WO2015143361A1 - Method of increasing the surface energy of a non-woven fabric - Google Patents

Abstract

The present disclosure provides a method of influencing the surface energy of a non- woven fabric that includes a plurality of fibers. The method includes the steps of providing a particular polyolefin that includes a matrix structure and providing a surface energy modifier. The surface energy modifier is chosen from particular first, second, and third alkoxylates, a fluorocarbon, an alkyl polyglycoside, and two particular modified fatty alcohol polyglycolethers, and combinations thereof. The method also includes the step of combining the polyolefin and the surface energy modifier to disperse the surface energy modifier throughout the matrix structure to form a mixture. The method subsequently includes the step of forming the plurality of fibers and the non-woven fabric from the mixture.

Description

METHOD OF INCREASING THE

SURFACE ENERGY OF A NON- WOVEN FABRIC

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The subject patent application claims priority to and all the benefits of U.S.

Provisional Patent Application No. 61/968,762, filed on March 21, 2014, and U.S.

Provisional Patent Application No. 62/115,302, filed on February 12, 2015, the disclosures of which are each herein independently incorporated by reference in their entirety.

FIELD OF THE DISCLOSURE

[0002] The present disclosure generally relates to a method of increasing the surface energy of a non-woven fabric and the non-woven fabric itself. More specifically, the non-woven fabric includes a plurality of fibers that includes a polyolefin and a surface energy modifier that increases the surface energy (e.g. the hydrophilicity) of the fibers.

DESCRIPTION OF THE RELATED ART

[0003] Non-woven fabrics have become one of the fast growing industries in the textile world and are typically processed by web forming and web consolidation, which differ from the processing of conventional textile fabrics. With non-woven fabrics moving into more technical end-uses, polypropylene (PP) fibers have grown to be one of the dominant materials in the non-woven fabric industry. It is estimated that over 90% of all melt-blown non-woven fabrics are made from polypropylene because of low cost, ease of processing, favorable chemical and physical properties, such as lack of heat shrinkage, impact strength, tensile strength, and an ability to be drawn into very fine fibers. However, polypropylene is a typical hydrophobic polymer which causes the non-woven fabrics made therefrom to have poor hydrophilicity, which limits their use in some applications.

[0004] To improve wettability and increase the surface energy of polypropylene (thereby increasing its hydrophilicity), many techniques have been studied to introduce polar groups to the surface of the polypropylene and enrich surface functionality. Chemical treatments have been used to create hydroxyl and carboxylic acid groups on polypropylene. Corona, plasma, and flame treatments have also been used along with chromium or acidic oxidation techniques. Surface coatings with a solution containing hydrophilic compounds have also been attempted. However, these treatments are not economical or sustainable, tend to be technically challenging, and can be potentially harmful to the environment.

[0005] In addition, use of migratory additives, i.e., materials that exhibit controlled migration to the surface of nonwoven fabrics, has also been attempted. These migratory additives are typically recognized as low cost materials that can generate desirable surface properties without altering the bulk properties of the non-woven fabrics. Nevertheless, over time, the migratory additives migrate entirely, or almost entirely, out of the non-woven fabrics thereby reducing their useful lifetime. Accordingly, there remain opportunities for improvement.

SUMMARY OF THE DISCLOSURE

[0006] The present disclosure provides a method of increasing the surface energy of a non- woven fabric that includes a plurality of fibers. The method includes the steps of providing a polyolefin comprising a matrix structure and having the formula: (CH₂CH₂)_n or (CH₂CHR)_n, wherein R is -CH₃ or CH₂CH₃ and n is 2 or greater. The method also includes the step of providing a surface energy modifier. The surface energy modifiers is chosen from:

(1) a first alkoxylate having one or more oxyethylene moieties having the formula: R"0(CH₂CH₂0)_xR³, wherein R" is a C₈ to Ci₈ linear or branched alkyl group, R³ is H, CH₃, CH₂CH₃, CH₂CH₂CH₃ or CH₂CH₂CH₂CH₃, and x is a number from 4 to 30,

(2) a second alkoxylate different from the first alkoxylate and having the formula:

R⁴(OCH₂CH₂)_a(OCH₂CHR⁵)_bR⁶, wherein R⁴ is a C₈ to C₁₈ linear or branched alkyl group, R⁵ is -CH₃ or -CH₂CH₃, R⁶ is -OH, -OCH₃, -OCH₂CH_3, -OCH₂CH₂CH₃, or -OCH2CH2CH2CH_3, and wherein each of a, and b is independently a number from 0 to 14 with the proviso that at least one of a and b is 1 to 14,

(3) a third alkoxylate different from the first and second alkoxylates and having the formula:

R⁷(CH₂CHR⁸0)_d(CH2CH20)_c(CH2CHR⁸0)_eR⁹, wherein R⁷ is a linear or branched C₈ to Ci₈ alkyl group, R⁸ is -CH₃ or -CH₂CH₃, R⁹ is -OH, -OCH₃, - OCH2CH_3, -OCH2CH2CH₃, or -OCH2CH2CH2CH_3, wherein c is a number from 0 to 14, and each of d and e is independently a number from 0 to 20,

(4) a fluorocarbon having the formula CF₃(CF2)fS0₃H, wherein f is a number from 4 to 12,

(5) an alkyl polyglycoside having the formula R¹⁰OG_y wherein R¹⁰ is a C₆ to Ci₈ linear or branched alkyl alcohol group, G is a glycoside, and y is an average degree of polymerization, wherein y is a number greater than 0 and up to 3,

(6) a modified fatty alcohol polyglycolether having the formula: R¹¹(OCH₂CH₂)_zOR¹², wherein R¹¹ is C₈ to C₁₈ linear or branched alkyl group and R¹² is a C₈ to Ci₈ linear or branched alkyl group wherein at least one carbon atom is functionalized with -OH or -COOH, and z is a number from 4 to 30,

(7) a modified fatty alcohol polyglycolether having the formula: R¹³(OCH₂CH2)_g(OCH₂CH R¹⁴)_hOR¹⁵, wherein R¹³ is a C₈ to Ci₈ linear or branched alkyl group, R¹⁴ is -CH₃ or -CH₂CH₃, and R¹⁵ is a C₈ to Ci₈ linear or branched alkyl group wherein at least one carbon atom is functionalized with OH or -COOH, and wherein each of g and h is independently a number from 0 to 14 with the proviso that at least one of g, and h is 1 to 14,

and combinations of (l)-(7). The method further includes the step of combining the polyolefin and the surface energy modifier to disperse the surface energy modifier throughout the matrix structure to form a mixture. The method includes the step of subsequently forming the plurality of fibers and the non-woven fabric having increased surface energy from the mixture.

[0007] The disclosure further provides a non-woven fabric having increased surface energy (i.e., increased hydrophilicity) and including the plurality of fibers. In this non- woven fabric, each of the plurality of fibers also includes the polyolefin and the surface energy modifier. This non-woven fabric typically exhibits a water contact angle of less than 90 degrees when evaluated using ASTM D7490-13.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Other advantages of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0009] Figure 1 is a bar graph of strike through times of various examples;

[0010] Figure 2A is a table of contact angle measurements of various examples;

[0011] Figure 2B is a line graph of the data of Figure 2A; and

[0012] Figure 3 is a line graph of additional contact angle measurements of additional examples.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0013] The present disclosure provides a method of increasing the surface energy of a non- woven fabric that includes a plurality of fibers. In various embodiments, the terminology "non-woven fabric" describes a sheet, layer or web that includes the plurality of fibers, e.g. a structure of individual fibers, filaments, or threads that are positioned in a substantially random manner to form a planar material, as opposed to a knitted or woven fabric, as is understood in the art. Non-limiting examples non-woven fabrics include meltblown webs, spunbond webs, carded webs, air-laid webs, wet-laid webs, and spunlaced webs.

[0014] In one embodiment, the non-woven fabric is further defined as a textile and is neither woven nor knit. The non-woven fabric may be manufactured by putting individual fibers together in the form of a sheet or web, and then binding them either mechanically, with an adhesive, or thermally by melting a binder onto the textile. Non-woven textiles may include staple non-woven textiles and spunlaid non-woven textiles. Staple non-woven textiles are typically made by spinning fibers that are spread in a uniform web and then bonded by using either resin or heat. Non-woven fabrics or textiles may also include films and fibrillates and can be formed using serration or vacuum-forming to form patterned holes.

[0015] In another embodiment, the non-woven fabric is further defined as a spunlaid non- woven fabric. Spunlaid non-woven fabrics/textiles are typically made in one continuous process by spinning fibers directly disposed into a web. The spunlaid process can be combined with a meltblowing process to form a SMS (spun-melt-spun) non-woven textile. In one embodiment, the spunlaid non-woven fabric is a multi-layer composite fabric including a layer of meltblown fibers bonded between two layers of spunbond fibers (e.g., a spunbond- meltblown- spunbond (SMS)). The SMS nonwoven fabric can include multiple layers of spunbond or meltblown fibers, such as an SMMS (spunbond-meltblown-meltblown- spunbond), SMSS (spunbond-meltblown-spunbond-spunbond), or the like.

[0016] In still another embodiment, the non-woven fabric is defined as a sheet or web structure bonded together by entangling fibers or filaments mechanically, thermally or chemically. In another embodiment, the non-woven fabric is a flat or tufted porous sheet that is made directly from separate fibers. Typically, non-woven fibers are not made by weaving or knitting and do not require converting the fibers to yarn. In still another embodiment, the non-woven fabric is described as an engineered fabric that may be described as a limited life, single-use fabric or a durable fabric. The non-woven fabric may be absorbent, repellant to liquid, resilient to tearing, flame retardant, washable, insulating, etc. It is well understood in the art that the terminology "non-woven" is not simply any fabric that isn't woven, e.g. a simple collection of random fibers. The differently, the terminology "non-woven" is not simply any fabric that fails to be woven together. Instead, the terminology "non-woven" is understood in the textile/fabric arts.

[0017] The non- woven fabric may be itself, or may be used to form, any article of the art. For example, the article may be or include wipes, diapers, water or air filters, membranes, or packaging. Alternatively, the article may be further defined as clothing or apparel. Still further, the non-woven fabric may be itself or may be used to form one or more of surgical gowns, masks, and apparel, medical packaging, gasoline, oil and air filters, food grade filters, pharmaceutical filters, mineral processing filters, liquid cartridge and bag filters, vacuum bags, allergen membranes, laminates, geotextiles, carpet backing, laminates, backing for embroidery, insulation, pillows, cushions, mattress cores, and upholstery padding, envelopes, tarps, tenting and transportation wrapping, (disposable), weather resistant house wrap, and the like.

Plurality of Fibers:

[0018] As described above, non-woven fabric further includes the plurality of fibers. The terminology, "fiber(s)" may be substituted below for either "the plurality of fibers", "each of the plurality of fibers", or both. The fibers may be in monofilament form, collated fibrillated form, ribbon form, or any core-sheath, core-shell, mono component, or bi-component form or any other form known in the art.

[0019] The fibers may be of any size and/or dimension known in the art. For example, each of the plurality of fibers may have a basis weight 10 to 80 grams per square meter (gsm) or 10 to 60 gsm or 10 to 55 gsm, or 10 to 55 gsm or 10 to 45 gsm and 0.5 to 35 denier. In various embodiments, each of the plurality of fibers may have a denier of from 0.5 to 35, from 1 to 20, from 1 to 5, from 1 to 10, from 1 to 4, of from 1.5 to 3 denier, of from 1.5 to 2.5 denier, of from 1.5 to 2 denier, of from 1.6 to 2 denier. In additional non- limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.

[0020] In one embodiment, spunbond fibers have an average basis weight of greater than 10 gsm. Spunbond webs can be formed by laying spunbond fibers randomly on a collecting surface, and subsequently bonding the fibers, such as by thermal bonding, hydroentanglement, or the like. In another embodiment, meltblown fibers have an average basis weight of less than about 10 gsm. Meltblown webs can be formed by laying meltblown fibers randomly on a collecting surface, and bonding, such as by thermal bonding, hydroentanglement, or the like. The spunbond fibers and meltblown fibers can be substantially continuous fibers but are not limited thereto. For example, staple fibers or carded fibers may be used instead or in conjunction with substantially continuous fibers. The non- woven fabric typically includes approximately 100% by weight of the plurality of fibers but may include from 90 to 99, or from 95 to 99, % by weight of the plurality of fibers.

[0021] Referring back to the method, the method includes the steps of providing a polyolefin that includes a matrix structure and providing a surface energy modifier. The method also includes the step of combining the polyolefin and the surface energy modifier to disperse the surface energy modifier throughout the matrix structure to form a mixture. Subsequently, the method includes the step of forming the plurality of fibers and the non-woven fabric from the mixture.

Polyolefin:

[0022] Referring now to the polyolefin, the polyolefin is not particularly limited. Suitable non-limiting polyolefins include polymers and copolymers formed from the polymerization of ethylene or propylene monomers. Mixtures of pure polyolefins with copolymers are also suitable in various embodiments. The poly olefin may alternatively be combined with other synthetic or natural polymers, for example cellulose, polylactic acid or hemp. In still other embodiments, the polyolefin is, includes, consists essentially of, or consists of, one or more of, poly (ethylenes), such as HDPE (high-density polyethylene), LDPE (low-density polyethylene), VLDPE (very-low-density polyethylene), LLDPE (linear low-density polyethylene), MDPE (medium-density polyethylene), UHMPE (ultra high molecular polyethylene), VPE (crosslinked polyethylene), HPPE (high-pressure polyethylene); poly (propylenes), such as isotactic polypropylene; syndiotactic polypropylene; metallocene- catalyzed polypropylene, high-impact polypropylene, random copolymers based on ethylene and propylene, block copolymers based on ethylene and propylene; EPM (poly[ethylene-co- propylene]); EPDM (poly[ethylene-co-propylene-co-unconjugated diene]), and/or combinations thereof. In one embodiment, the polyolefin is chosen from polyethylene, polypropylene, polymethylpentene, polybutene-1, and combinations thereof. The terminology "consists essentially of describes an embodiment wherein the polyolefin is free of any monomers or polymers not described above.

[0023] The polypropylene may be isotactic, syndiotactic, or atactic. For descriptive purposes only, generic chemical structures of atactic, isotactic, and syndiotactic polypropylene are shown below:

Isotactic Polypropylene

Syndiotactic Polypropylene

Atactic Polypropylene

wherein n may be any integer. A non-limiting example of a suitable polypropylene is commercially available from LyondellBasel Industries of Houston, TX, under the trade name of Metocene™, such as Metocene™ MF650W.

[0024] In various embodiments, the polyolefin has the formula (CH₂CH₂)_n or (CH₂CHR)_n, wherein R is C¾ or CH₂CH₃ and n is 2 or greater. For example, n may be from 2 to 10, from 10 to 50, from 10 to 100, from 100 to 500, from 100 to 1,000, from 500 to 1,000, from 1,000 to 1,000,000, from 1,000 to 10,000, from 10,000 to 100,000, from 100,000 to 1,000,000, from 100,000 to 500,000, from 500,000 to 1,000,000, greater than 1,000, greater than 10,000, greater than 50,000, greater than 100,000, greater than 500,000, or greater than 1,000,000. In additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.

[0025] Each of the plurality of fibers typically includes at least 90 parts by weight of the polyolefin based on 100 parts by weight of each of the plurality of fibers. However, the polyolefin may be used in a lesser weight percent. Alternatively, each of the plurality of fibers may include at least 92 parts by weight, at least 94 parts by weight, at least 96 parts by weight, at least 97 parts by weight, at least 98 parts by weight, or at least 99 parts by weight of the polyolefin, each based on 100 parts by weight of each of the plurality of fibers. In additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.

[0026] The polyolefin includes a matrix structure. Typically, the matrix structure is formed from the monomers that are polymerized to form the polyolefin. In other words, the matrix structure is typically formed from a series of oligomer and/or polymer chains that are entwined or intermingled to form the polyolefin as a whole. The matrix structure is typically porous at a micro-level but may appear solid at a macro-level.

Surface Ener2V Modifier:

[0027] Referring now to the surface energy modifier, the surface energy modifier is dispersed in the matrix structure. Typically, the surface energy modifier is dispersed homogenously throughout the matrix structure, e.g. evenly or consistently or uniformly throughout the matrix structure. In other embodiments, the surface energy modifier is dispersed heterogeneously throughout the matrix structure, e.g. unevenly, randomly, or non-uniformly throughout the matrix structure. In still other embodiments, the surface energy modifier may be dispersed homogeneously in one or more portions of the matrix structure and heterogeneously in one or more other portions of the matrix structure.

[0028] The surface energy modifier may be bonded to the matrix structure, e.g. by covalent bonds. Alternatively, the surface energy modifier may be subject to one or more intermolecular forces with the matrix structure, e.g. hydrogen bonding or van der Waals forces.

[0029] The surface energy modifier may be present in the polyolefin, each fiber itself, and/or non-woven fabric in an amount of from 0.1 to 5, 0.2 to 4.9, 0.3 to 4.8, 0.4 to 4.7, 0.5 to 4.6, 0.6 to 4.5, 0.7 to 4.4, 0.8 to 4.3, 0.9 to 4.2, 1 to 4.1, 1.1 to 4, 1.2 to 3.9, 1.3 to 3.8, 1.4 to 3.7, 1.5 to 3.6, 1.6 to 3.5, 1.7 to 3.4, 1.8 to 3.3, 1.9 to 3.2, 2 to 3.1, 2.1 to 3, 2.2 to 2.9, 2.3 to 2.8, 2.4 to 2.7, or 2.5 to 2.6, weight percent based on a total weight of the polyolefin, fibers, and/or non-woven fabric.

Increasing the Surface Energy of the Polyolefin, Fibers, and/or Non- Woven Fabric:

[0030] The particular surface energy modifier may be chosen to increase the surface energy (e.g. the hydrophilicity) of, and decrease the hydrophobicity of, the polyolefin, fibers, and/or non-woven fabric. The increased surface tension and/or hydrophilicity can be quantified, for example, by water contact angle, which is described in greater detail below.

[0031] The surface energy modifier is chosen from;

(1) a first alkoxylate having one or more oxyethylene moieties having the formula: R"0(CH₂CH₂0)_xR³, wherein R" is a C8 to C i8 linear or branched alkyl group, R³ is H, CH₃, CH₂CH₃, CH₂CH₂CH₃ or CH₂CH₂CH₂CH₃, and x is a number from 4 to 30,

(2) a second alkoxylate different from the first alkoxylate and having the formula:

R⁴(OCH₂CH₂)_a(OCH₂CHR⁵)_bR⁶, wherein R⁴ is a C₈ to Ci₈ linear or branched alkyl group, R⁵ is -CH₃ or -CH₂CH₃, R⁶ is -OH, -OCH₃, -OCH₂CH_3, -OCH₂CH₂CH₃, or -OCH₂CH₂CH₂CH_3i and wherein each of a, and b is independently a number from 0 to 14 with the proviso that at least one of a and b is 1 to 14,

(3) a third alkoxylate different from the first and second alkoxylates and having the formula:

R⁷(CH₂CHR⁸0)_d(CH₂CH₂0)c(CH₂CHR⁸0)_eR⁹, wherein R⁷ is a linear or branched C₈ to Ci₈ alkyl group, R⁸ is -CH₃ or -CH₂CH₃, R⁹ is -OH, -OCH₃, - OCH₂CH_3, -OCH₂CH₂CH₃, or -OCH₂CH₂CH₂CH_3, wherein c is a number from 0 to 14, and each of d and e is independently a number from 0 to 20, (4) a fluorocarbon having the formula CF₃(CF2)_fSC>3H, wherein f is a number from 4 to 12,

(5) an alkyl polyglycoside having the formula R¹⁰OG_y wherein R¹⁰ is a C₆ to Ci₈ linear or branched alkyl alcohol group, G is a glycoside, and y is an average degree of polymerization, wherein y is a number greater than 0 and up to 3,

(6) a modified fatty alcohol polyglycolether having the formula: R¹¹(OCH₂CH₂)_zOR¹², wherein R¹¹ is C₈ to Ci₈ linear or branched alkyl group and R¹² is a C_& to Ci₈ linear or branched alkyl group wherein at least one carbon atom is functionalized with -OH or -COOH, and z is a number from 4 to 30,

(7) a modified fatty alcohol polyglycolether having the formula: R¹³(OCH₂CH₂)_g(OCH₂CH R¹⁴)_hOR¹⁵, wherein R¹³ is a C₈ to Ci₈ linear or branched alkyl group, R¹⁴ is -CH₃ or -CH₂CH₃, and R¹⁵ is a C_& to Ci₈ linear or branched alkyl group wherein at least one carbon atom is functionalized with OH or -COOH, and wherein each of g and h is independently a number from 0 to 14 with the proviso that at least one of g, and h is 1 to 14,

and combinations of (l)-(7).

(1) First Alkoxylate:

[0032] The first alkoxylate has one or more oxyethylene moieties having the formula: R"0(CH₂CH₂0)_xR³. In this formula, R" is a C₈ to Ci₈ linear or branched alkyl group. In other words, R" may have any number or range of numbers from 8 to 18 relative to the number of carbon atoms. For example, R" may be a Cs to C₁₆, Cs to C , CS to C₁₂, Cs to C₁₀,

Cio tO C_l8, Cio tO C_l6, Cio tO C_l4, Cio tO C₁₂, C₁₂ tO C_l8, C₁₂ tO C_l6, C₁₂ tO C_l4, C_l4 tO C_l8, C_l4 to Ci₈, or Ci6 to Ci₈, linear or branched alkyl group. In addition, R³ is H, C¾, CH₂CH₃, CH₂CH₂CH₃ or CH2CH2CH2CH₃. Moreover, x is a number from 4 to 30. In various embodiments x is from 6 to 28, from 8 to 26, from 10 to 24, from 12 to 22, from 14 to 20, from 16 to 18, 4, 5, 6, 7, 8, 9, or 10, etc. All values and ranges of values including and between the aforementioned values are hereby expressly contemplated in various non- limiting embodiments.

(2) Second Alkoxylate:

[0033] The second alkoxylate is different from the first alkoxylate and has the formula: R⁴(OCH2CH2)_a(OCH₂CHR⁵)_bR⁶ In this formula, R⁴ is a C₈ to Ci₈ linear or branched alkyl group. R⁴ may have any number or range of numbers from 8 to 18 relative to the number of carbon atoms. In various embodiments, R⁴ is a C₈ to C₁₆, C₈ to C₁₄, C₈ to C₁₂, C₈ to C₁₀, C₁₀ tO C_l8, Cio tO C_l6, Cio tO C_l4, Cio tO C_l2, C_l2 tO C_l8, C_l2 tO C_l6, C_l2 tO C_l4, C_l4 tO C_l8, C_l4 to

Ci₈, or Ci6 to Ci₈, linear or branched alkyl group.

[0034] Moreover, R⁵ is -CH₃ or -CH₂CH₃. R⁶ is -OH, -OCH₃, -OCH₂CH_3, -OCH₂CH₂CH₃, or -OCH2CH2CH2CH₃. Furthermore, each of a and b is independently a number from 0 to 14 with the proviso that at least one of a and b is 1 to 14. The differently, each of a and b can independently be any number or range of numbers from 0- 14 so long as one of a or b is a number or range of numbers from 1 to 14 (i.e., both a and b cannot be zero). In various embodiments, a and/or b are 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, or 14, or any range thereof. For example, a and/or b can be 4 to 10, 4 to 8, 4 to 6, etc. In other embodiments a or b is 0, 1 , 2, 3, 4, 5, or 6, or any range thereof. All values and ranges of values including and between the aforementioned values are hereby expressly contemplated in various non-limiting embodiments.

(3) Third Alkoxylate:

[0035] The third alkoxylate is different from the first alkoxylate and different from the second alkoxylate. The third alkoxylate has the formula:

R⁷(CH₂CHR⁸0)_d(CH2CH20)_c(CH₂CHR⁸0)_eR⁹. In this formula, R⁷ is a linear or branched C₈ to Ci₈ alkyl group. R⁷ may have any number or range of numbers from 8 to 18 relative to the number of carbon atoms. In various embodiments, R⁷ is a Cs to C₁₆, Cs to C₁₄, Cs to C₁₂, Cs tO Cio, Cio tO C_l8, Cio tO C_l6, Cio tO C_l4, Cio tO C_l2, C_l2 tO C_l8, C_l2 tO C_l6, C_l2 tO C_l4, C_l4 to

Ci₈, CM to Ci₈, or Ci6 to Ci₈, linear or branched alkyl group. Moreover, R⁸ is -CH₃ or - CH2CH₃. R⁹ is -OH, -OCH₃, -OCH2CH_3, -OCH2CH2CH₃, or -OCH₂CH₂CH₂CH₃. In addition, c is a number from 0 to 14 and each of d and e is independently a number from 0 to 20. The differently, each of c, d, and e can each independently be any number or range of number from 0-14 (relative to c) or from 0 to 20 (relative to d and e). In other words, each of c, d, and/or e can independently be 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20, or any range thereof. In one embodiment, c is from 4 to 10. In another embodiment, d is from 0 to 4. In still another embodiment, e is from 0 to 4. All values and ranges of values including and between the aforementioned values are hereby expressly contemplated in various non-limiting embodiments.

(4) Fluorocarbon:

[0036] The fluorocarbon has the formula CF₃(CF₂)_fSC>₃H. In this formula, f is a number from 4 to 12. The differently, f may be any number or range of numbers from 4 to 12. In various embodiments, f is 4, 5, 6, 7, 8, 9, 10, 11, or 12, or, for example, from 8 to 10, from 10 to 12, from 8 to 12, etc. All values and ranges of values including and between the aforementioned values are hereby expressly contemplated in various non-limiting embodiments.

(5) Alkyl Polyglycoside:

[0037] The alkyl polyglycoside has the formula R¹⁰OG_y. In this formula, R¹⁰ is a C₆ to Cis linear or branched alkyl alcohol group. R¹⁰ may have any number or range of numbers from 8 to 18 relative to the number of carbon atoms. In various embodiments, R¹⁰ is a Cs to Ci₆, Cs to Ci4, Cs to C12, Cs to Cio, Cio to Cis, Cio to Ci₆, Cio to C14, Cio to C12, C12 to Cis, C^ to Ci₆, C12 to Ci4, Ci4 to Cis, Ci4 to Cis, or Ci6 to Cis, linear or branched alkyl group. Moreover, G is a glycoside. The glycoside may be a molecule wherein a sugar is bound to another functional group via a glycosidic bond. More specifically, the glycoside may be a sugar group that is bonded through its anomeric carbon to another group via a glycosidic bond. Glycosides can be linked by an O- (an O-glycoside), N- (a glycosylamine), S-(a thio glycoside), or C- (a C-glycoside) glycosidic bond. The glycoside may be alternatively described as a "glycosyl compound." In some embodiments, the sugar is bonded to a non- sugar thus excluding polysaccharides. In such embodiments, the sugar group can be described as a glycone and the non-sugar group as an aglycone. The glycone can be a single sugar group (a monosaccharide) or several sugar groups (an oligosaccharide). In one embodiment, the sugar or glycone group is, or is based on, glucose. Furthermore, y is an average degree of polymerization and is a number greater than 0 and up to 3 (i.e., 0 < y < 3), or any value or range of values therebetween. For example, in various embodiments, y is 1.1 to 2, 1.2 to 1.9, 1.3 to 1.8, from 1.4 to 1.7, from 1.5 to 1.6, from 1.2 to 1.7, etc. All values and ranges of values including and between the aforementioned values are hereby expressly contemplated in various non-limiting embodiments.

(6) Modified Fatty Alcohol Polyglycolether:

[0038] This modified fatty alcohol polyglycolether (6) is different from the aforementioned modified fatty alcohol polyglycolether (7) first introduced above and described in detailed below. The modified fatty alcohol polyglycolether (6) has the formula: R^N(OCH2CH2)_zOR¹². In this formula, R¹¹ is Cs to C₁₈ linear or branched alkyl group. R¹¹ may have any number or range of numbers from 8 to 18 relative to the number of carbon atoms. In various embodiments, R¹¹ is a Cs to C₁₆, Cs to C₁₄, Cs to C₁₂, Cs to C₁₀, C₁₀ to C₁₈, C₁₀ to C₁₆, C₁₀ to CM, Cio to Ci2, Ci2 to Cis, Ci2 to Ci6, Ci2 to CM, C₁₄ to Cis, CM to Cis, or Ci6 to Cis, linear or branched alkyl group. Moreover, R¹² is a Cs to Cis linear or branched alkyl group wherein at least one carbon atom is functionalized with -OH or -COOH. Similarly, R¹² may have any number or range of numbers from 8 to 18 relative to the number of carbon atoms. In various embodiments, R¹² is a Cs to C₁₆, C₈ to C₁₄, C₈ to C₁₂, C₈ to C₁₀, C₁₀ to Cis, C₁₀ to C₁₆, C₁₀ to CM, Cio to Ci2, Ci2 to Ci8, C₁₂ to Ci6, Ci2 to CM, C₁₄ to Ci8, CM to C₁₈, or Ci6 to Ci8, linear or branched alkyl group wherein at least one carbon atom is functionalized with -OH or - COOH. Furthermore, in this formula, z is a number from 4 to 30, e.g. 6 to 28, 8 to 26, 10 to 24, 12 to 22, 14 to 20, 16 to 18, 20 to 24, 20 to 26, 22 to 24, 22 to 26, etc. All values and ranges of values including and between the aforementioned values are hereby expressly contemplated in various non-limiting embodiments.

(7) Modified Fatty Alcohol Polyglycolether:

[0039] This modified fatty alcohol polyglycolether (7) is different from the aforementioned modified fatty alcohol polyglycolether (6) described immediately above. The modified fatty alcohol polyglycolether (7) has the formula: R¹³(OCH₂CH2)_g(OCH₂CHR¹⁴)_hOR¹⁵. In this formula, R¹³ is a Cs to C₁₈ linear or branched alkyl group. R¹³ may have any number or range of numbers from 8 to 18 relative to the number of carbon atoms. In various embodiments, R¹³ is a Cs to Ci6, Cs to C₁₄, Cs to C₁₂, Cs to do, do to C₁₈, do to C₁₆, do to C₁₄, do to C₁₂, C₁₂ to Cis, C₁₂ to Ci6, C₁₂ to CM, C to Cis, CM to Cis, or C₁₆ to C₁₈, linear or branched alkyl group. Moreover, R¹⁴ is -CH₃ or -CH₂CH₃. R¹⁵ is a C₈ to Cis linear or branched alkyl group wherein at least one carbon atom is functionalized with OH or -COOH. Similarly, R¹⁵ may have any number or range of numbers from 8 to 18 relative to the number of carbon atoms. In various embodiments, R¹⁵ is a Cs to C₁₆, Cs to C₁₄, Cs to C₁₂, Cs to do, do to Cis, do ^to Ci6, do to Ci4, do to C₁₂, C₁₂ to Cis, C₁₂ to Ci₆, C₁₂ to C₁₄, C₁₄ to Cis, C₁₄ to Cis, or C₁₆ to Cis, linear or branched alkyl group. Furthermore, in this formula, each of g and h is independently a number from 0 to 14 with the proviso that at least one of g and h is 1 to 14. The differently, each of g and h can independently be any number or range of numbers from 0-14 so long as one of g or h is a number or range of numbers from 1 to 14 (i.e., both g and h cannot be zero). In various embodiments, g and/or h is independently from 1 to 10, from 2 to 10, from 1 to 9, from 2 to 8, from 3 to 7, from 4 to 6, from 4 to 5, or from 5 to 6. All values and ranges of values including and between the aforementioned values are hereby expressly contemplated in various non-limiting embodiments.

[0040] In various embodiments, combinations of the aforementioned surface energy modifiers are utilized. Any combination of two or more surface energy modifiers may be utilized. For example, a combination of (1), (5), and (6), may be utilized. In such a combination, the amount of (5) may be increased to increase hydrophilicity of the final product. Alternatively, the amount of (1) may be increased to increase the hydrophobicity of the final product. The proportions of the combination are not particularly limited. In various embodiments, the proportions are about 1: 1:1, each independently + 1-15 wt % or any values or ranges of values therebetween, respectively. In other embodiments, the ratio is about 40:30:30, each independently + 1-15 wt % or any values or ranges of values therebetween, respectively. Any two or more of the surface energy modifiers (l)-(7) may be utilized. In other words, a combination of 2, 3, 4, 5, 6, or 7 surface energy modifiers may be utilized or only a single one of surface modifiers (1), (2), (3), (4), (5), (6), or (7) may be used. In these combinations, each of the surface modifiers may be in any ratio between 0.5 and 99.5 as related to any one or more other surface energy modifiers.

Water Contact An2le/Water Absorptive Capacity/Strike Throu2h Time:

[0041] Referring back to contact angle, the non-woven fabric typically exhibits a water contact angle of less than 90 degrees. As described above, water contact angle measurements can be used to quantify surface tension, i.e., hydrophilicity.

[0042] The surface energy modifier may lower the interfacial tension between water and the polyolefin, fibers, and/or non-woven fabric thereby increasing the surface energy and the hydrophilicity of the polyolefin, fibers, and/or non-woven fabric and permitting the water to "wet" the polyolefin, fibers, and/or non-woven fabric. In general, the terminology "wetting" describes the ability of a liquid to maintain contact with a solid resulting from intermolecular interactions when the liquid and solid are combined. This "wetting" of the polyolefin, fibers, and/or non-woven fabric may be evaluated by determining the contact angle that water exhibits with a molded sheet and/or with the polyolefin, fibers, and/or non-woven fabric. A lower contact angle generally indicates that the polyolefin, fibers, and/or non-woven fabric has increased hydrophilicity. Water typically exhibits a contact angle with polypropylene (without the surface energy modifier) of about 90° according to modified ASTM D7490-13. In this disclosure, the polyolefin, fibers, and/or non-woven fabric may exhibit a water contact angle of less than 90 °, or less than or equal to 85 °, 80°, 75°, 70°, 65°, 60°, 55°, 50°, 45°, or 40°, each according to modified ASTM D7490-13. Typically, the surface energy modifier allows the polyolefin, fibers, and/or non-woven fabric to exhibit a water contact angle of less than 90°, according to modified ASTM D7490-13. Alternatively, these surface energy modifiers may be described as allowing the polyolefin, fibers, and/or non-woven fabric to exhibit a water contact angle that is less than a reference contact angle measured using the same polyolefin, fibers, and/or non-woven fabric without the surface energy modifier, according to modified ASTM D7490-13.

[0043] The plurality of non-woven fibers may also have a water absorptive capacity of from 50 to 100%, or from 100 to 150%, or from 150% 200%, from 200 to 250%, or from 250 to 300%, as determined using ISO 9073-6:2000(E). In addition, the plurality of non-woven fibers may have a strike through time of from 1 to 14 sec, 1 to 2 sec, from 2 to 3 sec, from 3 to 5 sec, 5 to 10 sec, from 10 to 14 sec, as determined using ED ANA 150.5 - 02.

Additives:

[0044] The polyolefin, fibers, and/or non- woven fabric may also include one or more additives. Suitable non-limiting examples of additives are dyes, pigments, lubricants, sizing agents, delustrants, antistats, bleaches, flame retardants, biocides, antifungals, or antibacterials, and combinations thereof. For example, a biocidal, antifungal, or antibacterial additive may be added to the polyolefin, fibers, and/or non-woven fabric. A suitable non- limiting example of a biocidal additive is a silver-zinc glass composition, e.g. Irgaguard^® B7000, commercially available from BASF Corporation.

[0045] In various embodiments, the additive is chosen from calcium carbonate, calcium sulfate, titanium dioxide and combinations thereof. In other embodiments, the additive is chosen from nitriloacetic acid, ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, hydroxyethylenediaminetriacetic acid, methylglycinediacetic acid, and combinations thereof.

[0046] For example, the additive may be present in the polyolefin, fibers, and/or non- woven fabric in an amount of from 0.1 to 3, 0.2 to 2.9, 0.3 to 2.8, 0.4 to 2.7, 0.5 to 2.6, 0.6 to 2.5, 0.7 to 2.4, 0.8 to 2.3, 0.9 to 2.2, 1 to 2.1, 1.1 to 2, 1.2 to 1.9, 1.3 to 1.8, 1.4 to 1.7, or 1.5 to 1.6, weight percent, based on a total weight of the polyolefin, fibers, and/or non-woven fabric. In other embodiments, the additive is present in the polyolefin, fibers, and/or non-woven fabric in an amount of from 0 to 10, 1.5 to 9.5, 2 to 9, 2.5 to 8.5, 3 to 8, 3.5 to 7.5, 4 to 7, 4.5 to 6.5, 5 to 6, 5.5 to 6, weight percent, based on a total weight of the polyolefin, fibers, and/or non- woven fabric, or any value or ranges of values therebetween.

Softness Additive:

[0047] In various embodiments, polyolefin, fibers, and/or non-woven fabric may also include one or more softness additives. The one or more softness additives are typically utilized to impart softness to non-woven fabrics and improve skin compatibility.

[0048] In various non-limiting embodiments, the softness additive is chosen from Polyquaternium 37 with Propylene Glycol Dicaprylate and PPG- 1 Trideceth - 6; or Polyquaternium 37 with Dicaprylyl Carbonate and Lauryl Glucoside. [0049] In other embodiments, the softness additive has the formula MDaD'_bM wherein M is (R¹)(CH₃)₂Si0_1/2, D is (CH₃)₂Si0_1/2, D' is (CH₃)Si0_1/2(CH₂CH₂CH₂0(R²)H), R¹ is CH₃, or OH, OCH₃, or OCH₂CH₃, or -CH₂CH₂CH₂0(EO)_n(PO)_m-H and R² is (EO)_n, (PO)_n, [(EO/A)_m(A)_nH]_x, [(A)₀(EO)_m(A)_nH]_x, or [(A)₀(EO/A)_m(A)_nH]_x, wherein EO is an ethylene oxide group and PO is a propylene oxide group. In these formulae, a and b are each independently 0 to 100, or any value or range of values there between. Moreover, R² can be an EO and/or PO polymer or an EO/PO block/heteric copolymer. In addition, relative to the formula, [(EO/A)_m(A)_nH]_x, x is typically 1 to 6, m is typically 0 to 110, and n is typically 0 to 110. Relative to the formula [(A)₀(EO)_m(A)_nH]_x, x is typically 1 to 6, m is typically 0 to 110, n is typically 0 to 110, and o is typically 0 to 110. Moreover, relative to the formula [(A)₀(EO/A)_m(A)_nH]_x, x is typically 1 to 6, m is typically 0 to 110, n is typically 0 to 110, and o is typically 0 to 110. Furthermore, A is typically chosen from propylene oxide, butylene oxide, tetrahydrofuran, and combinations thereof. In various non-limiting embodiments, it is contemplated that any and all values or ranges of values between and including each of the end points of the aforementioned ranges, independently, may be utilized. Non-limiting examples of suitable softness additives include polyether functional siloxanes, such as, Nuwet^® 237 and Nuwet^®550, each of which are commercially available from Momentive.

[0050] In still other embodiments, the softness additive has the formula R-Si (OR')3 and is a silane that can be non-hydrolyzed, and/or partially hydrolyzed, and/or fully hydrolyzed; wherein R is -CH₂CH₂CH₂0(EO)_n(PO)_mH and/or -CH₂CH₂CH₂0(CF₂)_nCF₃, R' is H, or CH₃, or CH₂CH₃, and m and n are as described above.

[0051] In still other embodiments, the softness additive has the formula MD_aD'_bD"_cM wherein M is typically (R¹)(CH )SiOi ₂, D is typically (CH )₂SiOi ₂, D' is typically (CH₃)Si0_1/2 (CH₂CH₂CH₂0(R²)H), D" is typically (CH₃)Si0_1/2(CH₂CH₂CH₂NR³R⁴), R¹ is typically OH, OCH₃, or OCH₂CH₃, R² is typically (EO)_n, (PO)_n, [(EO/A)_m(A)_nH]_x, [(A)_o(EO)_m(A)„H]_x, or [(A)₀(EO/A)_m(A)„H]_x, R³ is typically H or an alkyl amine group having from 1 to 10 carbon atoms, R⁴ is typically or an alkyl amine group having 1 to 10 carbon atoms, a and b are each independently 1 to 100, c is from 1 to 50, EO is an ethylene oxide group, and PO is a propylene oxide group. Moreover, R² can be an EO and/or PO polymer or an EO/PO block/heteric copolymer. Relative to the formula [(EO/A)_m(A)_nH]_x, x is typically 1 to 6, m is typically 0 to 110, and n is typically 0 to 110. Relative to the formula [(A)_o(EO)_m(A)_nH]_x, x is typically 1 to 6, m is typically 0 to 110, n is typically 0 to 110, and o is typically 0 to 110. Moreover, relative to the formula [(A)₀(EO/A)_m(A)_nH]_x, x is typically 1 to 6, m is typically 0 to 110, n is typically 0 to 110, and o is typically 0 to 110. Furthermore, A is typically chosen from propylene oxide, butylene oxide, tetrahydrofuran, and combinations thereof. In various non-limiting embodiments, it is contemplated that any and all values or ranges of values between and including each of the end points of the aforementioned ranges, independently, may be utilized. Non-limiting examples of suitable softness additives include alkylamine and Polyether functional siloxanes, such as, Magnasoft^® CJS, which is commercially available from Momentive. Softness can be qualitatively assessed via touch.

[0052] Alternatively, the additives may be antioxidants and/or light stabilizers. The antioxidant may be or include a first and/or a second antioxidant. However, it is to be appreciated that the fiber may include any number of antioxidants. The light stabilizer may be or include hindered amine light stabilizers (HALS). The additives typically minimize degradation of the plastic from heat and shear during formation of the fiber. In addition, the additives typically provide the fiber with long term heat stability.

[0053] The first antioxidant may be present in the plurality of the fibers in an amount of from 0.001 to 1 part(s) by weight, of from 0.01 to 0.2 parts by weight, or of from 0.05 to 0.15 parts by weight, each based on 100 parts by weight of each of the plurality of fibers. A non- limiting example of a suitable primary antioxidant is commercially available from BASF Corporation of Florham Park, NJ, under the trade name of Irganox^®, such as Irganox^® 3114 (AO) and Irganox^® B 1411 (AO). In additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.

[0054] The second antioxidant may be present in the plurality of fibers in an amount of from 0.001 to 1 part(s) by weight, of from 0.01 to 0.2 parts by weight, or of from 0.05 to 0.15 parts by weight, each based on 100 parts by weight of each of the plurality of fibers. A non- limiting example of a suitable secondary antioxidant is commercially available from BASF Corporation of Florham Park, NJ, under the trade name of Irgafos^®, such as Irgafos^® 168 (AO). In additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.

Method Steps:

[0055] Referring back to the method, the method includes the step of combining the polyolefin and the surface energy modifier to disperse the surface energy modifier throughout the matrix structure to form a mixture. As described above, the surface energy modifier may be dispersed homogeneously or heterogeneously throughout the matrix structure. For example, the polyolefin and the surface energy modifier may be combined by any method known in the art and may be blended dry and then compounded by extrusion to form extrudates. These extrudates may then be extruded, spun, and then drawn to form the plurality of fibers.

[0056] In certain embodiments, the polyolefin and the surface energy modifier are combined to form a mixture prior to forming the plurality of fibers. The mixture may be described as a masterbatch. The polyolefin and the surface energy modifier may be combined by any method known in the art to form the mixture. The polyolefin and the surface energy modifier may be combined in a mixing vessel and/or a blender, such as a Henschell blender or Mixaco mixer. In various embodiments, the polyolefin may be present in the masterbatch in an amount of from 40 to 99, from 40 to 95, from 45 to 90, from 50 to 85, from 55 to 80, from 60 to 75, from 65 to 70, or from 70 to 75, weight percent based on a total weight of the masterbatch. In other embodiments, the surface energy modifier may be present in the masterbatch in an amount of from 1 to 60, from 5 to 60, from 5 to 55, from 10 to 50, from 15 to 45, from 20 to 40, from 25 to 35, from 25 to 30, or from 30 to 35, weight percent based on a total weight of the masterbatch. In various embodiments, the masterbatch includes a combination of 40 wt % of the (5) alkyl polyglycoside, 30 wt % of the (6) modified fatty alcohol polyglycolether, and 30 wt % of the (1) first alkoxylate, each independently ± 1-15 wt % or any values or ranges of values therebetween, respectively. In various non-limiting embodiments, all values and ranges of values between the aforementioned ranges are hereby expressly contemplated.

[0057] Subsequently, the method includes the step of forming the plurality of fibers and the non-woven fabric from the mixture (e.g. from the combination of the polyolefin and the surface energy modifier that is dispersed throughout the matrix structure). The plurality of fibers may be formed by any method in the art. For example, the plurality of fibers may be extruded and/or spun, e.g. via wet spinning, dry spinning, melt spinning, extrusion spinning, direct spinning, gel spinning, and/or electro spinning.

[0058] In certain embodiments, the step of combining the polyolefin and the surface energy modifier includes extruding the polyolefin and the surface energy modifier through a first extruder at a temperature of from 185° C to 215° C to form at least one strand. The step of extruding the polyolefin and the surface energy modifier to form at least one strand may alternatively be described as compounding. The polyolefin and the surface energy modifier may be extruded by any extrusion process known in the art, such as direct extrusion, indirect extrusion and/or hydrostatic extrusion. It is believed that extruding the polyolefin and the surface energy modifier to form at least one strand results in increased dispersion of the surface energy modifier in the plurality of fibers. In additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.

[0059] The first extruder may be any extruder known in the art to form the at least one strand. The first extruder may be further defined as a single screw extruder, twin screw, or multiscrew extruder. In various embodiments, the first extruder is further defined as a single screw extruder. In other embodiments, the first extruder is further defined as a twin screw extruder. The first extruder may be further defined as a (fully) intermeshing extruder. The first extruder may be further defined as a co-rotating extruder. The first extruder may have a length to diameter ratio (L/D) of from 35 to 1 to 45 to 1 , alternatively, 36 to 1 to 44 to 1 , 37 to 1 to 43 to 1, 38 to 1 to 42 to 1 , or 39 to 1 to 41 to 1. The first extruder may include a screw rotating at a speed of 140 to 160 revolutions per minute (RPM), alternatively, 145 to 155 RPM, 146 to 154 RPM, 147 to 153 RPM, 148 to 152 RPM, 149 to 151 RPM. The screw of the first extruder may be primarily conveying the mixture of the polyolefin and the surface energy modifier. The first extruder may be a Leistritz 27 mm co-rotating twin screw extruder. In additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.

[0060] In various embodiments, the first extruder includes multiple heating zones, e.g. nine heating zones, with each heating zone at a temperature of from 185° C to 215° C. However, it is to be appreciated that the first extruder may operate at any temperature known in the art. More specifically, the polyolefin and the surface energy modifier may be extruded as a hot extrusion and/or a warm extrusion which may depend on the melt temperature of the polyolefin and the surface energy modifier. It is also to be appreciated that the first extruder may have any number of heating zones such as 1, 2, 3, 4, 5, 6, 7, 8, 10, 11, 12, 13, 14, 15, etc. with each heating zone independently at a temperature of from 185° C to 215° C. In additional non-limiting embodiments, all values and ranges of values, both whole and fractional, within one or more of the aforementioned ranges, are hereby expressly contemplated.

[0061] In other embodiments, the step of combining the polyolefin and the surface energy modifier includes quenching the at least one strand with water and subsequently cutting the at least one strand quenched with water to form pellets. The at least one strand may be quenched in a water bath, by spray quenching, and/or by water wall quenching. In other embodiments, the at least one strand is quenched by air quenching to form pellets. Cutting the at least one strand quenched with water (or by air quenching) may be performed by any cutting method known in the art such as with a ConAir pelletizer. The pellets may have any dimensions and/or size distribution known in the art. In various embodiments, the pellets have a diameter of from 1/16 to 1/4 inch and a length of from 1/16 to 1/4 inch.

[0062] In various embodiments, the step of combining the polyolefin and the surface energy modifier includes extruding the pellets through a second extruder to form the plurality of fibers. The second extruder may be any extruder known in the art to form the plurality of fibers. The pellets may be extruded by extrusion spinning. The plurality of fibers may be cut such that each of the plurality of fibers has a length of 1/4 to 3 inches. However, it is to be appreciated that the plurality of fibers may be cut to a length of any size known in the art.

[0063] After formation of the plurality of fibers, the non-woven fabric may be manufactured by binding the plurality of fibers together in the form of a sheet or web. The plurality of fibers may be bound together mechanically (e.g. by interlocking with serrated needles such that inter-fiber friction results in a stronger fabric), with an adhesive, or thermally (e.g. by applying binder (in the form of powder, paste, or polymer melt) and melting the binder onto the web by increasing temperature).

[0064] In one embodiment, the non-woven fabric is further defined as a staple non-woven fabric. The staple non-woven fabric may, for example, be constructed using a number of steps. In one embodiment, the plurality of fibers is spun, cut to length, and put into bales. The plurality of fibers may then be blended, opened in a one or multistep process, dispersed (e.g. using a conveyor) and spread in a uniform or non-uniform web by a wetlaid, airlaid, or carding/crosslapping process. Wetlaid processes typically utilize 1/4 to ¾ inch long fibers, but are not limited in this manner. Airlaid processing typically utilizes 0.5 to 4.0 inch long fibers. Carding operations typically utilize 1.5 inch long fibers. Staple non- woven fabrics are typically bonded either thermally or by using resin. Bonding can be throughout the web by resin saturation or overall thermal bonding or in a distinct pattern via resin printing or thermal spot bonding.

[0065] Melt blown non-woven fabrics may be produced by extruding melted fibers through a spinneret or die with 1162 to 2222 holes per 0.5 meter to form the plurality of fibers which are stretched and cooled by passing hot air over the plurality of fibers as they fall from the die. The resultant web may be collected into rolls and subsequently converted to finished products. In various embodiments, melt blown fibers may be added to spun bond fibers to form spun-melt or spun-melt- spun webs.

[0066] In still another embodiment, the non-woven fabric is further described as a spunlaid non-woven fabric. Spunlaid non-woven fabrics can be formed using a continuous process. For example, the plurality of fibers may be spun and dispersed into a web using deflectors or with air streams. In other embodiments, the non-woven fabric may be described as a wet laid mat, e.g. wherein the plurality of fibers has a denier of 1.0 to 30. [0067] The non-woven fabric typically includes the plurality of fibers bonded to each other. For example, one or more of the plurality of fibers may be bonded via thermal bonding, e.g. using a heat sealer, an oven, or via calendaring using heated rollers. In other embodiments, one or more of the plurality of fibers may be bonded via hydro-entanglement, e.g. by mechanical intertwining the one or more fibers using water jets. In still another embodiment, one or more of the plurality of fibers may be bonded using ultrasonic pattern bonding, needle punching/needle felting (i.e., mechanical intertwining of one or more fibers by needles), or via chemical bonding. The chemical bonding may be further described as a wetlaid process and may include use of binders to chemically bond one or more fibers together. Alternatively, one or more of the plurality of fibers may be bonded using meltblowing techniques, e.g. bonding fibers as air attenuated fibers intertangle with themselves during simultaneous fiber and web formation.

EXAMPLES

[0068] A series of mixtures of the polyolefin and the surface energy modifier are formed. More specifically, the surface energy modifier is compounded into a polypropylene resin to disperse the surface energy modifier in the matrix structure of the polypropylene in a masterbatch. Subsequently, samples of non-woven fabrics (i.e., a plurality of fibers) are formed using the masterbatch and evaluated to determine a variety of physical properties.

Hydrophilization of Polypropylene:

[0069] Hydrophilization of polypropylene is accomplished by blending and compounding a polypropylene resin with a surface energy modifier in varying amounts. More specifically, the blending and compounding are accomplished using the conditions and surface energy modifiers described below. Conditions For Compounding/Formation of Plaques:

[0070] Polypropylene and a surface energy modifier are combined to form mixtures in a Henschell or Mixaco mixer. More specifically, the polypropylene is in solid form as a powder or pellet and formed from a 500 melt flow index polypropylene homopolymer. The mixture is blended thoroughly into masterbatch such that the surfactant and the additives are uniformly dispersed with the polypropylene. The mixture is compounded in a Leistritz 27 mm co- rotating twin screw extruder (first extruder) to form at least one strand. The first extruder is a co-rotating and fully intermeshing extruder. The screw of the first extruder is primarily conveying and rotating at a speed of 150 RPM. The first extruder has a L/D of 40 to 1. The first extruder is equipped with a K-tron screw type feeder. The first extruder has nine heating zones with each zone having a temperature profile as shown below.

Zone #2: 190 °C; Zone #3: 195 °C; Zone #4: 200 °C; Zone #5: 200 °C; Zone #6: 200 °C; Zone

7: 200 °C; Zone #8: 200 °C; Zone #9: 200 °C; Melt Zone: 210 °C The mixture is heated in Zone #2 and Zone #4 and the die is heated in Zone #9. The at least one strand is quenched in a water bath, and subsequently cut with a ConAir pelletizer to form pellets such that the masterbatch pellets have a diameter of approximately 1/8 inch and a length of approximately 1/8 inch. The masterbatch pellets are extruded in a second extruder to form the plurality of fibers (i.e., the non-woven fabric). The masterbatch is subsequently diluted with 35 melt flow index polypropylene homopolymer to the desired surface modifier concentration.

[0071] These pluralities of fibers are molded into plaques using a compression molder. The plaques are evaluated to determine strike through time and water contact angle.

Control/Comparative Examples:

[0072] Control/comparative examples of polypropylene are also formed. The polypropylene is subjected to the same conditions described above except that no surface energy modifier is used or a surface energy modifier that is not representative of this disclosure is used. These pluralities of fibers are molded into plaques using the same conditions as described above. The plaques are also evaluated to determine strike through time and water contact angle. Determination of Strike-Through Time:

[0073] Pluralities of fibers are formed as described above. More specifically, samples of the plurality of fibers are wet with 0.5 wt % solutions of the Surface Energy Modifiers set forth below. These pluralities of fibers are evaluated using ED ANA 150.5 - 02 to determine Strike-Through Time with 0.9% Sodium Chloride solution. The results are set forth in Table 1 below and graphically represented in Figure 1.

[0074] Each example is evaluated three times and the values below are reported as an average thereof. Examples 1-41 are representative of various embodiments of this disclosure. Comparative Examples 1-13 do not include the surface energy modifier of this disclosure. In Table 1 , the ratios are by weight.

TABLE 1

Surface Energy Modifier - Strike

Surface Energy Modifier -

Example Generic Chemical Through

Commercial Name

Description Time (sec)

Example

Lutensol TDA 3 Alcohol Ethoxylate 2.2 1

Example

Lutensol TDA 6 Alcohol Ethoxylate 2.1 2

Example

Lutensol TDA 9 Alcohol Ethoxylate 2.4 3

Example

Inoterra EHC Alcohol Ethoxylate 1.9 4

Example

AT 25 : Dehypon WET (1 :1) Alcohol Ethoxylate blend 2.4 5

Example

Novec FC4430 Fluorosurfactant Fluorosurfactant 2.2 6

Guerbet Alcohol Ethoxylate

Example

Lutensol XL 50 2.3 7

Example

Lutensol XP 30 Guerbet Alcohol Ethoxylate 2.5 8

Example

Lutensol XP 50 Guerbet Alcohol Ethoxylate 2.1 9 Example

Lutensol XP 90 Guerbet Alcohol Ethoxylate 2.1 10

Example

Lutensol AO 3 Alcohol Ethoxylate 2.4 11

Example

Lutensol A 65 N Alcohol Ethoxylate 2.6 12

Example

Dehypon WET Alcohol Ethoxylate 1.7 13

Example

Dehypon Advanced Alcohol Ethoxylate 1.9 14

Example

Dehypon LS 54 Alcohol Ethoxylate 2.4 15

Example

Dehypon LT 104 Alcohol Ethoxylate 2.2 16

Example

Dehypon 2574 Alcohol Ethoxylate 2.2 17

Example

Plurafac LF 120 Alcohol Ethoxylate 2.7 18

Example

Plurafac LF 900 Alcohol Ethoxylate 2.4 19

Example

Plurafac SLF 180 Alcohol Ethoxylate 2.6 20

Example

Plurafac RA 300 Alcohol Ethoxylate 2.4 21

Example

Plurafac SL 62 Alcohol Ethoxylate 2.4 22

Example

Pluronic L 61 EO/PO Block Copolymer 2.3 23

Example

Pluronic L 92 EO/PO Block Copolymer 2.4 24

Example

Pluronic L 101 EO/PO Block Copolymer 2.1 25

Example

Pluronic L 121 EO/PO Block Copolymer 2.2 26

Example

Pluronic P 104 EO/PO Block Copolymer 2.5 27

Example

Glucopon 420 UP Alkylpolyglucoside 2.0 28

Example Dehypon LT 104 : Inoterra EHC Alcohol Ethoxylate / Alcohol

2.4 29 (3:7) Alkoxylate

Example Pluronic P 104 : Inoterra EHC Block Copolymer / Alcohol

2.4 30 (5:5) Alkoxylate

Example Pluronic P 104 : Dehypon WET Block Copolymer / Alcohol

2.3 31 (5:5) Ethoxylate

Example

Glucopon 600 UP Alkylpolyglucoside 1.7 32

Example

Glucopon 50 G Alkylpolyglucoside 1.5 33

Example Glucopon 425 N Alkylpolyglucoside 1.9 34

Example Glucopon 50 G : Dehypon WET Alkylpolyglucoside / Alcohol

1.7 35 (1 :1) Alkoxylate

Example Glucopon 420 UP : Dehypon WET Alkylpolyglucoside / Alcohol

1.9 36 (1 :1) Alkoxylate

Example Glucopon 600 UP : Dehypon WET Alkylpolyglucoside / Alcohol

1.7 37 (1 :1) Alkoxylate

Example Glucopon 425 N : Dehypon WET Alkylpolyglucoside / Alcohol

1.8 38 (1 :1) Alkoxylate

Example Glucopon 215 UP (Intermediate

Alkylpolyglucoside 1.7 39 product from plant - waterfree)

Example Glucopon 225 DK (Intermediate

Alkylpolyglucoside

product from plant - waterfree) 1.8 40

Example Glucopon 600 UP (Intermediate

Alkylpolyglucoside 1.7 41 product from plant - waterfree)

TABLE 1 (cont .

* The surface energy modifier of these comparative examples did not wet the plurality of fibers.

Determination of Contact Angle - Compounded:

[0075] Additional molded plaques are also formed as described above. These molded plaques are evaluated using ASTM D7490-13 to determine Water Contact Angle. The results are set forth in Figures 2 A and 2B. More specifically, each of the Surface Energy Modifiers set forth below was added to polypropylene to make the molded plaques via a 20 wt % masterbatch. Said different, independent masterbatches of 20 wt % of each of the Surface Energy Modifiers set forth below were used. Relative to the Irgasurf, a masterbatch of approximately 60 wt % was used. Moreover, water was used to determine the contact angle. The Examples and Comparative Examples are formed as set forth in Table 2 below. In Table 2, the ratios are by weight.

TABLE 2

Determination of Contact An2le - APG:

[0076] Additional molded plaques are also formed as described above. These molded plaques are evaluated using ASTM D7490-13 to determine Water Contact Angle. The results are set forth in Figure 3. These molded plaques are formed from pure polypropylene with no Surface Energy Modifier added. After formation, 0.05 wt % solutions of the Surface Energy Modifiers set forth below are formed. Droplets of these solutions are then used to determine contact angle on the polypropylene plaques.

TABLE 3

[0077] The data set forth above and in the Figures demonstrate that the surface energy of a polvolefin can be increased. It is believed that the crystalline portions of the surface energy modifiers are compatible with the polyolefin thereby allowing the modifiers to be anchored into a polyolefin matrix. The data also show that when the surface energy is increased, the surface is made more hydrophilic and the polyolefin becomes easier to wet with polar solvents such as water. This data also show that surface energy modifiers are durable when blended. This can be compared to surface coated polyolefins that do not have a durable surface.

[0078] In addition, through use of the blending and compounding techniques of this disclosure, the surface energy modifiers can give hydrophilic properties targeted to specific applications, such as, cleaning wipes, filters, adult incontinence, feminine napkins, and diapers to allow fast strike through time as in diaper applications or increase absorption as in cleaning wipes or medical garments.

[0079] Blending and compounding of polyolefins with the surface energy modifiers, followed by co-spinning into a plurality of fibers and formation into non-woven fabric is economical, durable and permanent. The instant method is effective in improving the hydrophilicity of the non-woven fabric and allows for customization of other properties, such as antibacterial and antifungal control. In addition, the instant method provides permanent and sustainable hydrophilicity and hydrophobicity properties to the non-woven fabrics.

[0080] One or more of the values described above may vary by ± 5%, ± 10%, ± 15%, ± 20%, ± 25%, etc. so long as the variance remains within the scope of the disclosure. Unexpected results may be obtained from each member of a Markush group independent from all other members. Each member may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims. The subject matter of all combinations of independent and dependent claims, both singly and multiply dependent, is herein expressly contemplated. The disclosure is illustrative including words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described herein.

Claims

CLAIMS What is claimed is:

1. A method of increasing the surface energy of a non- woven fabric comprising a plurality of fibers, said method comprising the steps of:

A. providing a polyolefin comprising a matrix structure and having the formula: (CH₂CH₂)_n or (CH₂CHR)_n, wherein R is -CH₃ or CH₂CH₃ and n is 2 or greater;

B. providing a surface energy modifier chosen from;

(1) a first alkoxylate having one or more oxyethylene moieties having the formula: R"0(CH₂CH₂0)_xR³, wherein R" is a C₈ to Ci₈ linear or branched alkyl group, R³ is H, CH₃, CH₂CH₃, CH₂CH₂CH₃ or CH₂CH₂CH₂CH₃, and x is a number from 4 to 30,

(2) a second alkoxylate different from said first alkoxylate and having the formula:

R⁴(OCH₂CH₂)_a(OCH₂CHR⁵)_bOR⁶, wherein R⁴ is a C₈ to C₁₈ linear or branched alkyl group, R⁵ is -CH₃ or -CH₂CH₃, R⁶ is -OH, -OCH₃, -OCH₂CH_3, -OCH₂CH₂CH₃, or -OCH₂CH₂CH₂CH_3i and wherein each of a, and b is independently a number from 0 to 14 with the proviso that at least one of a and b is 1 to 14,

(3) a third alkoxylate different from said first and second alkoxylates and having the formula:

R⁷(CH₂CHR⁸0)_d(CH₂CH₂0)c(CH₂CHR⁸0)_eR⁹, wherein R⁷ is a linear or branched C₈ to Ci₈ alkyl group, R⁸ is -CH₃ or -CH₂CH₃, R⁹ is -OH, -OCH₃, - OCH₂CH_3, -OCH₂CH₂CH₃, or -OCH₂CH₂CH₂CH_3, wherein c is a number from 0 to 14, and each of d and e is independently a number from 0 to 20,

(4) a fluorocarbon having the formula CF₃(CF₂)_fS0₃H, wherein f is a number from 4 to 12, (5) an alkyl polyglycoside having the formula R OG_y wherein R is a C₆ to Ci₈ linear or branched alkyl alcohol group, G is a glycoside, and y is an average degree of polymerization, wherein y is a number greater than 0 and up to 3,

(6) a modified fatty alcohol polyglycolether having the formula: R¹¹(OCH₂CH₂)_zOR¹², wherein R¹¹ is C₈ to C₁₈ linear or branched alkyl group and R¹² is a C₈ to Ci₈ linear or branched alkyl group wherein at least one carbon atom is functionalized with -OH or -COOH, and z is a number from 4 to 30,

(7) a modified fatty alcohol polyglycolether having the formula: R¹³(OCH₂CH₂)_g(OCH₂CHR¹⁴)_hOR¹⁵, wherein R¹³ is a C₈ to Ci₈ linear or branched alkyl group, R¹⁴ is -CH₃ or -CH₂CH₃, and R¹⁵ is a C₈ to Ci₈ linear or branched alkyl group wherein at least one carbon atom is functionalized with OH or -COOH, and wherein each of g and h is independently a number from 0 to 14 with the proviso that at least one of g, and h is 1 to 14, and combinations of (l)-(7),

C. combining the polyolefin and the surface energy modifier to disperse the surface energy modifier throughout the matrix structure to form a mixture; and subsequently

D. forming the plurality of fibers and the non-woven fabric having increased surface energy from the mixture.

2. The method of claim 1 wherein n is from 1 ,000 to 1 ,000,000.

3. The method of claim 1 or 2 wherein R" is a C₈ to Ci₂ linear or branched alkyl group.

4. The method of any one of claims 1-3 wherein x is from 4 to 10.

5. The method of any one of claims 1-4 wherein R⁴ is a C₈ to Ci₂ linear or branched alkyl group.

6. The method of any one of claims 1-5 wherein R⁵ is -CH₃.

7. The method of any one of claims 1-6 wherein a is from 4 to 10.

8. The method of any one of claims 1-7 wherein b is from 0 to 6.

9. The method of any one of claims 1-8 wherein R⁷ is a Cs to C₁₂ linear or branched alkyl group.

10. The method of any one of claims 1-9 wherein R⁸ is -CH₃.

11. The method of any one of claims 1-10 wherein R⁹ is -OH.

12. The method of any one of claims 1-11 wherein c is from 4 to 10.

13. The method of any one of claims 1-12 wherein d is from 0 to 4.

14. The method of any one of claims 1-13 wherein e is from 0 to 4.

15. The method of any one of claims 1-14 wherein f is 8 to 10.

16. The method of any one of claims 1-15 wherein y is 1.2 to 1.7.

17. The method of any one of claims 1-16 wherein R¹⁰ is a Cs to C₁₆ linear or branched alkyl alcohol group.

18. The method of any one of claims 1-17 wherein R¹¹ is a Cs to C₁₄ linear or branched alkyl group.

19. The method of any one of claims 1-18 wherein R¹² is a Cs to C₁₄ linear or branched alkyl group wherein at least one carbon atom is functionalized with -OH.

20. The method of any one of claims 1-19 wherein z is 20 to 24

21. The method of any one of claims 1-20 wherein R¹³ is Cs to C₁₄ linear or branched alkyl group.

22. The method of any one of claims 1-21 wherein R¹⁴ is -CH₃.

23. The method of any one of claims 1-22 wherein R¹⁵ is a Cs to C₁₄ linear or branched alkyl group wherein at least one carbon atom is functionalized with -OH.

24. The method of any one of claims 1-23 wherein g and/or h is 2 to 10.

25. The method of any one of claims 1-24 wherein the non- woven fabric exhibits a water contact angle of less than 90 degrees when evaluated using ASTM D7490-13.

26. The method of any one of claims 1-25 wherein the surface energy modifier is present in an individual fiber in an amount of 0.1 to 5 parts by weight per 100 parts by weight of the individual fiber.

27. The method any one of claims 1-26 wherein the surface energy modifier is homogeneously dispersed in the matrix structure.

28. The method of any one of claims 1-27 wherein the surface energy modifier is further defined as a combination of (1) the first alkoxylate, (5) the alkyl polyglycoside, and (6) the modified fatty alcohol polyglycolether.

29. A non-woven fabric having increased hydrophilicity and comprising a plurality of fibers, wherein each of said plurality of fibers comprises:

A. a polyolefin comprising a matrix structure and having the formula:

(CH₂CH₂)_n or (CH₂CHR)_n, wherein R is -CH₃ or CH₂CH₃ and n is 2 or greater; and

B. a surface energy modifier chosen from

(1) a first alkoxylate having one or more oxyethylene moieties having the formula: R"0(CH₂CH₂0)_xR³, wherein R" is a Cs to Ci₈ linear or branched alkyl group, R³ is H, CH₃, CH₂CH₃, CH₂CH₂CH₃ or CH₂CH₂CH₂CH₃, and x is a number from 4 to 30,

(2) a second alkoxylate different from said first alkoxylate and having the formula:

R⁴(OCH₂CH₂)_a(OCH₂CHR⁵)_bR⁶, wherein R⁴ is a C₈ to Ci₈ linear or branched alkyl group, R⁵ is -CH₃ or -CH₂CH₃, R⁶ is -OH, -OCH₃, -OCH₂CH_3, -OCH₂CH₂CH₃, or -OCH₂CH₂CH₂CH_3i and wherein each of a, and b is independently a number from 0 to 14 with the proviso that at least one of a and b is 1 to 14,

(3) a third alkoxylate different from said first and second alkoxylates and having the formula: R⁷(CH2CHR⁸0)_d(CH2CH20)_c(CH₂CHR⁸0)eR⁹, wherein R⁷ is a linear or branched C₈ to Ci₈ alkyl group, R⁸ is -CH₃ or -CH₂CH₃, R⁹ is -OH, -OCH₃, - OCH₂CH_3, -OCH₂CH₂CH₃, or -OCH₂CH₂CH₂CH_3, wherein c is a number from 0 to 14, and each of d and e is independently a number from 0 to 20,

(4) a fluorocarbon having the formula CF₃(CF₂)fS0₃H, wherein f is a number from 4 to 12,

(5) an alkyl polyglycoside having the formula R¹⁰OG_y wherein R¹⁰ is a C₆ to Ci₈ linear or branched alkyl alcohol group, G is a glycoside, and y is an average degree of polymerization, wherein y is a number greater than 0 and up to 3,

(6) a modified fatty alcohol polyglycolether having the formula: Rⁿ(OCH₂CH₂)_zOR¹², wherein R¹¹ is C₈ to Ci₈ linear or branched alkyl group and R¹² is a C₈ to Ci₈ linear or branched alkyl group wherein at least one carbon atom is functionalized with -OH or -COOH, and z is a number from 4 to 30,

(7) a modified fatty alcohol polyglycolether having the formula: R¹³(OCH₂CH₂)_g(OCH₂CHR¹⁴)_hOR¹⁵, wherein R¹³ is a C₈ to C₁₈ linear or branched alkyl group, R¹⁴ is -CH₃ or -CH₂CH₃, and R¹⁵ is a C₈ to Ci₈ linear or branched alkyl group wherein at least one carbon atom is functionalized with OH or -COOH, and wherein each of g and h is independently a number from 0 to 14 with the proviso that at least one of g, and h is 1 to 14, and combinations of (l)-(7),

wherein said non-woven fabric exhibits a water contact angle of less than 90 degrees when evaluated using ASTM D7490-13.

30. The non-woven fabric of claim 29 wherein said surface energy modifier is (1) said first alkoxylate.

31. The non- woven fabric of claim 29 wherein said surface energy modifier is (2) said second alkoxylate.

32. The non-woven fabric of claim 29 wherein said surface energy modifier is (3) said third alkoxylate.

33. The non- woven fabric of claim 29 wherein said surface energy modifier is (4) said fluorocarbon.

34. The non-woven fabric of claim 29 wherein said surface energy modifier is (5) said alkyl polyglycoside.

35. The non- woven fabric of claim 29 wherein said surface energy modifier is (6) said modified fatty alcohol polyglycolether.

36. The non-woven fabric of claim 29 wherein said surface energy modifier is (7) said modified fatty alcohol polyglycolether.

37. The non- woven fabric of claim 29 wherein said surface energy modifier is further defined as a combination of (1) said first alkoxylate, (5) said alkyl polyglycoside, and (6) said modified fatty alcohol polyglycolether.

38. The non-woven fabric of any one of claims 29-37 wherein said surface energy modifier is present in an individual fiber in an amount of 0.1 to 5 parts by weight per 100 parts by weight of said individual fiber.

39. The non-woven fabric of any one of claims 29-37 wherein said surface energy modifier is homogeneously dispersed in said matrix structure.