U.S. patent application number 09/773845 was filed with the patent office on 2001-06-14 for nonwoven fabrics and fabric laminates from multiconstituent polyolefin fibers.
Invention is credited to Austin, Jared A., Fowells, William, Gessner, Scott L., Gillespie, J. Darrell, Newkirk, David D..
Application Number | 20010003693 09/773845 |
Document ID | / |
Family ID | 26993910 |
Filed Date | 2001-06-14 |
United States Patent
Application |
20010003693 |
Kind Code |
A1 |
Gessner, Scott L. ; et
al. |
June 14, 2001 |
Nonwoven fabrics and fabric laminates from multiconstituent
polyolefin fibers
Abstract
Nonwoven fabrics and fabric laminates are formed from continuous
filaments or staple fibers of a select blend of specific grades of
polyethylene and polypropylene which give improved fabric
performance not heretofore recognized or described, such as high
abrasion resistance, good tensile properties, excellent softness
and the like. Furthermore, these blends have excellent melt
spinning and processing properties which permit efficiently
producing nonwoven fabrics at high productivity levels. The
polymers are present as a lower-melting dominant continuous phase
and at least one higher-melting noncontinuous phase dispersed
therein. The lower-melting continuous phase forms at least 70
percent by weight of the fiber and comprises a linear low density
polyethylene polymer of a melt index of greater than 10 and a
density of less than 0.945 g/cc. At least one higher-melting
noncontinuous phase comprises a polypropylene polymer with melt
flow rate of greater than 20 g/10 min.
Inventors: |
Gessner, Scott L.;
(Encinitas, CA) ; Gillespie, J. Darrell;
(Simpsonville, SC) ; Austin, Jared A.; (Greer,
SC) ; Newkirk, David D.; (Greer, SC) ;
Fowells, William; (Washougal, WA) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA
101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Family ID: |
26993910 |
Appl. No.: |
09/773845 |
Filed: |
January 31, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09773845 |
Jan 31, 2001 |
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08815551 |
Mar 12, 1997 |
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6207602 |
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08815551 |
Mar 12, 1997 |
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08648201 |
May 14, 1996 |
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08648201 |
May 14, 1996 |
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08344419 |
Nov 23, 1994 |
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Current U.S.
Class: |
442/363 ;
442/365; 525/240 |
Current CPC
Class: |
D04H 1/498 20130101;
D04H 1/54 20130101; Y10T 442/3886 20150401; Y10T 442/3976 20150401;
Y10T 442/679 20150401; Y10T 442/68 20150401; Y10T 442/62 20150401;
Y10T 442/674 20150401; D04H 1/56 20130101; D04H 3/007 20130101;
B32B 5/04 20130101; D04H 3/16 20130101; Y10T 442/663 20150401; Y10T
442/64 20150401; Y10T 442/678 20150401; Y10T 442/642 20150401; D04H
1/4291 20130101; D04H 1/559 20130101; Y10T 442/66 20150401; Y10T
442/348 20150401; D04H 3/14 20130101 |
Class at
Publication: |
442/363 ;
442/365; 525/240 |
International
Class: |
D01F 006/46; D04H
001/54; C08L 023/04; C08L 023/10 |
Claims
That which we claim is:
1. A nonwoven fabric comprising fibrous material in the form of
continuous filaments or staple fibers of a size less than 15
dtex/filament randomly arranged and bonded to one another at
discrete locations, said fibrous material being formed of a
dispersed blend of at least two different polyolefin polymers, said
polymers being present as a lower-melting dominant continuous phase
and at least one higher-melting noncontinuous phase dispersed
therein, said lower-melting continuous phase forming at least 70
percent by weight of the fibrous material and comprising a linear
low density polyethylene polymer of a melt index of greater than 10
and a density of less than 0.945 g/cc and said at least one
higher-melting noncontinuous phase comprising a polypropylene
polymer with melt flow rate of greater than 20 g/10 min.
2. A nonwoven fabric according to claim 1 wherein said filaments or
fibers are bonded to one another at discrete locations by thermal
point bonds.
3. A nonwoven fabric according to claim 1 wherein said
lower-melting continuous phase forms at least 80 percent by weight
of the fibrous material and comprises a linear low density
polyethylene having a density of 0.90-0.945 g/cc and a melt index
of greater than 25.
4. A nonwoven fabric according to claim 1 wherein said
lower-melting continuous phase forms at least 90 percent by weight
of the fibrous material and comprises a linear low density
polyethylene having a density of 0.90-0.945 g/cc, and said at least
one higher-melting noncontinuous phase comprises an isotactic
polypropylene polymer with melt flow rate of at least 20 g/10
min.
5. A nonwoven fabric according to claim 1, wherein said
lower-melting polymer phase comprises linear low density
polyethylene and said higher-melting polymer phase comprises an
isotactic polypropylene with a melt flow rate greater than 30 g/10
minutes.
6. A nonwoven fabric according to claim 1, wherein said
lower-melting polymer phase comprises linear low density
polyethylene with a melt index of greater than 30.
7. A nonwoven fabric according to claim 1, wherein said
higher-melting polymer phase comprises at least one copolymer or
terpolymer of propylene.
8. A nonwoven fabric according to claim 1, wherein said
lower-melting polymer phase comprises at least 80 percent by weight
low pressure, solution process, linear short chain branched
polyethylene with a melt index of greater than 30 and a density of
0.945 g/cc and said higher-melting polymer phase comprises 1 to 20
percent by weight of isotactic polypropylene.
9. A nonwoven fabric according to claim 1, wherein said
lower-melting polymer phase comprises linear low density
polyethylene with a melt index of 27 and said higher-melting
polymer phase comprises an isotactic polypropylene with a melt flow
rate of 35 g/10 minutes.
10. A nonwoven fabric comprising fibrous material in the form of
continuous filaments or staple fibers of a size less than 15
dtex/filament randomly arranged and bonded to one another at
discrete locations, said fibrous material being formed of a
dispersed blend of at least two different polyolefin polymers, said
polymers being present as a lower-melting dominant continuous phase
and at least one higher-melting noncontinuous phase dispersed
therein, said lower-melting continuous phase forming at least 70
percent by weight of the fibrous material and comprising a
polyethylene and said at least one higher-melting noncontinuous
phase comprising at least one copolymer or terpolymer of
propylene.
11. A nonwoven fabric according to claim 10 wherein said
polyethylene comprises one or more polyethylenes selected from the
group consisting of low density polyethylene, high pressure long
chain branched polyethylene, linear low density polyethylene, high
density polyethylene and copolymers thereof.
12. A nonwoven fabric according to claim 10 wherein said copolymer
or terpolymer of propylene comprises a random copolymer of
propylene with ethylene.
13. A nonwoven fabric laminate comprising a spunbonded nonwoven web
comprised of continuous filaments of a size less than 15
dtex/filament randomly arranged and bonded to one another at
discrete locations, said continuous filaments being formed of a
dispersed blend of at least two different polyolefin polymers, said
polymers being present as a lower-melting dominant continuous phase
and at least one higher-melting noncontinuous phase dispersed
therein, said lower-melting continuous phase forming at least 70
percent by weight of the fiber and comprising a linear low density
polyethylene polymer of a melt index of greater than 15 and a
density of less than 0.945 g/cc and said at least one
higher-melting noncontinuous phase comprising a polypropylene
polymer with melt flow rate of at least 20 g/10 min.; and at least
one other web bonded to said spunbonded nonwoven web to form a
unitary nonwoven laminate structure.
14. A nonwoven fabric laminate according to claim 13, wherein said
spunbonded web is bonded to said at least one other web by
hydroentanglement, thermal bonding or adhesive bonding.
15. A nonwoven fabric laminate according to claim 13, including a
multiplicity of discrete thermal bonds bonding said spunbonded web
to said at least one other web.
16. A nonwoven fabric laminate according to claim 13, wherein said
at least one other web comprises a web of meltblown
microfibers.
17. A nonwoven fabric laminate according to claim 13, wherein said
at least one other web comprises a polymer film.
18. A nonwoven fabric laminate according to claim 13, wherein said
polypropylene polymer comprises a copolymer of polypropylene with
up to 5 percent by weight ethylene.
19. A nonwoven fabric laminate according to claim 13, wherein said
lower-melting continuous phase forms at least 80 percent by weight
of the fiber and comprises a linear low density polyethylene having
a density of 0.90-0.945 g/cc and a melt index of greater than
25.
20. A nonwoven fabric laminate according to claim 13, wherein said
lower-melting polymer phase comprises at least 80 percent by weight
low pressure, solution process, linear short chain branched
polyethylene with a melt index of greater than 50 and a density of
0.925 g/cc and said higher-melting polymer phase comprises 1 to 20
percent by weight of an isotactic polypropylene with a melt flow
rate greater than 20 g/10 minutes.
21. A nonwoven fabric laminate according to claim 13, wherein said
lower-melting polymer phase comprises linear low density
polyethylene with a melt index of 27 and said higher-melting
polymer phase comprises an isotactic polypropylene with a melt flow
rate of 35 g/10 minutes.
22. A nonwoven fabric laminate according to claim 13, wherein said
spunbonded nonwoven web includes a multiplicity of thermal
bonds.
23. A nonwoven fabric laminate according to claim 13, wherein said
multiconstituent fibers comprise continuous filamentary strands
randomly disposed and bonded to one another to form a spunbonded
fabric.
24. A nonwoven fabric laminate comprising a nonwoven web of staple
fibers of a size less than 15 dtex/filament randomly arranged and
bonded to one another at discrete locations, said fibers being
formed of a dispersed blend of at least two different polyolefin
polymers, said polymers being present as a lower-melting dominant
continuous phase and at least one higher-melting noncontinuous
phase dispersed therein, said lower-melting continuous phase
forming at least 70 percent by weight of the fiber and comprising a
linear low density polyethylene polymer of a melt index of greater
than 10 and a density of less than 0.945 g/cc and said at least one
higher-melting noncontinuous phase comprising a polypropylene
polymer with melt flow rate of at least 20 g/10 min.; and at least
one other web bonded to said nonwoven web to form a unitary
nonwoven laminate structure.
25. A nonwoven fabric laminate comprising a spunbonded nonwoven web
comprised of continuous filaments of a size less than 15
dtex/filament randomly arranged and bonded to one another at
discrete locations, said continuous filaments being formed of a
dispersed blend of at least two different polyolefin polymers, said
polymers being present as a lower-melting dominant continuous phase
and at least one higher-melting noncontinuous phase dispersed
therein, said lower-melting continuous phase forming at least 70
percent by weight of the fibrous material and comprising a
polyethylene and said at least one higher-melting noncontinuous
phase comprising at least one copolymer or terpolymer of propylene,
and at least one other web bonded to said spunbonded nonwoven web
to form a unitary nonwoven laminate structure.
26. A nonwoven fabric according to claim 25 wherein said
polyethylene comprises one or more polyethylenes selected from the
group consisting of low density polyethylene, high pressure long
chain branched polyethylene, linear low density polyethylene, high
density polyethylene and copolymers thereof.
27. A disposable absorbent personal care product comprising a
plurality of layers, at least one of said layers comprising a
nonwoven fabric comprised of fibrous material in the form of
continuous filaments or staple fibers of a size less than 15
dtex/filament formed of a dispersed blend of at least two different
polyolefin polymers, said polymers being present as a lower-melting
dominant continuous phase and at least one higher-melting
noncontinuous phase dispersed therein, said lower-melting
continuous phase forming at least 70 percent by weight of the
fibrous material and comprising a linear low density polyethylene
polymer of a melt index of greater than 10 and a density of less
than 0.945 g/cc and said at least one higher-melting noncontinuous
phase comprising a polypropylene polymer with melt flow rate of
greater than 20 g/10 min.
28. The disposable personal care product according to claim 27
wherein the fibrous material comprises continuous filaments
randomly arranged and bonded to one another at discrete locations
to form a nonwoven spunbonded fabric.
29. The disposable personal care product according to claim 27
wherein said lower-melting continuous phase forms at least 80
percent by weight of the fiber and comprises a linear low density
polyethylene having a density of 0.90-0.945 g/cc and a melt index
of greater than 25.
30. The disposable personal care product according to claim 27
wherein said disposable absorbent personal care product is a diaper
or incontinence pad.
31. The disposable personal care product according to claim 27
wherein said disposable absorbent personal care product is a diaper
having leg cuffs, said leg cuffs being formed by said least one
layer comprised of fibers a highly dispersed blend of at least two
different polyolefin polymers.
32. The disposable personal care product according to claim 27
wherein said disposable absorbent personal care product is a
sanitary napkin.
Description
[0001] This invention relates to nonwoven fabrics and to fabric
laminates which comprise multiconstituent fibers formed from a
select combination of polyolefin polymers. The invention more
particularly relates to nonwoven fabrics and laminates of the type
described having improved fabric properties and processing
characteristics.
[0002] Nonwoven fabrics produced from spun polymer materials are
used in a variety of different applications. Among other uses, such
nonwoven fabrics are employed as the cover sheet for disposable
diapers or sanitary products. There is considerable interest in
making disposable diapers more comfortable and better fitting to
the baby. An important part of the diaper comfort is the softness
or hardness of the nonwovens used to make the diaper, including the
diaper topsheet, barrier leg cuffs, and in some advanced designs,
the fabric laminated to the backsheet film. In some diaper designs,
a high degree of fabric elongation is needed to cooperate with
elastic components for achieving a soft comfortable fit.
[0003] One approach to improved diaper topsheet softness is to use
linear low density polyethylene (LLDPE) as the resin instead of
polypropylene for producing spunbonded diaper nonwoven fabrics. For
example, Fowells U.S. Pat. No. 4,644,045 describes spunbonded
nonwoven fabrics having excellent softness properties produced from
linear low density polyethylene. However, the above-described
softness of LLDPE spunbonded fabric has never been widely utilized
because of the difficulty in achieving acceptable abrasion
resistance in such products. The bonding of LLDPE filaments into a
spunbonded web with acceptable abrasion resistance has proven to be
very difficult. Acceptable fiber tie down is observed at a
temperature just below the point that the filaments begin to melt
and stick to the calender. This very narrow bonding window has made
the production of LLDPE spunbond fabrics with acceptable abrasion
resistance very difficult. Thus, the softness advantage offered by
LLDPE spunbonded fabrics has not been successfully captured in the
marketplace.
[0004] The present invention is based upon the discovery that
blending a relatively small proportion of polypropylene of a select
class with the polyethylene imparts greatly increased abrasion
resistance to a nonwoven fabric formed from the polymer blend,
without significant adverse effect on the fabric softness
properties. It is believed that the polyethylene and the
polypropylene form distinct phases in the filaments. The
lower-melting polyethylene is present as a dominant continuous
phase and the higher-melting polypropylene is dispersed in the
dominant polyethylene phase.
[0005] A number of prior publications describe fibers formed of
blends of linear low density polyethylene and polypropylene. For
example, U.S. Pat. No. 4,839,228 and EP 394,954 teach that useful
fibers are formed from blends which are predominantly
polypropylene. WO 90/10672 describes that useful fibers are
prepared from blends of polypropylene and polyethylene, especially
LLDPE, where the ratio of polypropylene to polyethylene is from 0.6
to 1.5. U.S. Pat. No. 4,874,666 describes fibers formed from a
blend of LLDPE and high molecular weight crystalline polypropylene
of melt flow rate below 20 g/10 minutes. U.S. Pat. Nos. 4,632,861
and 4,634,739 describe fibers formed from a blend of a branched low
density polyethylene blended with from 5 to 35 percent
polypropylene.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, nonwoven fabrics
and nonwoven fabric laminates are formed from fibers of a select
blend of specific grades of polyethylene and polypropylene which
give improved fabric performance not heretofore recognized or
described, such as high abrasion resistance, good tensile
properties, excellent softness and the like. Furthermore, these
blends have excellent melt spinning and processing properties which
permit efficiently producing nonwoven fabrics at high productivity
levels.
[0007] The nonwoven fabrics of the present invention are comprised
of fibrous material in the form of continuous filaments or staple
fibers of a size less than 15 dtex/filament formed of a dispersed
blend of at least two different polyolefin polymers. The polymers
are present as a lower-melting dominant continuous phase and at
least one higher-melting noncontinuous phase dispersed therein. The
lower-melting continuous phase forms at least 70 percent by weight
of the fiber. The physical and rheological behavior of these blends
is part of a phenomenon observed by applicants wherein a small
amount of a higher modulus polymer reinforces a softer,
lower-modulus polymer and gives the blend better spinning, bonding
and strength characteristics than the individual constituents. The
lower melting, relatively low molulus polyethylene provides
desirable properties such as softness, elongation and drape; while
the higher-melting, higher modulus polypropylene phase imparts one
or more of the following properties to the dominant phase: improved
ability to bond the web; improved filament tie-down (reduces fuzz);
improved web properties--tensiles, and/or elongation and/or
toughness; rheological characteristics which improve spinning
performance and/or web formation (filament distribution).
[0008] According to one advantageous and important aspect of the
present invention, the lower-melting continuous phase comprises a
linear low density polyethylene polymer of a melt index of greater
than 10 (ASTM D1238-89, 190.degree. C.) and a density of less than
0.945 g/cc (ASTMD-792). At least one higher-melting noncontinuous
phase comprises a polypropylene polymer with melt flow rate of
greater than 20 g/10 min (ASTM D1238-89, 230.degree. C.).
[0009] In one of the preferred embodiments of the invention, the
lower-melting continuous phase forms at least 80 percent by weight
of the fiber and comprises a linear low density polyethylene having
a density of 0.90-0.945 g/cc and a melt index of greater than 25
g/10 minutes.
[0010] In another preferred embodiment, said lower-melting polymer
phase comprises linear low density polyethylene as described above
and said higher-melting polymer phase comprises an isotactic
polypropylene with a melt flow rate greater than 30 g/10
minutes.
[0011] In still another preferred embodiment said lower-melting
polymer phase comprises at least 80 percent by weight low pressure,
solution process, linear short chain branched polyethylene with a
melt index of greater than 30 and a density of 0.945 g/cc and said
higher-melting polymer phase comprises 1 to 20 percent by weight of
isotactic polypropylene.
[0012] In another embodiment of the invention, said lower-melting
polymer phase comprises linear low density polyethylene with a melt
index of 27 and said higher-melting polymer phase comprises an
isotactic polypropylene with a melt flow rate of 35 g/lo
minutes.
[0013] According to another aspect of the present invention, the
lower-melting dominant continuous phase is blended with a
higher-melting noncontinuous phase of propylene co- and/or ter-
polymers. When propylene co- and/or ter- polymers are used as the
higher-melting noncontinuous phase, the lower melting continuous
phase may be comprised of one or more polyethylenes selected from
the group consisting of low density polyethylene, high pressure
long chain branched polyethylene, linear low density polyethylene,
high density polyethylene and copolymers thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] In the drawings which form a portion of the original
disclosure of the invention:
[0015] FIG. 1 diagrammatically illustrates one method and apparatus
for manufacturing the nonwoven webs according to the invention;
[0016] FIG. 2 is a fragmentary plan view of a nonwoven web of the
invention;
[0017] FIG. 3 is a diagrammatical cross-sectional view of a
nonwoven fabric laminate in accordance with the invention; and
[0018] FIG. 4 is a diagrammatical cross-sectional view of a
laminate of the nonwoven fabric of FIG. 2 with a film.
DETAILED DESCRIPTION
[0019] Linear low density polyethylene (LLDPE) is produced in
either a solution or a fluid bed process. The polymerization is
catalytic. Ziegler Natti and single-site metallocene catalyst
systems have been used to produce LLDPE. The resulting polymers are
characterized by an essentially linear backbone. Density is
controlled by the level of comonomer incorporation into the
otherwise linear polymer backbone. Various alpha-olefins are
typically copolymerized with ethylene in producing LLDPE. The
alpha-olefins which preferably have four to eight carbon atoms, are
present in the polymer in an amount up to about 10 percent by
weight. The most typical comonomers are butene, hexene,
4-methyl-1-pentene, and octene. The comonomer influences the
density of the polymer. Density ranges for LLDPE are relatively
broad, typically from 0.87-0.95 g/cc (ASTM D-792).
[0020] Linear low density polyethylene melt index is also
controlled by the introduction of a chain terminator, such as
hydrogen or a hydrogen donator. The melt index for a linear low
density polyethylene can range broadly from about 0.1 to about 150
g/10 min. For purposes of the present invention, the LLDPE should
have a melt index of greater than 10, and preferably 15 or greater
for spunbonded filaments. Particularly preferred are LLDPE polymers
having a density of 0.90 to 0.945 g/cc and a melt index of greater
than 25.
[0021] Examples of suitable commercially available linear low
density polyethylene polymers include the linear low density
polyethylene polymers available from Dow Chemical Company, such as
the ASPUN series of Fibergrade resins, Dow LLDPE 2500 (55 MI, 0.923
density), Dow LLDPE Type 6808A (36 MI, 0.940 density), and the
Exact series of linear low density polyethylene polymers from Exxon
Chemical Company, such as Exact 2003 (31 MI, density 0.921).
[0022] The higher-melting polypropylene component can be an
isotactic or syndiotactic polypropylene homopolymer, or can be a
copolymer or terpolymer of propylene. The melt flow rate of the
polypropylene should be greater than 20 g/10 min., and preferably
25 or greater. Particularly suitable are polypropylene polymers
having an MFR of 35 to 65. Examples of commercially available
polypropylene polymers which can be used in the present invention
include SOLTEX Type 3907 (35 MFR, CR grade), HIMONT Grade
X10054-12-1 (65 MFR), Exxon Type 3445 (35 MFR), Exxon Type 3635 (35
MFR) AMOCO Type 10-7956F (35 MFR), and Aristech CP 350 J (melt flow
rate approximately 35). Examples of commercially available
copolymers of propylene include Exxon 9355 which is a random
propylene copolymer with 3% ethylene, 35 melt flow rate; and co-
and ter-polymers of propylene from the Catalloy.TM. series from
Himont.
[0023] The lower-melting polyethylene component and the
higher-melting polypropylene component can be present in
proportions ranging from 70 percent by weight polyethylene and 30
percent polypropylene to 99 percent by weight polyethylene and 1
percent polypropylene. In these proportions, the lower-melting
polyethylene component is present as a substantially continuous
phase and the higher-melting polypropylene is present as a
discontinuous phase dispersed in the polyethylene phase.
[0024] Appropriate combinations of polymers are combined and
blended before being melt-spun into fibers or fibrous webs. A high
degree of mixing is used in order to prepare blends in which the
polypropylene component is highly dispersed in the polyethylene
component. In some cases such mixing may be achieved in the
extruder as the polymers are converted to the molten state.
However, in other cases it may be preferred to use an extra mixing
step. Among the commercially available mixers that can be used are
the Barmag 3DD three-dimensional dynamic mixer supplied by Barmag
AG of West Germany and the RAPRA CTM cavity-transfer mixer supplied
by the Rubber and Plastics Research Association of Great
Britain.
[0025] The blended polymer dispersion is then either melt-spun into
fibers, which may be formed into a web for instance by carding,
airlaying, or wetlaying, or melt-spun directly into fibrous webs by
a spunbonding or meltblowing process. The web can then be bonded to
form a strong, soft biconstituent-fiber nonwoven fabric. Webs of
the blended polymer dispersion can be made according to any of the
known commercial processes for making nonwoven fabrics, including
processes that use mechanical, electrical, pneumatic, or
hydrodynamic means for assembling fibers into a web, for example
carding, wetlaying, carding/ hydroentangling,
wetlaying/hydroentangling, and spunbonding. The webs of the blended
polymer dispersion can then be bonded by a multiplicity of thermal
bonds to give the webs sufficient strength and abrasion resistance
to be useful in, for example, diaper applications. Preferably the
bonds are thermal bonds formed by heating the fibers so that via a
combination of heat and pressure they become tacky and fuse
together at point of contact between the fibers. The thermal bonds
may be formed using any of the techniques known in the art for
forming discrete thermal bonds, such as calendering. Other thermal
bonding techniques, such as through-air bonding and the like, may
also be used.
[0026] FIG. 1 is a diagrammatical view of an apparatus, indicated
generally by the reference number 10, for producing a spunbonded
nonwoven web in accordance with the present invention. Various
spunbonding techniques exist, but all typically include the basic
steps of extruding continuous filaments, quenching the filaments,
drawing or attenuating the filaments by a high velocity fluid, and
collecting the filaments on a surface to form a web. The
spunbonding apparatus 10 is illustrated as a slotdraw type
spunbonding apparatus, although, as will be appreciated by the
skilled artisan, other spunbonding apparatus may be used.
Spunbonding apparatus 10 includes a melt spinning section including
a feed hopper 12 and an extruder 14 for the polymer. The extruder
14 is provided with a generally linear die head or spinneret 16 for
melt spinning streams of substantially continuous filaments 18. The
substantially continuous filaments 18 are extruded from the
spinneret 16 and typically are quenched by a supply of cooling air
20. The filaments are directed to an attenuation device 22,
preferably in the form of an elongate slot which includes
downwardly moving attenuation air which can be supplied from forced
air above the slot, vacuum below the slot, or eductively within the
slot, as is known in the art. In the attenuation device 22, the
filaments become entrained in a high velocity stream of attenuation
air and are thereby attenuated or drawn. The air and filaments are
discharged from the lower end of the attenuation device 22 and the
filaments are collected on a forming wire 24 as a nonwoven spunbond
web W.
[0027] The web W is conveyed to a bonding station 26 to form a
coherent bonded nonwoven fabric. In the embodiment shown, the web
is thermally bonded using a pair of heated calender rolls 27 and
28. Thermal bonds are formed by heating the filaments so that they
soften and become tacky, and fuse together contacting portions of
the filaments. The operating temperature and the compression force
of the heated rolls 27 and 28 should be adjusted to a surface
temperature and pressure such that the filaments present in
nonwoven web soften and bind the fibrous nonwoven web to thereby
form a coherent nonwoven fabric. The pattern of the calender rolls
may be any of those known in the art, including point bonding
patterns, helical bonding patterns, and the like. The term point
bonding is used herein to be inclusive of continuous or
discontinuous pattern bonding, uniform or random point bonding, or
a combination thereof, all as are well known in the art.
[0028] Although bonding station 26 has been illustrated in FIG. 1
as heated calender rolls, the rolls can, in other embodiments of
the invention, be replaced by other thermal activation zones. For
example, the bonding station may be in the form of a through-air
bonding oven, a microwave or other RF treatment zone. Other bonding
stations, such as ultrasonic welding stations, can also be used in
the invention. In addition other bonding techniques known in the
art can be used, such as adhesive bonding.
[0029] The thermally bonded nonwoven fabric is then wound by
conventional means onto roll 29. The nonwoven fabric can be stored
on roll 29 or passed to end use manufacturing processes, for
example for use as a component in a disposable personal care
article such as diapers and the like, medical fabrics, wipes, and
the like.
[0030] FIG. 2 illustrates a thermally bonded spunbonded nonwoven
fabric W produced in accordance with the present invention. The
nonwoven fabric W may be laminated into structures having a variety
of desirable end-use characteristics. FIG. 3 is a diagrammatical
cross-sectional view of a nonwoven fabric laminate in accordance
with one embodiment of the invention. In this embodiment, the
laminate, generally indicated at 40, is a two-ply laminate. Ply 41
comprises a web which may be a meltblown nonwoven web, a spunbonded
web, or a web of staple fibers. Ply 42 comprises a nonwoven web
formed of a highly dispersed blend of polyolefin polymers, such as
the nonwoven fabric W produced as described above.
[0031] The plies may be bonded and/or laminated in any of the ways
known in the art. Lamination and/or bonding may be achieved, for
example, by hydroentanglement of the fibers, spot bonding,
through-air bonding and the like. For example, when ply 41 is a
fibrous web, lamination and/or bonding may be achieved by
hydroentangling, spot bonding, through-air bonding and the like. In
the embodiment shown in FIG. 3, plies 41 and 42 are laminated
together by passing through a heated patterned calender to form
discrete thermal point bonds indicated at 43. It is also possible
to achieve bonding through the use of an appropriate bonding agent,
i.e., an adhesive. The term spot bonding is inclusive of continuous
or discontinuous pattern bonding, uniform or random point bonding
or a combination thereof, all as are well known in the art.
[0032] The bonding may be made after assembly of the laminate so as
to join all of the plies or it may be used to join only selected of
the fabric plies prior to the final assembly of the laminate.
Various plies can be bonded by different bonding agents in
different bonding patterns. Overall, laminate bonding can also be
used in conjunction with individual layer bonding.
[0033] Laminates of a spunbond web from the highly blended polymer
dispersion as described above with a web of meltblown microfibers
have utility as barrier fabrics in medical applications, protective
clothing applications, and for hygiene applications such as barrier
leg cuffs. Of particular utility for hygiene applications are
spunbond/meltblown laminates of reduced basis weight, such as made
with a 17 grams per square meter (gsm) spunbonded web of this
invention and 2-3 gsm meltblown web. Such barrier laminates could
be used, for example, as barrier leg cuffs in diapers.
[0034] Another type of nonwoven fabric laminate may be made by
combining nonwoven web of this invention with a film, for example a
film of a thermoplastic polymer, such as a polyolefin, to make
barrier fabrics useful for hygiene applications such as barrier leg
cuffs and diaper backsheets. FIG. 4 illustrates one such laminate,
which includes a ply or layer 42' comprising a nonwoven web formed
of a highly dispersed blend of polyolefin polymers, such as the
nonwoven fabric W of FIG. 2, laminated to a polyolefin film layer
44, such as for example a polyethylene film of a thickness of 0.8
to 1 mil. Lamination and/or bonding of the nonwoven layer 42' to
the film layer 44 can be achieved by adhesive lamination using a
continuous or discontinuous layer of adhesive. This adhesive
approach may yield a diaper backsheet with superior softness and
hand. The nonwoven fabric laminate could also be produced by
thermal lamination of the nonwoven fabric of this invention and
film webs together. This approach has the advantage of eliminating
the cost of the adhesive. It may also be desirable to utilize
coextruded film webs that include a sealing/bonding layer in
combination with a polyolefin layer in the film web that, when
combined with the nonwoven fabrics of the invention, maximize
softness and good thermal bonding characteristics. The nonwoven
fabric laminate could also be produced by direct extrusion of the
film layer 44 on ply 42'.
EXAMPLE 1
[0035] Ninety percent by weight of a linear low density
polyethylene (LLDPE) with a melt flow of 27 (Dow 6811 LLDPE) and
ten percent by weight of a polypropylene (PP) polymer with a melt
flow approximately 35 (Aristech CP 350 J) were dry blended in a
rotary mixer. The dry-blended mixture was then introduced to the
feed hopper of an extruder of a spunbond nonwoven spinning system.
Continuous filaments were meltspun by a slot draw process at a
filament speed of approximately 600 m/min and deposited upon a
collection surface to form a spunbond nonwoven web, and the web was
thermally bonded using a patterned roll with 12% bond area. For
comparison purposes, nonwoven spunbond fabrics were produced under
similar conditions with the same polymers, using 100% PP and 100%
LLDPE.
[0036] As shown in table 1, the 100% LLDPE spunbond samples
exhibited superior softness (75 and 77.5) compared to the 100%
polypropylene spunbond sample (30). However, the abrasion
resistance of the 100% LLDPE sample, as seen from the fuzz
measurement, was relatively high (12.5 and 2.4) compared to the
100% PP sample (0.3). The nonwoven fabric formed from the 90%
LLDPE/10% PP blend had a high softness (67.5) only slightly less
than the 100% LLDPE fabric, and had abrasion resistance (fuzz
value) of 1.0 mg., which is significantly better than the values
seen for 100% LLDPE. The blend sample also showed improved CD
tensile compared to products made with 100% LLDPE.
1TABLE 1 Sample A B C D C = comparison C C C I I = invention
Composition: % polypropylene 100 0 0 10 % polyethylene 0 100 100 90
filament dia. (microns) 17.5 20.9 20.9 22.5 Basis weight
(gsm).sup.1 23.1 25.2 24.6 24.8 Loft @ 95 g/in.sup.2 9.8 9.0 7.8
9.3 (mils).sup.2 Fuzz (mg).sup.3 0.3 12.5 2.4 1.0 Softness.sup.4 30
75 77.5 67.5 Strip Tensile (g/cm).sup.5 CD 557 139 157 164 MD 1626
757 639 467 Peak Elongation (%) CD 90 116 129 108 MD 93 142 106 119
TEA (in.g./in CD 852 297 346 354 MD 2772 2222 1555 1389 .sup.1gsm =
grams per square meter .sup.2Loft was determined by measuring the
distance between the top and the bottom surface of the fabric sheet
while the sheet was under compression loading of 95 grams per
square inch. The measurement is generally the average of 10
measurements. .sup.3Fuzz is determined by repeatedly rubbing a soft
elastomeric surface across the face of the fabric a constant number
of times. The fiber abraded from the fabric surface is then
weighed. Fuzz is reported as mg weight observed. .sup.4Softness was
evaluated by an organoleptic method wherein an expert panel
compared the surface feel of Example Fabrics with that of controls.
Results are reported as a softness score with higher values
denoting a more pleasing hand. Each reported value is for a single
fabric test sample, but reflects the input of several panel
members. .sup.5Tensile, Peak Elongation and TEA were evaluated by
breaking a one inch by seven inch long sample generally following
ASTM D1682-64, the one-inch cut strip test. The instrument
cross-head speed was set at 5 inches per minute and the gauge
length was set at 5 inches per minute. The Strip Tensile Strength,
reported as grams per centimeter, is generally the average of at
least 8 measurements. Peak Elongation is the percent # increase in
length noted at maximum tensile strength. TEA, Total Tensile Energy
Absorption, is calculated from the area under the stress-strain
curve generated during the Strip Tensile test.
EXAMPLE 2 (Control)
[0037] A control fiber was made by introducing 100% Dow LLDPE 2500
(55 MI, 0.923 density) to a feed hopper of a spinning system
equipped with an extruder, a gear pump to control polymer flow at
0.75 gram per minute per hole, and a spinneret with 34 holes of
L/D=4:1 and a diameter of 0.2 mm. spinning was carried out using a
melt temperature in the extruder of 215.degree. C. and a pack melt
temperature of 232.degree. C. After air quench, the resulting
filaments were drawn down at a filament speed of approximately 1985
m/min using an air aspiration gun operating at 100 psig to yield a
denier of 3.01 and denier standard deviation of 0.41.
EXAMPLE 3
[0038] Ninety parts by weight of Dow LLDPE Type 2500 (55 MI, 0.923
density) and ten parts of Himont X10054-12-1 polypropylene (65 MFR)
were dry blended in a rotary mixer and then introduced to the feed
hopper of the spinning system described in Example 2. Spinning was
carried out using a pack melt temperature of 211.degree. C. After
air quench, the resulting filaments were drawn down at a filament
speed of approximately 2280 M/Min using an air aspiration gun
operating at 100 psig to yield a denier of 2.96 and a denier
standard deviation of 1.37.
EXAMPLE 4
[0039] Ninety parts by weight of Dow LLDPE Type 2500 (55 MI, 0.923
density) and ten parts of Soltex 3907 polypropylene (35 MFR, 1.74
die swell, CR grade) were dry blended in a rotary mixer and then
introduced to the feed hopper of the spinning system described in
Example 2. Spinning was carried out using a pack melt temperature
of 231.degree. C. and an extruder melt temperature of 216.degree.
C. After air quench, the resulting filaments were drawn down at a
filament speed of approximately 2557 M/Min using an air aspiration
gun operating at 100 psig to yield a denier of 2.64 and a denier
standard deviation of 0.38.
EXAMPLE 5
[0040] Ninety parts by weight of Dow LLDPE Type 6808A (36 MI, 0.940
density) and ten parts of Soltex 3907 polypropylene (35 MFR, 1.74
die swell, CR grade) were dry blended in a rotary mixer and then
introduced to the feed hopper of the spinning system described in
Example 2. Spinning was carried out using a pack melt temperature
of 231.degree. C. and an extruder melt temperature of 216.degree.
C. After air quench, the resulting filaments were drawn down at a
filament speed of approximately 2129 M/Min using an air aspiration
gun operating at 100 psig to yield a denier of 3.17 and a denier
standard deviation of 2.22.
[0041] The quality of spinning for a given formulation has been
found to roughly correlate with the denier standard deviation. A
reduced standard deviation suggests more stable or higher quality
spinning. Thus it is unexpected and contrary to the teaching of the
prior art that the blend using a 35 MFR polypropylene in Example 4
yielded a more stable spinning than seen with the corresponding
LLDPE control in Example 2.
EXAMPLE 6
[0042] Eighty parts by weight of a linear low density polyethylene
pellets of 55 melt index and 0.925 g/cc density and twenty parts by
weight polypropylene pellets of 35 melt flow rate were dry blended
in a rotary mixer. The dry-blended mixture was then introduced to
the feed hopper of a spinning system equipped with an extruder with
a 30:1 l/d ratio, a static mixer, and a gear pump for feeding the
molten polymer to a heated melt block fitted with a spinneret.
Filaments were extruded from the spinneret and drawn using air
aspiration.
EXAMPLE 7
[0043] Samples of continuous filament spunbonded nonwoven webs were
produced from blends of a linear low density polyethylene with a
melt flow rate of 27 (Dow 6811A LLDPE) and a polypropylene
homopolymer (Appryl 3250YR1, 27 MFR) in various blend proportions.
Control fabrics of 100 percent polypropylene and 100 percent
polyethylene were also produced under similar conditions. The
fabrics were produced by melt spinning continuous filaments of the
various polymers or polymer blends, attenuating the filaments
pneumatically by a slot draw process, depositing the filaments on a
collection surface to form webs, and thermally bonding the webs
using a patterned calender roll with a 12 percent bond area. The
fabrics had a basis weight of approximately 25 gsm and the
filaments had an average mass/length of 3 dtex. The tensile
strength and elongation properties of these fabrics and their
abrasion resistance were measured, and these properties are listed
in Table 2. As shown, the 100 percent polypropylene control fabric
had excellent abrasion resistance, as indicated by no measurable
fuzz generation; however the fabrics had relatively low elongation.
The 100 percent polyethylene control fabric exhibited good
elongation properties, but very poor abrasion resistance (high fuzz
values and low Taber abrasion resistance) and relatively low
tensile strength. Surprisingly, the fabrics of the invention made
of blends of polypropylene and polyethylene exhibited an excellent
combination of abrasion resistance, high elongation, and good
tensile strength. It is noted that the CD elongation values of the
blends actually exceeded that of the 100% polyethylene control.
This surprising increase in elongation is believed to be
attributable to the better bonding of the filaments of the blend as
compared to the bonding achieved in the 100% polyethylene control,
which resulted in the fabrics of the invention making good use of
the highly elongatable filaments without bond failure.
2TABLE 2 MECHANICAL PROPERTIES OF POLYPROPYLENE (PP)/POLYETHYLENE
(PE) BLEND FABRICS 25/75 15/85 Fabric 100% PP PP/PE PP/PE 100% PE
MD Tensile 925 764 676 296 (g/cm).sup.6 CD Tensile 405 273 277 63
(g/cm).sup.6 MD Elongation 62 170 199 168 (%).sup.6 CD Elongation
70 190 224 131 (%).sup.6 Fuzz (mg).sup.7 0.0 0.3 0.5 19.0 Taber
Abrasion.sup.8 40 32 22 10 (cycles-rubber wheel) Taber
Abrasion.sup.8 733 200 500 15 (cycles - felt wheel) .sup.6Tensile
and Peak Elongation were evaluated by breaking a one inch by seven
inch long sample generally following ASTM D1682-64, the one-inch
cut strip test. The instrument cross-head speed was set at 5 inches
per minute and the gauge length was set at 5 inches per minute. The
Strip Tensile Strength, reported as grams per inch, is generally
the average of at least 8 measurements. Peak Elongation is the
percent increase in length noted at maximum tensile strength.
.sup.7Fuzz is determined by repeatedly rubbing a soft elastomeric
surface across the face of the fabric a constant number of times.
The fiber abraded from the surface is then weighed. Fuzz is
reported as mg weight observed. .sup.8Conducted according to ASTM
D3884-80 where the number of cycles was counted until failure.
Failure was defined as the appearance of a hole of one square
millimeter or greater in the surface of the fabric.
* * * * *