WO2017048897A1 - Matériau de substrat de renfort tissé comprenant des additifs détectables fonctionnels et destiné à être utilisé avec un tissu non tissé et un matériau composite - Google Patents

Matériau de substrat de renfort tissé comprenant des additifs détectables fonctionnels et destiné à être utilisé avec un tissu non tissé et un matériau composite Download PDF

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Publication number
WO2017048897A1
WO2017048897A1 PCT/US2016/051836 US2016051836W WO2017048897A1 WO 2017048897 A1 WO2017048897 A1 WO 2017048897A1 US 2016051836 W US2016051836 W US 2016051836W WO 2017048897 A1 WO2017048897 A1 WO 2017048897A1
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WO
WIPO (PCT)
Prior art keywords
scrim
particulate
polymer
laminated article
fiber
Prior art date
Application number
PCT/US2016/051836
Other languages
English (en)
Inventor
Karen S. Mertins
Robert Harrison MARTIN
Original Assignee
Illinois Tool Works Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Illinois Tool Works Inc. filed Critical Illinois Tool Works Inc.
Priority to CA2996185A priority Critical patent/CA2996185C/fr
Priority to EP16781885.5A priority patent/EP3350362A1/fr
Publication of WO2017048897A1 publication Critical patent/WO2017048897A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D01F1/106—Radiation shielding agents, e.g. absorbing, reflecting agents
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L13/00—Implements for cleaning floors, carpets, furniture, walls, or wall coverings
    • A47L13/10—Scrubbing; Scouring; Cleaning; Polishing
    • A47L13/16—Cloths; Pads; Sponges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0223—Vinyl resin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0292—Polyurethane fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202—Conductive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/58—Cuttability
    • B32B2307/581—Resistant to cut
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2432/00—Cleaning articles, e.g. mops or wipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00—Personal care

Definitions

  • the present invention relates to the technical field of polymeric composite fibers, and in particular to a scrim material formed with polymeric fibers with high loadings of metal or other particulate that render articles formed from such fibers X-ray or magnetic detectable.
  • Common plastic packaging or sendee articles that are inadvertently brought into production exclusion zones include aerosol cans, grease cartridge tubes, grease tube caps, plastic fiber toweling, packing straps, pail lids, jar caps, personal protective clothing and brushes.
  • Metal detectors are commonly found on food processing lines to assure that metal shards that represent a laceration hazard do not end up in food products.
  • pharmaceutical and biomedical device production are also vulnerable to not only the hazards associated with metal debris ending up in product streams, but also the prospect that such metal can degrade active pharmaceutical ingredients or serve as a potential source of infection.
  • U.S. Patent No. 5,897,673 teaches fibers containing fine metallic particles that are cross-linked to the polymeric fiber. While various pure metals are contemplated in the literature, little attention has been paid to the unique problems associated with stainless steel particulate. As many foods and manufactured substances can only be exposed to stainless steel, the lack of stainless steel particle filled fibers precludes the usage of many useful articles from these controlled manufacturing sites. By way of example various wipes, scrub pads, hair covers, suits, aprons and shoe covers and other manufacturing aids or personal protective equipment if made from stainless steel containing fibers could allow better quality control of manufacturing with less stringent audit processes as any such articles lost in a production stream could be detected by X-ray or magnetic anomaly.
  • thermoplastic fiber filled scrim structure with detectable particulate or functional additives.
  • process and retain properties of conventional thermoplastic fibers to promote production of various articles from fibers that have the added benefit of being X-ray or magnetically detectable while operating in a manner similar to conventional articles.
  • a scrim or web material made from polymer containing functional additives, and other additives is provided, where the scrim may be used as a substrate for nonwoven fabric or other laminated engineered materials.
  • the base web material forming the scrim may have properties imparted by the various functional additives that are incorporated into the polymer prior to web formation, and may be manufactured by any of several means commercially known such as injection molding, extrusion, weaving extruded filaments, or thermally bonding laid scrim, or by methods currently unknown.
  • Properties imparted to the scrim materials may include electromagnetic spectral detectability, thereby making the scrim suitable for usage in a variety of fields including food production, medical, and pharmaceutical production environments.
  • a process for forming a multi-layered laminated scrim-containing material with functional additives is also provided.
  • FIGS. 1A-C illustrate the sequential formation of a multi-layered laminated scrim-containing fabric with functional additives in accordance with embodiments of the invention.
  • the present invention has utility as a scrim or web material made from polymer containing functional additives, and other additives, where the scrim may be used as a substrate for nonwoven fabric or other laminated engineered materials.
  • Embodiments of the base web material forming the scrim may have properties imparted by the various functional additives that are incorporated into the polymer prior to web formation, and may be manufactured by any of several means commercially known such as injection molding, extrusion, weaving extruded filaments, or thermally bonding laid scrim, or by methods currently unknown.
  • Properties imparted to the scrim materials may include electromagnetic spectral detectability, thereby making the scrim suitable for usage in a variety of fields including food production, medical, and pharmaceutical production environments.
  • Embodiments of the inventive detectable scrim may be used independently or fashioned into a laminated material by the addition of one or more layers of secondary materials.
  • a non-limiting illustrative example of an embodiment of a laminated composite material is a metal detectable scrim layered between a face and back layer of absorbent fibers.
  • a specific inventive example is a hydroentangled hybrid wipe composed of extruded metal detectable scrim bound to wet laid absorbent fiber layers resulting in a wiping cloth which is both absorbent and metal detectable.
  • the nonwoven engineered wipe is both absorbent and metal detectable making it employable for various wiping applications such as personal hygiene, equipment and parts cleaning in food processing critical environments.
  • the innovative detectable scrim by itself would not have the characteristics of a wipe.
  • a useful wipe may be fashioned.
  • the laminated material allows multiple functionalities in a single product.
  • the term "fiber” defines both fibers of finite length, such as conventional preselected length fiber, as well as substantially continuous structures, such as continuous filaments, unless otherwise indicated.
  • the fibers of the present invention are appreciated to be hollow or solid fibers, and further can have a substantially round or circular cross-section or cross-sections of different symmetry space groups with other cross-sections illustratively including oval; lobular; polygonal such as triangular, square, rectangular, trapezoidal, pentagonal, and hexagonal.
  • a fiber of the present invention in some embodiments has a sheath that varies in polymer or particulate, with the variation being as to composition or concentration, or both such properties.
  • multi-component fibers is defined to include preselected length fiber and continuous filaments with two or more discrete structured domains of deliberately different composition or component concentration and is intended to specifically include sheath/core and island configurations.
  • the term “yarn” defines multiple fibers wound together into a single continuous strand.
  • range is intended to encompass not only the end point values of the range but also intermediate values of the range as explicitly being included within the range and varying by the last significant figure of the range.
  • a recited range of from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4.
  • both the cross-sectional shape of the fiber and the configuration of the particulate and other components therein depends upon the equipment that is used in the preparation of the fiber, the process conditions, and the melt viscosities of the various components.
  • a wide variety of fiber configurations are readily produced according to the present invention to achieve loadings sufficient for magnetic or X-ray detection.
  • the polymeric component of the fiber is readily selected from any of the types of polymers known in the art that are capable of being formed into fibers, including polyolefins, polyvinyl, polyvinyl alcohol, polyesters, polyamides, co-polymers containing any of the aforementioned polymers as blocks of a copolymer, and combinations thereof.
  • polyolefins operative herein illustratively include polypropylene; polyethylene; polybutene; and polyisobutylene; polyamides such as NYLON 6 and NYLON 6,6; polyacrylates; polystyrenes; polyurethanes; acetal resins; polyethylene vinyl alcohol; polyesters such as polyethylene terephthalate (PET), polyethylene naphthalate, polytrimethylene terephthalate, poly(l ,4- cyclohexylene dimethvlene terephthalate) (PCT), polycarbonates; and aliphatic polyesters such as polylactic acid (PLA); polyphenylene sulfide; thermoplastic elastomers; polyacrylonitrile; cellulose and cellulose derivatives; polyaramids; acetals; fluoropolymers; copolymers and terpolymers thereof and mixtures or blends thereof, and without regard as whether a given polyolefin is syndiotacic,
  • aliphatic polyesters operative in the present invention include fiber forming polymers formed from a combination of an aliphatic glycol such as ethylene glycol, propylene glycol, butylene glycol, hexanediol, octanediol or decanediol) or an oligomer of ethylene glycol (e.g., diethylene glycol or triethylene glycol) with an aliphatic dicarboxylic acid such as succinic acid, adipic acid, hexanedicarboxylic acid or decaneolicarboxylic acid); or the self-condensation of hydroxy carboxylic acids other than poly(lactic acid), such as polyhydroxy butyrate, polyethylene adipate, polybutylene adipate, polyhexane adipate, and copolymers containing the same.
  • an aliphatic glycol such as ethylene glycol, propylene glycol, butylene glycol, hexanedi
  • Aromatic polyesters operative in the present invention include fiber forming polymers formed from polyesters of alkylene glycols having 2-10 carbon atoms and aromatic diacids; polyalkylene naphthalates, which are polyesters of 2,6-naphthalenedicarboxylic acid and alkylene glycols, as for example polyethylene naphthalate; or polyesters derived from 1 ,4-cyclohexanedimethanol and terephthalic acid, as for example polycyclohexane terephthalate.
  • Exemplary polyalkylene terephthalates include polyethylene terephthalate (also PET) and polybutylene terephthalate.
  • the particulate is stainless steel.
  • Other compositions of particulate to render an inventive fiber magnetic or X-ray signal detectable include iron, bronze, brass, steel, barium salts, cobalt, titanium, tin, copper, tungsten, platinum, silver, bismuth, zinc, lead, molybdenum, neodymium, samarium, alloys of any of the aforementioned, oxides of any of the aforementioned metals, nitrides of any of the aforementioned.
  • cobalt alloys such as cobalt-samarium, and neodymium alloys have exceptionally high magnetic moments that allow for magnetic detection at lower weight loading compared for ferrite.
  • the stainless steel is ferromagnetic and detectable by magnetic induction coil detectors.
  • Specific grades of stainless particulate operative herein include 300 series, 400 series and in particular 306 (L), 316 and 430 compositions
  • the present invention attempts to retain the processing and performance properties of the native polymer while imparting the ability to render the fiber and articles formed therefrom X-ray or magnetic anomaly detectable. This is achieved by inclusion of particulate having a shortest linear dimension, as measured from among the three orthogonal Cartesian coordinate axes X-Y-Z that is less than or equal to one half the fiber cross-sectional average dimension along the three orthogonal Cartesian coordinate axes X-Y-Z. For the purposes of calculation of the particulate dimension, the average particle dimension is used for polydisperse particulate.
  • a circular cross-section fiber with a diameter of 35 microns is loaded with spherical particulate having a diameter of less or equal to 17 microns.
  • the ratio of rod length to diameter is between 1.3-20: 1 and in still other embodiments between 1.5-8: 1
  • each of the polymeric components of an inventive fiber includes other substances known conventionally to modify a processing property or performance property.
  • additive substances illustratively include antioxidants, stabilizers, surfactants, waxes, flow promoters, solid solvents, dyes, pigments, plasticizers and combinations thereof.
  • a pigment can encompass a composition of a particulate material detailed above to impart detectability to the inventive fiber and in such instances the pigment is compositionally distinct from the particulate and present in a lower weight percentage than the particulate.
  • the loading of particulate to achieve X-ray or magnetic detection of articles formed from inventive fibers is dictated by factors including the X-ray cross- section or the magnetic susceptibility of a given particulate.
  • ferromagnetic materials are detectable at loadings of from > 2 total weight percent by magnetic induction detection.
  • typical loadings are from 2 to 4 total weight percent for magnetic induction detection.
  • typical loadings are from 5 to 25 total weight percent for magnetic induction detection. It is appreciated that the above typical loading can be exceeded, yet often at the expense of detrimentally influencing processibilitv or increasing material financial costs with only incremental improvements in detection.
  • the continuous filaments in certain inventive embodiments are mechanically crimped and cut into a desirable fiber length, thereby producing staple fiber.
  • the length of the staple fibers typically ranges from 25 to 50 millimeters, although the fibers can be cut to any desired length outside this range.
  • the multi-component fibers of the invention can be staple fibers, continuous filaments, or meltblown fibers.
  • staple fibers, multifilament, and spunbond fibers formed in accordance with the present invention can have a fineness of 0.1 to 500 microns per filament.
  • Meltblown filaments can have a fineness of 0.1 to 500 microns.
  • Monofilament fibers can have a fineness of 0.1 to 500 microns.
  • the multi-component fibers of the invention are useful in the production of a wide variety of products, including without limitation nonwoven structures, such as but not limited to scrims used in forming carded webs, wet laid webs, dry laid webs, spunbond webs, meltblown webs, and the like.
  • the nonwoven webs can be bonded to transform the webs into a coherent nonwoven fabric using bonding techniques known in the industry.
  • Exemplary bonding techniques for nonwoven webs include mechanical bonding, such as hydro-entanglement and needle punching, adhesive bonding, thermal bonding, and the like.
  • An example of thermal bonding is through air bonding, although other thermal bonding techniques, such as calendaring, microw r ave or other RF treatments are readily employed.
  • the inventive fibers are subjected to a coating, laminate, or otherwise cover the outer and/or inner surfaces of threads or layers of material contained within any final product without falling outside the scope of the invention.
  • This is a practice well known to those experienced in the art, and is commonly used to impart non-stick, low-friction, or additional chemical and heat resistance properties to the final product.
  • additional non-polymeric particles identical, similar, or fundamentally different to the particles already contained within the composite fibers of the invention are readily added to the fibers. Such additions can come, at the expense of lowering the overall metal content loading of the resultant article.
  • a fiber or core portion of a sheathed fiber has particulate protruding from the wall of the fiber and a concomitant relative depletion of particulate from the central region of a fiber.
  • the inclusion of a particulate protrusions and centrally depleted fiber region has been found to afford considerable benefits in increasing the loading amount of particulate to detectable levels and the energy needed to slide fibers past one another.
  • the fibers or other non-woven creations of the invention are coated, dusted, or otherwise induced to carry on the exterior of individual filaments or layers additional particulate identical, similar, or fundamentally different to the particulate already contained within the composite fibers of the invention.
  • Particulate is most easily adhered to the outside of the fibers using a process which passes the extruded filament or non-woven creation through an enclosed chamber, in which a fan system lifts and circulates the particulate throughout the air contained within the chamber such that a fraction of the particles that contact the filament will adhere to the surface.
  • the fibers of the invention are used to weave or knit a scrim.
  • an inventive scrim is laminated to a woven, knit, or non- woven fabric layer.
  • custom composite fibers of the invention are woven or otherwise used in the construction of fabric or fabric-like structures.
  • the fabric performs comparably to standard polymer containing fabrics with respect to most attributes, such as strength, durability, and hand, yet like the fibers exhibits properties which deviate significantly from those normally associated with the polymeric material by those experienced in the art, these unique properties beside detectability illustratively include high density, conductivity, electromagnetic shielding, cut-resistance, heat-resistance, and radiation shielding relative to the base polymer absent particulate loading.
  • Modem metal detection is based on creating a magnetic field with a transmitter coil and two receiving coils wired in reverse. The resulting field is interrupted when a conductive or magnetic contaminant passes through the field. The contaminant is detected by measuring the change in voltage abov e the change in voltage of non-contaminated product. If a contaminant is detected, that product is rejected. Contaminants are generally categorized as sphere equivalents in millimeters. The sensitivity and throughput are machine dependent.
  • X-ray inspection is based on density. The higher the density of the object being examined, the more energy is absorbed. X-ray detection measures how much energy is absorbed by a product or contaminant. X-ray detection can detect contaminants such as glass or bone that a metal detector will not detect. X-ray detection can perform other quality functions outside the scope of product contamination. The present invention focuses on contaminant detection. The contaminants are generally categorized as sphere equivalents. The sensitivity and throughput are machine dependent. In a production setting, the X-ray detector or the magnetic detector is associated with a production line that can be stopped when an inventive scrim is detected by way of detector signal in the production stream. As a result, the effects of the contamination event are mitigated. Alternatively, a rejected product is shunted from the production line in response to the positive detector signal of contaminant being present.
  • FIGS. 1A-C illustrate a process 10 for the formation of a multi-layered laminated scrim-containing structure 18 with functional additives in accordance with embodiments of the invention.
  • a scrim 12 is formed from functional polymer.
  • an upper layer 14 and a lower layer 16 are introduced and laminated to the scrim 12 (FIG. 1C) to form a multi- layered laminated scrim-containing structure 18.
  • the upper layer 14 and lower layer 16 may be made of the same or of different materials, and illustratively may include functional or nonfunctional fibers.
  • Spherical stainless steel particulate (430 series) having a Poisson size distribution and an average particle size of 12 microns is mixed into polypropylene (PP) to form pellets with a particulate loading of 12 percent.
  • the particles are melt-spun by running through a five screen of 40 mesh, 100 mesh, (34 micron), 60 mesh, and 31 mesh, and the melt is then drawn to a fiber. Some of the particulate is noted to be flattened or misshaped.
  • the resulting fibers where formed into a non-woven cloth and subjected to metal detector response on a Loma IQ + balanced coil metal detector alone or with various food products of a box of 8 packages of crackers, 1 pound of chicken on a tray and plastic w r rapped, or pizza in a cardboard box.
  • the results are provided in Table 2 for various sizes of cloths and fold configures. The values in millivolts for triplicate repeats with the threshold detections being noted.
  • Table 3 is a plot of the ferrous sphere size equivalents of the fibers, where the metal detector was set to a wet conductive product with a phase out point of -90°.
  • Example 1 The process of Example 1 is repeated with like conditions except that a 10% by weight sheath of PP devoid of stainless steel particulate
  • the melt pumps for the sheath and core polymers are set to produce a ratio of 90%: 10% of the cross sectional area of each fiber occupied by the polymeric core and particulate loaded core, respectively.
  • the properties are noted to be superior to that to Example 1 with the addition of a surface treatment to enhance water absorption to 600% of the fiber mass for a non-woven fabric.
  • the results are provided in Table 4 for various sizes of cloths and fold configures. The values in millivolts for triplicate repeats with the threshold detections being noted.
  • Table 5 is a plot of the ferrous sphere size equivalents of the fibers where the metal detector was set to a wet conductive product with a phase out point of

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne un matériau de renfort tissé ou de bande réalisé à partir d'un polymère contenant des additifs fonctionnels, et d'autres additifs, le renfort tissé pouvant être utilisé en tant que substrat pour un tissu non tissé ou d'autres matériaux modifiés stratifiés. La matériau de bande de base formant le renfort tissé peut présenter des propriétés conférées par les divers additifs fonctionnels qui sont incorporés dans le polymère, avant la formation de la bande, et peut être fabriqué par l'un quelconque des différents moyens connus dans le commerce, tels que le moulage par injection, l'extrusion, le tissage de filaments extrudés ou le renfort tissé thermolié, ou par des procédés actuellement inconnus. Les propriétés conférées aux matériaux de renfort tissé peuvent comprendre une détectabilité spectrale électromagnétique, ce qui rend le renfort tissé adapté à être utilisé dans divers domaines comprenant la production alimentaire, la médecine, et des environnements de production pharmaceutique.
PCT/US2016/051836 2015-09-15 2016-09-15 Matériau de substrat de renfort tissé comprenant des additifs détectables fonctionnels et destiné à être utilisé avec un tissu non tissé et un matériau composite WO2017048897A1 (fr)

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CA2996185A CA2996185C (fr) 2015-09-15 2016-09-15 Materiau de substrat de renfort tisse comprenant des additifs detectables fonctionnels et destine a etre utilise avec un tissu non tisse et un materiau composite
EP16781885.5A EP3350362A1 (fr) 2015-09-15 2016-09-15 Matériau de substrat de renfort tissé comprenant des additifs détectables fonctionnels et destiné à être utilisé avec un tissu non tissé et un matériau composite

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US201562218570P 2015-09-15 2015-09-15
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US10619268B2 (en) 2013-11-13 2020-04-14 Illinois Tool Works, Inc. Metal detectable fiber and articles formed from the same
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EP3350362A1 (fr) 2018-07-25
CA2996185A1 (fr) 2017-03-23

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