chemical Industries Limited Method of making non-woven fabrics
US4125645A (en) * 1975-09-29 1978-11-14 Northern Telecom Limited Latex modified pulp insulated conductors
US4219024A (en) * 1978-09-21 1980-08-26 Colgate-Palmolive Company Absorbent article
US4326000A (en) * 1973-04-30 1982-04-20 Scott Paper Company Soft, absorbent, unitary, laminate-like fibrous web
US4529465A (en) * 1983-02-15 1985-07-16 Rohm And Haas Company Method of print bonding non-woven webs
US4973382A (en) * 1988-07-26 1990-11-27 International Paper Company Filtration fabric produced by wet laid process
EP0672787A3 (en) * 1994-03-18 1996-07-10 James River Corp Pre-wettable, very soft paper product with temporary wet strength.
US6187140B1 (en) 1997-12-31 2001-02-13 Kimberly-Clark Worldwide, Inc. Creping process utilizing low temperature-curing adhesive
US6429261B1 (en) 2000-05-04 2002-08-06 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6444214B1 (en) 2000-05-04 2002-09-03 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
WO2002059422A3 (en) * 2001-01-26 2002-10-10 Procter & Gamble Multi-purpose absorbent and shred-resistant sheet material
US6500289B2 (en) 1998-11-12 2002-12-31 Kimberly-Clark Worldwide, Inc. Method of using water-borne epoxies and urethanes in print bonding fluid and products made therefrom
US6548592B1 (en) 2000-05-04 2003-04-15 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6579570B1 (en) 2000-05-04 2003-06-17 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6586529B2 (en) 2001-02-01 2003-07-01 Kimberly-Clark Worldwide, Inc. Water-dispersible polymers, a method of making same and items using same
US6599848B1 (en) 2000-05-04 2003-07-29 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6630558B2 (en) 1998-12-31 2003-10-07 Kimberly-Clark Worldwide, Inc. Ion-sensitive hard water dispersible polymers and applications therefor
US6653406B1 (en) 2000-05-04 2003-11-25 Kimberly Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6683143B1 (en) 2000-05-04 2004-01-27 Kimberly Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6689298B2 (en) * 2000-01-31 2004-02-10 Japan Blower Ind. Co., Ltd. Bamboo fiber board method
US6713414B1 (en) 2000-05-04 2004-03-30 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6815502B1 (en) 2000-05-04 2004-11-09 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersable polymers, a method of making same and items using same
US6828014B2 (en) 2001-03-22 2004-12-07 Kimberly-Clark Worldwide, Inc. Water-dispersible, cationic polymers, a method of making same and items using same
US6835678B2 (en) 2000-05-04 2004-12-28 Kimberly-Clark Worldwide, Inc. Ion sensitive, water-dispersible fabrics, a method of making same and items using same
US6897168B2 (en) 2001-03-22 2005-05-24 Kimberly-Clark Worldwide, Inc. Water-dispersible, cationic polymers, a method of making same and items using same
US6908966B2 (en) 2001-03-22 2005-06-21 Kimberly-Clark Worldwide, Inc. Water-dispersible, cationic polymers, a method of making same and items using same
US20060128248A1 (en) * 2004-11-16 2006-06-15 Pgi Polymer, Inc. Nonwoven sanitizing wipe including an anionic binder formulation
US7070854B2 (en) 2001-03-22 2006-07-04 Kimberly-Clark Worldwide, Inc. Water-dispersible, cationic polymers, a method of making same and items using same
US7101612B2 (en) 2000-05-04 2006-09-05 Kimberly Clark Worldwide, Inc. Pre-moistened wipe product
US20060292948A1 (en) * 2005-06-27 2006-12-28 Geel Paul A Fibrous veil impregnated with surface finish formulation
US20070071946A1 (en) * 2005-09-29 2007-03-29 Northern Elastomeric, Inc. Rubberized roof underlayment
US7276459B1 (en) 2000-05-04 2007-10-02 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US20080014814A1 (en) * 2006-07-13 2008-01-17 Geel Paul A Highly filled fibrous veil
US20100119784A1 (en) * 2005-09-29 2010-05-13 Northern Elastomeric, Inc. Rubberized roof underlayment
US20100143684A1 (en) * 2004-06-18 2010-06-10 Owens Corning Fibrous veil impregnated with surface finish formulation
US20110104461A1 (en) * 2009-09-28 2011-05-05 Owens Corning Intellectual Capital, Llc Underlayment with slip-resistant surface
US20170162294A1 (en) * 2014-08-22 2017-06-08 Leoni Bordnetz-Systeme Gmbh Cable harness and method for producing the cable harness
CN109466154A (zh) * 2018-10-19 2019-03-15 德阳科吉高新材料有限责任公司 一种水泥基复合材料的制造方法
US11028537B2 (en) 2016-12-30 2021-06-08 Kimberly-Clark Worldwide, Inc. Dispersible wet wipes constructed with patterned binder

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Cited By (57)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3940535A (en) * 1972-11-23 1976-02-24 Basf Aktiengesellschaft Reversible moisture-vapor-absorptive sheet structures and process
US4326000A (en) * 1973-04-30 1982-04-20 Scott Paper Company Soft, absorbent, unitary, laminate-like fibrous web
US3908058A (en) * 1974-01-16 1975-09-23 Johnson & Johnson Spot-bonded nonwoven fabrics and methods of making the same
US4088726A (en) * 1974-04-26 1978-05-09 Imperial Chemical Industries Limited Method of making non-woven fabrics
US4050977A (en) * 1974-09-19 1977-09-27 Fiberlok, Inc. Composite batt and method for producing same
US3976075A (en) * 1975-02-24 1976-08-24 Personal Products Company Tampon blank with reduced sloughing properties
US4002171A (en) * 1975-03-17 1977-01-11 Personal Products Company Water-dispersible ionic polyurethane binder for nonwoven fabrics
US4047991A (en) * 1975-09-12 1977-09-13 Fiberlok, Inc. Polyester batt and method for producing such
US4051294A (en) * 1975-09-12 1977-09-27 Fiberlok, Inc. Fiberous batt and method for producing such
US4053674A (en) * 1975-09-12 1977-10-11 Fiberlok, Inc. Glow-resistant batt and process for producing such
US4053673A (en) * 1975-09-12 1977-10-11 Fiberlok, Inc. Glow-resistant batt and process for producing such
US4125645A (en) * 1975-09-29 1978-11-14 Northern Telecom Limited Latex modified pulp insulated conductors
US4219024A (en) * 1978-09-21 1980-08-26 Colgate-Palmolive Company Absorbent article
US4529465A (en) * 1983-02-15 1985-07-16 Rohm And Haas Company Method of print bonding non-woven webs
US4973382A (en) * 1988-07-26 1990-11-27 International Paper Company Filtration fabric produced by wet laid process
EP0672787A3 (en) * 1994-03-18 1996-07-10 James River Corp Pre-wettable, very soft paper product with temporary wet strength.
US5958187A (en) * 1994-03-18 1999-09-28 Fort James Corporation Prewettable high softness paper product having temporary wet strength
US6187140B1 (en) 1997-12-31 2001-02-13 Kimberly-Clark Worldwide, Inc. Creping process utilizing low temperature-curing adhesive
US6500289B2 (en) 1998-11-12 2002-12-31 Kimberly-Clark Worldwide, Inc. Method of using water-borne epoxies and urethanes in print bonding fluid and products made therefrom
US6855790B2 (en) 1998-12-31 2005-02-15 Kimberly-Clark Worldwide, Inc. Ion-sensitive hard water dispersible polymers and applications therefor
US6630558B2 (en) 1998-12-31 2003-10-07 Kimberly-Clark Worldwide, Inc. Ion-sensitive hard water dispersible polymers and applications therefor
US6689298B2 (en) * 2000-01-31 2004-02-10 Japan Blower Ind. Co., Ltd. Bamboo fiber board method
US6602955B2 (en) 2000-05-04 2003-08-05 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6444214B1 (en) 2000-05-04 2002-09-03 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US7101612B2 (en) 2000-05-04 2006-09-05 Kimberly Clark Worldwide, Inc. Pre-moistened wipe product
US6429261B1 (en) 2000-05-04 2002-08-06 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6599848B1 (en) 2000-05-04 2003-07-29 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6548592B1 (en) 2000-05-04 2003-04-15 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6835678B2 (en) 2000-05-04 2004-12-28 Kimberly-Clark Worldwide, Inc. Ion sensitive, water-dispersible fabrics, a method of making same and items using same
US6653406B1 (en) 2000-05-04 2003-11-25 Kimberly Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6683143B1 (en) 2000-05-04 2004-01-27 Kimberly Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6579570B1 (en) 2000-05-04 2003-06-17 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6713414B1 (en) 2000-05-04 2004-03-30 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6814974B2 (en) 2000-05-04 2004-11-09 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
US6815502B1 (en) 2000-05-04 2004-11-09 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersable polymers, a method of making same and items using same
US7276459B1 (en) 2000-05-04 2007-10-02 Kimberly-Clark Worldwide, Inc. Ion-sensitive, water-dispersible polymers, a method of making same and items using same
WO2002059422A3 (en) * 2001-01-26 2002-10-10 Procter & Gamble Multi-purpose absorbent and shred-resistant sheet material
US6579816B2 (en) 2001-01-26 2003-06-17 The Procter & Gamble Company Multi-purpose absorbent and shred-resistant sheet material
US6586529B2 (en) 2001-02-01 2003-07-01 Kimberly-Clark Worldwide, Inc. Water-dispersible polymers, a method of making same and items using same
US6908966B2 (en) 2001-03-22 2005-06-21 Kimberly-Clark Worldwide, Inc. Water-dispersible, cationic polymers, a method of making same and items using same
US7070854B2 (en) 2001-03-22 2006-07-04 Kimberly-Clark Worldwide, Inc. Water-dispersible, cationic polymers, a method of making same and items using same
US6897168B2 (en) 2001-03-22 2005-05-24 Kimberly-Clark Worldwide, Inc. Water-dispersible, cationic polymers, a method of making same and items using same
US6828014B2 (en) 2001-03-22 2004-12-07 Kimberly-Clark Worldwide, Inc. Water-dispersible, cationic polymers, a method of making same and items using same
US20090130416A1 (en) * 2004-06-18 2009-05-21 Geel Paul A Highly Filled Fibrous Veil
US20100143684A1 (en) * 2004-06-18 2010-06-10 Owens Corning Fibrous veil impregnated with surface finish formulation
US20060128248A1 (en) * 2004-11-16 2006-06-15 Pgi Polymer, Inc. Nonwoven sanitizing wipe including an anionic binder formulation
US20060292948A1 (en) * 2005-06-27 2006-12-28 Geel Paul A Fibrous veil impregnated with surface finish formulation
US20100119784A1 (en) * 2005-09-29 2010-05-13 Northern Elastomeric, Inc. Rubberized roof underlayment
US20070071946A1 (en) * 2005-09-29 2007-03-29 Northern Elastomeric, Inc. Rubberized roof underlayment
US9702148B2 (en) 2005-09-29 2017-07-11 Owens Corning Intellectual Capital, Llc Rubberized roof underlayment
US20080014814A1 (en) * 2006-07-13 2008-01-17 Geel Paul A Highly filled fibrous veil
US20110104461A1 (en) * 2009-09-28 2011-05-05 Owens Corning Intellectual Capital, Llc Underlayment with slip-resistant surface
US9493954B2 (en) 2009-09-28 2016-11-15 Owens Corning Intellectual Capital, Llc Underlayment with slip-resistant surface
US20170162294A1 (en) * 2014-08-22 2017-06-08 Leoni Bordnetz-Systeme Gmbh Cable harness and method for producing the cable harness
US10068680B2 (en) * 2014-08-22 2018-09-04 Leoni Bordnetz-Systeme Gmbh Cable harness and method for producing the cable harness
US11028537B2 (en) 2016-12-30 2021-06-08 Kimberly-Clark Worldwide, Inc. Dispersible wet wipes constructed with patterned binder
CN109466154A (zh) * 2018-10-19 2019-03-15 德阳科吉高新材料有限责任公司 一种水泥基复合材料的制造方法

Also Published As

Publication number Publication date
FR2170872A1 (enrdf_load_stackoverflow) 1973-09-21
GB1362665A (en) 1974-08-07
FR2170872B1 (enrdf_load_stackoverflow) 1975-08-29
NL7200198A (enrdf_load_stackoverflow) 1973-07-10
AU465071B2 (en) 1975-09-01
DE2200243A1 (de) 1973-08-02
AU3703871A (en) 1973-06-21

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