WO1995003443A1 - Textile non tisse elastique composite - Google Patents

Textile non tisse elastique composite Download PDF

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Publication number
WO1995003443A1
WO1995003443A1 PCT/US1993/006747 US9306747W WO9503443A1 WO 1995003443 A1 WO1995003443 A1 WO 1995003443A1 US 9306747 W US9306747 W US 9306747W WO 9503443 A1 WO9503443 A1 WO 9503443A1
Authority
WO
WIPO (PCT)
Prior art keywords
elastomeric
net
nonwoven fabric
spunbond
elastic
Prior art date
Application number
PCT/US1993/006747
Other languages
English (en)
Inventor
Thomas E. Quantrille
Original Assignee
Fiberweb North America, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US07/825,016 external-priority patent/US5334446A/en
Application filed by Fiberweb North America, Inc. filed Critical Fiberweb North America, Inc.
Priority to AU46828/93A priority Critical patent/AU4682893A/en
Publication of WO1995003443A1 publication Critical patent/WO1995003443A1/fr

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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
    • B32B5/02—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
    • 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
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/02—Layered products comprising a layer of natural or synthetic rubber with fibres or particles being present as additives in the layer
    • 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
    • B32B5/04—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 characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G25/00—Lap-forming devices not integral with machines specified above
    • 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
    • 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
    • D04H1/56—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 in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • 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
    • D04H3/04—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 in rectilinear paths, e.g. crossing at right angles
    • D04H3/045—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 in rectilinear paths, e.g. crossing at right angles for net manufacturing
    • 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
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding

Definitions

  • the invention relates to composite elastic nonwoven fabrics and to processes for producing them. More specifically, the invention relates elastic to nonwovens having desirable strength, conformability, aesthetic, and stretch and recovery properties, and which can be readily manufactured using existing textile equipment.
  • Nonwoven elastic fabrics have been the subject of considerable attention and effort.
  • Elastic fabrics are desirable for use in bandaging materials, garments, diapers, supportive clothing and personal hygiene products because of their ability to conform to irregular shapes and to allow more freedom of body movement than fabrics with limited extensibility.
  • Elastomeric materials have been incorporated into various fabric structures to provide stretchable fabrics. In many instances, such as where the fabrics are made by knitting or weaving, there is a relatively high cost associated with the fabric. In cases where the fabrics are made using nonwoven technologies, the fabrics can suffer from insufficient strength and/or only limited stretch and recovery properties.
  • Elastic nonwoven webs have been produced by meltblowing of elastomers. This involves melting the elastomer in an extruder and feeding the molten resin to a melt-blowing die having a plurality of linearly arranged small diameter capillaries. The resin emerges from the die orifices as molten threads into a high velocity stream of gas, usually, air.
  • meltblown elastomeric webs are only moderately strong because the meltblowing process is normally conducted using relatively low molecular weight, and relatively high melt flow rate polymers.
  • elastomeric meltblown webs are only moderately elastic for similar reasons. These deficiencies in elasticity can be seen in relatively high creep, i.e., the time dependent increase in elongation when the web is subjected constant stress; and also in relatively high stress relaxation, i.e., the time dependent loss of retractive power when the web is held in a stretched condition.
  • elastomeric nonwoven fabrics also suffer from poor aesthetics. Elastomers often have an undesirable rubbery feel. As a result, elastomeric nonwoven fabrics often have a hand and texture that is perceived by the user as sticky or rubbery and therefore undesirable.
  • U.S. Patent 4,775,579 to Hagy, et al. discloses desirable composite elastic nonwoven fabrics containing staple textile fibers intimately hydroentangled with an elastic web or an elastic net.
  • One or more webs of staple textile fibers and/or wood pulp fibers can be hydroentangled with an elastic net according to the disclosure of this invention.
  • the resulting composite fabric exhibits characteristics comparable to those of knit textile cloth and possesses superior softness and extensibility properties.
  • the rubbery feel traditionally associated with elastomeric materials can be minimized or eliminated in these fabrics.
  • U.S. 4,413,623 to Pieniak discloses a laminated structure such as a disposable diaper which can incorporate an elastic net into portions of the structure.
  • the elastic net can be inserted in a stretched condition between first and second layers of the structure and bonded to the layers while in the stretched condition. Subsequent relaxation of the elastic net can result in gathering of the structure.
  • U.S. 4,525,407 to Ness discloses elastic fabrics which include an elastic member, which may be an elastic net, intermittently bonded to a substrate which prior to stretching is less easily extensible than the elastic member. The nonelastic member is bonded to the elastic member and the entire composite is rendered elastic by stretching and relaxation.
  • U.S. 4,606,964 to ideman discloses a bulked composite web which can be prepared by bonding a gatherable web to a differentially stretched elastic net. Subsequent relaxation of the differentially stretched net is said to result in gathering of the fabric.
  • thermoplastic elastomers can lose elastic properties when stressed at elevated temperatures and allowed to cool fully or partially while stressed, and/or the thermoplastic fibers and filaments can break, resulting in an elastic fabric with minimal elastic properties.
  • the resultant fabric when relaxation with concomitant gathering is used as the basis for stretch in the final composite, the resultant fabric often has an excessive thickness which can also be aesthetically objectionable. And in many instances, the final fabric exhibits a low extensibility which is well below the possible extensibility afforded by the elastomeric component.
  • the invention provides composite elastic nonwoven fabrics which exhibit improved strength, elastic, and aesthetic properties.
  • Composite fabrics provided according to the invention can have a high degree of elastic stretch, while problems of insufficient strength, insufficient retention of elastic properties during fabric use, and excessive fabric thickness, can be minimized or eliminated.
  • nonwoven elastic fabrics of the invention can exhibit desirable hand, cover and barrier characteristics. The fabrics of the invention can be readily manufactured while many of the difficulties associated with manufacturing of prior art composite elastic fabrics are avoided.
  • the elastic nonwoven composite fabrics of the invention are formed from the combination of a plurality of cooperative elastomeric layers including an elastomeric fibrous layer and an elastomeric net layer which has different elastic properties as compared to the elastomeric fibrous layer.
  • the net has higher strength, higher elastic recovery, lower stress relaxation and/or lower creep than the elastomeric fibrous layer.
  • the plural elastomeric layers are joined together into a unitary elastic fabric structure to provide a composite having a desirable combination of elastic properties.
  • the elastomeric net component imparts desirable strength, stretch, and recovery properties to the composite fabric.
  • the elastomeric fibrous web imparts desirable cover, barrier, and/or porosity properties to the composite, both when the fabric is relaxed and when it is stretched. Because the component layers used to form the composites of the invention are elastic structures, no stretching and subsequent relaxation are required to impart elastic properties to the composite.
  • one or more elastomeric meltblown fabric layers are combined with an elastomeric net.
  • the resulting composite has the desirable stretch, barrier and cover properties of an elastomeric meltblown and also has strength and recovery properties not previously available from elastic meltblowns, which previously have been subject to tearing and/or rupture when subjected to significant forces, or have been reinforced with other materials which significantly limit extensibility and often greatly increase fabric thickness.
  • the composite nonwoven elastic net/elastic meltblown fabrics of the invention can be manufactured by relatively simple and straightforward manufacturing processes which involve forming at least one elastomeric meltblown layer directly on a preformed elastomeric net.
  • the elastomeric meltblown can be formed onto one side of the elastomeric net and onto both sides.
  • the elastomeric net/elastomeric meltblown composite fabrics of the invention can be viewed as an elastic fibrous composite with a corresponding elastic reinforcing scrim.
  • the elastic meltblown layer provides coverage with elasticity, and the elastic net layer provides structural integrity while maintaining elasticity and recovery. Importantly, neither the coverage layer nor the reinforcing scrim layer reduce elasticity; instead both layers are highly elastic.
  • one or more elastomeric spunbond fabric layers are joined to an elastomeric net to provide a composite elastic nonwoven fabric of improved stretch and hand.
  • the elastomeric spunbond layer or layers can be joined to the elastomeric net by a thermal or adhesive bonding process. Preferably, joining of the net and spunbond elastomeric layers is accomplished by point bonding using heat and pressure with a calender.
  • One preferred fabric according to this embodiment of the invention is a fabric of the structure: elastomeric spunbond/elastomeric net/elastomeric spunbond.
  • the elastomeric spunbond/elastomeric net composites of the invention can provide good extensibility and good hand from the elastomeric spunbond layer, while the elastomeric net layer provides good recovery. Nonwoven composites made from these materials have stretch in both directions, with no need to laminate additional materials of low extensibility.
  • the composite elastic fabrics of the invention provide improved and different elastic properties as compared to numerous prior art fabrics.
  • Fabrics according to the invention can be used in personal care and hygiene products, diapers, disposable training pants, bandages, disposable medical and industrial garments and in industrial products such as for filtration.
  • Fabrics of the invention can be provided with controllable filtration properties such that filtration ability can be changed simply by varying elongation of the fabric. This can be extremely useful in industrial systems because as a filter becomes clogged from trapped particulates, the fabric can be slightly elongated and used for a longer time.
  • the fabrics of the invention avoid manufacturing complexities associated with many prior art fabrics. Thus the fabrics of the invention in many cases can lower the costs and substantially improve manufacturing efficiencies previously associated with composite elastic fabrics.
  • Figure 1 illustrates in perspective view an elastomeric net in roll form which can be used in producing fabrics of the invention
  • Figure 2 schematically illustrates one preferred method and apparatus for manufacturing one preferred composite elastic nonwoven web from the combination of meltblown elastomeric layers and an elastomeric net according to the invention
  • Figure 3 is a fragmentary cross-sectional view taken along line 3-3 of Figure 2 and schematically illustrates the structure of the composite formed according to the process of Figure 2 and shows strands of an elastomeric net contained within the fibrous structure of meltblown elastomeric webs;
  • Figure 4 schematically illustrates one preferred method and apparatus for manufacturing another preferred composite elastic nonwoven fabric of the invention from the combination of spunbond elastomeric layers and an elastomeric net;
  • Figure 5 is a fragmentary cross-sectional view taken along line 5-5 of Figure 4 and schematically illustrates the structure of the composite formed according to the process of Figure 4 and shows strands of an elastomeric net sandwiched between spunbond elastomeric webs and also illustrates point bonding zones where the layers are thermally joined together.
  • the various fibrous and other nonwoven fabric and/or sheet layers used in this invention for forming the composite fabrics of this invention are elastomeric layers having elastic properties.
  • elastomeric is used with reference to nonwoven layers, to mean nonwoven layers, including nets, fabrics or webs capable of substantial recovery, i.e. greater than about 75%, preferably greater than about 90% recovery, when stretched in an amount of about 30% at room temperature expressed as:
  • % recovery (L, - L r )/(L, - Lford) X 100 where: L s represents stretched length; L r represents recovered length measured one minute after recovery; and L 0 represents original length of material.
  • elastomeric nets used in composites of the invention have a low stress relaxation at 100 °F of less than 30 % decrease in stress, preferably less than 20% decrease in stress, when held at 100 % elongation for 5 minutes.
  • Figure 1 illustrates in perspective view an elastomeric net 10, shown in roll form, which can be used in producing fabrics of the invention.
  • the elastomeric net 10 includes an elastic material making up the strands 12 of the net including the longitudinal, i.e. machine direction, strands and the transverse, i.e. cross machine direction, strands, (assuming the net is rectangular) .
  • the elastic net 10 can be prepared by any of various well known processes including the process disclosed in U.S. Patent
  • the elastic net is made by extruding a plurality of substantially elastomeric strands in the machine direction while simultaneously or thereafter extruding and joining to the machine direction strands, a plurality of elastomeric polymeric strands oriented substantially in the cross machine direction.
  • strands of the net intersect to form substantially regular, rectangular shaped openings, it will be apparent that the net can also have a non-rectangular geometry, e.g., having strands oriented to form diamond shaped openings or the like.
  • the elastomeric material making up the strands 12 of the net normally comprise at least one thermoplastic elastomer.
  • Suitable thermoplastic elastomers include the diblock, triblock, radial and star copolymers based on polystyrene (S) and unsaturated or fully hydrogenated rubber blocks.
  • the rubber block can consist of butadiene (B) , isoprene (I) , or the hydrogenated version, ethylene-butylene (EB) .
  • B butadiene
  • I isoprene
  • EB ethylene-butylene
  • S-B, S-I, S-EB, as well as S-B-S, S-I-S, S-EB-S linear block copolymers can be used.
  • thermoplastic elastomers of this type can include the KRATON polymers sold by Shell Chemical Company or the VECTOR polymers sold by DEXCO.
  • Other elastomeric thermoplastic polymers include polyurethane elastomeric materials such as ESTANE sold by BF Goodrich Company; polyester elastomers such as HYTREL sold by E. I. Du Pont De Nemours Company; polyetherester elastomeric materials such as ARNITEL sold by Akzo Plastics; and polyetheramide elastomeric materials such as PEBAX sold by ATO Chemie Company; and the like.
  • the elastomeric strands of the elastomeric net 10 can also be prepared from blends of thermoplastic elastomers with other polymers such as polyolefin polymers, e.g. blends of Kraton polymers with polyolefins such as polypropylene and polyethylene, and the like. These polymers can provide lubrication and decrease the melt viscosity, allow for lower melt pressures and temperatures and/or increase throughput, and provide better bonding properties too.
  • such other polymers can be included in the blend as a minor component, for example in an amount of between about 5% by weight up to 50% by weight, preferably from about 10 to about 30% by weight of the mixture.
  • Suitable thermoplastic polymers include, in addition to the polyolefin polymers, poly(ethylene-vinyl acetate) polymers having an ethylene content of up to about 50% by weight, preferably between 15 and 30% by weight and copolymers of ethylene and acrylic acid or esters thereof, such as poly(ethylene-methyl acrylate) or poly(ethylene-ethyl acrylate) wherein the acrylate acid or ester component ranges from about 5 to about 50% by weight, preferably from about 15 to about 30% by weight.
  • polystyrene and poly(alpha-methyl styrene) can be used.
  • the strands can comprise an adherence promoting additive to improve the adherence of the machine direction strands to the cross-machine direction strands.
  • Preferred additives to improve adherence include poly(ethylene-vinyl acetate) polymers having an ethylene content of up to about 50% by weight, preferably between about 15 and about 30% by weight, and copolymers of ethylene and acrylic acid or esters thereof, such as poly(ethylene-methyl acrylate) or poly(ethyl acrylate) wherein the acrylic acid or ester component ranges from about 5 to about 50% by weight, preferably from about 15 to 30% by weight.
  • These materials are preferably included in strands in an amount of between about 2 and about 50% by weight, preferably between about 10 and about 30% by weight depending on the primary component of the strand.
  • other materials such as plasticizers, tackifiers, talc, and the like can be compounded into the resin at low levels to promote bonding.
  • the degree of elasticity of the longitudinal and transverse strands 12 of a rectangular elastomeric net can be the same or different. Fabrics having differential stretch in the longitudinal and transverse directions can be provided in accordance with the invention by employing strands 12 in the elastomeric net in either the transverse or longitudinal direction which have only little elasticity.
  • the number of strands per inch in the longitudinal and transverse dimensions be different. Generally, there are between about 2 to about 30 strands per inch in both the longitudinal and transverse directions although greater numbers of strands can be employed where desirable.
  • the fabric of the invention can be used in articles wherein an edge of the fabric is exposed. In such instances it can be desirable to minimize the diameter of the strands which will be exposed along the cut edge of the fabric.
  • the elastomeric nets used in the invention will have a basis weight ranging from about 15 grams per square meter, to about 200 grams per square meter, more preferably from about 75 to about 100 grams per square meter and can employ strands having diameters ranging from 50 to 600 microns,
  • FIG. 2 schematically illustrates one preferred method and apparatus for manufacturing one preferred composite elastic nonwoven web from the combination of meltblown elastomeric layers and an elastomeric net according to the invention.
  • a conventional meltblowing apparatus 14 forms a meltblown elastomeric fibrous stream 16 which is deposited onto a forming screen 18.
  • Meltblowing processes and apparatus are known to the skilled artisan and are disclosed, for example, in U.S. Patent 3,849,241 to Buntin, et al. and U.S. 4,048,364 to Harding, et al.
  • the meltblowing process involves extruding a molten thermoplastic elastomer 20 (which can be formed of the elastomers described above in regard to the elastomeric net 10) , through fine capillaries 22 into fine filamentary streams.
  • the filamentary streams exit the meltblowing spinneret head where they encounter converging streams of high velocity heated gas 24, typically air, supplied from a pair of converging nozzles.
  • the converging streams of high velocity heated gas attenuate the polymer streams and break the attenuated streams into meltblown fibers.
  • An elastomeric meltblown web 20 is thus formed on, and conveyed by forming screen to the next station at which a conventional supply system applies the elastomeric net 10 onto the moving meltblown web 20.
  • the elastomeric net 10 includes spaced apart machine direction and cross machine direction strands which intersect to form apertures.
  • a roll 26 applies tension to the two- layered structure 28 which is formed from the combination of the meltblown web and the net layer 10. The two layer structure is advanced in the machine direction by forming screen 18.
  • a second meltblowing apparatus 30, constructed the same as meltblowing apparatus 14, deposits a second elastomeric meltblown fibrous layer 34 onto the composite structure 28.
  • the elastomeric meltblown layer 34 entangles with and/or bonds to the previously formed composite structure 28 to thereby form a composite elastic fabric 36.
  • This fabric is conveyed by a conveying roll 38 for wind-up and storage as a roll 38.
  • the fabric 36 stored on roll 38 may be immediately or later passed to end use manufacturing processes, for example, for use in bandages, diapers, disposable undergarments, personal hygiene products, industrial products and the like.
  • the composite elastic fabric formed by the process of Figure 2 is illustrated in Figure 3.
  • the composite fabric is a unitary structure including meltblown elastomeric fibers 38 and elastomeric strands 12 from net 10 within an interior portion of the composite fabric 36.
  • meltblown layer 34 onto net 10
  • at least a portion of the meltblown fibers 38 extend through apertures in the elastomeric net and/or are bonded to strands 12 of the net.
  • the meltblowing apparatus 30 which forms a meltblown layer on net 10 is sufficiently closely spaced to the forming wire 18 and operated at a force sufficient to force at least a portion of the meltblown fibers into and/or through the apertures in the elastomeric net 20.
  • FIG. 2 The method illustrated in Figure 2 is susceptible to numerous preferred variations.
  • the schematic illustration of Figure 1 shows meltblown webs being formed directly during the in-line process, it will be apparent that one or both of the webs can be preformed and supplied as rolls of preformed webs, although this is not preferred. In such an instance thermal bonding from heated calanders or the like, or adhesive bonding, can be used to unite the layers into a unitary structure.
  • the elastomeric net is shown being supplied as a roll of a preformed net, the , net can be formed directly in-line.
  • meltblown webs 20 and 34 both above and below the elastomeric net 20
  • a single meltblown web such as web 34 can be employed or more than two meltblown webs can be employed.
  • both meltblown webs can be formed directly onto net 10 by forming a first meltblown layer onto the net to form an intermediate composite structure, and then turning over the composite to expose the net side and forming the second meltblown layer thereon.
  • FIG. 4 schematically illustrates one preferred method and apparatus for manufacturing another preferred composite elastic nonwoven fabric of the invention from the combination of spunbond elastomeric layers and an elastomeric net.
  • the spunbond elastomeric layers employed in this embodiment of the invention are preferably formed in accordance with the teachings of U.S. Patent Application Serial No. 07/829,923 of Gessner, et al.; filed February 3, 1992; and entitled "Elastic Nonwoven Webs and Method of Making Same", which is hereby incorporated in its entirety into this application by reference.
  • Elastomeric spunbond layers are preferably produced by melt spinning substantially continuous filaments of a thermoplastic olefin-based elastomer.
  • olefinic elastomers are formed using metallocene polymerization catalysis and are commercially available as the EXACT resins from Exxon, which are linear low-density polyethylenes, and the CATALLOY resins from Himont, which are crystalline olefin, heterophasic copolymers including a crystalline base polymer fraction, i.e., block, and an amorphous copolymer fraction or block with elastic properties as a second phase blocked to the crystalline base polymer fraction via a semi-crystalline polymer .fraction.
  • spunbond fabrics have a desirable soft hand and elastomeric properties such that the spunbonds exhibit a root mean square (RMS) recoverable elongation of at least about 75% in both the machine direction (MD) and the cross direction (CD) after 30% elongation and one pull.
  • RMS root mean square
  • the spunbond fabrics are prepared by conducting a slot draw spunbonding process at a rate of less than 2000 meters per minute, e.g., less than 1500 m/min. employing an elastomeric thermoplastic resin as feed.
  • a spunbond apparatus is shown at 50 and is preferably a slot drawing apparatus as known in the art.
  • Slot drawing apparatus 50 includes a melt spinning section including a feed hopper 52 and an extruder 53 for the polymer.
  • the extruder 53 is provided with a generally linear die head or spinneret 54 for melt spinning streams of substantially continuous filaments 55.
  • the substantially continuous filaments 55 are extruded from the spinneret 54 and typically are quenched by a supply of cooling air (not shown) .
  • the filaments are directed to an attenuation slot 56 which includes downwardly moving attenuation air which can be supplied from forced air above the slot, vacuum below the slot, or eductively within the slot, as known in the art.
  • the attenuation slot may be separate from or integral with the drawing slot as also known in the art.
  • the air and filaments exit the attenuation slot 56 and are collected on a forming wire 58 as a nonwoven spunbond web 60.
  • the filaments 55 are extruded from the spinneret 54 at a rate sufficient to provide drawn filaments at a spinning rate of about 100 to about 2000 meters per minute.
  • the forming wire 58 is typically moved at a slower linear velocity than the spinning rate (linear velocity of the filaments) to increase the density and cover,of the spunbond web 60.
  • the filaments 55 are produced at a rate of about 450 to about 1200 meters per minute. Drawing forces sufficient to provide a spinning rate in excess of 1200-2000 meters per minute are advantageously avoided because excess filament breakage can occur due to the elastic nature of polymer.
  • the filaments of the spunbond web 60 have a denier per filament in the range less than about 50 denier per filament, more preferably from about 1 to about 10 denier per filament, and most preferably from about 2 to about 6 denier per filament.
  • Preferred polymers for forming elastomeric spunbond layers used in the composites of the invention are the EXACT elastomeric linear low density polymers (Exxon) . These polymers come in multiple grades.
  • Spunbond fabrics spun from the above polymers also have differences in hand.
  • the lowest density materials have a distinctly unfavorable rubbery hand. These materials are tacky and feel clammy to the skin.
  • the medium density materials have a very soft, good feeling hand.
  • the presently preferred elastic spunbond fabric for use in the composites of the invention is made from EXACT 3017.
  • the base spunbond material has the following mechanical properties, in a five cycle 100% elongation hysteresis test (machine direction only) :
  • thermoplastic primarily crystalline olefin block copolymers having elastic properties are also advantageously used to form spunbonds.
  • These polymers are commercially available from Himont, Inc., Wilmington, Delaware, and are disclosed in European Patent Application Publication 0416379 published March 13, 1991, which is hereby incorporated by reference.
  • the polymer is a heterophasic block copolymer including a crystalline base polymer fraction and an amorphous copolymer fraction having elastic properties which is blocked thereon via a semi-crystalline homo- or copolymer fraction.
  • the thermoplastic primarily crystalline olefin polymer is comprised of at least about 60 to 85 parts of the crystalline polymer fraction, at least about 1 up to less than 15 parts of the semi-crystalline polymer fraction and at least about 10 to less than 39 parts of the amorphous polymer fraction.
  • the primarily crystalline olefin block copolymer comprises 65 to 75 parts of the crystalline copolymer fraction, from 3 to less than 15 parts of the semi-crystalline polymer fraction, and from 10 to less than 30 parts of the amorphous copolymer fraction.
  • the amorphous copolymer block with elastic properties of the heterophasic copolymer comprises an alpha-olefin and propylene with or without a diene or a different alpha-olefin termonomer
  • the semi-crystalline copolymer block is a low density, essentially linear copolymer consisting substantially of units of the alpha-olefin used to prepare the amorphous block or the alpha-olefin used to prepare the amorphous block present in the greatest amount when two alpha-olefins are used.
  • elastomeric polymers such as those listed above, with one another and with other thermoplastic polymers, such as polyethylene, polypropylene, polyester, nylon, and the like, may also be used in the invention.
  • thermoplastic polymers such as polyethylene, polypropylene, polyester, nylon, and the like.
  • elastomer properties can be adjusted by polymer chemistry and/or by blending elastomers with non- elastomeric polymers to provide elastic properties ranging from fully elastic stretch and recovery properties to relatively low stretch and recovery properties.
  • a low to medium elastic property elastomer is used in the spunbond process as evidenced by a flexural modulus ranging from about 200 psi to about 10,000 psi, and preferably from about 2000 psi to about 8000 psi.
  • the thermoplastic spunbond webs are formed from a resin including the thermoplastic elastomer in an amount sufficient to give the fabric at least about a 75% root mean square (RMS) average recoverable elongation based on machine direction (MD) and cross direction (CD) values after 30% elongation and one pull.
  • RMS root mean square
  • the fabrics have at least about a 70% RMS recoverable elongation after tyo such 30% pulls. More preferably, the fabrics comprise the thermoplastic elastomer in an amount sufficient to give the fabric at least about a 65% RMS recoverable elongation based on machine direction and cross direction values after 50% elongation and one pull, and even more preferably at least about 60% RMS recoverable elongation after two such pulls.
  • the elastomer constitutes at least about 50%, most preferably at least about 75%, by weight of the filament.
  • Elastic properties of fabrics of the invention are measured using an Instron Testing apparatus, using a 5 inch gauge length and a stretching rate of 5 inches per minute. At the designated stretch or percent elongation value, the sample is held in the stretched state for 30 seconds. The elongation of the sample is then decreased at the same rate of 5 in./min. until the original 5 inch gauge length is obtained. The percent recovery can then be measured.
  • the elastomeric spunbond fabric 60 is thus formed on, and conveyed by forming screen 58 to the next station at which a conventional supply system applies the elastomeric net 10 onto the moving spunbond web 20.
  • a roll 62 applies tension to the two-layered structure 64 which is formed from the combination of the spunbond web and the net layer 10.
  • the two layer structure is advanced in the machine direction by forming screen 58.
  • a second spunbond apparatus 66 constructed the same as spunbond apparatus 50, forms a curtain of filaments 68 which are deposited as a second elastomeric spunbond fibrous layer 69 onto the composite structure 64.
  • the three layered structure 70 is then conveyed to a pair of heated calender rolls 72 and 74.
  • the operating temperature of heated rolls 72 and 74 should be adjusted to a surface temperature such that the spunbond fibers are heated sufficiently to soften the fibers and to bond the composite web into a unitary structure.
  • the heat transfer conditions are advantageously maintained to avoid thermal degradation or melting of the elastomeric net 10 which is present within the interior of the composite web 70.
  • the bonding conditions can, in some instances depending on the fibers and net used, be controlled to obtain fiber bonding to the net, while simultaneously avoiding thermal degradation of the elastomer or its stretch and recovery properties.
  • melting of the elastomeric net 10 can, in some instances, be desirable and helpful for bonding of the spunbond fibers in the composite web to the net
  • melting of the elastomeric net is advantageously avoided.
  • avoidance of melting of the net is achieved in part by selecting an elastomer resin for forming the spunbond that has a melting point of at least 5 °C, preferably at least 10 °C, less than the melting point of the net. This allows use of low temperature, high pressure calender conditions for bonding of the composite without melting of strands of the net.
  • a thermally-bonded composite elastic fabric 76 is removed from the nip of the heated rolls 72 and 74 and wound by conventional means onto roll 80.
  • the composite elastic fabric 78 can be stored on roll 80 or immediately passed to end use manufacturing processes, for example for use in bandages, diapers, disposable undergarments, personal hygiene products and the like. Blocking of the layers of the composite on the roll can be avoided in accordance with the invention by employing resins having a very narrow molecular weight distribution for forming the spunbond, such as the linear low density polyethylene elastomer resins commercially available from Exxon discussed previously. Narrow molecular weight distribution minimizes the presence of very low molecular weight polymer fragments which can act like plasticizers and/or adhesives and cause blocking of adjacent layers on a roll.
  • the composite elastic fabric formed by the process of Figure 4 is illustrated in Figure 5.
  • the composite fabric is a unitary structure including spunbond layers 69 and 69 having elastomeric strands 12 from net 10 sandwiched between the two layers.
  • the three layer structure is joined into a unitary product by thermal spot bonds 82 which may be formed on one or both sides of the composite fabric.
  • the thermal bonds can be formed between only the two spunbond layers or between one or both of the spunbond layers and strands 12 of net 10.
  • Figure 2 The method illustrated in Figure 2 is susceptible to numerous preferred variations.
  • the schematic illustration of Figure 4 shows spunbond webs being formed directly during the in-line process, it will be apparent that one or both of the webs can be preformed, lightly bonded fabrics, and supplied as rolls of preformed fabrics.
  • the elastomeric net is shown being supplied as a roll of a preformed net, the net can be formed directly in-line.
  • Figure 4 illustrates use of two fibrous spunbond webs, one above and one below the elastomeric net 10, only a single spunbond web can be employed or more than two spunbond webs can be employed.
  • spunbond web or webs may be bonded or joined to the elastomeric net in any of the ways known in the art.
  • Lamination and/or bonding may be achieved, for example, various spot bonding techniques, by ultrasonic bonding or powder bonding. It is also possible to achieve bonding through the use of an appropriate bonding agent, i.e., an adhesive.
  • spot bonding is inclusive of continuous or discontinuous pattern bonding, uniform or random point bonding or a combination thereof, all as are well known in the art.
  • the elastomeric nonwoven composite fabrics of the invention are advantageously formed entirely from elastomeric layers, the fabric can be laminated or otherwise joined to other layers, fabrics and materials for the formation of various useful articles, such as diapers, disposable undergarments and the like.
  • the composite elastic nonwoven fabrics of the invention are also formed from the combination of elastomeric nets with fibrous elastomeric layers other than meltblown or spunbond webs, in accordance with the invention.
  • Such elastomeric fibrous webs include nonwoven webs formed from staple fibers and/or yarns and which have been coated or impregnated with an elastomeric material and consolidated into a web by adhesive and thermal bonding.
  • the composite elastic fabrics of the invention provide improved elastic properties as compared to numerous prior art fabrics and avoid manufacturing complexities associated with many prior art fabrics.
  • the Kraton G 1657 is a styrene-(ethylene-butylene)-styrene block copolymer.
  • the Optema TC-140 is a ethylene-methyl acrylate random copolymer. This 60/40 blend was meltblown onto an elastic net.
  • the elastic net consisted of styrene-isoprene-styrene block copolymer mixed with a styrene-butadiene-styrene blocK copolymer. These materials are known by the trade names Kraton D (marketed by Shell Chemical) or Vector (marketed by DEXCO, a Dow-Exxon Partnership) .
  • This resulting composite fabric had some very unique properties, and in particular would be very useful for filtration or controlled porosity applications.
  • Both the net and meltblown layers are highly extensible. Under low extension, the material has relatively low air permeability. As extension increases, air permeability in turn increases. Thus, porosity and air permeability can be controlled by simply stretching or relaxing the elastic composite exactly as desired.
  • EXAMPLE 2 An elastic composite was made in the same manner as Example 1, with the following exception: the elastic meltblown web was formed on one side of the net only. This material was much like that of Example 1, in that porosity could be readily controlled via elongation of the material. However, this material was clearly two-sided, with a relatively bumpy net on one side and a smooth meltblown layer on the other side.

Abstract

L'invention concerne des textiles non tissés élastiques composites et le procédé permettant leur fabrication. Les textiles non tissés élastiques composites selon l'invention sont formés par la combinaison d'une pluralité de couches élastiques coopérant entre elles et renfermant une couche fibreuse d'élastomère et une couche de filet d'élastomère dont les propriétés élastiques sont supérieures à celle de la couche fibreuse d'élastomère. Les différentes couches d'élastomère sont réunies pour former une structure de textile élastique unique et constituer un composite présentant une combinaison avantageuse de différentes propriétés élastiques. Les composites non tissés élatiques selon l'invention sont, de préférence, formés par combinaison d'un filet d'élastomère et d'une ou de plusieurs nappes d'élastomère en fils continus désorientés ou soufflés à chaud. Le filet d'élastomère confère au textile composite des propriétés de solidité et de reprise élastique avantageuses, alors que la nappe fibreuse en élastomère lui donne des porrosité de couverture, d'étanchéité et/ou de porosité souhaitables.
PCT/US1993/006747 1992-01-24 1993-07-19 Textile non tisse elastique composite WO1995003443A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU46828/93A AU4682893A (en) 1992-01-24 1993-07-19 Composite elastic nonwoven fabric

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US07/825,016 US5334446A (en) 1992-01-24 1992-01-24 Composite elastic nonwoven fabric
PCT/US1993/000566 WO1993015247A1 (fr) 1992-01-24 1993-01-22 Etoffe non tissee stable au traitement

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995032091A1 (fr) * 1994-05-24 1995-11-30 Exxon Chemical Patents Inc. Fibres et tissus incorporant des polymeres de propylene a faible point de fusion
WO1996038620A1 (fr) * 1995-06-01 1996-12-05 Kimberly-Clark Worldwide, Inc. Stratifies non tisses elastomeres plats
US5709921A (en) * 1995-11-13 1998-01-20 Kimberly-Clark Worldwide, Inc. Controlled hysteresis nonwoven laminates
WO2000063478A1 (fr) * 1999-04-19 2000-10-26 E.I. Du Pont De Nemours And Company Tissu non tisse recuperable apres etirage et son procede de fabrication
WO2001045927A1 (fr) * 1999-12-22 2001-06-28 The Procter & Gamble Company Stratifie elastique avec gaze elastomere et couche fibreuse liees a celui-ci et procede de fabrication correspondant
US6503855B1 (en) 1998-10-02 2003-01-07 3M Innovative Properties Company Laminated composites
US6680265B1 (en) 1999-02-22 2004-01-20 Kimberly-Clark Worldwide, Inc. Laminates of elastomeric and non-elastomeric polyolefin blend materials
US6758644B1 (en) * 2001-11-16 2004-07-06 Wayne E. Vick Composite restraint system for securing freight
FR2884528A1 (fr) * 2005-04-14 2006-10-20 Mdb Texinov Sa Soc Par Actions Complexe textile a base de non tisse et son procede de realisation
WO2007078344A1 (fr) * 2005-12-15 2007-07-12 Kimberly-Clark Worldwide, Inc. Materiaux composite constitue de filaments obtenus par soufflage et leurs procedes de fabrication
WO2009025975A1 (fr) * 2007-08-16 2009-02-26 3M Innovative Properties Company Stratifiés non tissés élastiques pouvant être étirés
EP2025825A3 (fr) * 2007-08-10 2016-03-23 Fiberweb, Inc. Matériau en feuille résistant à l'impact
CN111387571A (zh) * 2020-03-30 2020-07-10 广州市兴世机械制造有限公司 穿着物的制造工艺
WO2022105769A1 (fr) * 2020-11-18 2022-05-27 东丽纤维研究所（中国）有限公司 Matériau de tissu non tissé
RU2794581C1 (ru) * 2022-03-24 2023-04-21 Общество С Ограниченной Ответственностью "Ргк" Способ изготовления полимерной сетки для дренажного геокомпозита, полимерная сетка и дренажный геокомпозит, содержащий указанную сетку

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EP0007802A1 (fr) * 1978-08-01 1980-02-06 Teijin Limited Structure fibreuse composite comprenant une structure à maille à rapport de récupération élevé et une structure fibreuse à faible rapport de récupération, et utilisation d'une telle structure fibreuse pour l'isolation thermique des bâtiments
WO1993015247A1 (fr) * 1992-01-24 1993-08-05 Fiberweb North America, Inc. Etoffe non tissee stable au traitement

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0007802A1 (fr) * 1978-08-01 1980-02-06 Teijin Limited Structure fibreuse composite comprenant une structure à maille à rapport de récupération élevé et une structure fibreuse à faible rapport de récupération, et utilisation d'une telle structure fibreuse pour l'isolation thermique des bâtiments
WO1993015247A1 (fr) * 1992-01-24 1993-08-05 Fiberweb North America, Inc. Etoffe non tissee stable au traitement

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995032091A1 (fr) * 1994-05-24 1995-11-30 Exxon Chemical Patents Inc. Fibres et tissus incorporant des polymeres de propylene a faible point de fusion
WO1996038620A1 (fr) * 1995-06-01 1996-12-05 Kimberly-Clark Worldwide, Inc. Stratifies non tisses elastomeres plats
US5709921A (en) * 1995-11-13 1998-01-20 Kimberly-Clark Worldwide, Inc. Controlled hysteresis nonwoven laminates
EP0861343B2 (fr) † 1995-11-13 2009-03-18 Kimberly-Clark Worldwide, Inc. Stratifies non tisses a hysteresis regulee
US6503855B1 (en) 1998-10-02 2003-01-07 3M Innovative Properties Company Laminated composites
US6835256B2 (en) 1998-10-02 2004-12-28 3M Innovative Properties Company Laminated composites
US6680265B1 (en) 1999-02-22 2004-01-20 Kimberly-Clark Worldwide, Inc. Laminates of elastomeric and non-elastomeric polyolefin blend materials
US8314040B2 (en) 1999-02-22 2012-11-20 Kimberly-Clark Worldwide, Inc. Laminates of elastomeric and non-elastomeric polyolefin blend materials
WO2000063478A1 (fr) * 1999-04-19 2000-10-26 E.I. Du Pont De Nemours And Company Tissu non tisse recuperable apres etirage et son procede de fabrication
WO2001045927A1 (fr) * 1999-12-22 2001-06-28 The Procter & Gamble Company Stratifie elastique avec gaze elastomere et couche fibreuse liees a celui-ci et procede de fabrication correspondant
US6758644B1 (en) * 2001-11-16 2004-07-06 Wayne E. Vick Composite restraint system for securing freight
US7103941B2 (en) 2001-11-16 2006-09-12 Vick Wayne E Associated device of a composite restraint system for securing freight
US7260870B2 (en) 2001-11-16 2007-08-28 Vick Wayne E Associated strap of a composite restraint system for securing freight
WO2006108998A3 (fr) * 2005-04-14 2007-11-22 Mdb Texinov Sa Complexe textile λ base de non tisse et son procede de realisation
FR2884528A1 (fr) * 2005-04-14 2006-10-20 Mdb Texinov Sa Soc Par Actions Complexe textile a base de non tisse et son procede de realisation
WO2007078344A1 (fr) * 2005-12-15 2007-07-12 Kimberly-Clark Worldwide, Inc. Materiaux composite constitue de filaments obtenus par soufflage et leurs procedes de fabrication
KR101321215B1 (ko) * 2005-12-15 2013-10-23 킴벌리-클라크 월드와이드, 인크. 필라멘트-멜트블로운 복합재 및 이의 제조 방법
EP2025825A3 (fr) * 2007-08-10 2016-03-23 Fiberweb, Inc. Matériau en feuille résistant à l'impact
WO2009025975A1 (fr) * 2007-08-16 2009-02-26 3M Innovative Properties Company Stratifiés non tissés élastiques pouvant être étirés
CN111387571A (zh) * 2020-03-30 2020-07-10 广州市兴世机械制造有限公司 穿着物的制造工艺
WO2022105769A1 (fr) * 2020-11-18 2022-05-27 东丽纤维研究所（中国）有限公司 Matériau de tissu non tissé
RU2794581C1 (ru) * 2022-03-24 2023-04-21 Общество С Ограниченной Ответственностью "Ргк" Способ изготовления полимерной сетки для дренажного геокомпозита, полимерная сетка и дренажный геокомпозит, содержащий указанную сетку

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