WO2002055780A1 - Non tisse hydroenchevetre a base surfacique relativement faible et son procede de fabrication - Google Patents

Non tisse hydroenchevetre a base surfacique relativement faible et son procede de fabrication Download PDF

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Publication number
WO2002055780A1
WO2002055780A1 PCT/US2001/001166 US0101166W WO02055780A1 WO 2002055780 A1 WO2002055780 A1 WO 2002055780A1 US 0101166 W US0101166 W US 0101166W WO 02055780 A1 WO02055780 A1 WO 02055780A1
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WO
WIPO (PCT)
Prior art keywords
basis weight
fabric
low basis
filaments
precursor web
Prior art date
Application number
PCT/US2001/001166
Other languages
English (en)
Inventor
Michael Putnam
Richard Ferencz
Marlene Storzer
Jian Weng
Original Assignee
Polymer Group, 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 Polymer Group, Inc. filed Critical Polymer Group, Inc.
Priority to PCT/US2001/001166 priority Critical patent/WO2002055780A1/fr
Publication of WO2002055780A1 publication Critical patent/WO2002055780A1/fr

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Classifications

    • 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
    • D04H3/12—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 filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • 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
    • D04H18/00—Needling machines
    • D04H18/04—Needling machines with water jets
    • 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
    • D04H3/10—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 yarns or filaments made mechanically
    • D04H3/11—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 yarns or filaments made mechanically by fluid jet

Definitions

  • the present invention relates generally to nonwoven fabrics, and methods for producing such fabrics, and more particularly to a hydroentangled, low basis weight nonwoven fabric exhibiting desirable softness and strength characteristics in a three-dimensional patterned form, with manufacture from a lightly bonded precursor web facilitating efficient and high-speed production.
  • Nonwoven fabrics are used in a wide variety of applications where the engineered qualities of the fabric can be advantageously employed. These types of fabrics differ from traditional woven or knitted fabrics in that the fibers or filaments of the fabric are integrated into a coherent web without traditional textile processes. Entanglement of the fibrous elements of the fabric provides the fabric with the desired integrity, with the selected entanglement process permitting fabrics to be patterned to achieve desired aesthetics.
  • Evans-type technology These types of fibers are attenuated during known melt- blowing formation techniques, whereby the fibers have relatively small diameters.
  • This patent discloses the use of a belt or drum forming surface having a perforated or foraminated forming surface. Plural hydroentangling manifolds act against fibers positioned on the forming surface to displace the fibers from "knuckles" of the forming surface, and into openings or lower parts of the forming surface topography, as in Evans.
  • This patent contemplates use of a polymeric net or scrim for fabric formation, and the formation of fabric having apertures therein of two different sizes, including formation of fabric from a first layer of textile fibers or polymeric filaments, and a second layer of melt-blown microfibers.
  • U.S. Patent No. 5,516,572, to Roe discloses a disposable absorbent article including a liquid pervious topsheet, wherein the topsheet comprises a nonwoven fabric prepared from a homogeneous admixture of melt-blown fibers and staple length synthetic fibers.
  • the patent contemplates that fabrics formed in accordance with its teachings comprise a blend including up to 50% by weight of melt-blown fibers.
  • U.S. Patent No. 4,805,275, to Suzuki et al. also discloses a method for forming nonwoven fabrics by hydroentanglement.
  • This patent contemplates that hydroentanglement of a fibrous web be effected on a non-three-dimensional smooth-surfaced water-impermeable endless belt, but notes that at fabric weights below 15 grams per square meter that irregularities in the fibrous web occur, and fabrics with substantial uniformity cannot be obtained.
  • the present invention contemplates a process employing a three-dimensional image transfer device for forming relatively low basis weight nonwoven fabrics, which can be efficiently practiced for manufacture of patterned fabrics having a high degree of uniformity. Such uniformity facilitates use of such fabrics in a wide variety of applications, with efficient formation facilitating economical use.
  • a process of making a nonwoven fabric having a low basis weight in accordance with the principles of the present invention contemplates hydroentangling on a three-dimensional image transfer device of a precursor web comprising spunbonded continuous polymeric filaments.
  • spunbonding entails extrusion or "spinning" of thermoplastic polymeric material with the resultant filaments cooled and drawn or attenuated as they are collected.
  • the continuous, or essentially endless, filaments may be bonded, with the process of the subject invention contemplating that such spunbonded material be employed as the precursor web.
  • a precursor web having a basis weight from about 10 to about 30 grams per square meter is employed.
  • the present invention further contemplates that a three-dimensional image transfer device be provided, with the transfer device having a fabric-forming surface defined between three-dimensional surface features.
  • the transfer device having a fabric-forming surface defined between three-dimensional surface features.
  • at least some of the surface features have profiles which converge toward each other in a direction toward the fabric-forming surface, with the presently preferred image transfer device comprising rectilinear pyramidal array.
  • hydroentanglement is effected by application of high pressure liquid streams to the web.
  • Filaments of the web are rearranged by the fabric-forming surface of the image transfer device, including movement of at least some of the filaments off of the three-dimensional surface features of the device to regions of the forming surface between adjacent ones of the surface features.
  • filaments are displaced and compacted under the influence of the liquid streams, to regions between adjacent ones of the pyramids of the array.
  • a low basis weight web formed in accordance with the present invention comprises a web of hydroentangled polymeric filaments having a denier from 0.2 to 3.0.
  • the filaments are arranged in a substantially uniform array including interconnected bundles of filaments surrounding apertures extending through the web.
  • the fabric has a basis weight of from about 10 to about 30 grams per square meter, a cross-direction tensile strength of at least about 64 grams per centimeter at 59% cross direction elongation, and a machine direction tensile strength of at least about 242 grams per centimeter at 24% machine-direction elongation.
  • a low basis weight fabric formed in accordance with the present invention may be formed to include substantially continuous filaments (from a relatively lightly bonded spunbond precursor web), with the resulting fabric having a machine direction tensile strength of at least about 550 grams per centimeter at 50% machine-direction elongation.
  • the degree of bonding of the precursor web is specifically selected to facilitate handling of the web, with the contemplation that higher strength fabrics can be achieved if the filaments of the precursor web are maintained in a substantially continuous form.
  • the spunbond precursor web is subjected to bonding which provides no more than a minimum tensile strength which permits winding and unwinding of the precursor web.
  • the minimal tensile strength of the precursor web is selected to facilitate efficient handling during manufacturing of the present low basis weight nonwoven fabric.
  • FIGURE 1 is a diagrammatic view of a hydroentangling apparatus for practicing the process of the present invention, whereby low basis weight nonwoven fabrics embodying the principles of the present invention can be formed.
  • FIGURE 1 therein is illustrated a hydroentangling apparatus, generally designated 10, which can be employed for practicing the process of the present invention for manufacture of a relatively low basis weight nonwoven fabric.
  • the apparatus is configured generally in accordance with the teachings of U.S. Patent No. 5,098,764, to Drelich et al., hereby incorporated by reference.
  • the apparatus 10 includes an entangling drum 12 which comprises a three-dimensional image transfer device upon which hydroentangling of a precursor web is effected for formation of the present nonwoven fabric.
  • the image transfer device includes a fabric-forming surface defined between three- dimensional surface features of the device. At least some of the features have profiles which converge toward each other in a direction toward the fabric- forming surface, with the image transfer device defining drain openings positioned between adjacent ones of the surface features.
  • a rectilinear pyramidal array is employed for the three-dimensional image transfer device of entangling drum 12.
  • U.S. Patent No. 5,098,764 discloses various configurations for pyramidal arrays of the type which can be employed for the image transfer device of entangling drum 12. The following describes one of the forming surfaces which can be provided on the image transfer device for manufacture of the subject low basis weight nonwoven fabric.
  • 20 x 20 refers to a rectilinear forming pattern including an array of pyramids, wherein the pyramids are configured in a 20 per inch x 20 per inch array, in accordance with Figure 13 of U.S. Patent No. 5,098,764.
  • mid-pyramid drain holes (designated by reference numeral 109) are omitted. Drain holes are thus present at each corner of each pyramid, i.e., four holes surround each pyramid.
  • Pyramid height is 0.025 inches, with drain holes having a diameter of 0.02 inches. Drainage area is 12.5% of the surface area.
  • a plurality of hydroentangling manifolds act sequentially upon a precursor web P trained about entangling drum 12.
  • the precursor web P may be formed in-line with the entanglement apparatus, as generally illustrated in phantom line, or may be provided in the form of rolls of material fed into the entangling apparatus for processing.
  • precursor webs including fibrous and continuous filament webs
  • spunbonded continuous filament webs comprising polymeric filaments, preferably polyester (polyethylene terephthalate).
  • Filament denier is preferably 0.2 to 3.0, with 1.5 denier filaments being particularly preferred.
  • the precursor web preferably has a basis weight from about 10 to 30 grams per square meter, more preferably from about 15 to 20 grams per square meter.
  • Use of continuous filament precursor webs is presently preferred because the filaments are essentially endless, and thus facilitate use of relatively high energy input during entanglement without undesirably driving filaments into the image transfer device, as can occur with staple length fibers or the like.
  • filamentary precursor webs permits the filament to be subjected to elevated hydraulic energy levels without undesirable fouling of the pattern or drain holes of the image transfer device. Thus, fabrics are formed without substantially altering the basis weight of the precursor webs.
  • a particular benefit of finished fabrics formed in accordance with the present invention is uniformity of patterning. Fiber movement from the water jets from the hydroentangling manifolds is controlled by the shape and depth of the forming surface and drainage design. The use of higher pressures and flows is desirably achieved, thus permitting processing of webs at high speeds and low basis weights. Finished products in the 10 to 30 grams per square meter range are produced at operating speeds up to hundreds of feet per minute. The following are examples of low basis weight nonwoven fab ⁇ cs formed in accordance with the present invention. Reference to manifold pressures is in connection with water pressure, in pounds per square inch (psi), in the successive hydroentangling manifolds 14, 16, and 18, illustrated in FIGURE 1.
  • psi pounds per square inch
  • Each of these manifolds included o ⁇ fice st ⁇ ps having 33.3 holes or orifices per inch, each having a diameter of 0.0059 inches. All examples were made using a single pass beneath the hydroentangling manifolds, with each manifold acting against the same side of the precursor web to form the resultant fab ⁇ c. Testing of fabrics was conducted in accordance with ASTON testing protocols.
  • a lightly bonded precursor web may be produced on a commercial spunbond production line using standard processing conditions, except thermal point bonding calender temperatures are reduced, and may be at ambient temperature (sometimes referred to as cold calendering).
  • thermal point bonding calender is set at a temperature of 200 to 210 degrees C. to produce the bonded finished product.
  • the calender temperature is reduced to 160 degrees C.
  • the common thermal point calender conditions are 300 degrees F., and 320 pounds per linear inch (PLI) nip pressure.
  • a lightly bonded spunbond polyester precursor web was employed having a basis weight of 28 grams per square meter, with 1.8 denier filaments.
  • the precursor was lightly bonded as described above.
  • the precursor web was entangled at 80 feet per minute, with successive manifold pressures of 700, 4,000, and 4,000 psi.
  • a 20 x 20 three-dimensional image transfer device was employed. Energy input was 3.2 horsepower-hour per pound.
  • the resultant fabric exhibited a basis weight of 28 grams per square meter, a bulk of 0.380 millimeter, a cross-direction strip tensile strength of 310 grams per centimeter, at a cross-direction elongation of 77%, and a machine direction strip tensile strength of 550 grams per centimeter at a machine direction elongation of 50%.
  • Example 2 A more heavily bonded polyester filament precursor web was employed having a basis weight of 19.8 grams per square meter, and a filament denier of 1.8.
  • the precursor web was bonded as described above, except with a calender temperature of 300 degrees F., and a nip pressure of 320 PLI.
  • An image transfer device having a 20 x 20 three-dimensional image transfer device was employed. The precursor web was entangled at a speed of 100 feet per minute, with successive manifold pressures of 700, 4,000, and 4,000 psi. Energy input was 3.6 horsepower-hour per pound.
  • the resultant nonwoven fabric exhibited a basis weight of 19.8 grams per square meter, a bulk of 0.320 millimeters, a cross-directional strip tensile strength of 76 grams per centimeter at a cross- directional elongation of 59%, and a machine direction strip tensile strength of 257 grams per centimeter at a machine direction elongation of 22%.
  • Example 3 A relatively heavily bonded polypropylene spunbond/melt- blown/spunbond precursor web was employed having a basis weight of 18.3 grams per square meter, with polypropylene filament denier of 1.5. The precursor web was bonded as described in Example 3 The precursor web was hydroentangled at a rate of 100 feet per minute on a 20 x 20 three-dimensional image transfer device. The hydroentangling manifolds were operated at successive pressures of 700, 4,000, and 4,000 psi, to provide a horsepower-hour per pound energy input of 3.9.
  • a resultant fabric had a basis weight of 18.3 grams per square meter, a bulk of 0.29 millimeters, a cross-directional strip tensile strength of 64 grams per centimeter at a cross-directional elongation of 59%, and a machine dnection strip tensile strength of 242 grams per centimeter at a machine direction elongation of 24%
  • Example 4 A relatively well bonded polypropylene spunbond web having a basis weight of 18 7 grams per square meter was employed as the precursor web, with filament denier of 1 5 The precursor web was bonded as desc ⁇ bed in Example 3. The precursor web was processed for hydroentangling at a speed of 240 feet per minute on a 20 ⁇ 20 thiee-dimensional image transfer device.
  • Example 1 exhibited relatively greater tensile strength characteristics than Examples 2, 3, and 4.
  • Example 1 a relatively lightly bonded precursor web was employed and it is behev ed that when this type of web is subjected to hydroentanglement, theie is a breakage or disruption of the bonds without significant breakage ot the polymeric filaments of the precursor web.
  • Examples 2, 3, and 4 employed precursor webs which were relatively well-bonded, and thus, duimg hydroentanglement, disruption and breakage of the filament bonds is believed to have resulted in a relatively higher degree of filament breakage TABLE 1
  • Fabrics formed in accordance with the present invention are desirably lightweight, exhibiting desirable softness and bulk characteristics. Fabrics produced in accordance with the present invention are useful for nonwoven disposable products such as diaper facing layers, with the present fabrics exhibiting improved softness compared to typical spunbonded materials.
  • the present fabrics are preferable to thermally bonded lightweight webs, which tend to be undesirably stiff. It is believed that fabrics in accordance with the present invention can be readily employed in place of traditional point bonded and latex bonded nonwoven fabrics, dependent upon basis weight and performance requirements.
  • Precursor webs used in the above Examples which were characterized as lightly bonded were formed as specified, whereby the precursor web was bonded to exhibit no more than a minimal tensile strength which permits winding and unwinding of the web. If hydroentanglement is effected in-line with production of a spunbond precursor web, the precursor web may be lightly bonded a sufficient degree as to permit efficient movement of the precursor web into the hydroentangling apparatus.
  • the fabric being formed may be subjected to dewatering, as generally illustrated at 20, with chemical application (if any) and typical drying of the fabric thereafter effected.

Abstract

L'invention concerne un procédé permettant un hydroenchevêtrement de voiles de filaments polymères pour la production de non tissé à base surfacique relativement faible. Un dispositif (12) de transfert d'images tridimensionnelles est utilisé pour le patronage d'un voile précurseur (P) afin de former un tissu de préférence présentant un patron rectiligne. On peut atteindre une production à grande vitesse de tissus à base surfacique relativement faible, présentant des caractéristiques voulues au niveau de la douceur, de la régularité et de la résistance.
PCT/US2001/001166 2001-01-12 2001-01-12 Non tisse hydroenchevetre a base surfacique relativement faible et son procede de fabrication WO2002055780A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2001/001166 WO2002055780A1 (fr) 2001-01-12 2001-01-12 Non tisse hydroenchevetre a base surfacique relativement faible et son procede de fabrication

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2001/001166 WO2002055780A1 (fr) 2001-01-12 2001-01-12 Non tisse hydroenchevetre a base surfacique relativement faible et son procede de fabrication

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WO2002055780A1 true WO2002055780A1 (fr) 2002-07-18

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3485706A (en) * 1968-01-18 1969-12-23 Du Pont Textile-like patterned nonwoven fabrics and their production
US5098764A (en) * 1990-03-12 1992-03-24 Chicopee Non-woven fabric and method and apparatus for making the same
US5144729A (en) * 1989-10-13 1992-09-08 Fiberweb North America, Inc. Wiping fabric and method of manufacture
US5369858A (en) * 1989-07-28 1994-12-06 Fiberweb North America, Inc. Process for forming apertured nonwoven fabric prepared from melt blown microfibers
US5414914A (en) * 1985-09-20 1995-05-16 Uni-Charm Corporation Process for producing apertured nonwoven fabric
US5573841A (en) * 1994-04-04 1996-11-12 Kimberly-Clark Corporation Hydraulically entangled, autogenous-bonding, nonwoven composite fabric
US5632072A (en) * 1988-04-14 1997-05-27 International Paper Company Method for hydropatterning napped fabric

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3485706A (en) * 1968-01-18 1969-12-23 Du Pont Textile-like patterned nonwoven fabrics and their production
US5414914A (en) * 1985-09-20 1995-05-16 Uni-Charm Corporation Process for producing apertured nonwoven fabric
US5632072A (en) * 1988-04-14 1997-05-27 International Paper Company Method for hydropatterning napped fabric
US5369858A (en) * 1989-07-28 1994-12-06 Fiberweb North America, Inc. Process for forming apertured nonwoven fabric prepared from melt blown microfibers
US5144729A (en) * 1989-10-13 1992-09-08 Fiberweb North America, Inc. Wiping fabric and method of manufacture
US5098764A (en) * 1990-03-12 1992-03-24 Chicopee Non-woven fabric and method and apparatus for making the same
US5573841A (en) * 1994-04-04 1996-11-12 Kimberly-Clark Corporation Hydraulically entangled, autogenous-bonding, nonwoven composite fabric

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