WO2011080612A2 - Bulk enhancement for airlaid material - Google Patents
Bulk enhancement for airlaid material Download PDFInfo
- Publication number
- WO2011080612A2 WO2011080612A2 PCT/IB2010/055381 IB2010055381W WO2011080612A2 WO 2011080612 A2 WO2011080612 A2 WO 2011080612A2 IB 2010055381 W IB2010055381 W IB 2010055381W WO 2011080612 A2 WO2011080612 A2 WO 2011080612A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- sheet
- airlaid
- microspheres
- binder
- thermally expandable
- Prior art date
Links
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
- 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
- D04H1/413—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 containing granules other than absorbent substances
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
- D21H21/52—Additives of definite length or shape
- D21H21/54—Additives of definite length or shape being spherical, e.g. microcapsules, beads
-
- 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
- D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
-
- 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
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/30—Multi-ply
- D21H27/42—Multi-ply comprising dry-laid paper
Definitions
- the present invention generally relates to a method of incorporating thermally expandable microspheres into a material so that the resulting products have increased bulk. More particularly, the present invention is directed to the incorporation of thermally expandable microspheres into an airlaid material.
- thermally expandable microspheres are spherically formed particles with a gas-proof shell encapsulating a drop of liquid hydrocarbon. When exposed to heat, the microsphere volume expands about 50 times.
- the thermally expandable microspheres can be used for bulk enhancement of dispersible moist wipes and other airlaid-based products.
- a sheet of airlaid material made from fibers and having a thickness.
- a binder material is applied to the sheet to keep the microspheres in place.
- a method of making an airlaid sheet having a thickness including the steps of: (a) spraying an airlaid sheet with a bonding material; and (b) spraying the thermally expandable microspheres onto the airlaid sheet.
- an airlaid sheet including the step of incorporating the thermally expandable microspheres into a forming station along with fibers for airlaying so that the airlaid sheet has thermally expandable microspheres distributed at least partially through the sheet thickness prior to spraying the sheet with a binder.
- FIG.1 is a scanning electron microscopic (SEM) view of a cross section of a wetted airlaid substrate (a control).
- FIG. 2 is a plan view of the wetted airlaid substrate of FIG. 1.
- FIG. 3 is a SEM view of a cross section airlaid substrate showing the distribution of expanded thermally-expandable microspheres within the substrate.
- FIG. 4 is a plan view of the airlaid substrate of FIG. 3.
- FIG. 5 is a schematic representation of one embodiment of an airlaying forming station.
- FIG. 6 is a schematic representation of an airlaying process suitable for making the substrate of the present invention as formed in FIG. 5.
- One aspect of the present invention is an airlaid substrate for wet wipes that is treated with a binder and thermally activated microspheres. When heated, the microsperes expand thereby causing the airlaid substrate to expand in the z- direction (thickness). The result of the expansion is added bulk which gives the consumer a better hand feel and the perception that the wet wipes are more apt to clean better.
- Airlaid Substrate "Airlaying” is a well-known process by which a fibrous nonwoven layer can be formed.
- bundles of small fibers having typical lengths ranging from about 3 to about 52 millimeters (mm) are separated and entrained in an air supply and then deposited onto a forming screen, usually with the assistance of a vacuum supply.
- the randomly deposited fibers then are bonded to one another using, for example, hot air to activate a binder component or a latex adhesive.
- Airlaying is taught in, for example, U.S. Patent No. 4,640,810 to Laursen et al.
- the fibrous material may be formed from a single layer or multiple layers. In the case of multiple layers, the layers are generally positioned in a juxtaposed or surface-to-surface relationship and all or a portion of the layers may be bound to adjacent layers.
- the fibrous material may also be formed from a plurality of separate fibrous materials wherein each of the separate fibrous materials may be formed from a different type of fiber.
- the binder composition of the present invention may be applied to the entire thickness of the fibrous material, or each individual layer may be separately treated and then combined with other layers in a juxtaposed relationship to form the finished fibrous material.
- Airlaid nonwoven fabrics are particularly well suited for use as wet wipes.
- the basis weights for airlaid nonwoven fabrics may range from about 30 to about 350 grams per square meter (gsm) with staple fibers having a denier of about 0.5-10 and a length of about 6-15 millimeters.
- Wet wipe substrates may generally have a fiber dry density of about 0.025 g/cc to about 0.2 g/cc.
- Bonding Generally, there are three ways to bond fibers: (a) with an adhesive (b) thermally, or (c) a combination of adhesive and thermal bonding.
- binders there are two types, namely, dispersible and non-dispersible binders.
- a non-dispersible adhesive binder, such as a latex adhesive, used on an airlaid substrate is used to create a cohesive web which does not disperse/degrade when exposed to water.
- binder(s) may be a component of a web which enhances bonding of the fibers and/or filaments within a nonwoven web to provide wet strength to a wet wipe or the like.
- the binder(s) composition for a dispersible wipe is desirably ion-sensitive such that in the presence of water it becomes soluble, thus allowing the nonwoven web to disperse.
- Thermally activated binders can be used in airlaid structures to help provide mechanical integrity and stabilization.
- Such binders include fiber, liquid or other binder means that may be thermally activated. These binders may be dispersible or non-dispersible.
- these types of dispersible and non-dispersible binder(s) cause the substrate to collapse in the z-direction (a direction perpendicular to a plane defining a surface of the nonwoven web).
- the total amount of dispersible adhesive binder(s) composition present in the nonwoven web can range from about 5 to about 65 wt%, such as between about 7 to about 35 wt%, or between about 10 to about 25 wt% or between about 15 to 20 wt% based on the total weight of the nonwoven web.
- a sufficient amount of the binder(s) composition results in a nonwoven web that has desirable in-use integrity, but quickly disperses when disposed in tap water.
- thermally activated binder fibers are polyolefin fibers.
- Lower melting point polymers such as polyolefin polymers, provide the ability to bond the fabric together at fiber cross-over points upon the application of heat.
- fibers of a lower melting polymer like conjugate and biconstituent fibers are suitable for practice of this invention.
- Fibers having a lower melting polymer are generally referred to as "fusible fibers.”
- “lower melting polymers” what is meant are those fibers having a glass transition temperature less than about 175°C.
- Thermally activated fibers are available from many manufacturers such as Chisso of Tokyo, Japan and Fibervisions, L.L.C. of Wilmington, Delaware.
- the binder(s) composition can be processed on a commercial scale (i.e., the binder(s) may be capable of rapid application on a large scale, such as by spraying). Further, the binder(s) composition can further provide acceptable levels of sheet wetability. In addition, it is desirable that all components of the wet wipe, including the binder(s)
- microspheres may be added anywhere in the manufacturing of the airlaid making process.
- the microspheres may be added to the forming chamber in an airlaying forming station as described herein (see FIG. 5).
- EXPANCEL 091 DU 80 microspheres consist of hollow, white, spherically-formed polymer particles encapsulating a blowing agent (for example, liquid isobutane) under pressure.
- the EXPANCEL 091 DU 80 microspheres generally have a mean diameter of about 80 micrometers after expansion. The density of the microspheres is about 1000-1300 kg/m 3 .
- thermoplastic shell softens when heated so that the gasification of the blowing agent expands the microspheres to a final volume that is from 30 to more than 60 times larger than the original volume at constant weight.
- the density of the expanded microsphere is then below about 30 kg/m 3 .
- microspheres start to expand upon heating above a given temperature, depending on the chemistry of the shell copolymer. It is the shell that determines how and when the sphere will expand.
- EXPANCEL 091 DU 80 was expanded in the airlaid drying process.
- microspheres may expand at lower or higher temperatures and may, thus, be suitable for engineered applications. Cooling causes the expanded microsphere shells to stiffen and thus remain in the expanded state. It is noted that the temperature range of the airlaid heating process governs the expansion of the microspheres. Desirably, suitable microspheres are selected by considering the temperature of the airlaid heating process. Desirably, the amount of thermally expandable microspheres disposed in or on an airlaid substrate is from about 0.05 percent to about 20 percent based on the substrate basis weight. In another aspect, the microspheres disposed in or on an airlaid substrate is from about 0.5 percent to about 10 percent based on the substrate basis weight. In yet another aspect, the microspheres disposed in or on an airlaid substrate is from about 1 percent to about 5 percent based on the substrate basis weight.
- absorbent cores are typically composed of superabsorbent particles and/or pulp.
- a newer class of absorbents also uses a binder to improve wet stability and to ease converting into final products.
- Binders can be liquid adhesive or thermally expandable fibers typically present in amounts between 10 and 25 weight percent.
- the microspheres are sprayed onto one surface of the airlaid web before the adhesive binder(s) is applied to that surface.
- the binder(s) and microspheres are mixed and simultaneously applied to a surface of the airlaid web.
- the microspheres are applied to the surface of the airlaid web after the adhesive binder(s) is applied to the same surface.
- the airlaid web is impregnated with microspheres during the forming of the airlaid web and the adhesive binder(s) is subsequently sprayed onto the impregnated web.
- FIG. 5 schematically illustrates an airlaying forming station useful for airlaying a web of fibers to make an airlaid sheet in accordance with the Example below. If desired, there are different ways of imparting texture patterns to the tissue sheet for purposes of this invention. Fabric texture patterns associated with airlaying is one such method.
- the airlaying forming station 30 produces an airlaid web 32 on a forming fabric or screen 34.
- the forming fabric 34 can be in the form of an endless belt mounted on support rollers 36 and 38.
- a suitable driving device, such as an electric motor 40 rotates at least one of the support rollers 38 in a direction indicated by the arrows at a selected speed.
- the forming fabric 34 moves in a machine direction indicated by the arrow 42.
- the forming fabric 34 can be provided in other forms as desired.
- the forming fabric can be in the form of a circular drum which can be rotated using a motor as disclosed in U.S. Patent No. 4,666,647, U.S. Patent No. 4,761 ,258, or U.S. Patent No. 6,202,259, which are incorporated herein by reference.
- the airlaying forming station 30 includes a forming chamber 44 having end walls and side walls. Within the forming chamber 44 are a pair of material distributors 46 and 48 which distribute fibers and/or other particles inside the forming chamber 44 across the width of the chamber.
- the material distributors 46 and 48 can be, for instance, rotating cylindrical distributing screens.
- a single forming chamber 44 is illustrated in association with the forming fabric 34. It should be understood, however, that more than one forming chamber can be included in the system. By including multiple forming chambers, layered webs can be formed in which each layer is made from the same or different materials.
- Airlaying forming stations as shown in FIG. 5 are available commercially through Dan-Webforming Int. LTD. of Aarhus, Denmark. Other suitable airlaying forming systems are also available from M & J Fibretech of Horsens, Denmark. As described above, however, any suitable airlaying forming system can be used in accordance with the present invention.
- a vacuum source 50 such as a conventional blower, for creating a selected pressure differential through the forming chamber 44 to draw the fibrous material against the forming fabric 34.
- a blower can also be incorporated into the forming chamber 44 for assisting in blowing the fibers down on to the forming fabric 34.
- the vacuum source 50 is a blower connected to a vacuum box 52 which is located below the forming chamber 44 and the forming fabric 34.
- the vacuum source 50 creates an airflow indicated by the arrows positioned within the forming chamber 44.
- Various seals can be used to increase the positive air pressure between the chamber and the forming fabric surface.
- a fiber stock is fed to one or more defibrators (not shown) and fed to the material distributors 46 and 48.
- the material distributors distribute the fibers evenly throughout the forming chamber 44 as shown. Positive airflow created by the vacuum source 50 and possibly an additional blower force the fibers onto the forming fabric 34 thereby forming an airlaid non-woven web 32.
- the pulp fibers When wood pulp fibers are present in the airlaid web of the present invention, the pulp fibers may be in a rolled and fluffed form. As is known to those skilled in the art, fluffed fibers generally refer to fibers that have been shredded.
- the debonding agent can be an organic quaternary ammonium chloride and particularly a silicone based amine salt of a quaternary ammonium chloride.
- the debonding agent can be PROSOFT TQ1003 marketed by the Hercules Corporation.
- the forming chamber 44 can include multiple inlets for feeding the materials to the chamber. Once in the chamber, the materials can be mixed together if desired. Alternatively, the different materials can be separated into different layers in forming the web.
- FIG. 6 shown is a schematic diagram of an entire web forming system useful for making wipes in accordance with the present invention.
- the system includes three separate airlaying forming chambers 44A and 44B and 44C.
- the use of multiple forming chambers can serve to facilitate formation of the airlaid web at a desired basis weight. Further, using multiple forming chambers can allow the formation of layered webs.
- forming stations 44A, 44B and 44C contribute to the formation of the airlaid web 32.
- Airlaid web 32 after exiting the forming chambers 44A, 44B and 44C, is conveyed on a forming fabric 34 to a compaction device 54A.
- Compaction device 54A can be, for instance, a pair of opposing rolls that define a nip through which the airlaid web and forming fabric are passed.
- the compaction device can comprise a steel roll positioned above a rubber-coated roll.
- the compaction device moderately compacts the airlaid web to generate sufficient strength for transfer of the airlaid web to a transfer fabric such as, for instance, via an open gap arrangement.
- the compaction device increases the density of the web over the entire surface area of the web as opposed to only creating localized high density areas.
- the airlaid web 32 is transferred to a transfer fabric 52.
- a suitable transfer fabric is ElectroTech 56 manufactured by Albany International.
- the airlaid web can be fed through a second compaction device 54B and further compacted against the transfer fabric to generate a texture pattern in the sheet.
- the compaction device 54B can also be used to improve the appearance of the web, to adjust the caliper of the web, and/or to increase the tensile strength of the web.
- the airlaid web 32 is transferred to a spray fabric 53A and fed to a spray chamber 56.
- microspheres and binder(s) may be applied to the airlaid web.
- Under fabric vacuum may also be used to regulate and control penetration of the bonding material into the web.
- the binder(s) may add dry strength, wet strength, stretchability, and tear resistance.
- the expanded microspheres add bulk, resiliency, wet firmness and improved hand feel.
- the bonding material and microspheres can be applied so as to uniformly cover the entire surface area of one side of the web.
- the bonding material and microspheres can be applied to the first side of the web so as to cover at least about 80% of the surface area of one side of the web, such as at least about 90% of the surface area of one side of the web.
- the bonding material and microspheres can cover greater than about 95% of the surface area of one side of the web. It is possible that the microspheres will penetrate the web as seen in FIG. 4.
- the bonding material and microspheres can be applied so as to cover only part of the entire surface area of one side of the web. This covered area can have certain patterns and designs disposed on the web, such as lines, circles, etc.
- the airlaid web 32 is transferred to drying fabric 55A and fed to a drying apparatus 58.
- the drying apparatus 58 the web is subjected to heat causing the bonding material and microspheres to dry and/or cure and cause the microspheres to expand.
- the drying apparatus can be heated to a temperature of from about 120°C to about 170°C.
- the use of such expandable microspheres allows the opening up of the fiber structure so as to create a bulkier (i.e., less dense) web. Accordingly, when expandable microspheres are utilized in an airlaid product, the resulting airlaid product will have a bulkier structure than the same airlaid product at the same weight basis.
- the airlaid web is then transferred to a second spray fabric 53B and fed to a second spray chamber 60.
- a second bonding material is applied to the untreated side of the airlaid web.
- the first bonding material and the second bonding material can be different bonding materials or the same bonding material.
- the second bonding material may be applied to the nonwoven web as described above with respect to the first bonding material.
- the nonwoven web is then transferred to a second drying fabric 55B and passed through a second drying apparatus 62 for drying and/or curing the second bonding material.
- the airlaid web 32 is transferred to a return fabric 59 and may optionally be fed to a further compaction device 64 prior to being wound on a reel 66.
- the compaction device 64 can be similar to the first compaction device and may comprise, for instance, calendar rolls. Alternatively, the compaction device 64 can be a pair of embossing rolls used for the purpose of softening and further texturizing the sheet.
- the wetting composition for use in combination with the dispersible ion-sensitive nonwoven materials may desirably comprise an aqueous composition containing insolubilizing agent that maintains the coherency of the binder composition, and thus, the in-use strength of the wet-wipe steady until the insolubilizing agent is diluted with sufficient water to provide strength loss.
- a salt triggerable binder composition may be insoluble in a wetting composition, wherein the wetting composition comprises at least about 0.3 weight percent of an insolubilizing agent which may be comprised of one or more inorganic and/or organic salts containing monovalent and/or divalent ions. More desirably, the binder composition may be insoluble in the wetting composition, wherein the wetting composition comprises from about 0.3% to about 10% by weight of an insolubilizing agent which may be comprised of one or more inorganic and/or organic salts containing monovalent and/or divalent ions.
- the binder composition may be insoluble in the wetting composition, wherein the wetting composition comprises from about 0.5% to about 5% by weight of an insolubilizing agent which comprises one or more inorganic and/or organic salts containing monovalent and/or divalent ions.
- the binder composition may be insoluble in the wetting composition, wherein the wetting composition comprises from about 1.0% to about 4.0% by weight of an insolubilizing agent which comprises one or more inorganic and/or organic salts containing monovalent and/or divalent ions.
- Suitable monovalent ions include, but are not limited to, Na + ions, K + ions, Li + ions, NH 4 + ions, low molecular weight quaternary ammonium compounds (e.g., those having fewer than 5 carbons on any side groups), and a combination thereof.
- Suitable divalent ions include, but are not limited to, Zn 2+ , Ca 2+ and Mg 2+ .
- These monovalent and divalent ions may be derived from organic and inorganic salts including, but not limited to, NaCI, NaBr, KCI, NH 4 CI, Na 2 S0 4 , ZnCI 2 , CaCI 2 , MgCI 2 , MgS0 4 , and combinations thereof.
- alkali metal halides are the most desirable monovalent or divalent ions because of cost, purity, low toxicity, and availability.
- a particularly desirable salt is NaCI.
- the wetting composition may include a variety of additives or components, including those disclosed in U.S. Patent Publication No. 2002/0155281 , which is hereby incorporated by reference in a manner that is consistent herewith.
- Possible additives may include, but are not limited to skin-care additives, odor control additives, wetting agents and/or cleaning agents; surfactants, pH control agents, preservatives and/or anti-microbial agents.
- the wet wipes do not require organic solvents to maintain in- use strength, and the wetting composition may be substantially free of organic solvents. However, a small amount of organic solvents may be included in the wetting composition for different purposes other than maintaining in-use wet strength.
- the wetting composition may be applied to the airlaid substrate in several ways (e.g. spraying or dipping).
- thermally-bonded airlaid (TBAL) nonwoven basesheet was prepared using Weyerhaeuser CF405 bleached softwood Kraft pulp fiber, available from
- thermal binder fiber is added to the air former to an overall level of 50% by weight.
- the thermal binder fiber used is a bicomponent core / sheath-type fiber available from ES FiberVisions Inc., located in Athens, Georgia.
- the bicomponent fiber is a Polyethylene terephthalate-core / Polypropylene-sheath (PET-core/PP-sheath) with dimensions of 2.2 dtex and 6 mm fiber length. Enough materials are used in a laboratory-scale air former to prepare 50 gsm handsheets.
- EXPANCEL microspheres available from Akzo Nobel, Sundsvall, Sweden, were also added to the air former, in addition to the pulp and TENCEL®.
- the resulting lab-prepared TBAL basesheet is then compressed using a heated Carver press, model 4531 , available from Carver, Inc., located in Wabash, Indiana.
- the compression force is set to 30000 lb and the temperature of the plates is set to 175 degrees F, for duration of 1 minute.
- Basesheets of the nonwoven web used to prepare samples of adhesively-bonded airlaid (ABAL), were produced on a Dan-Web pilot line, available from Dan-Web, Risskov, Denmark.
- the un-bonded basesheet was prepared using Weyerhaeuser
- TENCEL® H400 945 synthetic fiber available from Lenzing Group, Lenzing, Austria.
- the ratio of CF405 to TENCEL® is 85:15.
- the basis weight of this material is 58.5 gsm.
- Aqueous adhesive binder solutions are then topically applied to both sides of the un-bonded airlaid basesheet.
- the binder solutions can be dispersible or non- dispersible in nature.
- the basesheet is placed on a screen which is under vacuum conditions during the spraying operation. Then the basesheet is sprayed on each side equally to achieve a final binder add-on of 18 to 20% by weight, in the handsheet.
- the binder composition is typically approximately 15 to 16% solids level.
- a Quick VEEJET® nozzle, type 8001 manufactured by Spraying Systems Co., Wheaton, Illinois, operating at approximately 80 psi was employed to spray the binder composition onto the fibrous material. The distance from the nozzle tip to the basesheet is 8 inches.
- Multi-bonded airlaid (MBAL) nonwoven basesheet was prepared using
- thermal binder fiber is added to the air former to an overall level of 20% by weight.
- the thermal binder fiber used is a bicomponent core / sheath-type fiber available from ES FiberVisions Inc., located in Athens, Georgia.
- the bicomponent fiber is a polyethylene terephthalate-core / polypropylene-sheath (PET-core / PP-sheath) with dimensions of 2.2 dtex and 6 mm fiber length. Enough materials are used in a laboratory-scale air former to prepare 50 gsm handsheets.
- the resulting lab-prepared basesheet is then compressed using a heated Carver press, model 4531 , available from Carver, Inc., located in Wabash, Indiana.
- the compression force is set to 15000 lb and the temperature of the plates is set to 175 degrees F, for duration of 1 minute.
- Aqueous adhesive binder solutions are then topically applied to both sides of the airlaid basesheet.
- the basesheet is placed on a screen which is under vacuum conditions during the spraying operation. Then the basesheet is sprayed on each side equally to achieve a final binder add-on of 18 to 20% by weight, in the handsheet.
- the binder composition is typically approximately 15 to 16% solids level.
- a Quick VEEJET® nozzle, type 8001 manufactured by Spraying Systems Co., Wheaton, Illinois, operating at approximately 80 psi was employed to spray the binder composition onto the fibrous material. The distance from the nozzle tip to the basesheet is 8 inches.
- EXPANCEL microspheres available from Akzo Nobel, Sundsvall, Sweden, were also sprayed onto the basesheet, either before, in combination with, or after, the adhesive binder solution, depending on the sample code.
- the resulting adhesive binder-sprayed airlaid basesheet is then transferred to and dried in a Werner Mathis Model LTV Through-Air Dryer, available from Mathis AG, located in Oberhasli, Switzerland.
- the Through-Air Dryer is set to 180 degrees C for 23 seconds at 100% fan speed.
- the stack of 10 lab-prepared wet wipes in the re- sealable plastic bag was compressed with a 22 lb metal roller, where the open bag containing the wipes is rolled four times each in both the MD and cross-direction (CD). The bag is sealed and then compressed under 1000 g of weight for 48 hours.
- the "thickness" of a web is measured with a 3-inch diameter, 5/8" thick, acrylic plastic disk connected to the spindle of a SONY Digital Indicator
- U60A (SONY Corporation, Tokyo, Japan) and which delivers a net load of 0.05 psi to the sample being measured.
- the SONY Digital Indicator is zeroed when the disk rests on a flat surface.
- a thickness reading can be obtained from the digital readout of the indicator.
- Stacks of 10 wet or dry wipes are measured in this manner with three replicates and averaged. The average is divided by 10 to obtain a caliper on a per-sheet basis.
- Thermally-bonded airlaid (TBAL) basesheets were prepared as described in the section "Lab Preparation of Thermally-Bonded Airlaid Nonwoven Material Basesheets". Samples were made with and without EXPANCEL thermally-expandable microspheres. The type of EXPANCEL used for these samples was "009 DU 80", available from Akzo Nobel, Sundsvall, Sweden.
- Dry and Wet Wipe samples were prepared from these TBAL basesheets as described in the sections "Lab-Prepared Dry Wipe Preparation Protocol” and "Lab-Prepared Wet Wipe Preparation Protocol.”
- Multi-bonded airlaid (MBAL) basesheets were prepared as described in the section "Lab Preparation of Multi-Bonded (Thermally and Adhesively) Airlaid Nonwoven Material Basesheets".
- the adhesive binder was an ion-sensitive dispersible binder composition, comprising a 70/30 combination of binder and co-binder mixed with de-ionized water to a solids level of 15.5%.
- the binder was a cationic ion-sensitive polyacrylate. More specifically, the cationic ion-sensitive polyacrylate is a copolymer of methyl acrylate (96 mol%) and [(2- acryloyloxy)ethyl] trimethyl ammonium chloride (4 mol%) with a weight average molecular weight between 140,000 to 200,000 g/mol as determined by gel permeation chromatography in a dimethylformamide/LiCI mobile phase.
- the co- binder was VINNAPAS® EZ123 (formerly known as AIRFLEX® EZ123), available from Wacker Chemie AG, Kunststoff, Germany.
- EXPANCEL thermally-expandable microspheres were made with and without EXPANCEL thermally-expandable microspheres.
- the type of EXPANCEL used for these samples are "091 DU 80", available from Akzo Nobel, Sundsvall, Sweden. These were mixed into the binder composition prior to spraying on the basesheet samples.
- Dry and Wet Wipe samples were prepared from these MBAL basesheets as described in the sections "Lab-Prepared Dry Wipe Preparation Protocol” and "Lab-Prepared Wet Wipe Preparation Protocol”. These samples are coded B1 , B2, B3, and B4. Pertinent information related to their composition is described in Table 3.
- Adhesively-bonded airlaid (ABAL) basesheets were prepared as described in the section "Lab Preparation of Adhesively-Bonded Airlaid Nonwoven Material Basesheets".
- the adhesive binder was an ion-sensitive dispersible binder composition, comprising a 70/30 combination of binder and co-binder mixed with de-ionized water to a solids level of 15.5%.
- the binder was a cationic ion-sensitive polyacrylate. More specifically, the cationic ion-sensitive polyacrylate is a copolymer of methyl acrylate (96 mol%) and [(2- acryloyloxy)ethyl] trimethyl ammonium chloride (4 mol%) with a weight average molecular weight between 140,000 to 200,000 g/mol as determined by gel permeation chromatography in a dimethylformamide/LiCI mobile phase.
- the co- binder was VINNAPAS® EZ123 (formerly known as AIRFLEX® EZ123), available from Wacker Chemie AG, Kunststoff, Germany.
- EXPANCEL thermally-expandable microspheres were made with and without EXPANCEL thermally-expandable microspheres.
- the type of EXPANCEL used for these samples are "009 DU 80", available from Akzo Nobel, Sundsvall, Sweden. These were mixed into the binder composition prior to spraying on the basesheet samples.
- Dry and Wet Wipe samples were prepared from these dispersible ABAL basesheets as described in the sections "Lab-Prepared Dry Wipe
- Stacks of 10 wet or dry wipes were then measured as described in the section "Wet or Dry Wipe Caliper (Thickness) Measurements”. This resulted in single sheet calipers after dividing the average measurements by 10. Additionally, the single sheet bulk can be calculated as the quotient of the single sheet caliper, expressed in microns, divided by the bone dry basis weight, expressed in grams per square meter (gsm). The resulting sheet bulk is expressed in cubic
- the sheet bulk increases from 18.4% to 83.7% for the dry dispersible ABAL wipes, depending on the amount of EXPANCEL added to the basesheet, while the sheet bulk increases from 12.2% to 105.8% for the wet dispersible ABAL wipes.
- Adhesively-bonded airlaid (ABAL) basesheets were prepared as described in the section "Lab Preparation of Adhesively-Bonded Airlaid Nonwoven Material Basesheets.”
- the adhesive binder was a non-dispersible binder composition, comprising a non-dispersible binder mixed with de-ionized water to a solids level of 15.5%.
- the binder was VINNAPAS® 192 available from Wacker Chemie AG, Kunststoff, Germany.
- EXPANCEL thermally-expandable microspheres were made with and without EXPANCEL thermally-expandable microspheres.
- the type of EXPANCEL used for these samples are "091 DU 80", available from Akzo Nobel, Sundsvall, Sweden. These were mixed into the binder composition prior to spraying on the basesheet samples.
- Dry and Wet Wipe samples were prepared from these non-dispersible ABAL basesheets as described in the sections "Lab-Prepared Dry Wipe
- the sheet bulk increases from 1 1.9% to 33.1 % for the dry non- dispersible ABAL wipes, depending on the amount of EXPANCEL added to the basesheet, while the sheet bulk increases from 37.0% to 1 17.9% for the wet non- dispersible ABAL wipes.
- EXPANCEL thermally-expandable microspheres increases the thickness of wet wipes by at least about 12%, when added at the 1 % level, to as much as about 132%, when added at the 5% level.
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2010337966A AU2010337966A1 (en) | 2009-12-28 | 2010-11-23 | Bulk enhancement for airlaid material |
MX2012007630A MX2012007630A (en) | 2009-12-28 | 2010-11-23 | Bulk enhancement for airlaid material. |
EP10840666A EP2519669A2 (en) | 2009-12-28 | 2010-11-23 | Bulk enhancement for airlaid material |
BR112012015396A BR112012015396A2 (en) | 2009-12-28 | 2010-11-23 | swelling for air deposited material |
IL220030A IL220030A0 (en) | 2009-12-28 | 2012-05-29 | Bulk enhancement for airlaid material |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/647,969 US20110155338A1 (en) | 2009-12-28 | 2009-12-28 | Bulk Enhancement For Airlaid Material |
US12/647,969 | 2009-12-28 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2011080612A2 true WO2011080612A2 (en) | 2011-07-07 |
WO2011080612A3 WO2011080612A3 (en) | 2011-11-10 |
Family
ID=44186024
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IB2010/055381 WO2011080612A2 (en) | 2009-12-28 | 2010-11-23 | Bulk enhancement for airlaid material |
Country Status (9)
Country | Link |
---|---|
US (1) | US20110155338A1 (en) |
EP (1) | EP2519669A2 (en) |
KR (1) | KR20120114278A (en) |
AU (1) | AU2010337966A1 (en) |
BR (1) | BR112012015396A2 (en) |
CO (1) | CO6561777A2 (en) |
IL (1) | IL220030A0 (en) |
MX (1) | MX2012007630A (en) |
WO (1) | WO2011080612A2 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2583697A1 (en) * | 2011-10-21 | 2013-04-24 | The Procter and Gamble Company | Absorbent core |
US8679296B2 (en) | 2012-07-31 | 2014-03-25 | Kimberly-Clark Worldwide, Inc. | High bulk tissue comprising expandable microspheres |
JP2021504600A (en) | 2017-11-22 | 2021-02-15 | エクストルージョン グループ, エルエルシーExtrusion Group, Llc | Melt blown die chip assembly and method |
EP4326213A2 (en) | 2021-04-23 | 2024-02-28 | Glatfelter Gernsbach GmbH | Foam-air laid combination and methods of use |
CN113633816B (en) * | 2021-07-08 | 2022-09-30 | 西安理工大学 | Preparation method of injectable self-expanding bone cement |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20030228460A1 (en) * | 1999-11-30 | 2003-12-11 | Younger Ahluwalia | Fire resistant structural material and fabrics made therefrom |
US20050130536A1 (en) * | 2003-12-11 | 2005-06-16 | Kimberly-Clark Worldwide, Inc. | Disposable scrubbing product |
US20060135026A1 (en) * | 2004-12-22 | 2006-06-22 | Kimberly-Clark Worldwide, Inc. | Composite cleaning products having shape resilient layer |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4100324A (en) * | 1974-03-26 | 1978-07-11 | Kimberly-Clark Corporation | Nonwoven fabric and method of producing same |
SE439599B (en) * | 1981-01-14 | 1985-06-24 | Kema Nord Ab | WAY TO DRY AND EXPAND IN LIQUID DISPERSED, THERMOPLASTIC MICROSPHERES CONTAINING, VOLTABLE, LIQUID JEWELERY |
SE453206B (en) * | 1983-10-21 | 1988-01-18 | Valmet Paper Machinery Inc | HYGIENE PAPER COAT, PROCEDURE FOR PREPARING THEREOF AND USING EXPANDABLE MICROSPHERES OF THERMOPLASTIC IN PREPARING HYGIENE PAPER COAT |
US5234757A (en) * | 1991-04-30 | 1993-08-10 | The Dexter Corporation | Expandable films and molded products therefrom |
US20020104632A1 (en) * | 1999-12-16 | 2002-08-08 | Graciela Jimenez | Opacity enhancement of tissue products with thermally expandable microspheres |
US6828014B2 (en) * | 2001-03-22 | 2004-12-07 | Kimberly-Clark Worldwide, Inc. | Water-dispersible, cationic polymers, a method of making same and items using same |
US7182837B2 (en) * | 2002-11-27 | 2007-02-27 | Kimberly-Clark Worldwide, Inc. | Structural printing of absorbent webs |
-
2009
- 2009-12-28 US US12/647,969 patent/US20110155338A1/en not_active Abandoned
-
2010
- 2010-11-23 BR BR112012015396A patent/BR112012015396A2/en not_active IP Right Cessation
- 2010-11-23 AU AU2010337966A patent/AU2010337966A1/en not_active Abandoned
- 2010-11-23 MX MX2012007630A patent/MX2012007630A/en not_active Application Discontinuation
- 2010-11-23 WO PCT/IB2010/055381 patent/WO2011080612A2/en active Application Filing
- 2010-11-23 EP EP10840666A patent/EP2519669A2/en not_active Withdrawn
- 2010-11-23 KR KR1020127016900A patent/KR20120114278A/en not_active Application Discontinuation
-
2012
- 2012-05-29 IL IL220030A patent/IL220030A0/en unknown
- 2012-06-27 CO CO12107621A patent/CO6561777A2/en not_active Application Discontinuation
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20030228460A1 (en) * | 1999-11-30 | 2003-12-11 | Younger Ahluwalia | Fire resistant structural material and fabrics made therefrom |
US20050130536A1 (en) * | 2003-12-11 | 2005-06-16 | Kimberly-Clark Worldwide, Inc. | Disposable scrubbing product |
US20060135026A1 (en) * | 2004-12-22 | 2006-06-22 | Kimberly-Clark Worldwide, Inc. | Composite cleaning products having shape resilient layer |
Also Published As
Publication number | Publication date |
---|---|
KR20120114278A (en) | 2012-10-16 |
EP2519669A2 (en) | 2012-11-07 |
AU2010337966A1 (en) | 2012-06-21 |
WO2011080612A3 (en) | 2011-11-10 |
US20110155338A1 (en) | 2011-06-30 |
BR112012015396A2 (en) | 2016-04-12 |
IL220030A0 (en) | 2012-07-31 |
CO6561777A2 (en) | 2012-11-15 |
MX2012007630A (en) | 2012-08-01 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP2148950B1 (en) | Layered dispersible substrate | |
US7758724B2 (en) | Bulky water-disintegratable cleaning article and process for producing water-disintegratable paper | |
RU2366768C2 (en) | Soft and voluminous copmposite materials | |
JP2004535842A (en) | Synthetic fiber blended with absorbent material and method for producing the material | |
US20110155338A1 (en) | Bulk Enhancement For Airlaid Material | |
RU2544157C2 (en) | Papermaking belt with bulge area, forming geometric pattern that is repeated in any smaller scale for production of irregular figures and surfaces | |
RU2769362C1 (en) | Biodegradable nonwoven fabric containing wood pulp and the method for its manufacture | |
JP2001522957A (en) | Method and apparatus for producing a fibrous web of cellulosic fibers for use in hygiene articles | |
EA029294B1 (en) | Method for production of a hydroentangled airlaid web and product obtained therefrom | |
JPH09500691A (en) | Tissue paper treated with a mixture of ternary biodegradable softeners | |
WO2011040176A1 (en) | Absorbent laminated sheet | |
RU2717928C2 (en) | Patterned non-woven material | |
US11155966B2 (en) | Hydrolytic sheet and method for manufacturing hydrolytic sheet | |
JP2016121427A (en) | Nonwoven fabric and producing method of nonwoven fabric | |
EP1931482A2 (en) | Method and device for making towel, tissue, and wipers on an air carding or air lay line utilizing hydrogen bonds | |
CN102481752A (en) | Flexible resilient absorbent cellulosic nonwoven structure | |
US11692291B2 (en) | Nonwoven material with high core bicomponent fibers | |
JP5506316B2 (en) | Absorbent articles | |
JP2010196220A (en) | Low density nonwoven fabric | |
EP0992250A2 (en) | Superabsorbent cellulosic natural or synthetic fibers and webs treated with polyelectrolytes and superabsorbent products made therefrom | |
JP4424541B2 (en) | Method for producing hydrolytic paper and hydrolytic paper | |
CN113994044B (en) | Wiping sheet and method for producing the same | |
WO2003057965A1 (en) | Textured airlaid materials |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 10840666 Country of ref document: EP Kind code of ref document: A1 |
|
WWE | Wipo information: entry into national phase |
Ref document number: 220030 Country of ref document: IL |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2010337966 Country of ref document: AU |
|
ENP | Entry into the national phase |
Ref document number: 2010337966 Country of ref document: AU Date of ref document: 20101123 Kind code of ref document: A |
|
WWE | Wipo information: entry into national phase |
Ref document number: 2010840666 Country of ref document: EP |
|
WWE | Wipo information: entry into national phase |
Ref document number: 12107621 Country of ref document: CO |
|
ENP | Entry into the national phase |
Ref document number: 20127016900 Country of ref document: KR Kind code of ref document: A |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
WWE | Wipo information: entry into national phase |
Ref document number: MX/A/2012/007630 Country of ref document: MX |
|
REG | Reference to national code |
Ref country code: BR Ref legal event code: B01A Ref document number: 112012015396 Country of ref document: BR |
|
ENP | Entry into the national phase |
Ref document number: 112012015396 Country of ref document: BR Kind code of ref document: A2 Effective date: 20120622 |