WO2018184927A1 - Tissu non tissé en fibre de cellulose ayant une teneur en métaux lourds extrêmement faible - Google Patents

Tissu non tissé en fibre de cellulose ayant une teneur en métaux lourds extrêmement faible Download PDF

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Publication number
WO2018184927A1
WO2018184927A1 PCT/EP2018/057866 EP2018057866W WO2018184927A1 WO 2018184927 A1 WO2018184927 A1 WO 2018184927A1 EP 2018057866 W EP2018057866 W EP 2018057866W WO 2018184927 A1 WO2018184927 A1 WO 2018184927A1
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WO
WIPO (PCT)
Prior art keywords
fabric
fibers
heavy metal
spinning solution
merging
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PCT/EP2018/057866
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English (en)
Inventor
Tom Carlyle
Mirko Einzmann
Gisela Goldhalm
Malcolm John Hayhurst
Katharina Mayer
Ibrahim Sagerer Foric
Original Assignee
Lenzing Aktiengesellschaft
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Application filed by Lenzing Aktiengesellschaft filed Critical Lenzing Aktiengesellschaft
Publication of WO2018184927A1 publication Critical patent/WO2018184927A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/013—Regenerated cellulose series

Definitions

  • the invention relates to a nonwoven cellulose fiber fabric, a method of
  • Lyocell technology relates to the direct dissolution of cellulose wood pulp or other cellulose-based feedstock in a polar solvent (for example n-methyl morpholine n- oxide, which may also be denoted as “amine oxide” or "AO”) to produce a viscous highly shear-thinning solution which can be transformed into a range of useful cellulose-based materials.
  • a polar solvent for example n-methyl morpholine n- oxide, which may also be denoted as "amine oxide” or "AO”
  • AO n-methyl morpholine n- oxide
  • the technology is used to produce a family of cellulose staple fibers (commercially available from Lenzing AG, Lenzing, Austria under the trademark TENCEL®) which are widely used in the textile industry.
  • Other cellulose products from lyocell technology have also been used.
  • Cellulose staple fibers have long been used as a component for conversion to nonwoven webs.
  • adaption of lyocell technology to produce nonwoven webs directly would access properties and performance not possible for current cellulose web products.
  • a nonwoven cellulose fiber fabric In order to achieve the object defined above, a nonwoven cellulose fiber fabric, a method of manufacturing a nonwoven cellulose fiber fabric, a device for manufacturing a nonwoven cellulose fiber fabric, a product or composite, and methods of use according to the independent claims are provided.
  • a (in particular solution-blown) nonwoven cellulose fiber fabric is provided (which is in particular directly (in particular in an in situ process or in a continuous process executable in a continuously operating production line) manufactured from lyocell spinning solution), and wherein a heavy metal content of the fibers (in particular of the fiber fabric) is not more than 10 ppm (in particular 10 mass ppm, i.e. 10 mg/kg) for each individual chemical heavy metal element.
  • a method of manufacturing (in particular solution-blown) nonwoven cellulose fiber fabric directly from lyocell spinning solution comprises extruding the lyocell spinning solution through a jet with orifices supported by a gas flow into a coagulation fluid atmosphere (in particular an atmosphere of dispersed
  • coagulation fluid to thereby form substantially endless fibers, collecting the fibers on a fiber support unit to thereby form the fabric, and selecting operating fluids (for instance the lyocell spinning solution, the coagulation fluid, and/or the gas flow) used during manufacturing the fabric so that, and selecting materials of a manufacturing device which are in contact with at least one of the lyocell spinning solution and the fibers during manufacturing the fabric so that a heavy metal content of the fibers (in particular of the fiber fabric) is not more than 10 ppm (in particular 10 mass ppm, i.e. 10 mg/kg) for each individual chemical heavy metal element.
  • 10 ppm in particular 10 mass ppm, i.e. 10 mg/kg
  • a device for manufacturing (in particular solution-blown) nonwoven cellulose fiber fabric directly from lyocell spinning solution comprising a jet with orifices configured for extruding the lyocell spinning solution supported by a gas flow, a coagulation unit configured for providing a coagulation fluid atmosphere for the extruded lyocell spinning solution to thereby form substantially endless fibers, a fiber support unit configured for collecting the fibers to thereby form the fabric, wherein materials of the device which are in contact with at least one of the lyocell spinning solution and the fibers during manufacturing the fabric are selected so that a heavy metal content of the fibers is not more than 10 ppm for each individual chemical heavy metal element. Fibers (in particular the fiber fabric) produced in the described way do/does hence preferably not comprise more than 10 ppm (in particular 10 mass ppm, i.e. 10 mg/kg) for each individual chemical heavy metal element.
  • a product or composite which comprises a fabric having the above mentioned properties.
  • a nonwoven cellulose fiber fabric having the above-mentioned properties is used for reinforcing at least one of the group consisting of an acoustic damping and a thermal isolation.
  • a nonwoven cellulose fiber fabric having the above-mentioned properties is used for at least one of the group consisting of a wipe, a dryer sheet, a filter, a hygiene product, a medical application product, a geotextile, agrotextile, clothing, a product for building technology, an automotive product, a furnishing, an industrial product, a product related to beauty, leisure, sports or travel, and a product related to school or office.
  • nonwoven cellulose fiber fabric (which may also be denoted as nonwoven cellulose filament fabric) may particularly denote a fabric or web composed of a plurality of substantially endless fibers.
  • the term “substantially endless fibers” has in particular the meaning of filament fibers having a significantly longer length than conventional staple fibers.
  • the term “substantially endless fibers” may in particular have the meaning of a web formed of filament fibers having a significantly smaller amount of fiber ends per volume than conventional staple fibers.
  • endless fibers of a fabric according to an exemplary embodiment of the invention may have an amount of fiber ends per volume of less than 10,000 ends/cm 3 , in particular less than 5,000 ends/cm 3 .
  • substantially endless fibers of the nonwoven cellulose fiber fabric may have a length of at least 200 mm, in particular at least 1000 mm.
  • a person skilled in the art will be aware of the fact that even endless cellulose fibers may have interruptions, which may be formed by processes during and/or after fiber formation.
  • a nonwoven cellulose fiber fabric made of substantially endless cellulose fibers has a significantly lower number of fibers per mass compared to nonwoven fabric made from staple fibers of the same denier.
  • a nonwoven cellulose fiber fabric may be manufactured by spinning a plurality of fibers and by attenuating and stretching the latter towards a preferably moving fiber support unit. Thereby, a three-dimensional network or web of cellulose fibers is formed, constituting the nonwoven cellulose fiber fabric.
  • the fabric may be made of cellulose as main or only constituent.
  • lyocell spinning solution may particularly denote a solvent (for example a polar solution of a material such as N-methyl-morpholine, NMMO, "amine oxide” or "AO") in which cellulose (for instance wood pulp or other cellulose-based feedstock) is dissolved.
  • the lyocell spinning solution is a solution rather than a melt.
  • Cellulose filaments may be generated from the lyocell spinning solution by reducing the concentration of the solvent, for instance by contacting said filaments with water. The process of initial generation of cellulose fibers from a lyocell spinning solution can be described as coagulation.
  • gas flow may particularly denote a flow of gas such as air substantially parallel to the moving direction of the cellulose fiber or its preform (i.e. lyocell spinning solution) while and/or after the lyocell spinning solution leaves or has left the spinneret.
  • coagulation fluid may particularly denote a non-solvent fluid (i.e. a gas and/or a liquid, optionally including solid particles) which has the capability of diluting the lyocell spinning solution and exchanging with the solvent to such an extent that the cellulose fibers are formed from the lyocell filaments.
  • a coagulation fluid may be water mist.
  • process parameters may particularly denote all physical parameters and/or chemical parameters and/or device parameters of substances and/or device components used for manufacturing nonwoven cellulose fiber fabric which may have an impact on the properties of the fibers and/or the fabric, in particular on fiber diameter and/or fiber diameter distribution.
  • process parameters may be adjustable automatically by a control unit and/or manually by a user to thereby tune or adjust the properties of the fibers of the nonwoven cellulose fiber fabric.
  • Physical parameters which may have an impact on the properties of the fibers may be temperature, pressure and/or density of the various media involved in the process (such as the lyocell spinning solution, the coagulation fluid, the gas flow, etc.).
  • Chemical parameters may be concentration, amount, pH value of involved media (such as the lyocell spinning solution, the coagulation fluid, etc.) .
  • Device parameters may be size of and/or distances between orifices, distance between orifices and fiber support unit, speed of transportation of fiber support unit, the provision of one or more optional in situ post processing units, the gas flow, etc.
  • Fibers may particularly denote elongated pieces of a material comprising cellulose, for instance roughly round or non-regularly formed in cross-section, optionally twisted with other fibers.
  • Fibers may have an aspect ratio which is larger than 10, particularly larger than 100, more particularly larger than 1000. The aspect ratio is the ratio between the length of the fiber and a diameter of the fiber.
  • Fibers may form networks by being interconnected by merging (so that an integral multi-fiber structure is formed) or by friction (so that the fibers remain separate but are weakly mechanically coupled by a friction force exerted when mutually moving the fibers being in physical contact with one another).
  • Fibers may have a substantially cylindrical form which may however be straight, bent, kinked, or curved. Fibers may consist of a single homogenous material (i.e. cellulose). However, the fibers may also comprise one or more additives. Liquid materials such as water or oil may be accumulated between the fibers.
  • a “jet with orifices” (which may for instance be denoted as an “arrangement of orifices”) may be any structure comprising an arrangement of orifices which are linearly arranged.
  • heavy metals may particularly denote metallic chemical elements having a density of more than 5 g/cm 3 and/or an atomic number of at least 24.
  • heavy metals may include the elements of the following list: Cr, Mn, Fe, Co, Ni, Cu, Zn, Zr, Mo, Cd, Sn, W, Pb, Bi.
  • ppm values mentioned in this application may all relate to mass ppm (rather than to volume ppm), i.e. may denote the ratio mg heavy metal / kg fibers.
  • chemical extraction can be carried out in accordance with EN 15587-2 (in the latest version as in force at the priority date of the present patent application).
  • the measurement of the heavy metal content can be carried out in accordance with EN 17294-2 (in the latest version as in force at the priority date of the present patent application), in particular by ICP-MS (Inductively Coupled Plasma Mass Spectrometry).
  • a nonwoven cellulose fiber fabric which has a very small content with heavy metals. It has turned out that a method of manufacturing such a fabric using a lyocell spinning solution composed of a dissolved cellulose source (such as wood pulp), a non-polar solvent (such as N-methyl-morpholine, NMMO) and water is capable of providing a nonwoven cellulose fiber fabric with less than 10 mass ppm (i.e. 10 mg heavy metal content/kg fibers) heavy metal content per chemical element (i.e.
  • the advantageous heavy metal depletion of the manufactured nonwoven cellulose fiber fabric can be obtained by omitting heavy metal content in the operating fluids (in particular lyocell spinning solution, coagulation fluid, optional wash liquor, gas flow) involved in the process and in the device components getting into physical contact with the operating fluids and the manufactured fibers.
  • the operating fluids in particular lyocell spinning solution, coagulation fluid, optional wash liquor, gas flow
  • a highly biocompatible fabric can be obtained which has a high degree of purity.
  • the fabric is in particular environmentally friendly and skin friendly due to its sustainable sourcing, its biodegradability and the very low heavy metal content.
  • the manufactured fabric is of high quality, since substantially no heavy metal content promoting decomposition of the lyocell spinning solution is present. This high degree of purity thus allows to obtain substantially endless fibers with a very small number of fiber ends and with reproducible physical properties.
  • the properties, in particular the mechanical properties, of such a fabric may therefore be adjusted precisely and predictively by controlling the process parameters without mentionable deteriorations by heavy metal impurities.
  • materials of the operating fluids i.e. liquids and/or gases on the basis of which the fibers are formed, and/or which interact with - in particular with physical contact to - the fibers or preforms thereof during the manufacturing process
  • materials of the manufacturing device for instance jets, fiber support unit, fluid containers, etc.
  • a nonwoven cellulose fiber fabric with an inherently small heavy metal content can be advantageously obtained. More specifically, it is possible in an embodiment that a raw material pulp as well as the materials inside the plant which are in contact with the cellulose are chosen such that the heavy metal content of the fibers or fabric meets the above-mentioned conditions.
  • nonwoven cellulose fiber fabric In the following, further exemplary embodiments of the nonwoven cellulose fiber fabric, the method of manufacturing a nonwoven cellulose fiber fabric, the device for manufacturing a nonwoven cellulose fiber fabric, the product or composite, and the methods of use are described.
  • the described low heavy metal content of the manufactured fabric it is possible to obtain a density of fiber ends in the fabric of less than 10,000 fiber ends per cm 3 , in particular of less than 5,000 fiber ends per cm 3 . Therefore, the mechanical integrity and therefore stability of the manufactured fabric is very high .
  • an overall heavy metal content of the fibers is not more than 30 ppm (in particular 30 mass ppm, i.e. 30 mg/kg).
  • a sum of all heavy metals of the individual chemical elements in the fabric may be at or below a level of 30 ppm.
  • the entire heavy metal content of the fabric integrated over all heavy metal elements in particular including summed contributions from the chemical elements of the group consisting of Cr, Mn, Fe, Co, Ni, Cu, Zn, Zr, Mo, Cd, Sn, W, Pb, Bi) may be kept below 30 ppm.
  • the fibers have (in particular the fiber fabric has) a copper content of less than 5 ppm (in particular 5 mass ppm, i.e. 5 mg/kg) and/or have a nickel content of less than 2 ppm (in particular 2 mass ppm, i.e. 2 mg/kg).
  • a lyocell spinning solution as a basis for the formation of the endless fiber-based fabric (in particular when involving a solvent such as N- methyl-morpholine, NMMO)
  • the content of the fabric with the mentioned particularly harmful heavy metals copper which may be harmful to health for human beings, in particular for children, when exceeding a certain dose
  • nickel which may cause allergic reactions of a user
  • the very small amount of copper content can be ensured by omitting a copper salt solution for preparing the spinning solution.
  • At least part of (in particular at least 10% of) the fibers are integrally merged at merging positions.
  • the term "merging" may particularly denote an integral interconnection of different fibers at the respective merging position which results in the formation of one integrally connected fiber structure composed of the previously separate fiber preforms. Merging may be denoted as a fiber-fiber connection being established during coagulation of one, some or all of the merged fibers. Interconnected fibers may strongly adhere to one another at a respective merging position without a different additional material (such as a separate adhesive) so as to form a common structure. Separation of merged fibers may require destruction of the fiber network or part thereof.
  • a nonwoven cellulose fiber fabric in which some or all of the fibers are integrally connected to one another by merging.
  • Merging may be triggered by a corresponding control of the process parameters of a method of manufacturing the nonwoven cellulose fiber fabric.
  • coagulation of filaments of lyocell spinning solution may be triggered (or at least completed) after the first contact between these filaments being not yet in the precipitated solid fiber state.
  • a degree of merging is a powerful parameter which can be used for adjusting the properties of the manufactured fabric.
  • mechanical stability of the network is the larger the higher the density of merging positions is.
  • By an inhomogeneous distribution of merging positions over the volume of the fabric it is also possible to adjust regions of high mechanical stability and other regions of low mechanical stability. For instance, separation of the fabric into separate parts can be precisely defined to happen locally at mechanical weak regions with a low number of merging positions.
  • merging between fibers is triggered by bringing different fiber preforms in form of lyocell spinning solution in direct contact with one another prior to coagulation. By such a coagulation process, single material common precipitation of the fibers is executed, thereby forming the merging positions.
  • the merging positions consist of the same material as the merged fibers.
  • the merging positions may be formed by cellulose material resulting directly from the coagulation of lyocell spinning solution. This not only renders the separate provision of a fiber connection material (such as an adhesive or a binder) dispensable, but also keeps the fabric clean and made substantially of a single material .
  • different ones of the fibers are located at least partially in different distinguishable (i.e. showing a visible separation or interface region in between the layers on a scanning electroscopic image) layers. More specifically, fibers of different layers are integrally merged at at least one merging position between the layers. Hence, different ones of the fibers being located at least partially in different distinguishable layers (which may be identical or which may differ concerning one or more parameters such as merging factor, fiber diameter, etc.) may be integrally connected at at least one merging position. For instance, two (or more) different layers of a fabric may be formed by serially aligning two (or more) jets with orifices through which lyocell spinning solution is extruded for coagulation and fiber formation.
  • a first layer of fibers is formed on the fiber support unit by the first jet, and the second jet forms a second layer of fibers on the first layer when the moving fiber support unit reaches the position of the second jet.
  • the process parameters of this method may be adjusted so that merging points are formed between the first layer and the second layer.
  • fibers of the second layer under formation being not yet fully cured or solidified by coagulation may for example still have exterior skin or surface regions which are still in the liquid lyocell solution phase and not yet in the fully cured solid state.
  • merging allows to control rigidity of the connection between the layers of the fabric.
  • Merging can be controlled, for example, by adjusting the degree of curing or coagulation before pre-fiber structures of a respective layer reach the fiber support plate on an underlying layer of fibers or pre-fiber structures.
  • the merging between the different layers is adjusted so that pulling on the layers in opposite directions results in a separation of the fabric at an interface between the different layers. This can be achieved when the merging is adjusted so that merging-based adhesion between the different layers is smaller than merging based adhesion within a respective one of the different layers.
  • a number of merging points or merging positions per volume may be larger in an interior of a respective one of the connected layers than at in an interface region between the layers. This can be manufactured by controlling the relation between /nter-layer coagulation and / ' /lira -layer coagulation.
  • an average diameter of the fibers of one of the layers is different from an average diameter of the fibers of another one of the layers.
  • a ratio between the average diameter of the fibers of the one layer and the average diameter of the fibers of the other layer may be at least 1.5, in particular may be at least 2.5, more particularly may be at least 4.
  • a nonwoven cellulose fiber fabric may be provided which can be manufactured as a network of substantially endless cellulose fibers showing a pronounced
  • fiber diameter may be adjusted in a more general way allowing to vary physical properties of the fabric over a broad range (wherein reinforcing stiffness is only one option or example). For instance, fiber diameter variation can also be a powerful tool for tuning moisture management of the manufactured fabric.
  • the fibers comprise or consists of microfibrillar cellulose.
  • a microfibril may be denoted as a very fine fibril, or fiber-like strand, consisting of cellulose.
  • Cellulose fibers may be built up of fiber bundles, which may be composed of smaller elements called microfibrils. Through a fibrillation process, the cellulose fibers may be converted into a three-dimensional network of microfibrils with a high surface area. As a result of the high purity and low heavy metals content of the fiber material, also the accurate formation of a microfibrillar structure is promoted.
  • the fabric is configured as a lotion delivery system.
  • the manufactured fabric is highly appropriate for cosmetic applications such as facial masks, make-up removal pads, or the like. Lotion may be stored or retained in an interior of the fabric and may be released when applying pressure during use or operation.
  • the fiber network comprises certain functions, in particular at least one of the group consisting of wicking, anisotropic behavior, oil retention, water retention, cleanability, and roughness.
  • a functionalization may be obtained by an adjustment of physical properties of the fibers and the fabric composed thereof, in particular by an adjustment of a merging factor, an adjustment of a multilayer configuration of a fabric, an adjustment of fiber thickness and an adjustment of the fabric density corresponding to number and dimension of hollow spaces in an interior of the fabric.
  • a functionalization can be performed with a multilayer fabric so that, in an embodiment, the fibers located in multiple layers may be provided with different functionalities.
  • the (in particular different) functionalities may be wicking properties (in particular different fluid distribution properties when sucking fluid), anisotropic behavior (in particular different mechanical, chemical and/or hydrodynamic properties in different directions of the fabric), oil absorbing capability (in particular a strong capability of absorbing oil in one layer, and a lower oil absorbing capability in another layer), water absorbing capability (in particular a strong capability of absorbing water in one layer, and a lower water absorbing capability in another layer), cleanability (in particular a stronger capability of cleaning dirt from a surface by the fabric in one layer, and a less pronounced capability of cleaning in another layer), and/or roughness (for instance one rougher surface layer and one smoother surface layer).
  • the lyocell spinning solution is free of copper salt, in particular is free of any heavy metal salt. This promotes purity of the
  • the method further comprises further processing the fibers and/or the fabric after collection on the fiber support unit but preferably still in situ with the formation of the nonwoven cellulose fiber fabric with endless fibers.
  • in situ processes may be those processes being carried out before the manufactured (in particular substantially endless) fabric is stored (for instance wound by a winder) for shipping to a product manufacture destination.
  • further processing or post processing may involve
  • Hydroentanglement may be denoted as a bonding process for wet or dry fibrous webs, the resulting bonded fabric being a nonwoven .
  • Hydroentanglement may use fine, high pressure jets of water which penetrate the web, hit a fiber support unit (in particular a conveyor belt) and bounce back causing the fibers to entangle. A corresponding compression of the fabric may render the fabric more compact and mechanically more stable. Additionally or alternatively to hydroentanglement, steam treatment of the fibers with a pressurized steam may be carried out. Additionally or alternatively, such a further processing or post processing may involve a needling treatment of the manufactured fabric.
  • a needle punching system may be used to bond the fibers of the fabric or web. Needle punched fabrics may be produced when barbed needles are pushed through the fibrous web forcing some fibers through the web, where they remain when the needles are withdrawn.
  • Impregnating the network of endless fibers may involve the application of one or more chemicals (such as a softener, a hydrophobic agent, an antistatic agent, etc.) on the fabric.
  • Still another further processing treatment of the fabric is calendering.
  • Calendering may be denoted as a finishing process for treating the fabric and may employ a calender to smooth, coat, and/or compress the fabric.
  • a nonwoven cellulose fiber fabric according to an exemplary embodiment of the invention may also be combined (for instance in situ or in a subsequent process) with one or more other materials, to thereby form a composite according to an exemplary embodiment of the invention.
  • Exemplary materials, which can be combined with the fabric for forming such a composite may be selected from a group of materials comprising, but not being limited to, the following materials or combinations thereof: fluff pulp, a fiber suspension, a wetlaid nonwoven, an airlaid nonwoven, a spunbond web, a meltblown web, a carded spunlaced or needlepunched web or other sheet like structures made of various materials.
  • connection between the different materials can be done by (but not limited to) one or a combination of the following processes : merging, hydroentanglement, needle punching, hydrogen bonding, thermobonding, gluing by a binder, laminating, and/or calendering.
  • cellulose fiber webs 100% cellulose fiber webs, or for example webs comprising or consisting of two or more fibers, or chemically modified fibers or fibers with incorporated materials such as anti-bacterial materials, ion exchange materials, active carbon, nano particles, lotions, medical agents or fire retardants, or bicomponent fibers may be as follows:
  • the nonwoven cellulose fiber fabric according to exemplary embodiments of the invention may be used for manufacturing wipes such as baby, kitchen, wet wipes, cosmetic, hygiene, medical, cleaning, polishing (car, furniture), dust, industrial, duster and mops wipes.
  • the nonwoven cellulose fiber fabric according to exemplary embodiments of the invention is used for manufacturing a filter.
  • a filter may be an air filter, a HVAC, air condition filter, flue gas filter, liquid filters, coffee filters, tea bags, coffee bags, food filters, water purification filter, blood filter, cigarette filter; cabin filters, oil filters, cartridge filter, vacuum filter, vacuum cleaner bag, dust filter, hydraulic filter, kitchen filter, fan filter, moisture exchange filters, pollen filter, HEVAC/HEPA/ULPA filters, beer filter, milk filter, liquid coolant filter and fruit juices filters.
  • the nonwoven cellulose fiber fabric may be used for manufacturing absorbent hygiene products.
  • absorbent hygiene products examples thereof are an acquisition layer, a coverstock, a distribution layer, an absorbent cover, sanitary pads, topsheets, backsheets, leg cuffs, flushable products, pads, nursing pads, disposal underwear, training pants, face masks, beauty facial masks, cosmetic removal pads, washcloths, diapers, and sheets for a laundry dryer releasing an active component (such as a textile softener).
  • the nonwoven cellulose fiber fabric may be used for manufacturing a medical application product.
  • medical application products may be disposable caps, gowns, masks and shoe cover, wound care products, sterile packaging products, coverstock products, dressing materials, one way clothing, dialyses products, nasal strips, adhesives for dental plates, disposal underwear, drapes, wraps and packs, sponges, dressings and wipes, bed linen, transdermal drug delivery, shrouds, underpads, procedure packs, heat packs, ostomy bag liners, fixation tapes and incubator mattresses.
  • the nonwoven cellulose fiber fabric may be used for manufacturing geotextiles. This may involve the production of crop protection covers, capillary matting, water purification, irrigation control, asphalt overlay, soil stabilisation, drainage, sedimentation and erosion control, pond liners, impregnation based, drainage channel liners, ground stabilisation, pit linings, seed blankets, weed control fabrics, greenhouse shading, root bags and biodegradable plant pots. It is also possible to use the nonwoven cellulose fiber fabric for a plant foil (for instance providing a light protection and/or a
  • the nonwoven cellulose fiber fabric may be used for manufacturing clothing.
  • interlinings, clothing insulation and protection, handbag components, shoe components, belt liners, industrial headwear/foodwear, disposable workwear, clothing and shoe bags and thermal insulation may be manufactured on the basis of such fabric.
  • the nonwoven cellulose fiber fabric may be used for manufacturing products used for building technology. For instance, roofing and tile underlay, underslating, thermal and noise insulation, house wrap, facings for plaster board, pipe wrap, concrete moulding layers, foundations and ground stabilisation, vertical drainages, shingles, roofing felts, noise abatement, reinforcement, sealing material, and damping material (mechanical) may be manufactured using such fabric.
  • the nonwoven cellulose fiber fabric may be used for manufacturing an automotive product.
  • automotive product examples are a cabin filter, boot liners, parcel shelves, heat shields, shelf trim, moulded bonnet liners, boot floor covering, oil filter, headliners, rear parcel shelves, decorative fabrics, airbags, silencer pads, insulation materials, car covers, underpadding, car mats, tapes, backing and tufted carpets, seat covers, door trim, needled carpet, and auto carpet backing.
  • Still another field of application of fabric manufactured according to exemplary embodiments of the invention are furnishings, such as furniture, construction, insulator to arms and backs, cushion thicking, dust covers, linings, stitch reinforcements, edge trim materials, bedding constructions, quilt backing, spring wrap, mattress pad components, mattress covers, window curtains, wall coverings, carpet backings, lampshades, mattress components, spring insulators, sealings, pillow ticking, and mattress ticking.
  • furnishings such as furniture, construction, insulator to arms and backs, cushion thicking, dust covers, linings, stitch reinforcements, edge trim materials, bedding constructions, quilt backing, spring wrap, mattress pad components, mattress covers, window curtains, wall coverings, carpet backings, lampshades, mattress components, spring insulators, sealings, pillow ticking, and mattress ticking.
  • the nonwoven cellulose fiber fabric may be used for manufacturing industrial products. This may involve electronics, floppy disc liners, cable insulation, abrasives, insulation tapes, conveyor belts, noise absorbent layers, air conditioning, battery separators, acid systems, anti-slip matting stain removers, food wraps, adhesive tape, sausage casing, cheese casing, artificial leather, oil recovery booms and socks, and papermaking felts.
  • Nonwoven cellulose fiber fabric according to exemplary embodiments of the invention is also appropriate for manufacturing products related to leisure and travel .
  • Examples for such an application are sleeping bags, tents, luggage, handbags, shopping bags, airline headrests, CD-protection, pillowcases, and sandwich packaging.
  • Still another field of application of exemplary embodiment of the invention relates to school and office products.
  • book covers, mailing envelopes, maps, signs and pennants, towels, and flags shall be mentioned.
  • Figure 1 illustrates a device for manufacturing nonwoven cellulose fiber fabric which is directly formed from lyocell spinning solution being coagulated by a coagulation fluid according to an exemplary embodiment of the invention .
  • Figure 2 to Figure 4 show experimentally captured images of nonwoven cellulose fiber fabric according to an exemplary embodiment of the invention in which merging of individual fibers has been accomplished by a specific process control.
  • Figure 5 and Figure 6 show experimentally captured images of nonwoven cellulose fiber fabric according to an exemplary embodiment of the invention in which swelling of fibers has been accomplished, wherein Figure 5 shows the fiber fabric in a dry non-swollen state and Figure 6 shows the fiber fabric in a humid swollen state.
  • Figure 7 shows an experimentally captured image of nonwoven cellulose fiber fabric according to an exemplary embodiment of the invention in which formation of two superposed layers of fibers has been accomplished by a specific process implementing two serial bars of nozzles.
  • Figure 8 shows a schematic image of a nonwoven cellulose fiber fabric according to still another exemplary embodiment of the invention composed of two stacked and merged layers of interconnected fibers having different fiber thicknesses.
  • Figure 9 illustrates a part of a device for manufacturing nonwoven cellulose fiber fabric composed of two stacked layers of endless cellulose fiber webs according to an exemplary embodiment of the invention.
  • Figure 10 shows a schematic image of nonwoven cellulose fiber fabric according to an exemplary embodiment of the invention composed of three stacked layers with different diameters of fibers.
  • Figure 1 illustrates a device 100 according to an exemplary embodiment of the invention for manufacturing nonwoven cellulose fiber fabric 102 which is directly formed from lyocell spinning solution 104.
  • the latter is at least partly coagulated by a coagulation fluid 106 to be converted into partly-formed cellulose fibers 108.
  • a lyocell solution blowing process according to an exemplary embodiment of the invention may be carried out.
  • the term "lyocell solution-blowing process” may particularly encompass processes which can result in essentially endless filaments or fibers 108 of a discrete length or mixtures of endless filaments and fibers of discrete length being obtained.
  • nozzles each having an orifice 126 are provided through which cellulose solution or lyocell spinning solution 104 is ejected together with a gas stream or gas flow 146 for manufacturing the nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention.
  • wood pulp 110 other cellulose-based feedstock or the like may be supplied to a storage tank 114 via a metering unit 113.
  • Water from a water container 112 is also supplied to the storage tank 114 via metering unit 113.
  • the metering unit 113 under control of a control unit 140 described below in further detail, may define relative amounts of water and wood pulp 110 to be supplied to the storage tank 114.
  • a solvent such as N-methyl- morpholine, NMMO
  • NMMO N-methyl- morpholine
  • the aqueous lyocell spinning solution 104 can be a honey-viscous medium composed of (for instance 5 mass % to 15 mass %) cellulose comprising wood pulp 110 and (for instance 85 mass % to 95 mass %) solvent.
  • the lyocell spinning solution 104 is forwarded to a fiber formation unit 124 (which may be embodied as or which may comprise a number of spinning beams or jets 122).
  • a fiber formation unit 124 which may be embodied as or which may comprise a number of spinning beams or jets 122).
  • the number of orifices 126 of the jets 122 may be larger than 50, in particular larger than 100.
  • all orifices 126 of a fiber formation unit 124 (which may comprise a number of spinnerets or jets 122) of orifices 126 of the jets 122 may have the same size and/or shape.
  • size and/or shape of different orifices 126 of one jet 122 and/or orifices 126 of different jets 122 may be different.
  • the lyocell spinning solution 104 passes through the orifices 126 of the jets 122, it is divided into a plurality of parallel strands of lyocell spinning solution 104.
  • a vertically oriented gas flow i.e. being oriented substantially parallel to spinning direction, forces the lyocell spinning solution 104 to transform into increasingly long and thin strands which can be adjusted by changing the process conditions under control of control unit 140.
  • the gas flow may accelerate the lyocell spinning solution 104 along at least a part of its way from the orifices 126 to a fiber support unit 132.
  • the coagulation fluid 106 is
  • Process relevant properties of the coagulation fluid 106 are controlled by one or more coagulation units 128, providing the coagulation fluid 106 with adjustable properties.
  • the coagulation units 128 are controlled, in turn, by control unit 140.
  • respective coagulation units 128 are provided between the individual nozzles or orifices 126 for individually adjusting properties of respective layers of fabric 102 being produced.
  • each jet 122 may have two assigned coagulation units 128, one from each side. The individual jets 122 can thus be provided with individual portions of lyocell spinning solution 104 which may also be adjusted to have different controllable properties of different layers of manufactured fabric 102.
  • the solvent concentration of the lyocell spinning solution 104 is reduced, so that the cellulose of the former e.g. wood pulp 110 (or other feedstock) is at least partly
  • the cellulose fibers 108 are deposited on fiber support unit 132, which is here embodied as a conveyor belt with a planar fiber accommodation surface.
  • the cellulose fibers 108 form a nonwoven cellulose fiber fabric 102 (illustrated only schematically in Figure 1).
  • the nonwoven cellulose fiber fabric 102 is composed of continuous and substantially endless filaments or fibers 108.
  • the solvent of the lyocell spinning solution 104 removed in coagulation by the coagulation unit 128 and in washing in a washing unit 180 can be at least partially recycled.
  • the nonwoven cellulose fiber fabric 102 can be washed by washing unit 180 supplying wash liquor to remove residual solvent and may then be dried. It can be further processed by an optional but advantageous further processing unit 134. For instance, such a further processing may involve hydro-entanglement, needle punching,
  • the fiber support unit 132 may also transport the nonwoven cellulose fiber fabric 102 to a winder 136 on which the nonwoven cellulose fiber fabric 102 may be collected as a substantially endless sheet. The nonwoven cellulose fiber fabric 102 may then be shipped as roll-good to an entity manufacturing products such as wipes or textiles based on the nonwoven cellulose fiber fabric 102.
  • control unit 140 such as a processor, part of a processor, or a plurality of processors.
  • the control unit 140 is configured for controlling operation of the various units shown in Figure 1, in particular one or more of the metering unit 113, the mixing unit 119, the fiber formation unit 124, the coagulation unit(s) 128, the further processing unit 134, the dissolution unit 120, the washing unit 118, etc.
  • the control unit 140 (for instance by executing computer executable program code, and/or by executing control commands defined by a user) may precisely and flexibly define the process parameters according to which the nonwoven cellulose fiber fabric 102 is manufactured.
  • Design parameters in this context are air flow along the orifices 126, properties of the coagulation fluid 106, drive speed of the fiber support unit 132, composition, temperature and/or pressure of the lyocell spinning solution 104, etc. Additional design parameters which may be adjusted for adjusting the properties of the nonwoven cellulose fiber fabric 102 are number and/or mutual distance and/or geometric arrangement of the orifices 126, chemical composition and degree of concentration of the lyocell spinning solution 104, etc. Thereby, the properties of the nonwoven cellulose fiber fabric 102 may be properly adjusted, as described below.
  • Such adjustable properties may involve one or more of the following properties: diameter and/or diameter distribution of the fibers 108, amount and/or regions of merging between fibers 108, a purity level of the fibers 108, properties of a multilayer fabric 102, optical properties of the fabric 102, fluid retention and/or fluid release properties of the fabric 102, mechanical stability of the fabric 102, smoothness of a surface of the fabric 102, cross-sectional shape of the fibers 108, etc.
  • each spinning jet 122 may comprise a polymer solution inlet via which the lyocell spinning solution 104 is supplied to the jet 122. Via an air inlet, a gas flow 146 can be applied to the lyocell spinning solution 104.
  • the lyocell spinning solution 104 moves or is accelerated (by the gas flow 146 pulling the lyocell spinning solution 104 downwardly) downwardly through a respective orifice 126 and is laterally narrowed under the influence of the gas flow 146 so that continuously tapering cellulose filaments or cellulose fibers 108 are formed when the lyocell spinning solution 104 moves downwardly together with the gas flow 146 in the environment of the coagulation fluid 106.
  • processes involved in the manufacturing method described by reference to Figure 1 may include that the lyocell spinning solution 104, which may also be denoted as cellulose solution is shaped to form liquid strands or latent filaments, which are drawn by the gas flow 146 and significantly decreased in diameter and increased in length. Partial coagulation of latent filaments or fibers 108 (or preforms thereof) by coagulation fluid 106 prior to or during web formation on the fiber support unit 132 may also be involved.
  • the filaments or fibers 108 are formed into web like fabric 102, washed, dried and may be further processed (see further processing unit 134), as required.
  • the filaments or fibers 108 may for instance be collected, for example on a rotating drum or belt, whereby a web is formed.
  • the fibers 108 have a copper content of less than 5 ppm and have a nickel content of less than 2 ppm. This advantageously improves purity of the fabric 102.
  • the lyocell solution blown web i.e. the nonwoven cellulose fiber fabric 102
  • the lyocell solution blown web preferably exhibits one or more of the following properties:
  • the dry weight of the web is from 5 to 300 g/m 2 , preferably 10-80 g/m 2
  • the thickness of the web according to the standard WSP120.6 respectively DIN29073 is from 0.05 to 10.0 mm, preferably 0.1 to 2.5 mm
  • the specific tenacity of the web in MD according to EN29073-3, respectively ISO9073-3 ranges from 0.1 to 3.0 Nm 2 /g, preferably from 0.4 to 2.3 Nm 2 /g
  • the average elongation of the web according to EN29073-3, respectively ISO9073-3 ranges from 0.5 to 100%, preferably from 4 to 50%.
  • the MD/CD tenacity ratio of the web is from 1 to 12
  • the water retention of the web according to DIN 53814 is from 1 to 250%, preferably 30 to 150%
  • the water holding capacity of the web according to DIN 53923 (in particular in the latest version as in force at the priority date of the present patent application) ranges from 90 to 2000%, preferably 400 to 1100%.
  • the lyocell solution-blown web exhibits all of said properties (i) to (viii) mentioned above.
  • the process to produce the nonwoven cellulose fiber fabric 102 preferably comprises:
  • Constituents of the nonwoven cellulose fiber fabric 102 may be bonded by merging, intermingling, hydrogen bonding, physical bonding such as
  • the nonwoven cellulose fiber fabric 102 may be combined with one or more layers of the same and/or other materials, such as (not shown) layers of synthetic polymers, cellulosic fluff pulp, nonwoven webs of cellulose or synthetic polymer fibers, bicomponent fibers, webs of cellulose pulp, such as airlaid or wetlaid pulp, webs or fabrics of high tenacity fibers,
  • hydrophobic materials such as temperature resistant materials or flame retardant materials
  • layers imparting changed mechanical properties to the final products such as Polypropylene or Polyester layers
  • biodegradable materials e.g. films, fibers or webs from Polylactic acid
  • high bulk materials such as polypropylene or Polyester layers
  • the nonwoven cellulose fiber fabric 102 may essentially consist of cellulose alone. Alternatively, the nonwoven cellulose fiber fabric 102 may comprise a mixture of cellulose and one or more other fiber materials. The nonwoven cellulose fiber fabric 102, furthermore, may comprise a bicomponent fiber material. The fiber material in the nonwoven cellulose fiber fabric 102 may at least partly comprise a modifying substance.
  • the modifying substance may be selected from, for example, the group consisting of a polymeric resin, an inorganic resin, inorganic pigments, antibacterial products, nanoparticles, lotions, fire-retardant products, absorbency-improving additives, such as superabsorbent resins, ion-exchange resins, carbon compounds such as active carbon, graphite, carbon for electrical conductivity, X-ray contrast substances, luminescent pigments, and dye
  • the cellulose nonwoven web or nonwoven cellulose fiber fabric 102 manufactured directly from the lyocell spinning solution 104 allows access to value added web performance which is not possible via staple fiber route. This includes the possibility to form uniform lightweight webs, to manufacture microfiber products, and to manufacture continuous filaments or fibers 108 forming a web. Moreover, compared to webs from staple fibers, several manufacturing procedures are no longer required.
  • nonwoven cellulose fiber fabric 102 according to exemplary embodiments of the invention is biodegradable and manufactured from sustainably sourced raw material (i.e. wood pulp 110 or the like). Furthermore, it has advantages in terms of purity and absorbency. Beyond this, it has an adjustable mechanical strength, stiffness and softness.
  • nonwoven cellulose fiber fabric 102 may be manufactured with low weight per area (for instance 10 to 30 g/m 2 ). Very fine filaments down to a diameter of not more than 5 ⁇ , in particular not more than 3 ⁇ , can be manufactured with this technology. Furthermore, nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention may be formed with a wide range of web aesthetics, for instance in a flat crispy film-like way, in a paper-like way, or in a soft flexible textile-like way. By adapting the process parameters of the described process, it is furthermore possible to precisely adjust stiffness and mechanical rigidity or flexibility and softness of the nonwoven cellulose fiber fabric 102. This can be adjusted for instance by adjusting a number of merging positions, the number of layers, or by after-treatment (such as needle punch, hydro-entanglement and/or calendering). It is in particular possible to
  • nonwoven cellulose fiber fabric 102 with a relatively low basis weight of down to 10 g/m 2 or lower, to obtain filaments or fibers 108 with a very small diameter (for instance of down to 3 to 5 ⁇ , or less), etc.
  • Figure 2 Figure 3 and Figure 4 show experimentally captured images of nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention in which merging of individual fibers 108 has been accomplished by a corresponding process control.
  • the oval markers in Figure 2 to Figure 4 show such merging regions where multiple fibers 108 are integrally connected to one another. At such merging points, two or more fibers 108 may be interconnected to form an integral structure.
  • Figure 5 and Figure 6 show experimentally captured images of nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention in which swelling of fibers 108 has been accomplished, wherein Figure 5 shows the fiber fabric 102 in a dry non-swollen state and Figure 6 shows the fiber fabric 102 in a humid swollen state.
  • the pore diameters can be measured in both states of Figure 5 and Figure 6 and can be compared to one another. When calculating an average value of 30 measurements, a decrease of the pore size by swelling of the fibers 108 in an aqueous medium up to 47% of their initial diameter could be determined.
  • Figure 7 shows an experimentally captured image of nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention in which formation of two superposed layers 200, 202 of fibers 108 has been
  • an n-layer fabric 102 (n>2) can be manufactured by serially arranging n spinnerets or jets 122 along the machine direction.
  • Figure 8 shows a schematic cross sectional view of a nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention composed of two stacked and merged layers 200, 202 of interconnected fibers 108 having different fiber thicknesses d and D>d (see the lower two details of Figure 8). More specifically, different ones of the fibers 108 being located in the different layers 200, 202 differ concerning an averaged fiber diameter (i.e. averaged over the fibers 108 of the respective layer 200, 202). Fibers 108 of the respective layers 200, 202 are also merged at merging positions 204, compare the lower two details of Figure 8.
  • a further detail of the interface between the layers 200, 202 is shown as well, where a merging point 204 is visible which integrally couples fibers 108 of both layers 200, 202 at the interface for increasing stability of the fabric 102 at the interface (see the upper detail of Figure 8). Additionally, different ones of the fibers 108 being located in the different layers 200, 202 are integrally connected at at least one respective merging position 204.
  • Merging properties may be adjusted to obtain desired properties. For instance, a number of merging points 204 per volume of fabric 102 may be adjusted separately within the respective one of the layers 200, 202 and/or between the layers 200, 202. This can be done by adjusting the coagulation properties (in particular coagulation of filaments of lyocell spinning solution 104 upstream of the fiber accommodation surface of the fiber support unit 132, coagulation of filaments of lyocell spinning solution 104 after lay down of the filaments on the fiber accommodation surface of the fiber support unit 132, etc.).
  • the merging between the different layers 200, 202 may be adjusted so that pulling on the layers 200, 202 in opposite directions results in a separation of the fabric 102 at an interface between the different layers 200, 202. In other words, merging- based adhesion between the different layers 200, 202 may be adjusted to be smaller than merging based adhesion within a respective one of the different layers 200, 202.
  • the fibers 108 located in the different layers 200, 202 and being formed with different average diameter and different merging properties may be provided with tailored functionalities.
  • tailored functionalities may be achieved by the different average diameters, but may also be further promoted by a respective coating or the like.
  • Such different functionalities may for instance be a different behavior in terms of wicking, anisotropic behavior, different oil absorbing capability, different water absorbing capability, different cleanability, and/or different roughness.
  • the multilayer nonwoven cellulose fiber fabric 102 according to Figure 8 can be directly manufactured from lyocell spinning solution 104 using the device 100 and corresponding manufacturing method described below referring to Figure 9.
  • the partial heavy metal contents of the fibers 108 of the fabric 102 according to Figure 8 are not more than 10 ppm for each individual chemical heavy metal element (i.e. not more than 10 ppm for copper, not more than 10 ppm for nickel, not more than 10 ppm for cadmium, etc.) - Beyond this, an overall or entire heavy metals content of fabric 102 summed up for all heavy metal chemical elements together (i.e.
  • the fibers 108 have a copper content of less than 5 ppm and have a nickel content of less than 2 ppm.
  • the operating fluids in particular lyocell spinning solution 104, coagulation fluid 106, washing liquor, gas flow 146, etc.
  • the fibers 108 may be of high quality and may substantially consist of pure microfibrillar cellulose.
  • operating fluids used during manufacturing the fabric 102 are selected so that, and materials of a manufacturing device 100 which are in contact with at least one of the lyocell spinning solution 104 and the fibers 108 during manufacturing the fabric 102 are selected so that a heavy metal content of the fibers 108 is not more than 10 ppm for each individual chemical heavy metal element.
  • Figure 9 illustrates a part of a device 100 for manufacturing nonwoven cellulose fiber fabric 102 composed of two stacked layers 200, 202 of endless cellulose fibers 108 according to an exemplary embodiment of the invention.
  • the device 100 according to Figure 9 comprises two serially aligned jets 122 and respectively assigned coagulation units 128, as described above.
  • the upstream jet 122 on the left-hand side of Figure 9 produces layer 202.
  • Layer 200 is produced by the downstream jet 122 (see right hand side of Figure 9) and is attached to an upper main surface of the previously formed layer 202 so that a double layer 200, 202 of fabric 102 is obtained.
  • control unit 140 (controlling the jets 122 and the coagulation units 128) is configured for adjusting process parameters so that the fibers 108 of the different layers 200, 202 differ concerning fiber diameter by more than 50% in relation to a smallest diameter (see for example Figure 8). Adjusting the fiber diameters of the fibers 108 of the layers 200, 202 by the control unit 140 may comprise adjusting an amount of coagulation fluid 106 interacting with the lyocell spinning solution 104. Additionally, the embodiment of Figure 9 adjusts the process parameters for adjusting fiber diameter by serially arranging multiple jets 122 with orifices 126 (optionally with different properties) along the movable fiber support unit 132.
  • such different properties may be different orifice 126 diameters and or shapes, different speed of gas flow 146, different amounts of gas flow 146, and/or different gas flow 146 pressure.
  • one or more further nozzle bars or jets 122 may be provided and may be arranged serially along a transport direction of fiber support unit 132.
  • the multiple jets 122 may be arranged so that further layer 200 of fibers 108 may be deposited on top of the previously formed layer 202, preferably before the coagulation or curing process of the fibers 108 of the layer 202 and/or of the layer 200 is fully completed, which may trigger merging.
  • this may have advantageous effects in terms of the mechanical properties of a multilayer fabric 102.
  • the device 100 according to Figure 9 which is configured for the manufacture of multilayer fabric 102, implements a high number of process parameters which can be used for designing shape and/or diameter or diameter distribution of the fibers 108 as well as of fiber layers 200, 202. This is the result of the serial arrangement of multiple jets 122, each of which being operable with individually adjustable process parameters.
  • a fabric 102 composed of at least two layers 200, 202 (preferably more than two layers).
  • the fibers 108 of the different layers 200, 202 may have different values of the average fiber diameter and may be formed in one continuous process.
  • a highly efficient production of the nonwoven cellulose fiber fabric 102 can be ensured, which in particular allows to transfer the obtained multilayer fabric 102 in one transport procedure to a destination for further processing.
  • both //lira -layer adhesion of the fibers 108 of one layer 200, 202 as well as / ' nter-layer adhesion of the fibers 108 between adjacent layers 200, 202 may be properly and individually adjusted.
  • a corresponding separate control for each layer 200, 202 individually may be in particular obtained when the process parameters are adjusted so that coagulation or curing of the fibers 108 of one layer 202 is already completed when the other layer 200 of fibers 108 is placed on top thereof. All this can be obtained for a fabric 102 having a very low heavy metals content due to the adjusted lack of heavy metal sources along the process line.
  • Figure 10 shows a schematic image of nonwoven cellulose fiber fabric 102 according to another exemplary embodiment of the invention composed of three stacked layers 202, 200, 200 with different diameters of fibers 108.
  • an intermediate sandwich layer 200 has significantly smaller diameters of fibers 108 than the two exterior layers 200, 202 above and below.
  • the multilayer fabric 102 shown in Figure 10 is particularly appropriate for applications such as medical appliances, agricultural textiles, cosmetic
  • an active substance or a lotion may be stored in the inner layer 200 showing a high capillary action.
  • the exterior layers 200, 202 may be designed in terms of rigidity and surface haptic. This is advantageous for cleaning and medical applications.
  • the fiber layer design may be specifically configured in terms of evaporation properties and/or root penetration.
  • the multilayer fabric 102 shown in Figure 10 may be used as facial mask, industrial wipe, etc., wherein the central layer 200 may have a specifically pronounced fluid retaining capability.
  • the cover layers 200, 202 may be configured for adjusting fluid release properties.
  • the diameters of the fibers 108 of the respective layer 200, 200, 202 may be used as a design parameter for adjusting these functions.
  • the multilayer fabric 102 shown in Figure 10 may be configured as a lotion delivery system.
  • an exemplary embodiment of the invention provides a nonwoven cellulose fiber fabric 102 with a very low content with heavy metal elements. This is promoted on the one hand by the above described
  • the hardware configuration of the device 100 may be configured so that substantially no re-contamination of the processed lyocell spinning solution 104 and the manufactured fibers 108 with heavy metal impurities occurs along the line.
  • a biocompatible and biodegradable nonwoven cellulose fiber fabric 102 may be obtained.
  • cellulose filament production on the basis of lyocell spinning solution 104 it can be ensured that no production related heavy metal impurities accumulate in the manufactured fabric 102. This is particularly advantageous for post processing of such fabric 102 and when a correspondingly manufactured product gets into contact with human beings or natural organisms.
  • nonwoven cellulose fiber fabric 102 with low heavy metal content in particular low copper content
  • low heavy metal content in particular low copper content
  • toxicity of copper may be reinforced by other heavy metals such as Hg, Sn, Cd.
  • fabric 102 according to an exemplary embodiment of the invention being poor in terms of heavy metal content is particularly appropriate for biodegradation after use without
  • nonwoven cellulose fiber fabric 102 are provided substantially free of heavy metal contents, but additionally also the process environment may be adjusted so as to suppress an additional
  • all constituents of the device 100 shown in Figure 1 or Figure 9 may be configured for preventing heavy metal content impurities of these constituents to be introduced in the lyocell spinning solution 104, the manufactured fibers 108 and the manufactured fabric 102.
  • the mentioned constituents of the device 100 may undergo a surface treatment (for instance a passivating coating) preventing that the contact surfaces of the device 100 getting in physical contact with the lyocell spinning solution 104, the fibers 108 or the fabric 102 introduce heavy metals into the manufactured goods. This may also involve a corresponding conditioning of pressurized air, air guide system, washing system, etc.
  • an exemplary embodiment of the invention combining a heavy metal depleted fabrication of fabric 102 and the fabrication of multilayer fabric 102 allows to obtain biodegradable fabric 102 manufacturable with a high yield on an industrial scale.
  • additional design parameters for precisely adjusting various physical properties of the manufactured fabric are involved (in particular in terms of fiber diameter distribution, merging properties, shaping of the fibers 102, thickness control of fabric 102 or individual layers 200, 202 thereof, etc.).
  • a significant advantage of exemplary embodiments is the capability to form a fabric 102 with multiple merging positions 204 but without the additional use of binders or adhesive material at the transition or interface between different fibers 108 or fiber regions with different physical properties.
  • Merging variation in the vertical or thickness direction of a fabric 102 is in particular advantageous for a fabric 102 made from endless cellulose, since such a fabric type allows to manufacture different material properties (by specific functionalizations) in a similar process parameter window of the production (for instance swelling capability, hydrophilic character, oleophilic character, wicking, fluid retention capability, etc.).
  • a fabric 102 providing a pre-filter capability and a fine-filter capability may therefore be manufactured.
  • the fabric 102 can be hence used for manufacturing a filter.
  • a filter comprising the fabric 102
  • multiple layers 200, 202 of fibers 108 are combined for manufacturing a pre-filter and a main filter having different fiber diameters or different values of titer in the different layers 200, 202.
  • the low copper impurities (less than 5 ppm) of such a fabric 102 it is possible to use such a filter in an environment of easily oxidizable compounds such as sulfur-II-compounds (for instance thiol carboxylic acid) or other easily oxidizable chemicals (for instance ascorbic acid).
  • copper impurities may catalyze oxidation of the mentioned substances by molecular oxygen.
  • a fabric 102 according to an exemplary embodiment of the invention with low heavy metal impurities such undesired effects are efficiently suppressed.
  • the fabric 102 with the mentioned low heavy metal impurities can be used as a (in particular multilayer) fabric 102 specifically adapted for high temperature filters.
  • An upper temperature limit above which such a filter cannot be used any longer is defined by a temperature at which decomposition of cellulose (in particular by separation of water) starts. It has been found that, the higher the purity of the fibers 108 of the fabric 102, the higher is the starting temperature at which decomposition of the cellulose starts.
  • heavy metal impurities may function as a parasitic catalytic substance promoting undesired cellulose decomposition at higher temperatures.
  • the mentioned decomposition of cellulose (which is disturbing for many different applications of fabric 102, including but not only concerning filters) can further be triggered by unconnected ends of fibers (as occurs in a high concentration in fabrics made of staple fibers). It is believed that such unconnected fiber ends may function as microscopic starting points for decomposition.
  • endless fibers 108 in the heavy metal depleted nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention, the number of free fiber ends can be dramatically decreased (for instance less than 10,000 ends/cm 3 , in particular less than 5,000 ends/cm 3 in a fabric with a density of 0.1 g/cm 3 compared to staple fibers.
  • endless fibers 108 with a non-catalytic low heavy metal content provides significant improvements in terms of protection of the fabric 102 against undesired cellulose decomposition.
  • non-catalytic heavy metal depleted fabric 102 with a multilayer architecture and /nfra-fiber and/or /nter-fiber merging provides a sufficient number of design parameters for adjusting desired properties (for instance different fiber diameters) of the fabric 102 and in combination allows to obtain a fabric 102 which is appropriate for high
  • a nonwoven cellulose fiber fabric 102 according to an exemplary embodiment of the invention having the mentioned very low heavy metal impurities is
  • Heavy metal impurities may have an undesired catalytic effect for decomposing cellulose, for instance by triggering oxidation, dehydration, etc.
  • By suppressing such parasitic effects as a result of the low heavy metal impurity concentration of fabric 102 according to an exemplary embodiment of the invention it is possible to significantly increase the lifetime of such products. This particularly holds when heat and/or light is present in an environment of the fabric-based products, which can further accelerate the mentioned cellulose decomposition processes resulting from heavy metal impurities.
  • the heavy metal depleted fabric 102 is particularly
  • agrotextile appropriate for use with products coming into light contact during use, such as agrotextile, covers, filters, packages, and clothes.
  • the nonwoven cellulose fiber fabric 102 is used for a biodegradable product. After biodegradation, no binder material or adhesive material remains. In particular, no significant amount of heavy metals forms part of such a biodegradable product.
  • pronounced acoustic wave absorbing properties of cellulose may be advantageously used and further refined.
  • a fabric 102 according to an exemplary embodiment of the invention may be formed in which the acoustic wave absorbing properties of the cellulose may be refined in terms of a desired absorption frequency range and/or a selective damping strength.
  • the thermally insulating properties of cellulose may be advantageously used and further refined.
  • a fabric 102 according to an exemplary embodiment of the invention may be formed in which the thermal insulation properties of the cellulose may be refined.
  • a fabric 102 according to an exemplary embodiment of the invention with a high thermal insulation it is possible to take a provision that the cellulose fibers 108 do not become excessively wet. For instance, this may be accomplished by impregnating an exterior surface of the fabric with a hydrophobic material .
  • a low homogeneous fiber diameter may allow to obtain a high smoothness of the fabric 102
  • - multilayer fabric 102 with low fiber diameter may allow to obtain a high fabric thickness at a low fabric density
  • Different merging factors in the cellulose fiber fabric may be achieved by varying the coagulation spray flow while using a constant spinning solution (i.e. a spinning solution with a constant consistency), in particular a Lyocell spinning solution, and a constant gas flow (e.g. air throughput).
  • a constant spinning solution i.e. a spinning solution with a constant consistency
  • a Lyocell spinning solution i.e. a Lyocell spinning solution
  • a constant gas flow e.g. air throughput
  • the softness (described by the known Specific Hand measuring technique, measured with a so-called "Handle-O-Meter” on the basis of the nonwoven standard WSP90.3, in particular the latest version as in force at the priority date of the present patent application) may follow the above described trend of merging.
  • the tenacity (described by Fmax), for example according to EN29073- 3, respectively ISO9073-3, in particular the latest version as in force at the priority date of the present patent application, may also follow the described trend of merging.
  • Fmax for example according to EN29073- 3, respectively ISO9073-3, in particular the latest version as in force at the priority date of the present patent application, may also follow the described trend of merging.
  • the softness and the tenacity of the resulting nonwoven cellulose fiber fabric may be adjusted in accordance with the degree of merging (as specified by the merging factor).

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne un tissu non tissé en fibre de cellulose (102), en particulier fabriqué directement à partir d'une solution de filage de fibre Lyocell (104), le tissu (102) comprenant un réseau de fibres sensiblement sans fin (108), et une teneur en métaux lourds des fibres (108) n'étant pas supérieure à 10 ppm pour chaque élément de métaux lourds chimique individuel.
PCT/EP2018/057866 2017-04-03 2018-03-28 Tissu non tissé en fibre de cellulose ayant une teneur en métaux lourds extrêmement faible WO2018184927A1 (fr)

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EP17164619.3A EP3385432A1 (fr) 2017-04-03 2017-04-03 Tissu de fibres de cellulose non tissé ayant une très faible teneur en métaux lourds
EP17164619.3 2017-04-03

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WO1998026122A1 (fr) 1996-12-10 1998-06-18 Acordis Fibres (Holdings) Limited Procede de fabrication d'un textile non tisse
WO1999047733A1 (fr) 1998-03-16 1999-09-23 Weyerhaeuser Company Fibres lyocel, et compositions pour leur fabrication
WO1999064649A1 (fr) 1998-06-05 1999-12-16 Tencel Limited Procede servant a fabriquer un non-tisse
EP1358369A2 (fr) 2000-12-22 2003-11-05 Lüder Dr.-Ing. Gerking Procedes et dispositifs pour la production de filaments fins sensiblement continus
WO2005106085A1 (fr) 2004-04-26 2005-11-10 Biax Fiberfilm Corporation Appareil, produit et procede pour former des bandes non tissees cellulosiques microfibres
WO2007124521A1 (fr) 2006-04-28 2007-11-08 Lenzing Aktiengesellschaft Produits hydro-enchevêtrés comprenant des fibres de cellulose
WO2007124522A1 (fr) 2006-04-28 2007-11-08 Lenzing Aktiengesellschaft Produit non-tisse obtenu par fusion-soufflage
EP2013390A1 (fr) 2006-04-28 2009-01-14 Lenzing Aktiengesellschaft Produits hydro-enchevêtrés comprenant des fibres de cellulose
AT505476A1 (de) * 2007-07-11 2009-01-15 Chemiefaser Lenzing Ag Verfahren zur herstellung von cellulosischen formkörpern unter verwendung von bambuszellstoff und formkörper aus diesem verfahren

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