WO1998055295A1 - Composite de grande resistance pour nettoyage de bebe - Google Patents

Composite de grande resistance pour nettoyage de bebe Download PDF

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Publication number
WO1998055295A1
WO1998055295A1 PCT/US1998/011726 US9811726W WO9855295A1 WO 1998055295 A1 WO1998055295 A1 WO 1998055295A1 US 9811726 W US9811726 W US 9811726W WO 9855295 A1 WO9855295 A1 WO 9855295A1
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WO
WIPO (PCT)
Prior art keywords
spunbonded
fibers
fabric
nonwoven fabric
polypropylene
Prior art date
Application number
PCT/US1998/011726
Other languages
English (en)
Inventor
Ramesh Srinivasan
Angelo Colace
Original Assignee
Bba Nonwovens Simpsonville, 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
Application filed by Bba Nonwovens Simpsonville, Inc. filed Critical Bba Nonwovens Simpsonville, Inc.
Publication of WO1998055295A1 publication Critical patent/WO1998055295A1/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
    • B32B5/22—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
    • D04H1/4374—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 using different kinds of webs, e.g. by layering 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
    • D04H1/559—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
    • D04H3/08—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
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/04—Cellulosic plastic fibres, e.g. rayon
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/10—Natural fibres, e.g. wool, cotton

Definitions

  • the invention relates generally to nonwoven web laminates and, more particularly, to composite nonwoven fabrics suitable for use as a baby wipe and formed by a thermal bonding process .
  • Nonwoven web laminates have application in a variety of disposable products, including wipes, garments, medical drapes and absorbent articles such as diapers, sanitary napkins and adult incontinence products, etc. It is desirable in these applications to combine the properties of a soft outer fabric for contact with the skin of a user with a durable and strong fabric having fluid absorption capacity.
  • SMS laminates One class of such nonwoven web laminates is commonly referred to as spunbonded-meItblown-spunbonded (SMS) laminates. These SMS laminates generally consist of nonwoven outer layers of spunbonded polyolefins and an interior layer of meltblown polyolefins. Laminates consisting of only nonwoven layers of spunbonded polyolefins without the interior meltblown layer also have application in disposable products, and are commonly referred to as spunbonded-spunbonded (SS) laminates.
  • SS spunbonded-spunbonded
  • nonwoven web refers to a web that has a structure of individual fibers or filaments which are interlaid, but not in an identifiable repeating pattern.
  • spunbonded fibers refers to fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinnerette . Cooling air is fed to a quenching chamber wherein the filaments are cooled. The cooling air is then sucked through a nozzle, which accelerates the flow of air. The friction between the flowing air and the filaments creates a force which draws the filaments, i.e., attenuates the filaments to a smaller diameter. The drawn filaments are then passed through a diffusor and deposited on a conveyor belt to form a nonwoven web.
  • a conventional spinbonding technique is disclosed in U.S. Patent No. 4,340,563 to Appel, which is incorporated herein by reference.
  • meltblown fibers refers to fibers which are formed by extruding molten thermoplastic material as threads or filaments through a plurality of fine, usually circular capillaries of a die.
  • a high- velocity, usually heated gas (e.g., air) stream attenuates the filaments of molten thermoplastic material to reduce their diameter.
  • the meltblown fibers are carried by the high-velocity heated gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers.
  • a conventional meltblowing technique is disclosed in U.S. Patent No. 4,707,398 to Boggs, which is incorporated herein by reference.
  • meltblown fibers differ from spunbonded fibers in that the extruded polymer strands are broken up and dispersed into individual fibers by the forced gas stream before being deposited on the collecting surface. In addition, the meltblown fibers are substantially cooled by the air so that they do not significantly bond together. Bonding of the web to retain integrity and strength occurs as a separate downstream operation.
  • Baby wipes are then packaged in containers which maintain moisture and allow for easy dispensing, such as a "pop-up" containers which dispense one wipe at a time when pulled through an opening in the container. Therefore, baby wipes must exhibit a certain strength to prevent tearing while maintaining softness and sufficient absorbency.
  • Low end baby wipes typically comprise air-laid nonwoven webs, for example, of pulp or paper. Air-laid webs comprise fibers which are distributed by air currents to give a random orientation within the web and a fabric with isotropic properties, but lacking in strength.
  • High end baby wipes typically comprise spunlaced nonwoven webs. Spunlaced fabrics are produced by an expensive process which entangles fibers in a repeating pattern to form a strong fabric free of binders using high pressure water jets.
  • Conventional high end baby wipes comprise polyester, polypropylene, rayon or blends thereof.
  • the present invention is a nonwoven fabric laminate for use as a baby wipe product which is cost effective and has improved strength, durability and softness. More particularly, the baby wipe of the present invention is manufactured using a thermal bonding process by combining a layer of SS or SMS fabric with at least one fiber layer of absorbent, resilient and binder fibers. One fiber layer may be combined with an SS or SMS fabric to form a bi-laminate product, or two outer fiber layers may be combined with an intermediate SS or SMS fabric to form a tri-laminate product .
  • each fiber layer or layers preferably comprises a carded nonwoven web of fibers including thermoplastic fibers (e.g., polypropylene, polyethylene, polyester, or blends thereof) or non- thermoplastic fibers (e.g., rayon or cotton), or blends thereof.
  • the SS or SMS fabric layer preferably comprises polypropylene or polyethylene.
  • the composite nonwoven fabric structure of the invention provides strength, absorbency, softness and improved cleaning ability at a reduced cost as compared to spunlaced wipes known in the art.
  • the fabric's strength comes from the SS or SMS fabric layer which is composed of fine fibers and the improvement in absorbency and softness is primarily due to the addition of a carded fiber layer.
  • the composite of the present invention is also lightweight, and has a textured surface which enhances cleaning ability.
  • a layer of SS or SMS fabric is introduced between two layers of a blend of carded fibers and thermally bonded between heated calender rolls having a pressure from about 100 to 1200 pounds per linear inch (pli) , preferably 250-800 pli, and a temperature from about 250°F to 600°F, preferably 300- 400°F.
  • pli pounds per linear inch
  • FIGS. 1A, IB and 1C illustrate the thermal bonding technique in accordance with the invention for the general example of a tri-laminate baby wipe product.
  • FIG. 2 is a schematic diagram showing a process line for the manufacture of a thermally bonded baby wipe composite in accordance with a preferred embodiment of the invention.
  • FIG. 3A is a schematic diagram showing a sectional view of a portion of a bond roll used for thermal bonding in accordance with one preferred embodiment of the invention.
  • FIG. 3B is a schematic diagram showing the arrangement of circular bond dots in a hexagonal pattern on the outer circumferential surface of the bond roll of FIG. 3A.
  • FIG. 4 is a schematic diagram showing the construction of a conventional spunbonded-meltblown-spunbonded (SMS) fiber laminate.
  • SMS spunbonded-meltblown-spunbonded
  • FIG. 5 is a schematic diagram showing the essential components of a system for continuously producing an SS or SMS fiber laminate for use in making a high strength composite baby wipe material in accordance with a preferred embodiment of the invention.
  • a one-step bonding process is used for manuf cturing a nonwoven product using thermal bonding (heated calender) technology.
  • the nonwoven product is produced by combining one or two nonwoven layer (s) of fibers with a prebonded nonwoven web laminate layer of SS or SMS fabric.
  • SS or SMS fabric is sandwiched between two nonwoven fiber layers, a soft product having the same feel on both sides is made, referred to herein as a "tri- laminate" product.
  • a "bi-laminate" product having different feel on each side may be made by bonding one nonwoven fiber layer to a prebonded SS or SMS fabric layer.
  • FIGS. 1A-1C An example of the general process for forming a nonwoven baby wipe product in accordance with the invention is illustrated in FIGS. 1A-1C.
  • One or two outer nonwoven layers 10a, 10b and a prebonded SS or SMS fabric layer 12 are fed in superposed relation through the nip of a pair of heated calender rolls 20a, 20b.
  • the calender rolls have a plurality of calendering points or lands 22a, 22b which come together to apply heat and pressure to the superposed layers fed in between.
  • FIG. lb application of suitable heat and pressure causes the fibers of the webs 10a, 10b to bond together and to bond to the SS or SMS fabric layer 12.
  • FIG. 1A-1C An example of the general process for forming a nonwoven baby wipe product in accordance with the invention is illustrated in FIGS. 1A-1C.
  • One or two outer nonwoven layers 10a, 10b and a prebonded SS or SMS fabric layer 12 are fed in superposed relation through the
  • the heated calendering points 22a, 22b serve simultaneously to bond the layers together and to define indentations 30 in the outer surface 32 of nonwoven layers 10a, 10b.
  • the result is that the layered structure is thermally point bonded with a textured surface .
  • FIG. 2 a process line is shown schematically for the manufacture of a nonwoven baby wipe as a continuous roll product.
  • the thermoplastic or non-thermoplastic fibers are carded at card stations #1 and #2 and fed on card conveyors 14a, 14b, respectively, for the webs 10a, 10b of fibers.
  • the prebonded SS or SMS fabric 12 is unwound from an unwind stand 16 and fed in superposed relation between the two carded webs on the card conveyors 14a, 14b, and the prebonded composite of SMS or SS fabric sandwiched between two carded webs is fed by conveyor 17 to hot calender rolls 20a, 20b to be thermally bonded and textured.
  • FIG. 2 shows dual engraved calender rolls 20a, 20b, it is within the scope of this invention to form the baby wipe using a single engraved calender roll on the top 20a or on the bottom 20b.
  • thermoplastic fibers in the carded layer (s) 10a, 10b are bonded together and to the prebonded SS or SMS fabric layer 12 at the raised lands 22a, 22b to form a textured surface pattern.
  • the bonded and textured nonwoven fabric is wound up on a roll .
  • the temperature of the calender rolls may be in the range of 250-600°F, preferably 300-400°F.
  • the pressure between the top and bottom rolls may be in the range of 100-1200 pounds per linear inch (pli), preferably about 250-800 pli.
  • the line speed may be in the range of 50-600 feet per minute
  • the bond pattern on either or both of the calender rolls can have any one of a number of different geometries including, but not limited to, Novonette #1, Novonette #2 and a repeating 7 -dot pattern.
  • the total bonding area can be varied in the range of 5-36%.
  • the engraving pattern on the surface of one of the calender rolls (either top or bottom) has a repeating 7-dot pattern wherein each repeating unit of the bond pattern comprises circular bond spots arranged with their centers at the vertices of a regular hexagon.
  • the other calender roll is smooth.
  • the geometry of the lands of the engraved roll is shown in FIG.
  • each repeating unit of the bonding pattern is arranged in a hexagonal fashion.
  • the hexagonal unit is repeated at a distance of 0.261 inch in the machine direction and a distance of 0.463 inch in the cross direction.
  • Each hexagonal unit consists of a circular bond spot of 0.48-inch diameter at the center surrounded by an outer array of six circular spots of the same diameter at the vertices of a hexagon.
  • the center-to-center distance of the outer array of circular spots is 0.949 inch.
  • the outer circular spots are also radially spaced at a distance of 0.094 inch from the central circular spot.
  • the aforementioned 7 -point dot bond pattern has a total of 115 bond spots per square inch, resulting in a total bond area of 19.1%.
  • calender rolls engraved with a helical pattern of lands and grooves are used to thermally bond the layered structure to a bond area of about 25% (referred to herein as the "Novonette #2 pattern”) .
  • "Novonette #1" calender patterns produce fabrics having a bond area of about 27%.
  • the lands may be generally defined as a spaced set of parallel ellipsoids extending equidistant from the axis of the rolls and in a plane which is inclined relative to the roll axes.
  • the overall character of the bond area and fiber-displacement pattern will comprise three components: a highly compacted area where a land has traversed a land; more lightly compressed areas where a land on one roll has traversed a groove on the other roll; and a substantially unaffected are where a groove on one roll has traversed a groove on the other roll.
  • the degree to which these areas are permanently impressed onto composite fabric material processed between such rolls will depend on the thickness of the composite fabric material, its nature and the pressures and temperatures used in processing.
  • Novonette calendering rolls are disclosed in U.S. Patent No. 3,507,943 to Such et al . , which is incorporated herein by reference.
  • the fibers of the carded nonwoven layer (s) are preferably made of absorbent, resilient and binder fibers including thermoplastic fibers, for example, polypropylene, polyester, polyethylene, or blends thereof. Cellulosic fibers (e.g., rayon or cotton) may also be blended with the thermoplastic fibers.
  • Carded nonwoven layers in accordance with this invention have a basis weight in the range of 5-60 grams, preferably 30-45 grams, and a thickness of 10-50 mils measured using a Thwing-Albert caliper at 0.26 psi . A description of several preferred fibers and their properties are shown in Table 1.
  • Preferred prebonded SS or SMS fabric layers are commercially available from Veratec, Inc., Walpole, Massachusetts under the tradenames VeraspunTM and EverspunTM, respectively. Both of these fabrics comprise polypropylene fibers. However, other thermoplastic fibers, for example, polyethylene, may be used to form the SS or SMS layer. It has been found that a polyethylene SS layer provides an improved textured effect, which is believed to enhance cleaning ability.
  • SS or SMS fabric layers m accordance with this invention have a basis weight of 10-40 grams per square yard (gsy) and a thickness of 5-40 mils measured using a Thwing-Albert caliper at 0.26 psi .
  • Preferred SS fabrics have a basis weight of 14-17.5 gsy and preferred SMS fabrics have a basis weight of 10-14 gsy.
  • FIG. 4 illustrates a typical SMS fabric layer 12 for use in the present invention comprising a meltblown fabric layer 4 of thermoplastic polymeric microfibers and two spunbonded fabric layers 6 and 8 each made of thermoplastic polymer filaments.
  • the meltblown fabric layer 4 can be prepared by extruding a fiber- forming thermoplastic polymer resin in molten form through a plurality of fine, usually circular capillaries of a die.
  • a high-velocity, usually heated gas (e.g., air) stream attenuates the filaments of molten thermoplastic material to reduce their diameter.
  • the meltblown fibers are carried by the high- velocity heated gas stream and are deposited on a collecting surface to form a nonwoven web of randomly dispersed meltblown fibers.
  • the thermoplastic polymeric microfibers of meltblown fabric layer 4 are polypropylene. Polymers other than polypropylene, such as nylon, polyethylene, polyester, and copolymers and blends thereof, may also be used.
  • Each of the spunbonded fabric layers 6 and 8 may be produced by continuously extruding a thermoplastic polymer through a plurality of fine, usually circular capillaries of a spinnerette. Cooling air is fed to a quenching chamber wherein the filaments are cooled. The cooling air is then sucked through a nozzle, which accelerates the flow of air. The friction between the flowing air and the filaments creates a force which draws the filaments, i.e., attenuates the filaments to a smaller diameter. The filaments are drawn to achieve molecular orientation and tenacity. The continuous filaments are then deposited in a substantially random manner to form a web of substantially continuous and randomly arranged, molecularly oriented filaments. Spunbonded fabric layers 6 and 8 are prebonded and thus have structural integrity.
  • the preferred thermoplastic polymer used to make spunbonded fabric layers 6 and 8 is polypropylene, although nylon, polyethylene, polyester, and copolymers and blends thereof may be used.
  • FIG. 5 shows a production line 30 for producing a prebonded SMS fabric laminate 12 for use in the present invention.
  • This production line can be operated at a speed of 375 m/min.
  • the equipment of production line 30 consists of an endless foraminous forming belt 32 wrapped around rollers 34 and 36. The belt 32 is driven in the direction shown by the arrows.
  • the production line 30 includes a forming machine which has three stations: spunbond station 36, meltblown station 38 and spunbond station 40.
  • the spunbond station 36 lays down a web 8 of spunbonded fibers 37 onto the carrier belt 32. Then the meltblown station 38 lays down a web 4 of meltblown fibers 39 onto the spunbonded web 8. Lastly, the spunbond station 40 lays down a web 6 of spunbonded fibers 41 onto the meltblown web 4.
  • each of the component fabric layers may be formed separately, rolled, and later converted to an SMS fabric laminate offline.
  • the spunbond stations 36 and 40 are conventional extruders with spinnerettes which form continuous filaments of a polymer and deposit those filaments onto the forming belt 32 in a random interlaced fashion.
  • Each spunbond station may include one or more spinnerette heads depending on the speed of the process and the particular polymer being used.
  • Forming spunbonded material is a conventional process well known in the art.
  • the meltblown station 38 consists of a die 42 which is used to form microfibers 39. As the thermoplastic polymer exits the die 42, the polymer threads are attenuated and spread by high-pressure fluid, usually air, to form microfi- bers 39. The microfibers 39 are randomly deposited on top of the spunbond layer 8 and form a meltblown layer 4.
  • high-pressure fluid usually air
  • the SMS fabric laminate web 12 (see FIG. 5) is then fed through bonding rolls 44 and 46.
  • the surfaces of the bonding rolls 44 and 46 are provided with a pattern of raised lands which apply heat and pressure to thermally spot bond the three layers together.
  • the bonding rolls are heated to a temperature which causes the meltblown polymer to soften.
  • the composite material is compressed and heated by the bonding rolls in accordance with the pattern on the rolls to create a pattern of discrete bonding areas.
  • Such discrete area or spot bonding is well known in the art and can be carried out by means of heated rolls or by ultrasonic bonding.
  • the bond pattern is selected to provide desired fabric strength characteristics.
  • the pattern bonding area is not limited in accordance with the present invention.
  • a spunbonded fabric laminate is formed by operating only spunbond stations 36 and 40, i.e., meltblown station 38 is turned off.
  • the bonding rolls 44 and 46 must be heated to a temperature which causes the spunbonded polymer to soften.
  • the precursor SMS (or SS) fabric laminate exiting the bonding station is inherently hydrophobic .
  • samples of baby wipes were manufactured in accordance with the above-parameters on both a commercial line and a pilot line similar to the line shown in FIG. 2, and subjected to various tests, including absorbency, sinktime, tensile strength, elongation, and fuzz production.
  • the following examples illustrate the material composition ranges and properties of several preferred embodiments of the invention. All wet properties were tested using a proprietary baby lotion and a conventional baby lotion obtained by squeezing it out of commercially available baby wipes.
  • the first group of baby wipes manufactured and tested comprise a 17.5 grams per square yard (gsy) hydrophilic polyproplene SS middle layer (Veratec VeraspunTM) sandwiched between top and bottom carded fiber layers comprising the same blend of fibers and thermally bonded by calender rolls having the 7 -point bond pattern.
  • Each carded web of the first sample (No. L4 1007.1) has a fiber composition of 50% 2.0 dpf x 38 mm polypropylene staple fibers (Herculon ® T117) and 50% 1.5 dpf x 40 mm rayon fibers (Courtaulds 18453).
  • the carded webs of the second sample (No.
  • L4 1007.4 have a fiber composition of 50% 2.6 dpf x 38 mm polypropylene staple fibers (Herculon ® Till) and 50% 2.0 dpf x 40 mm rayon fibers (Courtaulds 14561).
  • the third sample (L4 1007.5) comprises carded webs having a fiber composition of 25% 2.6 dpf x 38 mm polypropylene (Herculon ® Till) , 25% 1.5 dpf x 38 mm polyester (Fortrel ® Type 472), and 50% 2.0 dpf x 40 mm rayon fibers (Courtaulds 14561) . Properties of these three samples are shown in Table 2.
  • sample L4 1007.1 As can be seen in Table 2, replacing the high tenacity, low elongation T117 hydrophilic polypropylene fibers in sample L4 1007.1 with low tenacity, high elongation Till hydrophilic fibers m sample L4 1007.4 resulted in a 40% increase in strength in the machine direction, and 81% increase in strength in the cross direction, and a 45% reduction in fuzz generation.
  • Sample L4 1007.5 was found to possess a softer hand which can be attributed to the introduction of polyester fibers into the outer carded fiber blends. All three samples exhibited good absorbency. Sink times do not play a significant roll in the performance of these nonwoven composite fabrics because they are sold as pre-moistened baby wipes.
  • the second group of samples comprise a middle layer of polypropylene SMS fabric (EverspunTM, manufactured by Veratec, Inc., alpole, Massachusetts) and outer carded layers each having a different matrix of fibers.
  • the top layer comprises 100% polypropylene (PP) and the bottom layer comprises a blend of polypropylene, polyester (PET) and rayon fibers.
  • the fiber composition of each layer in these samples is shown in Table 3 and the properties of the samples are shown in Table 4.
  • Sample No. L4 1019.2 exhibited a significant reduction in fuzz generation, about 80-85% less than in Sample Nos. L4 1010.2 and L4 1010.6, and about 70% less than Sample No. L4 1007.4 in example 1. This improvement can be attributed to the increased bond area (25%) provided by the Novonette #2 calender pattern.
  • the 13 gsy EverspunTM middle layer used in Sample Nos. L4 1010.2 and L4 1010.6 resulted in improved tensile strengths comparable to those obtained in the fabrics of example 1 which comprise 17.5 gsy VeraspunTM .
  • the following composite baby wipe fabrics were made using partially-bonded polyethylene SS fabrics in the middle layer and fiber layers on both sides comprising the same fiber or fiber blend.
  • the polyethylene (PEN) spunbonded fabrics were manufactured on a pilot line, unlike the previously mentioned VeraspunTM SS and EverspunTM SMS fabrics which were manufactured on a commercial line. These samples had a deep embossed look, which enhance texture and aesthetics of the wipe. It is also believed that these samples will have increased cleaning ability resulting from the deeper embossments and polyethylene spunbonded layer.
  • the fiber composition and properties of these samples are shown in Tables 5 and 6, respectively.

Abstract

L'invention concerne un tissu non tissé composite approprié à des fins de nettoyage de bébé, qui comporte une couche de fibres non tissées cardées liées thermiquement à un laminé (12) de tissu prélié filé-lié-fondu-soufflé-filé-lié (SMS), ou prélié filé-lié-filé-lié (SS). La couche de fibres non tissées cardées comporte des fibres de polypropylène, de polyester, de rayonne ou de coton, ou un mélange de celles-ci. Les laminés de tissu SMS ou SS sont fabriqués à partir de résines de polypropylène ou de polyéthylène. Les couches sont liées thermiquement à plusieurs points de liaison distincts par leur passage à travers des cylindres de calandre (20a, 20b) gravés.
PCT/US1998/011726 1997-06-05 1998-06-05 Composite de grande resistance pour nettoyage de bebe WO1998055295A1 (fr)

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WO2000053835A1 (fr) * 1999-03-05 2000-09-14 Kimberly-Clark Limited Torchon
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US7695799B2 (en) 2005-08-29 2010-04-13 Advantage Creation Enterprise Llc Apertured laminate and method of making
WO2011019675A1 (fr) * 2009-08-10 2011-02-17 E. I. Du Pont De Nemours And Company Stratifiés de barrière allergène non tissée durable
EP2331854A1 (fr) * 2008-09-05 2011-06-15 Nutek Disposables, Inc. Lingette composite
WO2011123584A1 (fr) * 2010-03-31 2011-10-06 The Procter & Gamble Company Structures fibreuses et leurs procédés de fabrication
WO2013163201A1 (fr) * 2012-04-27 2013-10-31 Providencia Usa, Inc. Lingette non tissée à motif de liaison
US8664128B2 (en) 2008-01-30 2014-03-04 Advantage Creation Enterprise Llc Elastic laminate and method of making
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
US9067334B2 (en) 2009-03-24 2015-06-30 Advantage Creation Enterprise Llc Embossed textured webs and method for making
EP2901991B1 (fr) 2014-01-31 2016-04-27 Ontex BVBA Support non tissé pour article absorbant
US9458573B2 (en) 2009-11-02 2016-10-04 The Procter & Gamble Company Fibrous structures and methods for making same
EP2901992B1 (fr) 2014-01-31 2016-12-28 Ontex BVBA Matériau absorbant multicouche
US9849602B2 (en) 2009-12-18 2017-12-26 Advantage Creation Enterprise Llc Method for making extrusion coated perforated nonwoven web
US10024000B2 (en) 2007-07-17 2018-07-17 The Procter & Gamble Company Fibrous structures and methods for making same
CN108660616A (zh) * 2018-05-29 2018-10-16 中原工学院 一种水平分支增强的仿生树形非织造复合材料及其制备方法
CN111041713A (zh) * 2019-12-30 2020-04-21 孙福胜 一种双肩包背幅的生产工艺
WO2020205360A1 (fr) 2019-04-02 2020-10-08 The Clorox Company Procédé de fabrication de substrats multicouches comprenant des couches en sandwich et du polyéthylène
US10828209B2 (en) 2015-12-16 2020-11-10 Avintiv Specialty Materials Inc. Soft nonwoven fabric and method of manufacturing thereof
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
CN113301838A (zh) * 2018-12-21 2021-08-24 克劳罗克斯公司 包含夹层和聚乙烯的多层基材
US11136699B2 (en) 2018-05-14 2021-10-05 Fitesa Simpsonville, Inc. Composite sheet material, system, and method of preparing same
WO2023000641A1 (fr) * 2021-07-19 2023-01-26 厦门延江新材料股份有限公司 Nontissé d'essuyage composite par filage direct et son procédé de fabrication

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US6550115B1 (en) 1998-09-29 2003-04-22 Kimberly-Clark Worldwide, Inc. Method for making a hydraulically entangled composite fabric
AU760428B2 (en) * 1998-09-29 2003-05-15 Kimberly-Clark Worldwide, Inc. A fabric
WO2000018996A1 (fr) * 1998-09-29 2000-04-06 Kimberly-Clark Worldwide, Inc. Tissu
WO2000053835A1 (fr) * 1999-03-05 2000-09-14 Kimberly-Clark Limited Torchon
US6322604B1 (en) 1999-07-22 2001-11-27 Kimberly-Clark Worldwide, Inc Filtration media and articles incorporating the same
WO2002027089A1 (fr) * 2000-09-29 2002-04-04 The Procter & Gamble Company Article d'essuyage doux, souple et jetable, comportant une impression en relief
WO2004044298A1 (fr) * 2002-11-13 2004-05-27 The Procter & Gamble Company Chiffon non tisse a epaisseur humide resiliente
US8921244B2 (en) 2005-08-22 2014-12-30 The Procter & Gamble Company Hydroxyl polymer fiber fibrous structures and processes for making same
US7695799B2 (en) 2005-08-29 2010-04-13 Advantage Creation Enterprise Llc Apertured laminate and method of making
US10513801B2 (en) 2007-07-17 2019-12-24 The Procter & Gamble Company Process for making fibrous structures
US11959225B2 (en) 2007-07-17 2024-04-16 The Procter & Gamble Company Fibrous structures and methods for making same
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US11346056B2 (en) 2007-07-17 2022-05-31 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
US9926648B2 (en) 2007-07-17 2018-03-27 The Procter & Gamble Company Process for making fibrous structures
US8664128B2 (en) 2008-01-30 2014-03-04 Advantage Creation Enterprise Llc Elastic laminate and method of making
AU2009289510B2 (en) * 2008-09-05 2015-04-02 Nutek Disposables, Inc. Composite wipe
EP2331854A4 (fr) * 2008-09-05 2012-02-01 Nutek Disposables Inc Lingette composite
EP2331854A1 (fr) * 2008-09-05 2011-06-15 Nutek Disposables, Inc. Lingette composite
US10729597B2 (en) 2009-03-24 2020-08-04 Advantage Creation Enterprise Llc Embossed textured webs and method for making
US9067334B2 (en) 2009-03-24 2015-06-30 Advantage Creation Enterprise Llc Embossed textured webs and method for making
CN105411754A (zh) * 2009-03-24 2016-03-23 詹姆士.W.克里 压花的有纹理的网幅及其制造方法
CN105411754B (zh) * 2009-03-24 2019-02-05 詹姆士.W.克里 压花的有纹理的网幅及其制造方法
CN102648092A (zh) * 2009-08-10 2012-08-22 纳幕尔杜邦公司 耐用非织造过敏原阻挡层压体
WO2011019675A1 (fr) * 2009-08-10 2011-02-17 E. I. Du Pont De Nemours And Company Stratifiés de barrière allergène non tissée durable
CN102648092B (zh) * 2009-08-10 2015-09-23 纳幕尔杜邦公司 耐用非织造过敏原阻挡层压体
US9458573B2 (en) 2009-11-02 2016-10-04 The Procter & Gamble Company Fibrous structures and methods for making 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
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US10821622B2 (en) 2009-12-18 2020-11-03 Advantage Creation Enterprise Llc Extrusion coated perforated nonwoven web and method for making
US9849602B2 (en) 2009-12-18 2017-12-26 Advantage Creation Enterprise Llc Method for making extrusion coated perforated nonwoven web
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FR2959518A1 (fr) * 2010-03-31 2011-11-04 Procter & Gamble Structures fibreuses et leurs procedes de preparation
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US10240297B2 (en) 2010-03-31 2019-03-26 The Procter & Gamble Company Fibrous structures and methods for making same
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