WO1998058110B1 - Method of making heteroconstituent and layered nonwoven materials - Google Patents
Method of making heteroconstituent and layered nonwoven materialsInfo
- Publication number
- WO1998058110B1 WO1998058110B1 PCT/US1998/012412 US9812412W WO9858110B1 WO 1998058110 B1 WO1998058110 B1 WO 1998058110B1 US 9812412 W US9812412 W US 9812412W WO 9858110 B1 WO9858110 B1 WO 9858110B1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- type
- filaments
- air stream
- nonwoven material
- spinpack
- Prior art date
Links
- 239000000463 material Substances 0.000 title claims 21
- 238000004519 manufacturing process Methods 0.000 title claims 8
- 239000000203 mixture Substances 0.000 claims abstract 14
- 229920000642 polymer Polymers 0.000 claims abstract 10
- 239000000835 fiber Substances 0.000 claims abstract 6
- 238000002788 crimping Methods 0.000 claims abstract 4
- 230000000996 additive Effects 0.000 claims abstract 3
- 239000000654 additive Substances 0.000 claims abstract 3
- 238000010791 quenching Methods 0.000 claims 10
- 238000000034 method Methods 0.000 claims 6
- 230000000171 quenching Effects 0.000 claims 6
- 239000005977 Ethylene Substances 0.000 claims 4
- 229920001577 copolymer Polymers 0.000 claims 4
- VGGSQFUCUMXWEO-UHFFFAOYSA-N ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims 3
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 claims 3
- 229920000570 polyether Chemical class 0.000 claims 2
- 239000004711 α-olefin Substances 0.000 claims 2
- 239000004952 Polyamide Substances 0.000 claims 1
- 239000005062 Polybutadiene Substances 0.000 claims 1
- 229920002367 Polyisobutene Polymers 0.000 claims 1
- 239000004721 Polyphenylene oxide Chemical class 0.000 claims 1
- 239000004793 Polystyrene Substances 0.000 claims 1
- 150000001336 alkenes Chemical class 0.000 claims 1
- 229920001400 block copolymer Polymers 0.000 claims 1
- 150000001993 dienes Chemical class 0.000 claims 1
- 229920001971 elastomer Polymers 0.000 claims 1
- 239000000806 elastomer Substances 0.000 claims 1
- 150000002148 esters Chemical class 0.000 claims 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims 1
- 229920000058 polyacrylate Polymers 0.000 claims 1
- 229920002647 polyamide Polymers 0.000 claims 1
- 229920002857 polybutadiene Polymers 0.000 claims 1
- 229920000728 polyester Polymers 0.000 claims 1
- 229920002223 polystyrene Polymers 0.000 claims 1
- 229920002635 polyurethane Polymers 0.000 claims 1
- 239000004814 polyurethane Substances 0.000 claims 1
- 229920001897 terpolymer Polymers 0.000 claims 1
Abstract
The present invention is directed to a method of forming a heteroconstituent nonwoven web including a mixture of different filament types simultaneously formed into the same web. The filament types may differ as to polymer composition, additive loadings, fiber size, fiber shape, and/or degree of crimping. The invention is also directed to a method of forming a multilayered nonwoven structure in which different filament types constituting different layers are simultaneously formed.
Claims
AMENDED CLAIMS
[received by the -International Bureau on 28 December 1998 (28.12.98); original claims 1-37 replaced by amended claims 1-58 (9 pages)]
1. A method of making a heteroconstituent nonwoven material including a mixture of polymer filaments of a first type A and filaments of a second type B, comprising the steps of: extruding filaments of the first type A from a first spinpack; extruding filaments of the second type B from a second spinpack; quenching the filaments of the first type A and second type B by supplying a first air stream laterally of the type A filaments and a second opposing air stream laterally of the type B filaments; the first and second opposing air streams having sufficient velocities and flow rates to bring the type A and type B filaments together and cause at least some mixing of the type A and type B filaments resulting in a heteroconstituent nonwoven material; wherein the first air stream and second air stream are supplied at about 5-25°C.
2. The method of Claim 1, further comprising the step of supplying a third air stream from in between the type A and type B filaments before they are brought together.
4. The method of Claim 2, wherein the third air stream is supplied at about 5-25°C.
5. The method of Claim 1, wherein the type A and type B filaments are extruded toward each other at angles of about 1-15 degrees from the vertical.
6. The method of Claim 1 , wherein the type A and type B filaments are extruded toward each other at angles of about 1-5 degrees from the vertical.
7. The method of Claim 1, wherein the first and second air streams are directed toward each other at angles of about 1-10 degrees from the horizontal.
19
8. The method of Claim 2, further comprising the step of supplying a fourth air stream from in between the type A and type B filaments before they are brought together.
9. The method of Claim 1, wherein the type A filaments and type B filaments have different compositions.
10. The method of Claim 1, wherein the type A filaments and type B filaments comprise different polymer compositions.
11. The method of Claim 10, wherein the type A filaments and type B filaments comprise polymers selected from the group consisting of polyamides, polyesters, copolymers of ethylene and propylene, copolymers of ethylene or propylene with a C4-C20 alpha-olefm, terpolymers of ethylene with propylene and a C4-C20 alpha olefin, ethylene vinyl acetate copolymers, propylene vinyl acetate copolymers, styrene-poly(ethylene-alpha- olefin)elastomers, polyurethanes, A-B block copolymers where A is formed of poly(vinyl arene) moieties such as polystyrene and B is an elastomeric midblock such as a conjugated diene or lower alkene, polyethers, polyether esters, polyacrylates, ethylene alkyl acrylates, polyisobutylene, polybutadiene, isobutylene-isoprene copolymers and combinations of any of the foregoing.
12. The method of Claim 10, wherein at least one of the type A filaments and type B filaments comprises bicomponent filaments.
13. The method of Claim 12, wherein the type A filaments and type B filaments comprise bicomponent filaments having different compositions.
14. The method of Claim 12, wherein the type A filaments and type B filaments comprise bicomponent filaments having different configurations.
15. The method of Claim 1, wherein the type A and type B filaments comprise different additive loadings.
20
16. The method of Claim 1, wherein the type A filaments and type B filaments comprise spunbond filaments.
17. The method of Claim 1, wherein the type A filaments and type B filaments have different levels of crimping.
'18. The method of Claim 17, wherein one of the filament types is uncrimped and the other of the filament types is crimped.
19. The method of Claim 17, wherein both filament types are crimped.
20. The method of Claim 17, wherein the type A filaments and type B filaments comprise spunbond filaments.
21. The method of Claim 1, wherein the type A filaments and type B filaments have different average filament sizes.
22. The method of Claim 21, wherein the type A filaments and type B filaments have different average fiber diameters.
23. The method of Claim 21, wherein the type A filaments and type B filaments have different average fiber lengths.
24. The method of Claim 21, wherein the type A filaments and type B filaments comprise spunbond filaments.
25. A method of making a multilayered nonwoven material including a layer of polymer filaments of a first type A and a layer of filaments of a second type B, comprising the steps of: extruding filaments of the first type A from a first spinpack; extruding filaments of the second type B from a second spinpack;
21
quenching the filaments of the first type A and second type B by supplying a first air stream laterally of the type A filaments and a second opposing air stream laterally of the type B filaments; the first and second opposing air streams having sufficient velocities and flow rates to bring the type A and type B filaments together in the form of layers resulting in a multilayered nonwoven material.
26. The method of Claim 25, further comprising the step of supplying a third air stream from in between the type A and type B filaments before they are brought together.
27. The method of Claim 25, wherein the first air stream and second air stream are supplied at about 5-25 °C.
28. The method of Claim 25, wherein the third air stream is supplied at about 5-25 °C.
29. The method of Claim 25, wherein the type A and type B filaments are extruded toward each other at angles of about 1-15 degrees from the vertical.
30. The method of Claim 25, wherein the type A and type B filaments are extruded toward each other at angles of about 1-5 degrees from the vertical.
31. The method of Claim 25, wherein the first and second air streams are directed toward each other at angles of about 1-10 degrees from the horizontal.
32. The method of Claim 26, further comprising the step of supplying a fourth air stream in between the type A and type B filaments before they are brought together.
22
33. A method of making a multilayered nonwoven material including at least three nonwoven layers, comprising the steps of: extruding a first bundle of filaments from a first spinpack; extruding a second bundle of filaments from a second spinpack; extruding a third bundle of filaments from a third spinpack located between the first and second spinpacks; supplying a first quench air stream laterally of the first bundle of filaments and a second opposing quench air stream laterally of the second bundle of filaments; supplying a third quench air stream between the first and third bundles of filaments; supplying a fourth quench air stream between the second and third bundles of filaments; and merging the first, second and third bundles of filaments together in the form of layers resulting in a multilayered nonwoven material.
34. The method of Claim 33, wherein the first bundle comprises filaments of a first type A and at least one of the second and third bundles comprises filaments of a second type B.
35. The method of Claim 34, wherein the second bundle comprises filaments of the first type A, and the third bundle comprises filaments of the second type B.
36. The method of Claim 34, wherein the second bundle comprises filaments of the second type B, and the third bundle comprises filaments of the first type A.
37. The method of Claim 34, wherein the other of the second and third bundles comprises filaments of a third type C.
38. A method of making a heteroconstituent nonwoven material including a mixture of polymer filaments of a first type A and filaments of a second type B, comprising the steps of: extruding filaments of the first type A from a first spinpack;
23
extruding filaments of the second type B from a second spinpack; quenching the filaments of the first type A and second type B by supplying a first air stream laterally of the type A filaments and a second opposing air stream laterally of the type B filaments; the first and second opposing air streams having sufficient velocities and flow rates to bring the type A and type B filaments together and cause at least some mixing of the type A and type B filaments resulting in a heteroconstituent nonwoven material; wherein the type A and type B filaments are extruded toward each other at angles of about 1-15 degrees from the vertical.
39. The method of Claim 38, further comprising the step of supplying a third air stream from in between the type A and type B filaments before they are brought together.
40. The method of Claim 38, wherein the type A and type B filaments are extruded toward each other at angles of about 1-5 degrees from the vertical.
41. The method of Claim 38, wherein the first and second air streams are directed toward each other at angles of about 1-10 degrees from the horizontal.
42. The method of Claim 39, further comprising the step of supplying a fourth air stream from in between the type A and type B filaments before they are brought together.
43. The method of Claim 38, wherein the type A filaments and type B filaments have different compositions.
44. The method of Claim 38, wherein the type A filaments and type B filaments comprise different polymer compositions.
45. The method of Claim 38, wherein the type A and type B filaments comprise different additive loadings.
24
46. The method of Claim 38, wherein the type A filaments and type B filaments comprise spunbond filaments.
47. A method of making a heteroconstituent nonwoven material including a mixture of polymer filaments of a first type A and filaments of a second type B, comprising the steps of: extruding filaments of the first type A from a first spinpack; extruding filaments of the second type B from a second spinpack; quenching the filaments of the first type A and second type B by supplying a first air stream laterally of the type A filaments and a second opposing air stream laterally of the type B filaments; the first and second opposing air streams having sufficient velocities and flow rates to bring the type A and type B filaments together and cause at least some mixing of the type A and type B filaments resulting in a heteroconstituent nonwoven material; wherein at least one of the type A filaments and type B filaments comprises bicomponent filaments.
48. The method of Claim 47, wherein the type A filaments and type B filaments comprise bicomponent filaments having different compositions.
49. The method of Claim 47, wherein the type A filaments and type B filaments comprise bicomponent filaments having different configurations.
50. The method of Claim 47, wherein the type A filaments and type B filaments comprise spunbond filaments.
51. A method of making a heteroconstituent nonwoven material including a mixture of polymer filaments of a first type A and filaments of a second type B, comprising the steps of: extruding filaments of the first type A from a first spinpack; extruding filaments of the second type B from a second spinpack;
25
quenching the filaments of the first type A and second type B by supplying a first air stream laterally of the type A filaments and a second opposing air stream laterally of the type B filaments-; the first and second opposing air streams having sufficient velocities and flow rates to bring the type A and type B filaments together and cause at least some mixing of the type A and type B filaments resulting in a heteroconstituent nonwoven material; wherein the type A filaments and type B filaments have different levels of crimping.
52. The method of Claim 51, wherein one of the filament types is uncrimped and the other of the filament types is crimped.
53. The method of Claim 51 , wherein both filament types are crimped.
54. The method of Claim 51, wherein the type A filaments and type B filaments comprise spunbond filaments.
55. A method of making a heteroconstituent nonwoven material including a mixture of polymer filaments of a first type A and filaments of a second type B, comprising the steps of: extruding filaments of the first type A from a first spinpack; extruding filaments of the second type B from a second spinpack; quenching the filaments of the first type A and second type B by supplying a first air stream laterally of the type A filaments and a second opposing air stream laterally of the type B filaments; the first and second opposing air streams having sufficient velocities and flow rates to bring the type A and type B filaments together and cause at least some mixing of the type A and type B filaments resulting in a heteroconstituent nonwoven material; wherein the type A filaments and type B filaments have different average filament sizes.
26
56. The method of Claim 55, wherein the type A filaments and type B filaments have different average fiber diameters.
57. The method of Claim 55, wherein the type A filaments and type B filaments have different average fiber lengths.
58. The method of Claim 55, wherein the type A filaments and type B filaments comprise spunbond filaments.
27
STATEMENT UNDER PCT ARTICLE 19
Claims 1, 25 and 33 have been replaced with amended Claims 1, 25 and
33. Claim 3 has been deleted. Claims 2, 4-24, 26-32 and 34-37 are unchanged in text,
but changed in scope due to their dependence on amended Claims 1, 25 and 33. New
Claims 38-58 have been added.
Amended Claim 1 differs from original Claim 1 by further reciting that
the first and second air streams are supplied at about 5-25°C. Amended Claim 1 also
recites that the process results in a heteroconstituent nonwoven material. Amended
28
Claims 25 and 33 differ from the respective original claims by further reciting that the
process results in a multilayered nonwoven material.
New Claim 38 differs from original Claim 1 by further reciting 1) that the
type A and type B filaments are extruded toward each other at angles of about 1-15
degrees from the vertical, and b) that the process results in a heteroconstituent
nonwoven material. New Claims 39-46 depend from Claim 38.
New Claim 47 differs from original Claim 1 by further reciting 1) that the
type A and type B filaments comprise bicomponent filaments, and 2) that the process
results in a heteroconstituent nonwoven material. New Claims 48-50 depend from
Claim 47.
New Claim 51 differs from original Claim 1 by further reciting 1) that the
type A and type B filaments have different levels of crimping, and 2) that the process
results in a heteroconstituent nonwoven material. New Claims 52-54 depend from
Claim 47.
New Claim 55 differs from original Claim 1 by further reciting 1) that the
type A and type B filaments have different average filament sizes, and 2) that the
process results in a heteroconstituent nonwoven material. New Claims 56-58 depend
from Claim 55.
29
Applicant believes that the amended claims and new claims better
distinguish the invention from the prior art cited in the International Search Report. No
new matter has been added.
30
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE1998622827 DE69822827T2 (en) | 1997-06-18 | 1998-06-15 | Process for making hetero-component and ply-nonwoven materials |
| AU79670/98A AU734074B2 (en) | 1997-06-18 | 1998-06-15 | Method of making heteroconstituent and layered nonwoven materials |
| EP98930229A EP0990065B1 (en) | 1997-06-18 | 1998-06-15 | Method of making heteroconstituent and layered nonwoven materials |
| BR9810120-0A BR9810120A (en) | 1997-06-18 | 1998-06-15 | Method for making heterocontituent and layered nonwoven materials |
| CA002291339A CA2291339A1 (en) | 1997-06-18 | 1998-06-15 | Method of making heteroconstituent and layered nonwoven materials |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/878,288 US5853635A (en) | 1997-06-18 | 1997-06-18 | Method of making heteroconstituent and layered nonwoven materials |
| US08/878,288 | 1997-06-18 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO1998058110A1 WO1998058110A1 (en) | 1998-12-23 |
| WO1998058110B1 true WO1998058110B1 (en) | 1999-02-18 |
Family
ID=25371730
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US1998/012412 WO1998058110A1 (en) | 1997-06-18 | 1998-06-15 | Method of making heteroconstituent and layered nonwoven materials |
Country Status (11)
| Country | Link |
|---|---|
| US (1) | US5853635A (en) |
| EP (1) | EP0990065B1 (en) |
| KR (1) | KR20010013915A (en) |
| CN (1) | CN1268195A (en) |
| AR (1) | AR013000A1 (en) |
| AU (1) | AU734074B2 (en) |
| BR (1) | BR9810120A (en) |
| CA (1) | CA2291339A1 (en) |
| DE (1) | DE69822827T2 (en) |
| WO (1) | WO1998058110A1 (en) |
| ZA (1) | ZA985084B (en) |
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| US5149576A (en) * | 1990-11-26 | 1992-09-22 | Kimberly-Clark Corporation | Multilayer nonwoven laminiferous structure |
| DE4224652C3 (en) * | 1991-08-06 | 1997-07-17 | Barmag Barmer Maschf | Spinning device for melt spinning, in particular thermoplastic multi-component threads |
| JP3134959B2 (en) * | 1992-03-17 | 2001-02-13 | チッソ株式会社 | Composite melt blow spinneret |
| US5382400A (en) * | 1992-08-21 | 1995-01-17 | Kimberly-Clark Corporation | Nonwoven multicomponent polymeric fabric and method for making same |
| US5336552A (en) * | 1992-08-26 | 1994-08-09 | Kimberly-Clark Corporation | Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and ethylene alkyl acrylate copolymer |
| US5387387A (en) * | 1993-09-30 | 1995-02-07 | Alex James & Associates, Inc. | Method and apparatus for dry spinning spandex |
| US5556589A (en) * | 1994-09-07 | 1996-09-17 | Hercules Incorporated | Process of using a spin pack for multicomponent fibers |
-
1997
- 1997-06-18 US US08/878,288 patent/US5853635A/en not_active Expired - Lifetime
-
1998
- 1998-06-11 ZA ZA985084A patent/ZA985084B/en unknown
- 1998-06-15 DE DE1998622827 patent/DE69822827T2/en not_active Expired - Fee Related
- 1998-06-15 WO PCT/US1998/012412 patent/WO1998058110A1/en not_active Application Discontinuation
- 1998-06-15 AU AU79670/98A patent/AU734074B2/en not_active Ceased
- 1998-06-15 KR KR1019997011937A patent/KR20010013915A/en active IP Right Grant
- 1998-06-15 CN CN98806447A patent/CN1268195A/en active Pending
- 1998-06-15 BR BR9810120-0A patent/BR9810120A/en not_active Application Discontinuation
- 1998-06-15 EP EP98930229A patent/EP0990065B1/en not_active Revoked
- 1998-06-15 CA CA002291339A patent/CA2291339A1/en not_active Abandoned
- 1998-06-17 AR ARP980102890A patent/AR013000A1/en not_active Application Discontinuation
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