WO2010012833A1 - Fibres et non-tissés avec rugosité de surface accrue - Google Patents

Fibres et non-tissés avec rugosité de surface accrue Download PDF

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Publication number
WO2010012833A1
WO2010012833A1 PCT/EP2009/059978 EP2009059978W WO2010012833A1 WO 2010012833 A1 WO2010012833 A1 WO 2010012833A1 EP 2009059978 W EP2009059978 W EP 2009059978W WO 2010012833 A1 WO2010012833 A1 WO 2010012833A1
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Prior art keywords
fibers
propylene copolymer
fiber
heterophasic propylene
rubber
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PCT/EP2009/059978
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English (en)
Inventor
Hugues Haubruge
Guillaume Pavy
Alain Standaert
Original Assignee
Total Petrochemicals Research Feluy
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Publication date
Application filed by Total Petrochemicals Research Feluy filed Critical Total Petrochemicals Research Feluy
Priority to EP20090802532 priority Critical patent/EP2307596A1/fr
Priority to US13/055,024 priority patent/US20110183568A1/en
Publication of WO2010012833A1 publication Critical patent/WO2010012833A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/32—Side-by-side structure; Spinnerette packs therefor
    • 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
    • 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
    • D04H3/147—Composite yarns or filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641—Sheath-core multicomponent strand or fiber material

Definitions

  • the present invention relates to fibers having an increased surface roughness. Further, the present invention relates to nonwovens, laminates and composites comprising such fibers. Additionally, the present invention relates to a process for producing such fibers, nonwovens, laminates and composites.
  • Polypropylene fibers are used in a wide range of applications, ranging from construction and agricultural industries over hygiene products, such as baby diapers, feminine hygiene products, adult incontinence products, or wipes, to medical applications, such as medical drapes and surgical gowns.
  • polypropylene fibers are not used as such but rather in the form of nonwovens, which can be produced for example by thermal bonding of staple fibers, the spunbonding process, the melt blown process, or the spunlacing (hydroentanglement) process.
  • the polypropylene therefore does not only need to have certain properties, such as mechanical properties, but also be adapted to a specific nonwoven-forming process. This is frequently done by applying spin finishes to the fibers either during or after their production. Alternatively, this can be done by blending the polypropylene with additives so that the additives are incorporated into the polypropylene and then migrate to the surface to give the desired functionality to the fiber.
  • a particular example of a transformation process that requires a spin finish is the spunlacing (hydroentanglement) process.
  • spunlacing polypropylene fibers are randomly distributed to form a nonconsolidated web, which is then consolidated using fine high-pressure water jets. Due to the action of the water jets a high percentage of the spin finish is lost to the process water, from which it then needs to be removed again for environmental reasons.
  • spin finishes are used to impart certain functionalities to the polypropylene fibers, for instance hydrophilic properties.
  • Known polypropylene fibers have a smooth surface, and therefore do not easily retain spin finishes. Thus, much more spin finish than would be required to obtain the desired level of functionality needs to be applied.
  • the functionality level that can be attained is limited by the surface area of the fibers.
  • an increase in the fiber surface area would also allow an increased level of functionalities, such as hydrophilicity.
  • EP-A-0604736 discloses a polymeric strand including a blend of a melt- extrudable polyolefin and a heterophasic polypropylene composition.
  • the heterophasic polypropylene composition is present in up to 40 wt%.
  • Fabric made with such blends is disclosed to have improved combinations of strength, abrasion resistance and softness properties. This document further discloses that the heterophasic polypropylene composition by itself is not melt- spinnable.
  • WO 2007/071496 discloses soft filaments and nonwovens obtained therefrom, said filaments comprising a blend of 55 - 95 wt% of a propylene copolymer and 5 - 55 wt% of a heterophasic propylene polymer composition.
  • US 5,900,306 discloses nonwoven fabric, particularly spunbond nonwoven fabric, produced with a blend including a heterophasic polymer in an amount up to 50 wt%.
  • EP-A-1452630 discloses fibers comprising a heterophasic propylene copolymer containing a) a matrix phase comprising a propylene random copolymer, and b) a disperse phase comprising an ethylene rubber copolymer. The fibers are characterized by excellent softness.
  • polypropylene fibers i.e. fibers comprising a polypropylene, that have improved retention of spin finishes.
  • the present invention provides a multicomponent fiber comprising an interior component and an exterior component, wherein said exterior component covers at least 50 % of the surface of said fiber and comprises at least 70 wt% of a heterophasic propylene copolymer relative to the total weight of the exterior component, said heterophasic propylene copolymer comprising a propylene polymer matrix and a rubber.
  • the present invention provides nonwovens, laminates and composites comprising such fibers.
  • the present invention provides a process for the production of such fibers, said process comprising the steps of
  • thermoplastic polymer (a) providing a thermoplastic polymer to a first extruder
  • step (c) melt-extruding the thermoplastic polymer of step (a) through a number of fine, usually circular, capillaries of a spinneret, (d) melt-extruding the polymer blend of step (b) through a number of fine openings surrounding said capillaries of step (c), and (e) combining the extrudates of steps (c) and (d) to form single fibers of an intermediate diameter, such that the extrudate of step (d) forms an exterior component covering at least 50 % of the surface of the fiber produced by combining the extrudates, wherein the polymer blend of step (b) comprises at least 70 wt% of a heterophasic propylene, said heterophasic propylene copolymer comprising a propylene polymer matrix and a rubber.
  • the present invention discloses the use of a heterophasic propylene copolymer in the exterior component of a multicomponent fiber, said multicomponent fiber comprising an interior component and an exterior component, to increase the surface roughness of said multicomponent fiber in comparison to the surface roughness of a fiber comprising an exterior component, said exterior component covering the entire surface of the fiber and consisting of a propylene homopolymer.
  • Figure 1 is a scanning electron microscope picture of the surface of bicomponent spunbond fibers with a heterophasic propylene copolymer as exterior component.
  • Figure 2 is a scanning electron microscope picture of the surface of monocomponent spunbond fibers made with a propylene homopolymer grade.
  • the present invention provides a multicomponent fiber that comprises an interior component and an exterior component, wherein said exterior component covers at least 50 % of the surface of said multicomponent fiber, and wherein said exterior component comprises at least 70 wt% of a heterophasic propylene copolymer relative to the total weight of said exterior component.
  • said exterior component covers at least 70 % of the surface of said multicomponent fiber, more preferably at least 90 %, even more preferably at least 95 %, still even more preferably at least 99 % and most preferably it covers the entire surface of the fiber.
  • said exterior component comprises at least 80 wt%, more preferably at least 90 wt%, even more preferably at least 95 wt%, 97 wt% or 99 wt% relative to the total weight of the exterior component, and most preferably said exterior component consists of a heterophasic propylene copolymer.
  • the exterior component may comprise additives or thermoplastic polymers that are miscible with the heterophasic propylene copolymer, such as for example propylene homopolymer or propylene random copolymer.
  • the polymer that is used in the interior component is not especially limited. It is, however, preferred that it is a thermoplastic polymer, more preferred that it is a polyolefin, and most preferred that it is a polypropylene.
  • thermoplastic polymers that are suited for use in the present invention can be selected from the group consisting of polyethylene, polyamide, polyester and polycarbonate. All of these are for example described in Stoeckhert, Kunststoff Lexikon, W. Woebcken (ed.), 9 th edition, Carl Hanser Verlag, M ⁇ nchen, Wien, 1998 or in R ⁇ mpp Chemie Lexikon, J. Falbe and M. Regitz (eds.), 9 th edition, Georg Thieme Verlag, Stuttgart, New York 1995.
  • the heterophasic propylene copolymer used in the present invention comprises a propylene polymer matrix and a rubber. Because the propylene polymer matrix and the rubber are immiscible, the heterophasic propylene copolymer used in the present invention is characterized by at least two distinct phases, with rubber particles dispersed within the propylene polymer matrix.
  • the heterophasic propylene copolymer has a melt flow index in the range from 5 dg/min to 2000 dg/min as measured according to ISO 1 133, condition L, at 230 °C and 2.16 kg.
  • the melt flow index of the heterophasic propylene copolymer is in the range from 5 dg/min to 40 dg/min.
  • the melt flow index of the heterophasic propylene copolymer is at least 10 dg/min, preferably at least 15 dg/min, and most preferably at least 20 dg/min.
  • the melt flow index of the heterophasic propylene copolymer is at most 300 dg/min, preferably at most 200 dg/min, more preferably at most 150 dg/min, even more preferably at most 100 dg/min, and most preferably at most 60 dg/min.
  • the melt flow index of the heterophasic propylene copolymer is at least 100 dg/min, preferably at least 150 dg/min, more preferably at least 200 dg/min, even more preferably at least 250 dg/min, and most preferably at least 300 dg/min.
  • the melt flow index of the heterophasic propylene copolymer is at most 2000 dg/min, more preferably at most 1800 dg/min or 1600 dg/min, even more preferably at most 1400 dg/min or 1200 dg/min, and most preferably at most 1000 dg/min.
  • the heterophasic propylene copolymer used in the present invention has a molecular weight distribution M w /Mn of at least 3.5, more preferably of at least 4.0, even more preferably of at least 4.1 , 4.2, 4.3 or 4.4, and most preferably of at least 4.5.
  • the molecular weight distribution M w /Mn is at most 8.0, more preferably at most 7.5 or 7.0, even more preferably at most 6.5 and most preferably at most 6.0.
  • the molecular weights and the molecular weight distribution can be determined by size exclusion chromatography (SEC) as described in more detail in the examples.
  • the molecular weight distribution M w /M n of the heterophasic propylene copolymer is too broad, such as is generally the case for polypropylene obtained with a Ziegler-Natta catalyst, it may be narrowed by chemical or thermal degradation from a starting melt flow index MFI 1 to a final melt flow index MFI 2 (measured according to ISO 1133, condition L, 230 °C, 2.16 kg). Chemical degradation (visbreaking) is preferred. For chemical degradation the propylene polymer is brought into intimate contact with a peroxide (e.g.
  • the propylene polymer matrix of the heterophasic propylene copolymers of the present invention comprises a propylene homopolymer or a random copolymer of propylene and at least one further olefin different from propylene.
  • said further olefin is preferably present in up to 4.0 wt% relative to the total weight of the random copolymer. More preferably it is present in up to 3.5 wt%, 3.0 wt%, or 2.0 wt%, even more preferably in up to 1.5 wt%, still even more preferably in up to 1.0 wt% and most preferably in up to 0.5 wt% relative to the total weight of the random copolymer.
  • Said further olefin is an ⁇ -olefin.
  • It may for example be ethylene, 1 -butene, 1 -pentene, 4-methyl-1 - pentene, 1 -hexene, or 1 -octene, of which ethylene and 1 -butene are preferred, with ethylene being the most preferred.
  • the melting temperature is at least 150°C, more preferably at least 155°C and most preferably at least 160°C. Without wishing to be bound by theory it is believed that a melting temperature of at least 150°C improves the processability of the heterophasic propylene copolymer in fiber production.
  • DSC DSC according to ISO 3146.
  • a temperature above the melting temperature e.g. to 200 °C, and kept there for a certain time, e.g. for 3 minutes.
  • the samples After cooling the samples are then reheated for the measurement of the melting temperature.
  • the heating and cooling rate is 20°C/min.
  • the preferred propylene polymer matrix is a propylene homopolymer.
  • the propylene polymer matrix has a tacticity of more than 95.0 % of mmmm pentads.
  • the percentage of mmmm pentads is determined on the insoluble heptane fraction of the xylene soluble fraction according to the method described by G.J. Ray et al. in Macromolecules, vol. 10, n° 4, 1977, p. 773-778). More preferably the tacticity is more than 96.0 %, even more preferably more than 97.0 %, and most preferably more than 98.0 %.
  • the propylene polymer matrix is comprised of a propylene polymer that is predominantly isotactic.
  • the propylene polymer matrix is a propylene homopolymer it is preferred that its xylene solubles content is at most 2.5 wt% and most preferably at most 2.0 wt%, relative to the total weight of the propylene homopolymer.
  • the xylene solubles content is determined by dissolving the polypropylene in refluxing xylene, cooling of the solution to 25°C, filtering the solution, and subsequent evaporation of the solvent. The residue, which is the xylene soluble portion of the polypropylene, is then dried and weighed.
  • the rubber of the heterophasic propylene copolymer of the present invention comprises a first olefin, which is different from propylene, and a second olefin, which is different from the first olefin.
  • said first and second olefin are independently selected from the group consisting of ethylene and ⁇ -olefins.
  • ⁇ -olefins that may be used are ethylene, propylene, 1 - butene, 1 -pentene, 4-methyl-1 -pentene, 1 -hexene, and 1 -octene.
  • first olefin ethylene and butene are more preferred, with ethylene being most preferred.
  • second olefin is propylene.
  • the most preferred rubber is an ethylene-propylene rubber (EPR).
  • the first olefin is present in an amount of from 2.0 wt% to 20.0 wt% relative to the total weight of the heterophasic propylene copolymer, more preferably from 4.0 wt% to 16.0 wt%, even more preferably from 5.0 wt% to
  • the total comonomer content can be determined for example by IR- or NMR-analysis, for example according to the method described by G.J. Ray et al. in Macromolecules, vol. 10, n ° 4, 1977, p. 773-778..
  • the rubber is present in an amount from 8.0 wt% to 24.0 wt%, more preferably from 10.0 wt% to 22.0 wt%, and most preferably from 14.0 wt% to 18.0 wt% relative to the total weight of the heterophasic propylene copolymer.
  • the amount of rubber is determined as the acetone insoluble fraction of the xylene soluble fraction.
  • the acetone insoluble fraction of the xylene soluble fraction is obtained by dissolving the heterophasic propylene copolymer in refluxing xylene, cooling the solution to 25 °C, filtering the solution, and subsequently agitating the solution together with acetone, which results in forming a precipitate.
  • the propylene polymer matrix and the rubber when taken together, comprise at least 90.0 wt% of the heterophasic propylene copolymer. More preferably, they comprise at least 95.0 wt% or 97.0 wt% or 99.0 wt%, even more preferably at least 99.5 wt% of the heterophasic propylene copolymer, and most preferably the heterophasic propylene copolymer consists of the propylene polymer matrix and the rubber.
  • the bicomponent fibers of the present invention are characterized by an increased surface roughness as compared to conventional polypropylene fibers made with for example a propylene homopolymer.
  • a comparison is shown in figure 1 and figure 2.
  • Figure 1 shows bicomponent fibers according to the present invention, i.e. having an exterior component comprising a heterophasic propylene copolymer
  • figure 2 shows fibers made from a propylene homopolymer. It can be clearly seen that the bicomponent fibers of figure 1 have increased surface roughness and also an increased surface area.
  • the rougher fiber surface was not at all expected by the present inventors.
  • the present invention also discloses the use of a heterophasic propylene copolymer to increase the surface roughness of a fiber.
  • the present invention is directed to the use of a heterophasic propylene copolymer in the exterior component of a multicomponent fiber, said multicomponent fiber comprising an interior component and an exterior component, to increase the surface roughness of said multicomponent fiber in comparison to the surface roughness of a fiber comprising an exterior component, said exterior component covering the entire surface of the fiber and consisting of a propylene homopolymer.
  • the present invention is directed to the use of a heterophasic propylene copolymer in the exterior component of a multicomponent fiber, said multicomponent fiber comprising an interior component and an exterior component, wherein said exterior component covers at least 50 % of the surface of said fiber and comprises at least 70 wt% of said heterophasic propylene copolymer relative to the total weight of the exterior component, said heterophasic propylene copolymer comprising a propylene polymer matrix and a rubber, to increase the surface roughness of said multicomponent fiber in comparison to the surface roughness of a fiber comprising an exterior component, said exterior component covering the entire surface of the fiber and consisting of a propylene homopolymer.
  • a multicomponent fiber comprising an exterior component entirely covering the surface of said bicomponent fiber, said exterior component consisting of a heterophasic propylene copolymer, protrudes, thus causing the roughness of the fiber.
  • protruding it is meant, that the diameter of said multicomponent fiber at a protruding point is more than the diameter of a comparative fiber comprising an exterior component, said exterior component covering the entire surface of the comparative fiber and consisting of a propylene homopolymer, under the condition that both, the said bicomponent fiber as well as the said comparative fiber, have substantially the same denier and have been produced by the same production process.
  • the difference in diameters between said multicomponent fiber said comparative fiber needs to be more than the error of measurement of the method used to determine the diameter. Fiber diameters can for example be determined from scanning electron microscope pictures.
  • the heterophasic propylene copolymers used in the present invention may also comprise additives, such as for example antioxidants, light stabilizers, acid scavengers, lubricants, antistatic agents, fillers, nucleating agents, clarifying agents, colorants.
  • additives such as for example antioxidants, light stabilizers, acid scavengers, lubricants, antistatic agents, fillers, nucleating agents, clarifying agents, colorants.
  • the heterophasic propylene copolymers used in the present invention are produced either by physical or chemical blending.
  • physical blending a propylene polymer matrix and a rubber, which have been produced independently from one another, are blended together, for example in an extruder.
  • chemical blending which is the preferred method, the propylene polymer matrix and the rubber are produced sequentially in at least two polymerization reactors in presence of a polymerization catalyst, usually a Ziegler-Natta or a metallocene-based polymerization catalyst, with Ziegler-Natta polymerization catalysts being preferred.
  • the rubber is produced in a gas-phase polymerization reactor.
  • the fiber of the present invention is a multicomponent fiber.
  • it is a bicomponent fiber.
  • Bi- or multi-component fibers or filaments are known in many different configurations, such as for example side-by-side, sheath-core, islands- in-the-sea, pie or stripe configurations.
  • Bi- or multi-component fibers can be formed by co-extrusion of at least two different components into one fiber or filament. This is done by feeding the different components to a corresponding number of extruders and combining the different melts into a single fiber.
  • the resulting fiber or filament has at least two different essentially continuous polymer phases.
  • Such fibers or filaments, their production as well as their forming a nonwoven are well known to the skilled person and are for example described in F. Fourne, Synthetician Fasern, Carl Hanser Verlag, 1995, chapter 5.2 or in B.C. Goswami et al., Textile Yarns, John Wiley & Sons, 1977, p. 371 -
  • fibers are produced by melting the polymer in an extruder, optionally passing the molten polymer through a melt pump to ensure a constant feeding rate and then extruding the molten polymer through a number of fine capillaries of a spinneret to form fibers. These still molten fibers are simultaneously cooled by air, drawn to an intermediate diameter and collected. They are for example collected on a winder or other suitable collecting means.
  • the process for the production of the multicomponent fibers of the present invention comprises the steps of (a) providing a thermoplastic polymer to a first extruder,
  • thermoplastic polymer of step (a) melt-extruding the thermoplastic polymer of step (a) through a number of fine, usually circular, capillaries of a spinneret,
  • step (d) melt-extruding the polymer blend of step (b) through a number of fine openings surrounding said capillaries of step (c), and
  • step (e) combining the extrudates of steps (c) and (d) to form single fibers of an intermediate diameter, such that the extrudate of step (d) forms an exterior component covering at least 50 % of the surface of the fiber produced by combining the extrudates, wherein the polymer blend of step (b) comprises at least 70 wt% of a heterophasic propylene copolymer as defined above.
  • the extrudate of step (d) forms an exterior component covering at least 70 %, more preferably at least 90 %, even more preferably at least 95 % or 99 % of the surface of the fiber, and most preferably it covers the entire surface of the fiber.
  • said exterior component comprises at least 80 wt%, more preferably at least 90 wt%, even more preferably at least 95 wt%, 97 wt% or 99 wt% and most preferably consists of a heterophasic propylene copolymer.
  • the exterior component may comprise additives or thermoplastic polymers that are miscible with the heterophasic propylene copolymer, such as for example propylene homopolymer or propylene random copolymer.
  • the single filaments of an intermediate diameter, which are obtained in step (e) may be drawn to a final diameter, i.e. the process for the production of the multicomponent fibers of the present invention further comprises the step of
  • step (f) rapidly reducing the intermediate diameter of the fibers obtained in step (e) to a final diameter.
  • the nonwovens of the present invention may be produced by any suitable method. Such methods include thermal bonding of staple fibers, the spunlacing process, the spunbonding process and the melt blown process.
  • the preferred methods are the spunlacing process, the spunbonding process and the melt blown process. Of these the spunlacing process and the spunbonding process are the more preferred ones, and the spunlacing process is the most preferred one.
  • the process further comprises the steps of
  • step (g) collecting the fibers obtained in step (e) or step (f) on a support, and (h) subsequently bonding the collected fibers to form a bonded nonwoven.
  • the bicomponent fibers of the present invention are cut into staple fibers having a length in the range from 5 to 30 mm. Said staple fibers are then carded, i.e. collected as a more or less continuous non-consolidated web on a support. In a final step the non- consolidated web is consolidated by thermal or chemical bonding, with thermal bonding being preferred. In the spunlacing process continuous fibers or staple fibers are distributed randomly a support to form a non-consolidated web, which is then consolidated by means of fine high-pressure water jets and dried.
  • thermoplastic polymer is melted in a first extruder, optionally passed through a melt pump to ensure a constant feeding rate and then extruded through a number of fine, usually circular capillaries of a spinneret.
  • a polymer blend comprising at least 70 wt% of a heterophasic propylene copolymer as defined above is melted in a second extruder, optionally passed through a melt pump and then extruded through a number of fine openings surrounding the fine, usually circular capillaries of the spinneret.
  • the extrudates of the molten thermoplastic polymer and the molten polymer blend are combined to form a single - essentially still molten - filament of an intermediate diameter.
  • the filament formation can either be done by using one single spinneret with a large number of holes, generally several thousand, or by using several smaller spinnerets with a correspondingly lower number of holes per spinneret.
  • the still molten filaments are quenched by a current of air.
  • the diameter of the filaments is then quickly reduced by a flow of high-pressure air. Air velocities in this drawdown step can range up to several thousand meters per minute.
  • the filaments are collected on a support, for example a forming wire or a porous forming belt, thus first forming an unbonded web, which is then passed through compaction rolls and finally through a bonding step. Bonding of the fabric may be accomplished by thermobonding, hydroentanglement, needle punching, or chemical bonding.
  • thermoplastic polymer is melted in a first extruder, optionally passed through a melt pump to ensure a constant feeding rate and then extruded through a number of fine, usually circular capillaries of a special melt blowing die.
  • a polymer blend comprising at least 70 wt% of a heterophasic propylene copolymer as defined above is melted in a second extruder, optionally passed through a melt pump and then extruded through a number of fine openings surrounding the fine, usually circular capillaries of the special melt blowing die.
  • the extrudates of the molten thermoplastic polymer and the molten polymer blend are combined to form a single - essentially still molten - filament of an intermediate diameter.
  • melt blown dies have a single line of capillaries through which the molten polymer passes.
  • the still molten filaments are contacted with hot air at high speed, which rapidly draws the fibers and, in combination with cool air, solidifies the filaments.
  • the nonwoven is formed by depositing the filaments directly onto a forming wire or a porous forming belt.
  • Composites may be formed from two or more nonwovens, of which at least one is made in accordance with the present invention. Said two or more nonwovens may either be bonded together, or they may be left "unbonded” to one another, i.e. just placed on top of each other.
  • the composites comprise a spunlace or spunbond nonwoven layer (S) according to the present invention or a melt blown nonwoven layer (M) according to the present invention.
  • Composites in accordance with the present invention can for example be SS, SSS, SMS, SMMSS or any other combination of spunlace or spunbond and melt blown nonwoven layers.
  • a first nonwoven or composite, said first nonwoven or composite being in accordance with the present invention, and a film may be combined to form a laminate.
  • the film preferably is a polyolefin film.
  • the laminate is formed by bringing the first nonwoven or composite and the film together and laminating them to one another for example by passing them through a pair of lamination rolls.
  • the laminates may further include a second nonwoven or composite, which can be but need not be according to the present invention, on the face of the film opposite to that of the first nonwoven or composite.
  • the film of the laminate is a breathable polyolefin film, thus resulting in a laminate with breathable properties.
  • the laminates may be formed by laminating a film to the bonded nonwoven obtained in step (h).
  • a composite may be formed by applying a nonwoven to the bonded nonwoven obtained in step (h).
  • the polypropylene fibers and filaments of the present invention can be used in carpets, woven textiles, and nonwovens.
  • the polypropylene spunbond nonwovens of the present invention as well as composites or laminates comprising it can be used for hygiene and sanitary products, such as for example diapers, feminine hygiene products and incontinence products, products for construction and agricultural applications, medical drapes and gowns, protective wear, lab coats, wipes, for example in sanitary but also in industrial applications, etc.
  • hygiene and sanitary products such as for example diapers, feminine hygiene products and incontinence products, products for construction and agricultural applications, medical drapes and gowns, protective wear, lab coats, wipes, for example in sanitary but also in industrial applications, etc.
  • polypropylene meltblown nonwovens of the present invention can be used in hygiene, filtration and absorption applications, such as diapers, feminine hygiene products, incontinence products, wraps, gowns, masks, filters, absorption pads etc. Frequently polypropylene meltblown nonwovens are used in combination with other nonwovens, such as for example spunbond nonwoven to form composites, which in turn may be used in the cited applications.
  • the melt flow index was measured according to ISO 1 133, condition L, at 230°C and 2.16 kg. Molecular weights are determined by Size Exclusion Chromatography (SEC) at high temperature (145 0 C). A 10 mg PP sample is dissolved at 160°C in 10 ml of TCB (technical grade) for 1 hour.
  • the analytical conditions for the Alliance GPCV 2000 from WATERS are : - Volume : +/- 400 ⁇ l
  • T m Melting temperatures T m were measured on a DSC 2690 instrument by TA Instruments according to ISO 3146. To erase the thermal history the samples were first heated to 200 °C and kept at 200 °C for a period of 3 minutes. The reported melting temperatures were then determined with heating and cooling rates of 20°C/min.
  • Fiber titers were measured on a Zweigle vibroscope S151/2 in accordance with norm ISO 1973:1995.
  • Fibers and nonwovens were produced using a commercial polypropylene homopolymer spunbond grade, denoted as PP1 , and a heterophasic propylene copolymer, denoted as PP2.
  • PP2 had a propylene homopolymer as matrix and an ethylene-propylene rubber dispersed therein, with the rubber being present in 19.5 wt%, relative to the total weight of PP2.
  • Total ethylene content of PP2 was 10.8 wt%. It was chemically degraded such that it had a final melt flow index (MFI) of 28 dg/min and a molecular weight distribution M w /M n of 4.7.
  • MFI final melt flow index
  • Polypropylenes PP1 and PP2 were used to produce the following spunbond nonwovens
  • Example 1 Bicomponent nonwoven with PP1 as interior component and PP2 as exterior component wherein the exterior layer comprised 30 wt% of the total weight of the fibers
  • the spunbond nonwovens were produced on a 1.1 m wide Reicofil 4 line with a single beam having about 6800 holes per meter length, the holes having a diameter of 0.6 mm.
  • the nonwoven had a fabric weight of 12 g/m 2 .
  • the nonwoven were thermally bonded using an embossed roll. Further processing conditions are given in table 2.
  • the bonding roll temperature reported in table 2 is the bonding temperature at which the highest values for elongation were obtained. Properties of the nonwoven obtained under these conditions are shown in table 3.
  • Figure 1 and figure 2 show a scanning electron microscope picture of the fibers of example 1 and comparative example 1.
  • the monocomponent fibers of comparative example 1 have a very smooth surface, which does not well hold on to any additives or spin finishes.
  • figure 1 shows the bicomponent fibers of example 1 , i.e. in accordance with the present invention. It can be seen that the heterophasic propylene copolymer, which forms the exterior component, gives rise to a very rough surface, which allows better retention of any additive or spin finish.
  • the bicomponent fibers of the present invention are characterized by an increased surface area. They allow therefore to an increased level of functionalities, such as for example hydrophilicity. Without wishing to be bound by theory it is believed that the uneven surface and the increased surface area allow a higher number of functionality-imparting molecules to be present on the fiber surface, thus rendering the fiber for example more hydrophilic.
  • the bicomponent fibers of the present invention are also expected to increase the fiber bulkiness, which is of advantage for bulk continuous filaments (BCF).

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Multicomponent Fibers (AREA)

Abstract

La présente invention concerne des fibres qui présentent une rugosité de surface accrue. De plus, la présente invention concerne des non-tissés, des stratifiés et des composites qui comportent de telles fibres. De plus, la présente invention concerne un procédé de fabrication de telles fibres et de tels non-tissés, stratifiés et composites.
PCT/EP2009/059978 2008-08-01 2009-07-31 Fibres et non-tissés avec rugosité de surface accrue WO2010012833A1 (fr)

Priority Applications (2)

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EP20090802532 EP2307596A1 (fr) 2008-08-01 2009-07-31 Fibres et non-tissés avec rugosité de surface accrue
US13/055,024 US20110183568A1 (en) 2008-08-01 2009-07-31 Fibers and nonwovens with increased surface roughness

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EP20080161651 EP2151512A1 (fr) 2008-08-01 2008-08-01 Fibres et non-tissés dotés d'une rugosité de surface améliorée
EP08161651.8 2008-08-01

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WO2012024049A1 (fr) * 2010-08-19 2012-02-23 Dow Global Technologies Llc Articles fabriqués comprenant des polyoléfines
WO2012024579A1 (fr) * 2010-08-19 2012-02-23 Dow Global Technologies Llc Résine de polypropylène adaptée pour des applications non tissées souples
WO2014170226A1 (fr) 2013-04-17 2014-10-23 Crown Packaging Technology Inc Procédé de fabrication de boîtes métalliques
US10604852B2 (en) 2011-11-08 2020-03-31 The University Court Of The University Of Glasgow Apparatus and methods for the electrochemical generation of oxygen and/or hydrogen

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US9827696B2 (en) 2011-06-17 2017-11-28 Fiberweb, Llc Vapor-permeable, substantially water-impermeable multilayer article
US10369769B2 (en) 2011-06-23 2019-08-06 Fiberweb, Inc. Vapor-permeable, substantially water-impermeable multilayer article
EP2723568B1 (fr) 2011-06-23 2017-09-27 Fiberweb, LLC Article multicouches perméable à la vapeur d'eau, mais essentiellement imperméable à l'eau
WO2012178011A2 (fr) 2011-06-24 2012-12-27 Fiberweb, Inc. Article multicouches perméable à la vapeur d'eau, mais essentiellement imperméable à l'eau
DE102016109115A1 (de) * 2016-05-18 2017-11-23 Reifenhäuser GmbH & Co. KG Maschinenfabrik Spinnvlies aus Endlosfilamenten
EP3585338B1 (fr) * 2017-02-27 2024-01-17 The Procter & Gamble Company Article pouvant être porté ayant des propriétés de matériau caractéristiques

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EP0604736A2 (fr) * 1992-12-28 1994-07-06 Kimberly-Clark Corporation Fils comportant une composition polymérique à base de propylène, étoffe non-tissée et articles realisés avec ceux-ci
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WO2012024049A1 (fr) * 2010-08-19 2012-02-23 Dow Global Technologies Llc Articles fabriqués comprenant des polyoléfines
WO2012024579A1 (fr) * 2010-08-19 2012-02-23 Dow Global Technologies Llc Résine de polypropylène adaptée pour des applications non tissées souples
US9683096B2 (en) 2010-08-19 2017-06-20 Braskem America, Inc. Polypropylene resin suitable for soft nonwoven applications
US10604852B2 (en) 2011-11-08 2020-03-31 The University Court Of The University Of Glasgow Apparatus and methods for the electrochemical generation of oxygen and/or hydrogen
WO2014170226A1 (fr) 2013-04-17 2014-10-23 Crown Packaging Technology Inc Procédé de fabrication de boîtes métalliques

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EP2307596A1 (fr) 2011-04-13
EP2151512A1 (fr) 2010-02-10
US20110183568A1 (en) 2011-07-28

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