WO1994019179A1 - Nouveau voile composite - Google Patents

Nouveau voile composite Download PDF

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Publication number
WO1994019179A1
WO1994019179A1 PCT/US1993/001783 US9301783W WO9419179A1 WO 1994019179 A1 WO1994019179 A1 WO 1994019179A1 US 9301783 W US9301783 W US 9301783W WO 9419179 A1 WO9419179 A1 WO 9419179A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
web
layer
man
composite web
Prior art date
Application number
PCT/US1993/001783
Other languages
English (en)
Inventor
Larry C. Wadsworth
Kermit E. Duckett
Venkataraman Balasubramanian
Original Assignee
The University Of Tennessee Research Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by The University Of Tennessee Research Corporation filed Critical The University Of Tennessee Research Corporation
Priority to JP51844394A priority Critical patent/JP3191940B2/ja
Priority to DE69328691T priority patent/DE69328691T2/de
Priority to DK93907081T priority patent/DK0715571T3/da
Priority to CA002104872A priority patent/CA2104872A1/fr
Priority to PCT/US1993/001783 priority patent/WO1994019179A1/fr
Priority to KR1019940703022A priority patent/KR100273482B1/ko
Priority to EP93907081A priority patent/EP0715571B1/fr
Publication of WO1994019179A1 publication Critical patent/WO1994019179A1/fr
Priority to HK98115783A priority patent/HK1014518A1/xx

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—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 welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/06—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter

Definitions

  • This invention relates to fibrous webs and particularly to novel composite webs comprising one or more layers of a thermoplastic nonwoven web in combination with a layer of cellulosic-based fibers.
  • Nonwoven webs are defined as "sheet or web structures made by bonding and/or interlocking fibers, yarns or filaments by mechanical, thermal, chemical or solvent means.” These webs do not require the conversion of fibers to yarn. Nonwoven webs are also called bonded or engineered webs and are manufactured by processes other than spinning, weaving or knitting, hence the name "nonwovens".
  • the basic structure of all nonwovens is a web of fibers or filaments. A single type of fiber or filament may be the basic element of a nonwoven. Fibers that are measured in centimeters or inches or fractions thereof are called staple fibers. Those fibers of extreme length are called filament fibers. In general filament fibers are measured in terms of kilometers or miles.
  • filament fibers are not readily measured, as they may be many, many yards in length. In fibers the length must be considerably greater than the diameter, e.g., a length-to-width (diameter) ratio of at least 100 and usually considerably higher.
  • Cotton fibers may measure from less than 1/2 inch to more than 2 inches in length and have a typical length- to-diameter ratio of about 1400. Other natural fibers exhibit typical ratios as follows: flax - 1200; ramie - 3000; and wool - 3000.
  • the terms "fiber” or “fibers” are intended to include both short and long fibers, i.e. staple fibers and filament fibers, unless otherwise specifically indicated by identifying the fibers as staple or filament.
  • spunbonded webs are formed of filament fibers
  • meltblown webs include an assortment of fiber lengths so that these webs commonly include both staple length and filament length fibers.
  • the individual fibers may be in an organized or in a random arrangement.
  • Tensile, elongation, and hand properties are imparted to the web by the type or types of bonding as well as fiber- to-fiber cohesion and reinforcement by its constituents.
  • the technology for making nonwoven webs is based on the following primary elements: fibers of various lengths and diameters; a web arranged according to the method of forming and processing; the bonding of fibers within the web and reinforcement by its constituents. The variation of one or several elements in combination allows for the enormous range of nonwoven fiber types.
  • Nonwoven webs have heretofore found acceptance in the medical industry as disposable substitutes for the prior art reusable cotton examination gowns, surgical gowns, surgical drapes, face masks, shoe covers, sterilization wrap and other products, to the extent that this market for nonwoven products is estimated to exceed one billion dollars annually. Further, nonwoven webs have found use in sanitary products, such as sanitary napkins, disposable diapers, incontinent pads and other similar products.
  • One of the benefits of nonwoven webs heretofore has been their relatively low cost, as compared to woven webs. The difference in cost between nonwoven and woven webs has heretofore been of a magnitude such that the end users can dispose of the nonwoven web product after a single use and yet realize a monetary gain over the multi-use woven webs.
  • Nonwoven webs generally have the reputation of notoriously lacking many of the properties of woven webs, in particular hand, wicking, and liquid absorption and retention.
  • Meltblown nonwoven webs for example, exhibit a void volume of about 85%; spunbonded nonwoven webs exhibit a void volume of between about 90 and 95%.
  • the filamentary nature of the fibers of many prior art webs and their methods of manufacture cause the fibers to lay in the webs with the length dimension of the fibers oriented substantially parallel to the plane of the web so that the webs have poor absorbency of liquids into the body of the web.
  • Considerable effort has been exerted heretofore to improve these properties of nonwoven webs, including modification of the manner of manufacturing and/or processing the web. This efforts, however, increase the cost of the nonwoven web and may adversely alter its monetary advantage over woven webs.
  • the fibers of nonwoven webs most commonly are petroleum-based and therefore have been subject to the substantial fluctuations in market price of this raw material, and the important considerations in ultimate disposal of the product after use.
  • the web of the present invention is multilayered and comprises a first layer of man-made fibrous material selected from the group consisting of thermoplastic meltblown man-made fibers, thermoplastic spunbonded man-made fibers, thermoplastic man-made staple fibers, and combinations thereof, this first layer being light weight and having a weight of between about 0.05 and about 10 oz/yd 2 , and a second layer of cellulosebased staple fibers, excluding wood fibers, and having a weight of between about 0.1 and about 10 oz/yd 2 , the fibers of the second layer having a fiber length of between about 0.5 and about 3.0 inches and a fineness of equivalent to between about 3 and 5 Micronaire units.
  • the layers are preferably thermally bonded together to form a coherent web, the area of bonding between the layers being between about 5 and about 75% of the area of one of the flat surfaces of the composite web.
  • the bonding contemplated in the present invention is of a type which does not adversely affect the hand and other physical characteristics of the web such as liquid wicking and retention rates. Accordingly, the preferred bonding is effected from only one side of the laminate.
  • the composite web includes at least a third layer of fibrous material selected from the group consisting of thermoplastic meltblown man-made fibers, thermoplastic spunbonded man-made fibers, thermoplastic man-made staple fibers and combinations thereof.
  • This third layer preferably also is light weight and has a weight of between about 0.05 and about 10 oz/yd 2 , and is disposed on that side of the second layer opposite the first layer and thermally bonded to at least the second layer such that the second layer is sandwiched between the first and third layers.
  • Other and additional like layers of like materials may be included in the composite.
  • the composite web product of the present invention preferably exhibits a final composite weight of between about 0.5 and about 24 oz/yd 2 in order to approximate a woven web in feel, drapability and other properties.
  • This limitation upon the present web requires that there be careful selection of the weight of each of the individuaal layers of the composite web which will provide other desirable or required properties such as strength, wicking, liquid absorption and retention, and barrier properties (ability to exclude liquids while permitting or even encouraging vapor and gas transfer through the thickness of the web).
  • the composite web of the present invention is particularly useful in the manufacture of disposable medical products because of its superior barrier properties, hand, breathability, strength, wicking and liquid absorption and retention, among other properties.
  • Figure 1 is a schematic representation of one embodiment of a web which incorporates various of the features of the present invention
  • Figure 2 is a schematic representation of another embodiment of a web which incorporates various of the features of the present invention.
  • Figure 3 is a schematic representation of a process for the formation of a web which incorporates various of the features of the present invention
  • Figure 4 is a schematic representation of a further process for the manufacture of a web which incorporates various of the features of the present invention
  • Figure 5 is a schematic representation of a still further process for the manufacture of a web and depicting in-line web-forming apparatus
  • Figure 6 is a representation of apparatus for use in liquid absorptivity and retention testing of webs
  • Figure 7 is a representation of apparatus for use in testing the wicking property of webs
  • Figures 8 through 34 are graphs depicting the wicking values of samples as identified in Table X.
  • Figure 35 is a graph depicting the wicking response of laminates in accordance with the present invention and having various cotton core weights
  • Figure 36 is a graph depicting the wicking response of nonlaminated cotton webs.
  • Figure 37 is a graph comparing the wicking response for laminates having a cotton core with a laminate having a ramie core.
  • the depicted composite web 10 comprises a first layer 12, and a second layer 14. As depicted, these layers are bonded one to the other as by a pattern of diamond-shaped bonds 16 that are each of substantially the same size and spaced apart from one another. These bond areas preferably extend over substantially the entire area of the composite web and thereby serving to integrate the layers into a coherent web.
  • a further web 10 which includes like first and second layers, 12 ' and 14' respectively, plus a third layer 20.
  • At least one of the layers of the composite web of the present invention is of thermoplastic man-made fibers. Accordingly, bonding of the layers of the web one to another may be accomplished by any of several well known thermal bonding means, such as passing the overlaid layers through a set of heated rolls. Preferably, at least one of these rolls is provided with a surface pattern of projections 30 (see Figure 3) which produce spaced apart bonded areas, such as the diamond-shaped areas depicted in Figure 1, by means of the pressure and heat combination provided by the rolls to the composite web as it is fed through the nip between these rolls. Other thermal bonding means such as ultrasonic welding and the like may be employed as desired.
  • Other techniques for joining the layers of the composite web of the present invention may include physical entanglement of the fibers of the several layers as by hydroentanglement, needle punching or the like.
  • the preferred bonding of the layers one to another is effected by means of spaced apart, and relatively small, bonding areas that extend over substantially the entire area of the composite web to effectively develop a unitar coherent web from the several layers without detrimental effect upon the desired properties of the web.
  • between about 5 and about 75% of the surface area of the composite web comprises bonding areas between the layers of the web.
  • the total percentage of bond area of the composite web is between about 10 and about 25% of the area of the composite web.
  • each of the layers of the web is formed individually and overlaid in a laminating-type operation. While held in their overlaid condition, the webs are bonded as described hereinabove. It is to be recognized, however, that the several layers of the present web may be formed substantially simultaneously, as in an inline production process, wherein one of the layers is formed and thereupon a second or further layer is formed on the first or previously formed layer. In this latter instance, the bonding operation may also be inline and at a location downstream of the formation of the final layer of the web.
  • FIG 3 there is depicted schemati- cally a process for overlaying previously formed layers 15, 17 and 19 into a web onto a forwardly moving conveyor 21 and thereafter bonding the layers into a coherent web 10 by passing the web through the nip 24 of a set of heated rolls 26 and 28.
  • the upper roll 28 is provided with a pattern of surface projections 30 which enhance the formation of the desired spaced apart bond areas 16.
  • the composite web 10 is collected in a roll 32 for storage and subsequent use.
  • each of the webs 15 and 19 is formed from man-made fibers, e.g. by spunbonding, meltblowing or other process which provide a coherent self-sustaining web.
  • FIG 4 there is depicted schematically a process for the manufacture of a web of the present invention in which a first layer 40 of man-made thermoplastic fibers is formed employing a conventional meltblowing or spunbonding process 44 and thereafter deposited on a forwardly moving conveyor 42.
  • a layer 48 of cellulosebased fibers produced either offline or inline as described in Figure 5 is overlaid onto the first layer 40 that is disposed on the moving conveyor 42.
  • a third layer 50 of thermoplastic man-made fibers is formed by a conventional meltblowing or spunbonding process 51 and overlaid onto the cellulose-based layer 48 to provide a three-layered web in which the cellulose-based fibrous layer 48 is disposed between outer layers 40 and 50 of man-made thermoplastic fibrous material.
  • these several overlaid layers are fed through the nip of a set of heated pressure rolls 54 and 56, one of which has a pattern of projections 58 on its outer surface, to thermally bond the several layers into a coherent web 59.
  • the composite web may be collected in a roll 60 for further use.
  • one or both of the first and second layers, 40 and 50 may be formed by conventional meltblowing, spunbonding or like techniques, including thermal bonding of man-made staple fiber webs.
  • a first web 64 of man-made fibers is formed as by means of an on-line conventional melt-blowing or spunbonding apparatus 66, fed past an idler roller 65, and deposited on the upper run of a first conveyor 67.
  • the process further includes an in-line carding section 68 in which a bale 69 of cellulose-based fibrous material is introduced to an in-line carding unit 70 from which a carded web 71 is fed directly from the carding unit onto a second conveyor 72.
  • the cellulosic web is fed forwardly onto the top of the web 64 on the conveyor 67.
  • a third web 74 of man-made fibers is formed as by means of a further in-line conventional meltblowing or spunbonding apparatus 75 and fed past an idler roller 76, and overlaid upon the top surface of the cellulosic web 71 wherein the cellulosic layer 71 becomes sandwiched between the webs 64 and 74 of man-made fibers.
  • a layer of man-made staple fibers may be formed into a web 87 as by means of. a conven- tional air laying web former 89 and interposed into the composite 83 between the cellulosic web 71 and one or both of the man-made fiber webs 64 and 74.
  • the composite web comprises at least two layers.
  • at least one of the layers is formed from cellulose-based fibers.
  • Cellulose-based as used herein is intended to include staple fibers which are composed of between about 25% and 100% cellulosic material. Suitable cellulosic materials from which the fibers may be obtained include cotton, ramie, hemp, jute, flax, kenaf, bagasse, eucalyptus, rayon (reconstituted cellulose) and combinations thereof, but does not include wood fibers.
  • the chosen cellulosic fiber typically is processed as is well known in the art to provide a clean, bright fiber which readily absorbs liq- uids.
  • cotton is scoured and bleached to remove the oils, etc. from the fiber and to render the fibers pliant and absorptive, as well as clean of foreign material and bright in color (white being deemed a color) .
  • a partial scour with little or no bleaching may provide sufficient absorbency and/or wicking for many applications.
  • the cellulosic fibers which are suitable for use in the web of the present invention are of a length of between about 0.5 and about 3 inches. Cotton fibers preferably range from about 0.5 to about 1.25 inches in length, whereas ramie or flax fibers may range up to about 3 inches in length. As desired, the longer fibers may be broken or chopped into shorter lengths.
  • the cellulosic fibers employed are not formed into yarns or threads.
  • the fibers may be processed, as by carding or the like, to orient the fibers or preferably to randomize their orientation, and form the fibers into a self-supporting web.
  • the fibers may be used directly from the bale as received from the fiber processing operation and in this instance will be introduced to the present web as a layer in which the fibers are carded more or less parallel to each other or are randomly oriented.
  • the cotton fibers preferably are of a fineness of between about 3 and 5 Micronaire units so as to be sufficiently flexible to permit the development of the desired hand and drapability, among other properties, of the composite web of the present invention.
  • Cotton fibers of a size larger than about 5 Micronaire units are less flexible and webs formed therefrom tend to be of harsh and unacceptable hand.
  • Cotton fibers are a preferred form of cellulose-based fibers for use in the composite web of the present invention.
  • Cotton fibers have a nonsmooth surface and exhibit a surface energy of about 44 dyne/cm as compared to a surface energy of polyolefins fibers of about 31 dyne/cm, and thereby exhibit a good tendency to remain in place once layered in the composite web of the present invention.
  • cotton fibers contribute to the composite web excellent properties, such as wicking, absorbency and liquid retention, bulk, liquid repellency but vapor and gas permeability, and strength in some of the composite constructions, particularly if meltblown webs lighter than 0.5 oz/yd 2 (17 g/m 2 ) are used.
  • the inner layer must be formed of staple length fibers, as opposed to filament length fibers.
  • the staple fibers being of relatively short individual lengths, most often being of a mixture of lengths, all of which are less than about 3 inches, and preferably less than about 2 inches, in length, provide a multiplicity of ends of fibers.
  • these fibers are not formed into yarns, but are present in the inner layer as individual fibers that preferably have no major orientation other than the fact that they are formed into a web that is sufficiently coherent to be handled by automated equipment for overlaying onto a conveyor or a further web on a conveyor, the fiber ends tend to extend in all directions within the web. Many of the fiber ends, therefore, extend generally laterally of the plane of the web and even project from the flat general surface of the web.
  • This characteristic of the staple fiber web is one of the major reasons that it is unacceptable in this form for use in medical applications.
  • this heretofore unacceptable web is captured between two webs of man-made nonwoven fibers such that the man-made webs serve to contain the short cellulosic fibers.
  • man-made fibrous webs must be carefully chosen so as to not deleteriously affect the hand and other of the desired properties of the resultant composite web.
  • the man-made fibrous webs are chosen for their ability to permit the cellulosic fibers of the inner lay to impart to the composite web those desirable properties of hand and liquid wicking and retention. This is accomplished in the present invention by employing webs of man-made fibers which have been formed into webs by processes which develop substantial void volumes in the webs, but which are formed of fibers having a degree of fineness which enables the webs to simultaneously serve the function of a barrier to bacteria, etc. and without adversely inhibiting the transfer of vapor or liquid through the thickness of the web and into the inner layer of cellulosic fibers where the liquid is rapidly captured and does not strike-through the composite web.
  • Those ends of the short staple fibers of the inner layer of the composite web which are oriented generally laterally of the plane of the inner layer serve to define many regions of liquid transport into this inner layer.
  • the outer layers of the man-made fibers are hydrophobic in nature and have low surface tension values. These fibers also are continuous in length and are poor transporters of liquids.
  • the staple fibers of the inner layer are hydrophilic and have relatively high surface tension values, are nonsmooth, buckled along their length, and present in large numbers so that they tend to draw the liquid into the body of the inner layer.
  • the many ends of the staple fibers of the inner layer which extend laterally of the plane of the inner layer define ready pathways for the transport of liquid into the inner layer, both by reason of their affinity to the liquid and the fact that their great numbers, their geometry, and physical orientation in the inner layer define large numbers of capillaries within the inner layer which further enhance the movement of liquids into, and aid in retention of the liquid within, the inner layer.
  • Cotton fibers also swell when wetted so these fibers are preferred in webs where the web is expected to both absorb liquids and serve a barrier function.
  • a web of cellulose-based fibers in which the fibers are not bonded one to another is useless in most disposable medical products.
  • the web is of insufficient strength to be self-sustaining, and second, the fibers tend to free themselves from the web and thereby introduce unacceptable potential sources of contamination.
  • Loose fibers in surgical gowns, for example, which enter an open wound or incision can be the source of granulomas within the patient and therefore in this application, the fibers must be adequately contained.
  • the cellulose-based fibers are combined with a layer of thermoplastic man-made fibers.
  • the combination of a layer of cellulose-based fibers with a layer of thermoplastic man-made fibers when the layers are thermally bonded together at spaced apart locations, provides a coherent composite web that exhibits enhanced properties, especially wicking, liquid retention, and strength.
  • the layer of man-made fibers provides strength and abrasion resistance to the composite web, and therefore, in a preferred composite web, the layer of cellulose-based fibers is sandwiched between outer layers of man-made fibers.
  • meltblown and spunbonded webs of thermoplastic man-made fibers of the prior art have required special and additional treatment following their formation in order to make these webs useful in disposable medical and sanitary products
  • the present inventors have found that through the combination of selected ones of these webs with selected cellulose-based layers in a bonded composite web, it is possible to produce a composite web which does not require that the man-made fibrous webs be specially treated, but rather these selected webs can be directly incorporated into the composite web of the present invention. This capability provides the present invention with a substantial economic advantage.
  • the webs of man-made fibers preferably are formed by meltblowing or spunbonding techniques.
  • Meltblown fibers of these man-made fibers preferably are of a diameter of between about 0.5 and about 10.0 micrometers; whereas, the diameters of the fibers in spunbond webs overlap with meltblown webs on the low end at about 8.0 micrometers and may range up'to 50 micrometers or more on the upper end of their diameter range.
  • Spunbond webs generally are coarser but stronger than meltblown webs because spunbond fibers are given notable orientation after quenching. In either instance, the fibers are formed into self-sustaining webs.
  • the preferred web weight of a meltblown web for use in the present invention is light weight, having a weight in the range of between about 0.05 and about 10 oz/yd 2 , and most preferably between about 0.25 and about 2 oz/yd 2 .
  • the preferred weight of a spunbonded web for use in the present invention is also light weight having a weight between about 0.1 and about 10 oz/yd 2 , and most preferably between about 0.3 and about 2 oz/yd 2 .
  • Webs of weights lighter than about 0.05 oz/yd 2 tend to be of insufficient fiber density for containing the cellulosic fibers and providing the strength and other properties desired in the composite web.
  • a preferred composite web in accordance with the present invention comprises an inner layer of cellulose-based fibers which is sandwiched between outer layers of man-made fibers.
  • the composite web therefore, may comprise different combinations of layers.
  • the composite web may include a first layer of meltblown man-made fibers facing one surface of the cellulose fibers and a third layer comprising spunbonded man- made fibers facing the opposite surface of the cellulose fiber layer.
  • the first and third layers may both be either meltblown or spunbonded fibers.
  • the cellulose fibers are to be protected by at least one outer layer, and preferably two outer layers, of man-made fibers. It will be recognized that the addition of further layers tc the composite web increases the cost of the web and may detract from the hand and other desirable properties of the composite web.
  • Samples of composite webs employing features of the present invention were manufactured employing the process depicted schematically in Figure 3.
  • the cellulose-based fibers were fed to an opener-mixer where the fibers from a bale were opened and uniformly mixed.
  • the fibers from the opener mixer were fed through a card wherein the fibers were carded to develop a web which was doffed directly from the card, without being wound up, and fed onto a layer of thermoplastic man-made fibers carried on a conveyor.
  • the card employed in the manufacture of the present samples had a randomizing unit attached to its exit end so that the fibers were randomly oriented in the web with little or no preferred orientation in the machine direction.
  • thermoplastic man-made fibers was overlaid on top of the cellulose fiber layer so that the cellulose fiber layer was sandwiched between the two outer layers of thermoplastic man-made fibers.
  • This laminate was then fed through the nip between a set of heated rolls, one of which was of a smooth surface and other of which was provided with a patterns of spaced projections, each of which was of a diamond-shaped cross section. Tables I and II provide further details regarding the operational parameters employed in the preparation of these samples and the composition of the various samples.
  • Barrier refers to the ability of a fabric to resist strike-through of fluid and microorganisms. Barrier properties protect the operating room staff and the patient from infection.
  • Drapability and Comfort Drapability of a nonwoven fabric refers to its ability to conform to the shape of the object it is covering.
  • the objects include patients, operating room tables and equipment.
  • Comfort relates to breathability, selection of materials and product design.
  • Sample No. 8 1.8 oz/sq.yd unfinished SMS (Spunbonded/melt bloun/spunbonded) fabric.
  • Sample No. 9 1.8 oz/sq.yd finished SHS fabric.
  • Sample No. 10 2.3 oz/sq.yd unfinished SHS fabric.
  • the data of Table III indicate that the lightweight laminate of the present invention exhibit strength values which are fully suitable for the anticipated use of these laminates as substitutes for the prior art fabrics formed solely from synthetic fibers or filaments, i.e. the prior art SMS fabrics which have heretofore been popular for use in medical applications.
  • the present laminates further exhibit good hand (bending length) and liquid barrier properties, relative to laminates which do not include a layer of cellulosic fibers.
  • the laminates of the present invention possess excellent properties relating to liquid absorption, retention and wicking which make the present laminates much more useful and desirable for medical uses, for example.
  • a fluorochemical finish was given to laminated samples in order to improve their repellency characteristics - toward water, oil, blood, alcohol, and other aqueous liquids - and barrier properties of the fabrics.
  • a padding technique a conventional method of applying continuous finish was used to give the laminate samples a fluorochemical finish.
  • the sample is immersed into the chemical mixture and then passed through the nip of a set of rollers to squeeze out the excess chemicals from the saturated laminate by the application of nip pressure.
  • the nip pressure is adjusted in order to get the desired wet pick up percentage (WPU%).
  • WPU% wet pick up is the amount of finish liquor absorbed by the laminate sample.
  • the unfinished samples were weighed after being cut.
  • the samples passed through the padding mangle for fluorochemical finishing were weighed after finishing treatment.
  • the wet pick up percentage was determined as follows:
  • Fluorochemical finishing was carried out using a 18" wide padding mangle.
  • the fluorochemical used to treat the laminate samples was 5% "Zonyl" PPR Fabric Protector from Dupont. A wet pick up of 140% was planned for.
  • the samples were given a fluorochemical finish in the padding mangle with two dips and two nips at a pressure of 30 psi.
  • the finished samples were then cured in a convection oven at 250°F for 3.5 minutes on a pin frame.
  • the following fluorochemical formulation was used:
  • the hydrostatic pressure levels needed to pass liquid through the samples were already notably high with the unfinished samples which attest to the good barrier properties provided by the meltblown webs.
  • the repellent finished samples 1, 2 and 3 which contained only cotton staple fiber in the center layer had much higher hydrostatic pressure levels than the corresponding unfinished samples, and had generally greater hydrostatic pressure values than the finished samples with only polypropylene (PP) in the center.
  • the hydrostatic pressures of most of the samples with only PP in the core were notably decreased by repellent finishes.
  • the water spray rating of the majority of the finished samples were seen to have increased as a result of fluorochemical finishing.
  • the poplin fabrics were evaluated after the stages of desizing, scouring and bleaching, durable process finishing and after the combination of durable press and fluorochemical finishing. All the preparatory finishing, and durable press and repellent finishing processes were performed using commercial eguipment at a commercial facility. Data further identifying these fabrics are given in Table VIII. The results of tests performed on the fabrics are given in Table IX.
  • the composite webs of the present invention exhibited hand and drapability approximating that of woven webs of the type heretofore used in surgical gowns and similar medical applications.
  • the air permeability of the present composite webs i.e, between about 25 and about 37 ft 3 /min/ft 2 , also is comparable to that of woven webs such as shirting material and therefore provides barrier properties and breathability equivalent to such woven webs.
  • the presence of the fibrous layer in the present composite web provides enhancement of the filtration efficiency of the present web over the single-layered woven webs of the prior art, thereby enhancing the usefulness of the present composite web in applications where the barrier properties of the web are of importance.
  • FIG. 6 depicts the testing apparatus which consists of a large funnel 80 with a glass frit 82 and a graduated collection cylinder 84.
  • a circular specimen 86 with an area of 100 cm 2 was conditioned over- night at 21°C and 65% RH. The sample was placed face upwards on the glass frit.
  • One hundred milliliters of liquid delivered at a rate of 7 mm/sec from a height of 2.54 cm was used to saturate the specimen.
  • a 100 cm 2 circular weight 88 of 100 gm was promptly placed on the saturated specimen and the assembly allowed to drain for 10 minutes.
  • the amount of liquid collected in the cylinder was determined and used to calculate the absorbent capacity (C) of the product by the following calculation.
  • the present fabrics also are lightweight and, in fact, those fabrics having lesser amounts (by weight) of meltblown material were noted to be superior with respect to liquid absorbent and retention capacities, thereby affording an economic advantage also. Further, even though 100% cotton webs were noted to lose some of their retention capacity as the weight of the web increased, when these same cotton webs were incorporated into the laminated structure of the present invention, the resultant laminate unexpectedly exhibited improved retention capacity with increasing weight of cotton in the inner layer.
  • Samples 20 and 21 were bonded at 150 PLI pressure with 41°C on the top patterned roll and 41°C on the bottom smooth roll at a fabric speed of 10 yd/min (9.1 m/min).
  • Samples 25A and 253 were bonded using a top roll temperature of 88°C and bottom roll temperature of 90°C with 250 PLI and a fabric speed of 10 yd/min (9.1 m/min).
  • Samples 26A and 26B were bonded using a top roll temperature of 105°C and bottom roll temperature of 100°C with 250 PLI and a fabric speed of 10 yd/min (9.1 m/min).
  • Samples 22, 23, 24, 27, 28A, 28B, 28C, 29A, 29B, 29C, 30A, 30B, 30C, 31A, 31B, 32A and 32B were bonded using a top roll temperature of 134°C and bottom roll, temperature of 129°C with 250 PLI and a fabric speed of 10 yd/min (9.1 m/min). The remainder of these samples, not otherwise designated, were laminated under the same conditions except the temperature of the top and bottom rolls were 125°C and 122°C respectively.
  • eguipment setup as shown in Figure 7.
  • This eguipment included a toploading balance 90 with attached printer 92; laboratory jack 94; water reservoir 95 to hold test liquid 96; funnel 98 with coarse (40-60 micron) glass frit 100; rubber tubing 102 to connect funnel 98 to water reservoir 94; 100g circular weight 106 (area, 100 cm 2 ); and a stopwatch (not shown).
  • the funnel 98 is vertically adjustably mounted on a ring stand 110.
  • One hundred cm 2 circular samples 108 are cut randomly from a sheet that had been conditioned at 20°C and 65% relative humidity overnight. Seven samples are cut from each sheet to be tested.
  • test liquid reservoir was raised until the surface of the glass frit was moist (but water was not standing on it).
  • the specimen was placed on the frit with the 100g circular weight on top.
  • a stopwatch was started with the placement of the weight on the sample and a reading of the weight of test liquid lost from the reservoir to the sample was taken every 10 seconds over an interval of 3 minutes. This provided sufficient time to allow the amount of liquid wicked into the sample to stabilize.
  • the result was plotted on a time versus amount curve. This procedure was replicated seven times for each sheet evaluated. Identification of the several samples is given in Table X. The time vs. amount curves which resulted from the testing of these samples are presented in Figures 8 through 34.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un voile composite non-tissé et à couches multiples (10) particulièrement utile pour remplacer les voiles telles que les voiles textiles. Ce voile composite a des propriétés améliorées d'absorption des liquides par capillarité et de rétention des liquides. La première couche (12) est constituée de matériau fibreux choisis dans le groupe des fibres artificielles thermoplastiques produites par fusion et soufflage, des fibres artificielles thermoplastiques continues et désorientées, de fibres coupées artificielles thermoplastiques ainsi que leurs combinaisons. Cette première couche est légère. La seconde couche (14) est constituée de fibres à base de cellulose, de préférence de fibres de coton. La première et la seconde couches sont fixées thermiquement ensemble (16) sur environ 5 à 75 % de la surface du tissu pour former un tissu cohérent présentant une perméabilité à l'air entre environ 25 et environ 37 pieds cubiques par minute par pied carré. Dans une forme d'exécution préférée, le tissu composite comprend au moins une troisième couche de fibres artificielles thermoplastiques et la couche de fibres à base de cellulose est prise en sandwich entre les deux couches de fibres artificielles thermoplastiques.
PCT/US1993/001783 1992-02-26 1993-02-26 Nouveau voile composite WO1994019179A1 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
JP51844394A JP3191940B2 (ja) 1993-02-26 1993-02-26 新規な複合ウエブ
DE69328691T DE69328691T2 (de) 1992-02-26 1993-02-26 Neue verbundbahn
DK93907081T DK0715571T3 (da) 1992-02-26 1993-02-26 Nyt kompositvæv
CA002104872A CA2104872A1 (fr) 1993-02-26 1993-02-26 Substrat non-tisse multicouches, absorbant, pour bandes tissees
PCT/US1993/001783 WO1994019179A1 (fr) 1993-02-26 1993-02-26 Nouveau voile composite
KR1019940703022A KR100273482B1 (ko) 1993-02-26 1993-02-26 다층 부직포 복합 웹
EP93907081A EP0715571B1 (fr) 1992-02-26 1993-02-26 Nouveau voile composite
HK98115783A HK1014518A1 (en) 1992-02-26 1998-12-28 Novel composite web

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA002104872A CA2104872A1 (fr) 1993-02-26 1993-02-26 Substrat non-tisse multicouches, absorbant, pour bandes tissees
PCT/US1993/001783 WO1994019179A1 (fr) 1993-02-26 1993-02-26 Nouveau voile composite

Publications (1)

Publication Number Publication Date
WO1994019179A1 true WO1994019179A1 (fr) 1994-09-01

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PCT/US1993/001783 WO1994019179A1 (fr) 1992-02-26 1993-02-26 Nouveau voile composite

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KR (1) KR100273482B1 (fr)
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WO (1) WO1994019179A1 (fr)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997013909A2 (fr) * 1995-10-11 1997-04-17 Jacob Holm Industries (France) Sas Non-tisses composites et procedes de realisation
US6808791B2 (en) 1999-12-21 2004-10-26 The Procter & Gamble Company Applications for laminate web
US6830800B2 (en) 1999-12-21 2004-12-14 The Procter & Gamble Company Elastic laminate web
EP1510334A1 (fr) * 2003-08-20 2005-03-02 Reifenhäuser GmbH & Co. Maschinenfabrik Lamine fibreux et preparation d'un lamine fibreux
WO2012163317A1 (fr) * 2011-05-30 2012-12-06 Ascania Nonwoven Germany Gmbh Procédé de fabrication d'un composite et composite
WO2014099895A1 (fr) * 2012-12-17 2014-06-26 Atex Technologies, Inc. Textile médical et ses procédés de fabrication
US8852474B2 (en) 2007-07-17 2014-10-07 The Procter & Gamble Company Process for making fibrous structures
US8921244B2 (en) 2005-08-22 2014-12-30 The Procter & Gamble Company Hydroxyl polymer fiber fibrous structures and processes for making same
US9458573B2 (en) 2009-11-02 2016-10-04 The Procter & Gamble Company Fibrous structures and methods for making same
US9631321B2 (en) 2010-03-31 2017-04-25 The Procter & Gamble Company Absorptive fibrous structures
US10024000B2 (en) 2007-07-17 2018-07-17 The Procter & Gamble Company Fibrous structures and methods for making same
CN110846809A (zh) * 2019-10-24 2020-02-28 浙江理工大学 一种单向导湿针刺复合多层絮片及其制备方法
US10858785B2 (en) 2007-07-17 2020-12-08 The Procter & Gamble Company Fibrous structures and methods for making same
US10895022B2 (en) 2009-11-02 2021-01-19 The Procter & Gamble Company Fibrous elements and fibrous structures employing same
US11414798B2 (en) 2007-07-17 2022-08-16 The Procter & Gamble Company Fibrous structures

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KR101681086B1 (ko) * 2014-12-05 2016-12-01 유영배 휠체어 브레이크 시스템
KR101996801B1 (ko) * 2017-03-11 2019-10-01 박희범 전후륜 순차 제동 브레이크 레버

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US4885202A (en) * 1987-11-24 1989-12-05 Kimberly-Clark Corporation Tissue laminate
US4950531A (en) * 1988-03-18 1990-08-21 Kimberly-Clark Corporation Nonwoven hydraulically entangled non-elastic web and method of formation thereof

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US4355066A (en) * 1980-12-08 1982-10-19 The Kendall Company Spot-bonded absorbent composite towel material having 60% or more of the surface area unbonded
US4885202A (en) * 1987-11-24 1989-12-05 Kimberly-Clark Corporation Tissue laminate
US4950531A (en) * 1988-03-18 1990-08-21 Kimberly-Clark Corporation Nonwoven hydraulically entangled non-elastic web and method of formation thereof

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Cited By (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997013909A3 (fr) * 1995-10-11 1997-05-29 Jacob Holm Ind France Sas Non-tisses composites et procedes de realisation
US5989688A (en) * 1995-10-11 1999-11-23 Jacob Holm Industries (France) Sas Composite nonwovens and methods for the preparation thereof
WO1997013909A2 (fr) * 1995-10-11 1997-04-17 Jacob Holm Industries (France) Sas Non-tisses composites et procedes de realisation
US6808791B2 (en) 1999-12-21 2004-10-26 The Procter & Gamble Company Applications for laminate web
US6830800B2 (en) 1999-12-21 2004-12-14 The Procter & Gamble Company Elastic laminate web
EP1510334A1 (fr) * 2003-08-20 2005-03-02 Reifenhäuser GmbH & Co. Maschinenfabrik Lamine fibreux et preparation d'un lamine fibreux
US8921244B2 (en) 2005-08-22 2014-12-30 The Procter & Gamble Company Hydroxyl polymer fiber fibrous structures and processes for making same
US11326276B2 (en) 2007-07-17 2022-05-10 The Procter & Gamble Company Process for making fibrous structures
US11414798B2 (en) 2007-07-17 2022-08-16 The Procter & Gamble Company Fibrous structures
US11959225B2 (en) 2007-07-17 2024-04-16 The Procter & Gamble Company Fibrous structures and methods for making same
US11639581B2 (en) 2007-07-17 2023-05-02 The Procter & Gamble Company Fibrous structures and methods for making same
US8852474B2 (en) 2007-07-17 2014-10-07 The Procter & Gamble Company Process for making fibrous structures
US11346056B2 (en) 2007-07-17 2022-05-31 The Procter & Gamble Company Fibrous structures and methods for making same
US9926648B2 (en) 2007-07-17 2018-03-27 The Procter & Gamble Company Process for making fibrous structures
US10024000B2 (en) 2007-07-17 2018-07-17 The Procter & Gamble Company Fibrous structures and methods for making same
US10858785B2 (en) 2007-07-17 2020-12-08 The Procter & Gamble Company Fibrous structures and methods for making same
US10513801B2 (en) 2007-07-17 2019-12-24 The Procter & Gamble Company Process for making fibrous structures
US10895022B2 (en) 2009-11-02 2021-01-19 The Procter & Gamble Company Fibrous elements and fibrous structures employing same
US9714484B2 (en) 2009-11-02 2017-07-25 The Procter & Gamble Company Fibrous structures and methods for making same
US11618977B2 (en) 2009-11-02 2023-04-04 The Procter & Gamble Company Fibrous elements and fibrous structures employing same
US9458573B2 (en) 2009-11-02 2016-10-04 The Procter & Gamble Company Fibrous structures and methods for making same
US10697127B2 (en) 2010-03-31 2020-06-30 The Procter & Gamble Company Fibrous structures and methods for making same
US10240297B2 (en) 2010-03-31 2019-03-26 The Procter & Gamble Company Fibrous structures and methods for making same
US9631321B2 (en) 2010-03-31 2017-04-25 The Procter & Gamble Company Absorptive fibrous structures
US11680373B2 (en) 2010-03-31 2023-06-20 The Procter & Gamble Company Container for fibrous wipes
WO2012163317A1 (fr) * 2011-05-30 2012-12-06 Ascania Nonwoven Germany Gmbh Procédé de fabrication d'un composite et composite
WO2014099895A1 (fr) * 2012-12-17 2014-06-26 Atex Technologies, Inc. Textile médical et ses procédés de fabrication
CN110846809A (zh) * 2019-10-24 2020-02-28 浙江理工大学 一种单向导湿针刺复合多层絮片及其制备方法

Also Published As

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KR100273482B1 (ko) 2000-12-15
JP3191940B2 (ja) 2001-07-23
CA2104872A1 (fr) 1994-08-27
JPH08509432A (ja) 1996-10-08

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