WO2021216844A1 - Filtres filés-liés présentant une faible chute de pression et une efficacité élevée - Google Patents

Filtres filés-liés présentant une faible chute de pression et une efficacité élevée Download PDF

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Publication number
WO2021216844A1
WO2021216844A1 PCT/US2021/028608 US2021028608W WO2021216844A1 WO 2021216844 A1 WO2021216844 A1 WO 2021216844A1 US 2021028608 W US2021028608 W US 2021028608W WO 2021216844 A1 WO2021216844 A1 WO 2021216844A1
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Prior art keywords
nylon
islands
microns
sea
manifolds
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PCT/US2021/028608
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English (en)
Inventor
Behnam Pourdeyhimi
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North Carolina State University
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Publication of WO2021216844A1 publication Critical patent/WO2021216844A1/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
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/11—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • 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
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • 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
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • 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
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0216—Bicomponent or multicomponent fibres
    • B01D2239/0233—Island-in-sea
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0627—Spun-bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/10—Filtering material manufacturing

Definitions

  • the invention disclosed herein relates generally to the manufacture of micro-denier fibers and nonwoven products manufactured from fully fibrillated and partially fibrillated bicomponent fibers.
  • Nonwoven spunbonded fabrics are used in many applications, especially those requiring a lightweight disposable fabric. Therefore, most spunbonded fabrics are designed for single use.
  • Spunbond refers to a process whereby fibers or filaments are extruded, cooled, drawn, and subsequently collected on a moving belt to form a web. The web is not bonded and the fibers or filaments must be bonded together thermally, mechanically, or chemically to form a fabric.
  • Thermal bonding is the most efficient and economical means for forming a fabric. Hydroentangling is not as efficient, but it leads to a much more flexible and, normally, stronger fabric when compared to thermally bonded fabrics.
  • Microdenier fibers are fibers that are smaller than 1 denier. Typically, microdenier fibers are produced utilizing a bicomponent fiber which is split. Splitting a bicomponent fiber allows multiple fibers with a smaller cross-sectional area to be produced from one larger filament.
  • One type of splittable fiber is commonly referred to as “pie wedge” or “segmented pie.”
  • U.S. Patent No. 5,783,503 illustrates a typical meltspun muticomponent thermoplastic continuous filament, which is split absent mechanical treatment. In the configuration described, it is desired to provide a hollow core filament. The hollow core prevents the tips of the wedges of like components from contacting each other at the center of the filament and promotes separation of the filament components.
  • bicomponent fibers for splitting When manufacturing bicomponent fibers for splitting, several characteristics of the fibers are typically required to ensure that the fiber may be adequately manufactured.
  • the affinity between the types of polymers used for the fiber’s different components affects the strength of the interface between the components, and therefore affects the ease with which the components can be split.
  • Exemplary combinations of polymers include polyester and polypropylene, polyester and polyethylene, nylon and polypropylene, nylon and polyethylene, and nylon and polyester. Since these bicomponent fibers are spun in a segmented cross-section, each component is exposed along the length of the fiber. Consequently, if the components selected do not have properties which are closely analogous, the fiber may suffer defects during manufacturing such as breaking, or crimping, or wrapping. Such defects would render the fiber unsuitable for further processing.
  • the mechanical properties of the polymers used for the components are also important, as they affect the processing of the fibers and the mechanical properties of fabrics made from the fibers, such as tensile strength and tear strength.
  • U.S. Patent No. 6,448,462 discloses another multicomponent filament having an orange-like multisegment structure representative of a pie configuration. This patent also discloses a side-by-side configuration. In these configurations, two incompatible polymers such as polyesters and a polyethylene or polyamide are utilized for forming a continuous multicomponent filament. These filaments are melt-spun, stretched and directly laid down to form nonwoven.
  • the segmented pie is only one of many possible splittable configurations. In the solid form, it is easier to spin; but in the hollow form, it is easier to split. To ensure splitting, dissimilar polymers are utilized. But even after choosing polymers with low mutual affinity, the fiber’s cross section can have an impact on how easily the fiber will split.
  • the cross section that is most readily splittable is a segmented ribbon. The number of segments must be odd so that the same polymer is found at both ends so as to “balance” the structure. This fiber is anisotropic and is difficult to process as a staple fiber. As a filament, however, it would be acceptable in the spunbond process.
  • segmented pie configurations Another challenge of using segmented pie configurations is that the overall fiber shape upon splitting is a wedge. This configuration is a direct result of the process to producing the small micro-denier fibers. Consequently, while suitable for their intended purpose, nonetheless, other shapes of fibers may be desired which produce advantageous application results. Such shapes are currently unavailable under standard segmented processes.
  • U.S. Patent No. 6,455,156 discloses one such structure.
  • a primary fiber component, the sea is utilized to envelope smaller interior fibers, the islands.
  • Such structures provide for ease of manufacturing but require the removal of the sea in order to reach the islands. This is done by dissolving the sea in a solution which does not impact the islands. Since it is necessary to extract the island components, the method restricts the types of polymers which may be utilized in that they are not affected by the sea removal solution. In addition, the process of removing the islands is not environmentally sound because of the use of solvents to remove the sea.
  • Such island-in-the-sea staple fibers are commercially available. They are most often used in making synthetic leathers and suedes in a dry lay process such as carding. Another end-use that has resulted in much interest in such fibers is in technical wipes, where the small fibers lead to a large number of small capillaries resulting in better fluid absorbency and better dust pick-up. For a similar reason, such fibers are of interest in filtration.
  • methods for producing bicomponent filaments are disclosed wherein the bicomponent filaments/fibers comprise islands-in the-sea fibers including a low amount of external “sea” component.
  • the filaments/fibers include a sea component from 5% to 15% of the fiber.
  • methods for producing micro denier fabrics are disclosed wherein bicomponent islands-in-the-sea fiber/filaments are fibrillated by hydroentangling. These relatively thin sections can be easily and fully or partially fibrillated using lower energy. Further, the surface of the drum used in hydroentangling is smooth that allows the separation of the fibrils after fibrillation.
  • the materials used for the external fiber component and the internal fiber component should be incompatible to facilitate fibrillation.
  • An additive may also be used to improve fibrillation.
  • micro-denier fabric is a nonwoven fabric. Filters and masks made of these fabrics are also disclosed.
  • Figure 1 depicts a typical bicomponent spunbonding process.
  • Figure 2 shows a typical process for hydroentangling.
  • Figure 3 shows an islands-in the sea bicomponent fiber.
  • Figure 4 depicts examples of 108 islands in an islands-in-the-sea bicomponent fibers produced in the spunbond processing.
  • Figures 5, 6, and 7 show examples of PP/PLA fibers with 37 islands and a sea content of 15%. Note that the sea is not fully fibrillated and the islands are dispersed.
  • Figure 8 is a pleated face mask made with the PP/PLA fiber material with 85/15 ratios of the two polymers.
  • Figures 9, 10 and 11 show examples of PP/PLA fibers with 37 islands and a sea content of 15%. Note that the sea is fully fibrillated and the islands are dispersed.
  • Figure 12 shows an example of mixed row islands in the sea with 37 islands and a sea content of 15%.
  • Figure 13 shows a schematic representation of the sectional arrangement of a spinneret for a row-mixed spunbond spin-pack.
  • a “staple fiber” means a fiber of finite length.
  • a staple fiber can be a natural fiber or a fiber cut from, for example, a filament.
  • a “filament” refers to a fiber that is formed into a substantially continuous strand.
  • nonwoven fabric means a fabric having a structure of individual fibers or filaments that are interlaid but not necessarily in an identifiable manner as with knitted or woven fabrics.
  • needle punching means to mechanically entangle a web of either non-bonded or loosely bonded fibers by passing barbed needles through the fiber web.
  • hydroentangle refers to a process by which a high velocity water jet or even an air jet is forced through a web of fibers causing them to become randomly entangled.
  • Hydroentanglement can also be used to impart images, patterns, or other surface effects to a nonwoven fabric by, for example, hydroentangling the fibers on a three-dimensional image transfer device such as that disclosed in U.S. Pat. No. 5,098,764 to Bassett et al. or a foraminous member such as that disclosed in U.S. Pat. No. 5,895,623 to Trokhan et al., both fully incorporated herein by reference for their teachings of hydroentanglement.
  • calender or “calendaring” refers to a process for imparting surface effects onto fabrics or nonwoven webs. Without intending to be limiting, a fabric or nonwoven web can be calendered by passing the fabric or nonwoven web through two or more heavy rollers, sometimes heated, under high nip pressures.
  • the subject matter disclosed herein relates to methods for partially fibrillating and fully fibrillating filaments.
  • the basis for these methods is the formation of a bicomponent filament that includes an external fiber component that envelopes an internal fiber component.
  • the internal fiber component comprises a plurality of fibers
  • the filament is of an island-in-the-sea configuration.
  • Partially fibrillated fabrics include a mixture of large and fine fibers with different fiber diameters when observed under a SEM.
  • Fully fibrillated materials include fibers with a uniform fiber diameter when observed under a SEM.
  • the methods disclosed herein further relate to the manufacturing of microdenier fabrics from bicomponent filaments.
  • the microdenier fabrics can be woven, knitted, or nonwoven.
  • the methods disclosed herein further relate to the manufacturing of nonwoven fabrics by spunbonding or through the use of bicomponent staple fibers formed into a web by any one of several means such as wetlay, drylay, etc., and bonded similarly to those used for the spunbonded filament webs.
  • Figure 1 shows an example of a typical bicomponent filament spunbonding process.
  • Polymer is fed from a hopper into an extruder.
  • the polymer is heated in the extruder, melting the polymer.
  • the polymer can be mixed with additives in the extruder.
  • the molten polymer passes through a filter and into a pump.
  • the polymer then moves into the spin pack which contains a spinneret.
  • the spinneret has holes that form the molten polymer into fibers or filaments. Quench air cools the polymer, causing the polymer to solidify. In attenuation, the polymer filaments are stretched, orienting the molecules in the polymer.
  • the polymer filaments are deposited on a forming belt to form a web.
  • the web then passes through a compaction roll and a calender, which bonds the filaments together to form a fabric.
  • Bonding methods used in spunbonding processes can include hydroentangling, needlepunching, thermal bonding, and other methods.
  • Figure 2 shows a typical process for hydroentangling.
  • Figure 2 shows a drum entangler using two drums and four injectors.
  • a pre-wet injector/manifold may be used as well, and there may be more drums and injectors used.
  • the methods disclosed herein for producing a nonwoven fabric include spinning a set of bicomponent filaments which includes an external fiber component and an internal fiber component, wherein the external fiber component enwraps the internal fiber component.
  • the external fiber component only partially enwraps the internal fiber component, leaving at least part of the internal fiber component exposed.
  • the external fiber component does not wrap the internal component.
  • the methods disclosed herein include producing an islands-in-the-sea bicomponent filament having multiple internal fiber components and an external fiber component.
  • the bicomponent filament comprises an island-in-the-sea fiber having from 2 to 1000 islands (internal components). In certain embodiments, the bicomponent filament has from 30 to 40 islands. In other embodiments, the bicomponent filament has from 2 to 100 islands, 100 to 200 islands, 300 to 400 islands, 400 to 500 islands, 500 to 600 islands, 600 to 700 islands, 700 to 800 islands, 800 to 900 islands, 900 to 1000 islands, 10 to 80 islands, 20 to 60 islands, or 30 to 50 islands.
  • Figure 3 shows a typical islands-in-the-sea bicomponent filament. The “islands” internal fiber components are enwrapped in the “sea” external fiber component. The islands in Figure 3 have a circular cross-section.
  • Figure 4 shows an islands-in-the-sea fiber with 108 islands. The ratio of islands to sea in the fiber shown in Figure 4 is 75/25%. The fibers shown in Figure 4 were produced by a spunbond process.
  • the internal fiber component can be produced having a non-round cross-section.
  • Such cross-section may be multi-lobal or round.
  • the internal fiber component comprises a thermoplastic polymer wherein said thermoplastic polymer is a copolyetherester elastomer with long chain ether ester units and short chain ester units joined head to tail through ester linkages.
  • the internal fiber component can comprise a thermoplastic polymer selected from the group consisting of nylon 6, nylon 6/6, nylon 6,6/6, nylon 6/10, nylon 6/11, nylon 6/12, nylon 11, nylon 12, polypropylene or polyethylene, polyesters, co polyesters or other similar thermoplastic polymers.
  • the internal fiber component can comprise a thermoplastic polymer selected from the group consisting of polyesters, polyamides, thermoplastic copolyetherester elastomers, polyolefins, poly acrylates, and thermoplastic liquid crystalline polymers.
  • the external fiber component comprises a thermoplastic polymer wherein said thermoplastic polymer is a copolyetherester elastomer with long chain ether ester units and short chain ester units joined head to tail through ester linkages.
  • the external fiber component comprises a thermoplastic polymer selected from the group consisting of nylon 6, nylon 6/6, nylon 6,6/6, nylon 6/10, nylon 6/11, nylon 6/12, nylon 11, nylon 12, polypropylene or polyethylene.
  • the external fiber component comprises a thermoplastic polymer selected from the group consisting of polyesters, polyamides, thermoplastic copolyetherester elastomers, polyolefins, poly acrylates, and thermoplastic liquid crystalline polymers. It is preferable to have internal and external fiber components that are not compatible, that is, they have minimal affinity for bonding to or sticking to one another.
  • the islands-in-the-sea fibers can comprise an additive in addition to the internal and external fiber components to facilitate fibrillation.
  • additives include a polyolefin with magnesium stearate.
  • the additive can be present at from 0 to 15 % by weight of the fiber, e.g., from 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15% by weight, where any of the stated endpoints can form an upper or lower endpoint of a range.
  • the external fiber component, or sea is fractured.
  • the sea component can remain in the finished nonwoven fabric instead of being removed by dissolving or other methods. Leaving the sea component in the finished nonwoven fabric has multiple advantages, including reducing the cost of production and being more environmentally sound because solvents are not needed to dissolve the sea.
  • the compatibility between the fiber components is measured by the chi factor (c) or the solubility parameter of the two polymers used. At the temperatures at which the polymers are processed, there can be chemical interactions between the two polymers, which can affect the interface between the polymer components.
  • the external fiber component comprises from 5%- 30% of the total fiber for ease of fibrillation. In some embodiments, the external component is less than 20% of the total fiber. In one embodiment, the external component is 10% or 15% of the total fiber. In other embodiments, the external fiber component is 5%-10%, 6%-10%, 7%-10%, 8%-10%, 9%-10%, 5%-15%, 6%-15%, 7%-15%, 8%-15%, 9%-15%, 10%- 15%, 11 %- 15%, 12%-15%, 13%-15%, 14%-15%, 15%, 5%-25%, 10%- 25%, 15%-25%, or 15%-30% of the total fiber.
  • the external sea component does not entirely enwrap the internal islands components. In certain embodiments, for example when the sea component is less than 20% of the total fiber, the sea forms a thin barrier between the islands due to the low amount of external sea component. This increases the ease of fibrillation.
  • the sea enwraps the islands less than 90%. In certain embodiments, the sea enwraps the islands less than 75%, less than 70%, less than 65%, less than 60%, less than 55%, less than 50%, from 1% to 90%, 10% to 90%, 20% to 90%, 30% to 90%, 40% to 90%, 50% to 90%, 60% to 90%, 70% to 90%, or 80% to 90%.
  • the fibrillation process utilizes hydroentangling energy for fibrillating the external fiber component.
  • the hydro energy used for fibrillation is also sufficient for hydroentangling the set of bicomponent filaments/fibers.
  • the hydroentanglement process typically occurs after the bicomponent filaments/fibers have been positioned onto a belt carrier in the form of a web. The process produces micro-denier fibers which can be from 0.1 and 5 microns in diameter.
  • the diameter is from 0.1 and 0.5 microns, 0.5 and 1 microns, 1 and 1.5 microns, 1.5 and 2 microns, 2 and 2.5 microns, 2.5 and 3 microns, 3 and 3.5 microns, 3.5 and 4 microns, 4 and 4.5 microns, 4.5 and 5 microns, 0.1 and 1 microns, 0.1 and 2 microns, 0.1 and 3 microns, 0.1 and 4 microns, 1 and 5 microns, 2 and 5 microns 3 and 5 microns, or 4 and 5 microns.
  • the web or the nonwoven fabric can be exposed to one or more hydroentangling manifolds to fibrillate and hydroentangle the fiber components.
  • the web or nonwoven fabric can have a first surface and a second surface.
  • the first surface is exposed to water pressure from one or more hydroentangling manifolds.
  • the first surface and second surface are exposed to water pressure from one or more hydroentangling manifolds.
  • the one or more hydroentangling manifolds can have a water pressure from 10 bars to 1000 bars.
  • the water pressure used for hydroentanglement can be from 10 bars and 500 bars.
  • the water pressure used for hydroentanglement is from 10 bars to 100 bars, 10 bars to 200 bars, 10 bars to 300 bars, 10 bars to 400 bars, 10 bars to 600 bars, 100 bars to 200 bars, 300 bars to 400 bars, 500 bars to 600 bars, 600 bars to 700 bars, 700 bars to 800 bars, 800 bars to 900 bars, 900 bars to 1000 bars, or 500 bars to 1000 bars.
  • the water pressured used for hydroentanglement is from 10 bars to 300 bars.
  • a series of injectors or manifolds are used, and the pressure is gradually increased.
  • the hydroentangling manifold water jets are spaced at least 600 microns away from each other.
  • the water jets are spaced from 600 microns to 4800 microns apart, e.g., from 600 microns to 1200 microns, from 600 microns to 1800 microns, 600 microns to 2400 microns, 1200 microns to 4800 microns apart, from 1200 microns to 1800 microns, 1200 microns to 2400 microns, 1800 microns to 2400 microns, 1800 microns to 2400 microns, or 2400 microns to 4800 microns apart.
  • Each water jet spacing pertains to one manifold. In certain embodiments, for the disclosed method, 3, 4, 5, 6, 7, 8, or 9 manifolds can be used. In other embodiments, more than 9 manifolds can be used.
  • hydroentangling can use multiple manifolds where the spacing of the water jets increases or decreases from the first manifold or set of manifolds to the last manifold or set of manifolds.
  • at least 3 manifolds can have jet spacings of at least 1200 microns, where the rest are below 1200 microns.
  • at least 4, 5, or 6 manifolds can have jets at least 1200 microns apart where the rest are below 1200 microns.
  • at least 3, 4, or 5 manifolds can have jet spaced at least 2400 microns apart where the rest are less than 2400 microns apart.
  • 6 manifolds can be used with at least three of the water jets being spaced 1200 microns apart, at least two of the water jets being spaced at least 2400 microns apart, and at least one of the water jets being spaced 600 microns apart.
  • 5 manifolds can be used with at least two of the water jets being spaced 1200 um apart, at least two of the water jets being spaced at least 2400 um apart, and at least one of the water jets being spaced 600 microns apart.
  • 4 manifolds can be used with at least two of the water jets being spaced 1200 um apart and at least two of the water jets being spaced at least 2400 microns apart.
  • 3 manifolds can be used with at least two of the water jets being spaced 1200 microns apart. This spacing of the manifold jet strips can lead to partial fibrillation of the bicomponent filaments/fibers.
  • the partial fibrillation allows for a low- density material with a low pressure drop while keeping a high efficiency.
  • the structure of the material is made up of fine fibrils and larger fibers. Partial fibrillation is defined by about 50% of the fibers being fibrillated. This can be determined by SEM micrographs.
  • from 80% to 10% of the fibers are fibrillated, e.g., 70%, 60%, 50%, 40%, 30%, 20%, or 10%, where any value can form the upper or lower endpoint of a range, can be fibrillated as determined by SEM micrographs.
  • Figures 5, 6, and 7 show nonwoven fabrics made from partially fibrillated bicomponent filaments, as described herein.
  • the sea is partially fibrillated, and the islands are dispersed. The smaller flat fibrils are the sea after fracturing or fibrillation.
  • the fibers shown in Figures 5, 6, and 7 are all made from a polypropylene islands and PLA.
  • the sea can be other thermoplastics such as polyesters, co-polyester, polyamides, etc. These polymer combinations are effective when there is a need to split the fibers mechanically.
  • the islands account for 85% to 95 % of the total mass of the fiber, while the sea is only 15% to 5%. In an embodiment, the sea is about 10% of the total mass of the fiber.
  • the islands can be made from PLA and the sea can be made from polypropylene. In other words, the island and the sea polymers can be switched.
  • the thickness of the fabric that results from this disclosed method can be from 1 to 2 mm, e.g., from 1 mm to 1.2 mm, from 1 mm to 1.4 mm, from 1.4 mm to 1. 6 mm, from 1.4 mm to 1.8 mm, or 1.4 mm to 2 mm.
  • Figures 9, 10, and 11 show nonwoven fabrics made from fully fibrillated bicomponent filaments, as described herein.
  • the sea is fully fibrillated and the islands are dispersed.
  • the smaller flat fibrils are the sea after fracturing or fibrillation.
  • the fibers shown in Figures 8, 9, and 10 are all made from a polypropylene islands and PLA.
  • the sea can be other thermoplastics such as 20 polyesters, co-polyester, polyamides, etc. These polymer combinations are effective when there is a need to split the fibers mechanically.
  • the islands account for 85% to 95 % of the total mass of the fiber, while the sea is only 15% to 5%. In an embodiment, the sea is about 10% of the total mass of the fiber.
  • the islands can be made from PLA and the sea can be made from polypropylene. In other words, the island and the sea polymers can be switched. Further, 25 adding an oil additive to the polypropylene facilitates fibrillation.
  • a nonwoven fabric comprising microfibers or nanofibers can be produced which can be used in high efficiency filters.
  • the structure can also be used in wipes, cleaning cloths, and textiles which are durable and have good abrasion resistance.
  • Facemask standards are specific to regulated fitted masks and surgical masks.
  • the performance of regulated masks such as N95, N99 and N100 are measured in terms of their ability to capture particles at 0.3 microns.
  • N95 means 95% or more
  • N99 means 99.9% or more
  • N100 means a minimum efficiency of 99.97% at capturing particles of 0.3 microns. The method for determining this is the NIOSH Standard Procedure No.
  • the fabric produced by the disclosed methods can be manufactured into a surgical mask, fitted mask, pleated mask, mask filter inserts, respirator, or multi layer mask.
  • FIG. 8 is an example of a pleated mask using a fabric prepared by the disclosed methods. It has a weight of 100.56 g/m 2 , an efficiency of 91.2% at 0.3 microns, and a pressure drop of 8.54 pascals.
  • multiple layers of the disclosed fabrics can have efficiency rate of over 95%, N95, N99, or N100.
  • two layers of the fabric produced by the disclosed methods have over a 95% efficiency while three layers have over a 99% efficiency.
  • most surgical masks have less than 70% efficiency rate at 0.3 microns.
  • the pressure drop is also a significant feature.
  • the regulated fitted masks have a pressure drop of 100 to 125 pascals measured at a flow rate of 85 L/min.
  • the disclosed fabrics can also have a pressure drop of 90 pascals or less.
  • a mask mad from a fabric as disclosed herein can have a pressure drop of 5-90, 5-70, 5-50, 5-30, 5-15, 10- 90, 10-70, 10-50, 10-30, 20-90, 20-70, 20-50, 20-30, 30-90, 30-70, 30-50, 40-90, 40-70, 40-50, 50-90, 50-70, 60-90, 60-70, 70-90, or 80-90 pascals at a flow rate of 85 L/min.
  • the disclosed fabrics can be used as part of the filter, the molded portion that surrounds the mouth and nose, or both.
  • the disclosed fabrics can also be sewn or quilted into surgical masks.
  • High efficiency filters are those capable of capturing particles 0.3 microns or lower.
  • the Minimum Efficiency Rating Value (MERV) set by ASHRAE defines high efficiency as filters that start at MERV 13 or higher, where MERV 16 has up to 95% capture efficiency for particles in the range of 0.3 to 1 micron. These correspond to the European standards of F7, F8 and Hll.
  • a fabric produced by the disclosed methods can be manufactured into an HVAC filter with a MERV rating of 13-16.
  • HEPA High efficiency particulate air
  • ULPA Ultra high efficiency particulate air
  • the ISO standard also requires that the electret charge be removed so that only mechanical efficiency is reported.
  • a fabric produced by the disclosed methods can meet or exceed these standards and match or exceed the performance of glass media at a lower pressure drop.
  • Spunbond fabrics contain large filaments - typically between 10 to 100 microns. Thus, they are not used in high efficiency filters or masks.
  • the micronfiber spunbonds of prior methods cannot be used for high efficiency filters due to defects due to poor fibrillation and their relatively high pressure drops.
  • a spinneret with 3 sections is used.
  • the first section of the spinneret includes islands in the sea
  • the second section of the spinneret includes solid islands
  • the third set of the spinneret includes islands in the sea.
  • the first section of the spinneret includes islands in the sea
  • the second section of the spinneret includes solid sea
  • the third set of the spinneret includes islands in the sea.
  • Figure 12 shows an example of mixed row islands in the sea with 37 islands and a sea content of 15%
  • Figure 13 shows a schematic representation of the sectional arrangement in a spinneret for a row-mixed spunbond spinpack.
  • compositions disclosed herein can meet or exceed these standards at an even lower pressure drop.
  • the lower pressure drop is achieved by using jets of water that are spaced apart 1200 microns or more.
  • the structure is and is only partially fibrillated. This leads to a lower density structure composed of fine fibrils and larger fibers.
  • Example 1 100 g/m 2 , 85% PP/5% PEA - Partially fibrillated 37 islands by using 7 injectors utilizing jet strips in hydroentangling where the jets are spaced at 2400, 2400, 1200, 1200, 1200, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 85.53 % at a pressure drop of 7 Pa.
  • Example 2 125 g/m 2 , 85% PP/15% PEA - Partially fibrillated 37 islands by using 7 injectors utilizing jet strips in hydroentangling where the jets are spaced 2400, 2400, 2400, 1200, 1200, 1200, 600 microns apart. These fabrics report an efficiency of mechanical 87.53 % at a pressure drop of 8.50 Pa.
  • Example 3 150 g/m 2 , 85% PP/15% PEA - Partially fibrillated 37 islands by using 7 injectors utilizing jet strips in hydroentangling where the jets are spaced 2400, 2400, 2400, 1200, 1200, 1200, 600 microns apart. These fabrics report an efficiency of 91.6% at a pressure drop of 15.2 Pa.
  • Example 4 175 g/m 2 , 85% PP/15% PEA - Partially fibrillated 37 islands by using 7 injectors utilizing jet strips in hydroentangling where the jets are spaced 2400, 2400, 2400, 1200, 1200, 1200, 600 microns apart. These fabrics report an efficiency of 95.24 % at a pressure drop of 22.1 Pa.
  • Example 5. 200 g/m 2 , 85% PP/15% PEA - Partially fibrillated 37 islands by using 7 injectors utilizing jet strips in hydroentangling where the jets are spaced 2400, 2400, 2400, 1200, 1200, 600 microns apart.
  • Example 7 Evaluation of Example 1.
  • the performance of the Example 1 by itself and in two layers were evaluated by using a PALAS filter testing unit to determine the minimum efficiency rating (MERV) for these filters.
  • MEV rating efficiencies are measured for particle sizes in the range of 0.3 to 1.0 microns (El), 1 to 3 microns (E2) and 3 to 10 microns (E3).
  • El 0.3 to 1.0 microns
  • E2 1 to 3 microns
  • E3 3 to 10 microns
  • a single layer meets the requirements for MERV 15 and a two layer exceeds the requirements for MERV 16. Table 1.
  • Example 8 Further Evaluation of Example 1. The performance of the Example 1 was evaluated multiple times to determine an average and standard deviation for the efficiency at 0.3 microns and pressure drop.
  • Example 9 Further Evaluation of Example 6. The performance of the Example 6 was also evaluated multiple times to determine an average and standard deviation for the efficiency at 0.3 microns and pressure drop.
  • Example 10 Further Evaluation of Example 1 in varying weights. The performance of Example 1 was evaluated in a variety of weights to determine an average and standard deviation for the efficiency at 0.3 microns and pressure drop.
  • Example 11 Performance of Example 1 after laundering.
  • the performance of the Example 1 was also evaluated after laundering in an increasing number of cycles to determine the effect that washing cycles had on efficiency.
  • the structure can be re charged after laundering by corona charging. The efficiency returning to its original level after charging shows that laundering does not damage the structural integrity of the fabric.
  • the structure is stronger than meltblown structures or composites of meltblown and spunbond structures.
  • Example 12 85% PP/5% PEA - Fully fibrillated 37 islands by using 12 injectors utilizing jet strips in hydroentangling where the jets are spaced 600 microns apart.
  • Example 13 90% PP/10% PEA - Fully fibrillated 37 islands by using 12 injectors utilizing jet strips in hydroentangling where the jets are spaced 1200 microns apart.
  • Example 14 85% PP/15% PEA - Fully fibrillated 37 islands by using 18 injectors utilizing jet strips in hydroentangling where the jets are spaced 600 microns apart.
  • Example 15 100 g/m 2 , 85% PP/15% PLA - Partially fibrillated 37 islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 80 to 83 % at a pressure drop of 6 to 8 Pa.
  • Example 16 125 g/m 2 , 85% PP/15% PLA - Partially fibrillated 37 islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 85 to 90 % at a pressure drop of 15 to 18 Pa. A double layer of these fabrics reports an efficiency of 94 to 98% at a pressure drop of 32 to 40 Pa.
  • Example 17 100 g/m 2 , 85% PP/15% PLA - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 81 to 84 % at a pressure drop of 5 to 7 Pa.
  • Example 18 125 g/m 2 , 85% PP/15% PLA - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart).
  • These fabrics report an efficiency of 86 to 91 % at a pressure drop of 14 to 16 Pa.
  • a double layer of these fabrics reports an efficiency of 96 to 99% at a pressure drop of 30 to 40 Pa.
  • Example 19 100 g/m 2 , 90% PTT/10% PLA - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 82 to 84 % at a pressure drop of 2 to 3 Pa.
  • Example 20 150 g/m 2 , 90% PTT/10% PLA - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 94 to 96 % at a pressure drop of 4 to 6 Pa.
  • Example 21 Example 21.
  • Example 22 100 g/m 2 , 90% PLA/10% PP - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 83 to 85 % at a pressure drop of 7 to 8 Pa.
  • Example 23 100 g/m 2 , 90% PTT/10% PEA - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 76 to 78 % at a pressure drop of 8 to 10 Pa.
  • Example 24 150 g/m 2 , 90% PTT/10% PEA - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 88 to 91 % at a pressure drop of 10 to 12 Pa.
  • Example 25 100 g/m 2 , 90% PLA/10% PE - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 74 to 76 % at a pressure drop of 10 to 12 Pa.
  • Example 26 100 g/m 2 , 90% PLA/10% PP - Partially fibrillated mixed row islands in the sea with 37 of islands by using 8 injectors utilizing jet strips in hydroentangling where the jets are spaced at 1200, 1200, 1200, 1200, 1200, 600, 600, 600 microns apart (a pre-wet manifold had jets 1200 microns apart). These fabrics report an efficiency of 75 to 79 % at a pressure drop of 10 to 15 Pa.

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

Abstract

Sont divulgués des procédés de fibrillation partielle ou complète de filaments à deux éléments de la configuration îlôt-dans-mer par hydroenchevêtrement. L'énergie d'hydroenchevêtrement peut à la fois fibriller l'élément de mer ainsi qu'entremêler les éléments de mer et d'îlot pour la liaison. Sont également divulgués des tissus fabriqués à partir de ces fibres au moins partiellement fibrillées et liées. Lesdits tissus présentent une faible chute de pression et une efficacité élevée et peuvent être utilisés pour des filtres et des masques.
PCT/US2021/028608 2019-02-25 2021-04-22 Filtres filés-liés présentant une faible chute de pression et une efficacité élevée WO2021216844A1 (fr)

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US20230279590A1 (en) * 2022-03-01 2023-09-07 Elc Management Llc Cosmetic Sheet Masks For Improved Product Delivery
US20230321571A1 (en) * 2022-04-08 2023-10-12 Delstar Technologies, Inc. Dual-layer gas filters and systems and methods for making the same
US20230321575A1 (en) * 2022-04-08 2023-10-12 Delstar Technologies, Inc. Filtration media incorporating nanoparticles and large linear density fibers
US20230321568A1 (en) * 2022-04-08 2023-10-12 Delstar Technologies, Inc. Filtration media and filters

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