U.S. patent application number 09/933099 was filed with the patent office on 2003-03-27 for method for preparing multiple component meltblown webs.
Invention is credited to Bansal, Vishal, Davis, Michael C., Rudisill, Edgar N..
Application Number | 20030057613 09/933099 |
Document ID | / |
Family ID | 24736308 |
Filed Date | 2003-03-27 |
United States Patent
Application |
20030057613 |
Kind Code |
A1 |
Bansal, Vishal ; et
al. |
March 27, 2003 |
Method for preparing multiple component meltblown webs
Abstract
A process for forming multiple component meltblown webs in which
a poor-spinning polymer is co-spun with a good-spinning polymer in
a meltblowing process using high throughput and short
die-to-collector distances.
Inventors: |
Bansal, Vishal; (Richmond,
VA) ; Davis, Michael C.; (Midlothian, VA) ;
Rudisill, Edgar N.; (Nashville, TN) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY
LEGAL PATENT RECORDS CENTER
BARLEY MILL PLAZA 25/1128
4417 LANCASTER PIKE
WILMINGTON
DE
19805
US
|
Family ID: |
24736308 |
Appl. No.: |
09/933099 |
Filed: |
August 20, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09933099 |
Aug 20, 2001 |
|
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|
09681683 |
May 21, 2001 |
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Current U.S.
Class: |
264/555 ;
264/103; 264/171.1; 264/172.14; 264/172.18; 264/211.12 |
Current CPC
Class: |
D01D 5/0985 20130101;
D01D 5/32 20130101 |
Class at
Publication: |
264/555 ;
264/103; 264/171.1; 264/172.14; 264/211.12; 264/172.18 |
International
Class: |
D01D 005/088; D01D
005/32; D01D 007/00; D01F 008/06; D01F 008/12 |
Claims
What is claimed is:
1. A process for forming a multiple component meltblown web
comprising the steps of: melt blowing at least first and second
molten polymers through a die comprising a plurality of spin
orifices to form multiple component meltblown fibers; and
collecting the multiple component meltblown fibers as a multiple
component meltblown web on a collector surface at a
die-to-collector distance of less than 15.2 cm.
2. The process according to claim 1 wherein the die-to-collector
distance is between about 7.6 to 14 cm.
3. The process according to claim 2 wherein the die-to-collector
distance is between about 11.4 to 14 cm.
4. The process according to claim 1 wherein the total polymer
throughput is greater than about 0.5 g/orifice/min.
5. The process according to claim 4 wherein the total polymer
throughput is greater than about 0.6 g/orifice/min.
6. The process according to claim 1 wherein the first polymer is a
good-spinning polymer when meltblown to form a single component web
at a die-to-collector distance of less than 15.2 cm and the second
polymer is a poor-spinning polymer when meltblown to form a single
component web at a die-to-collector distance of less than 15.2
cm.
7. The process according to claim 6 wherein the first polymer has a
specific heat less than about 1.6 kJ/kg/.degree. K and a glass
transition temperature greater than about 25.degree. C. and the
second polymer has a specific heat of greater than about 1.6
kJ/kg/.degree. K and a glass transition temperature less than about
25.degree. C.
8. The process according to claim 7 wherein the first polymer is
selected from the group consisting of poly(ethylene terephthalate),
poly(hexamethylene adipamide), poly(.epsilon.-caprolactam), and
polystyrene and the second polymer is a polyolefin.
9. The process according to claim 8 wherein the first polymer is
poly(ethylene terephthalate) and the second polymer is
polyethylene.
10. The process according to claim 8 wherein the first polymer is
poly(ethylene terephthalate) and the second polymer is
polypropylene.
11. The process according to claim 8 wherein the multiple component
meltblown fibers are bicomponent fibers.
12. The process according to claim 11 wherein the first and second
polymers are arranged in a side-by-side configuration.
13. A process for forming a multiple component meltblown web
comprising the steps of: melt blowing at least first and second
molten polymers through a die comprising a plurality of spin
orifices to form multiple component meltblown fibers; and
collecting the multiple component meltblown fibers on a collector
surface at a die-to-collector distance of less than about 20.3 cm;
wherein a formation ratio of less than about 30
cm.multidot.orifice.multidot.min/g is used.
14. The process according to claim 13 wherein the die-to-collector
distance is less than about 15.2 cm.
15. The process according to claim 13 wherein the first polymer is
a good-spinning polymer and the second polymer is a poor-spinning
polymer when each polymer is meltblown separately to form single
component webs using a die to collector distance of less than about
20.3 cm and a formation ratio of less than about 30
cm.multidot.orifice.multidot.min/g.
16. The process according to claim 14 wherein the first polymer is
a good-spinning polymer and the second polymer is a poor-spinning
polymer when each polymer is meltblown separately to form single
component webs using a die-to-collector distance of less than about
15.2 cm and a formation ratio of less than about 30
cm.multidot.orifice.multidot.min/g.
17. The process according claim 13 wherein the first polymer has a
specific heat less than about 1.6 kJ/kg/.degree. K and a glass
transition temperature greater than about 25.degree. C. and the
second polymer has a specific heat of greater than about 1.6
kJ/kg/.degree. K and a glass transition temperature less than about
25.degree. C.
18. The process according to claim 17 wherein the glass transition
temperature of the second polymer is less than about 0.degree.
C.
19. The process according to claim 13 wherein the formation ratio
is less than about 20 cm.multidot.orifice.multidot.min/g.
20. The process according to claim 13 wherein the formation ratio
is between about 14 and 18 cm.multidot.orifice.multidot.min/g.
21. The process according to either of claims 1 or 13 wherein the
polymers are blown by a high velocity gas jet at a temperature
within about 30.degree. C. of the temperature of the polymers as
they exit the die.
22. The process according to claim 21 wherein the gas jet is heated
to a temperature within about 10.degree. C. of the temperature of
the polymers as they exit the die.
23. The process according to claim 13 wherein the first polymer is
selected from the group consisting of polyamides, polyesters, and
polystyrene and the second polymer is a polyolefin.
24. The process according to claim 23 wherein the first polymer is
selected from the group consisting of poly(ethylene terephthalate),
poly(hexamethylene adipamide), poly(.epsilon.-caprolactam), and
polystyrene and the second polymer is selected from the group
consisting of polyethylene and polypropylene.
25. The process according to claim 24 wherein the first polymer is
poly(ethylene terephthalate) and the second polymer is
polyethylene.
26. The process according to claim 24 wherein the first polymer is
poly(ethylene terephthalate) and the second polymer is
polypropylene.
27. The process according to claim 17 wherein the multiple
component fibers are bicomponent fibers.
28. The process according to claim 27 wherein the first and second
polymers are arranged in a side-by-side configuration.
29. The process according to either of claims 1 or 13 wherein the
meltblown web has a basis weight of between about 2 and 40
g/m.sup.2 and a hydrostatic head of greater than about 30 cm
H.sub.2O, the hydrostatic head being measured when the meltblown
web is in a thermally point-bonded spunbond-meltblown-spunbond
composite having a bonded area of between about 10 to 30 percent.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a method for preparing meltblown
webs having improved uniformity and barrier properties at high
polymer throughput and low die-to-collector distances. More
specifically, the method involves meltblowing multiple component
meltblown fibers wherein at least one of the components is a
polymer that spins poorly at low die-to-collector distances and at
least one of the components is a polymer that spins well at low
die-to-collector distances.
[0003] 2. Description of Related Art
[0004] In a meltblowing process, a nonwoven web is generally formed
by extruding molten polymer through a die and attenuating the
extruded melt streams with a high-velocity gas stream to form
meltblown fibers which are collected as a web. Die-to-collector
distances (DCD) of at least about 12 inches are generally required
to provide fiber forming, cooling and attenuation. However such
distances often result in undesirable non-uniformities in the web.
Attempts to reduce the DCD generally results in the formation of
harsh stiff webs due to fusing and over-bonding of the meltblown
fibers which often contain solid polymer globules commonly referred
to as "shot". Certain polymers such as polyolefins are especially
difficult to form into meltblown webs at high polymer throughputs
and short die-to-collector distances. Lau, U.S. Pat. No. 4,526,733
describes a method for forming meltblown fibers and webs using an
attenuating quench gas having a temperature at least 100.degree. F.
(37.8.degree. C.) cooler than the molten polymer. The use of a
relatively cool attenuating gas allows short die-to-collector
distances to be used and provides meltblown webs having improved
properties, but also requires the use of insulated or heated dies,
or heating the polymers to higher than normal spinning temperatures
to avoid freezing of the polymer inside the die tip.
[0005] In the production of meltblown webs, it is sometimes
desirable to form meltblown fibers from more than one polymeric
material where each material can have different physical properties
and contribute different characteristics to the meltblown web.
There is a need to provide a new method for forming uniform
meltblown multiple component webs at high throughput.
BRIEF SUMMARY OF THE INVENTION
[0006] In one embodiment, the present invention is directed to a
process for forming a multiple component meltblown web comprising
the steps of melt blowing at least first and second molten polymers
through a die comprising a plurality of spin orifices to form
multiple component meltblown fibers, andcollecting the multiple
component meltblown fibers as a multiple component meltblown web on
a collector surface at a die-to-collector distance of less than
15.2 cm.
[0007] In a further embodiment, the present invention is directed
to a process for forming a multiple component meltblown web
comprising the steps of melt blowing at least first and second
molten polymers through a die comprising a plurality of spin
orifices to form multiple component meltblown fibers, and
collecting the multiple component meltblown fibers on a collector
surface at a die-to-collector distance of less than about 20.3 cm,
wherein a formation ratio of less than about 30
cm.multidot.orifice.multidot.min/g is used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic cross-sectional view of a meltblowing
die useful in practicing the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The present invention is directed toward a method for
forming multiple component meltblown webs having improved barrier
and uniformity properties. The multiple component webs are formed
at high polymer throughput in a meltblowing process using a short
die-to-collector distance without requiring specially insulated
dies or a relatively cool quench gas. The multiple component
meltblown fibers comprise a first polymeric component which does
not normally spin well at short die-to-collector distances, for
example a polyolefin, and a second polymeric component which has
good spinning properties at short die-to-collector distances, such
as a polyester. Surprisingly, it has been found that high quality
meltblown webs having good uniformity and barrier properties are
formed from a poor-spinning polymer when it is combined with a
good-spinning polymer to form a multiple component meltblown web
using a short die-to-collector distance and high polymer
throughput.
[0010] As used herein, the term "polymer" generally includes but is
not limited to, homopolymers, copolymers, such as for example,
block, graft, random and alternating copolymers, terpolymers, etc.
and blends and modifications thereof. Furthermore, unless otherwise
specifically limited, the term "polymer" shall include all possible
geometrical configurations of the material. These configurations
include, but are not limited to, isotactic, syndiotactic, atactic,
and random symmetries.
[0011] The term "polyolefin" as used herein, is intended to mean
any of a series of largely saturated open chain polymeric
hydrocarbons composed only of carbon and hydrogen atoms. Typical
polyolefins include polyethylene, polypropylene, polymethylpentene
and various combinations of the ethylene, propylene, and
methylpentene monomers.
[0012] The term "polyethylene" (PE) as used herein is intended to
encompass not only homopolymers of ethylene, but also copolymers
wherein at least 85% of the recurring units are ethylene units.
[0013] The term "polyester" as used herein is intended to embrace
polymers wherein at least 85% of the recurring units are
condensation products of dicarboxylic acids and dihydroxy alcohols
with linkages created by formation of ester units. This includes
aromatic, aliphatic, saturated, and unsaturated di-acids and
di-alcohols. The term "polyester" as used herein also includes
copolymers (such as block, graft, random and alternating
copolymers), blends, and modifications thereof. An example of a
polyester is poly(ethylene terephthalate) (PET) which is a
condensation product of ethylene glycol and terephthalic acid.
[0014] The term "meltblown fibers" as used herein, means fibers
which are formed by meltblowing, which comprises extruding a
melt-processable polymer through a plurality of capillaries as
molten streams into a high velocity gas (e.g. air) stream. The high
velocity gas stream attenuates the streams of molten thermoplastic
polymer material to reduce their diameter and form meltblown fibers
having a diameter between about 0.5 and 10 microns. Meltblown
fibers are generally discontinuous fibers but can also be
continuous. Meltblown fibers carried by the high velocity gas
stream are generally deposited on a collecting surface to form a
meltblown web of randomly dispersed fibers.
[0015] The term "nonwoven fabric, sheet or web" as used herein
means a structure of individual fibers, filaments, or threads that
are positioned in a random manner to form a planar material without
an identifiable pattern, as opposed to a knitted or woven
fabric.
[0016] The term "multiple component fiber" as used herein refers to
any fiber that is composed of at least two distinct polymers which
have been spun together to form a single fiber. The term "fiber" as
used herein refers to both discontinuous and continuous fibers. The
at least two polymeric components are preferably arranged in
distinct substantially constantly positioned zones across the
cross-section of the multiple component fibers and may extend
substantially continuously along the length of the fibers.
Preferably the multiple component fibers are bicomponent fibers
which are made from two distinct polymers. Multiple component
fibers are distinguished from fibers which are extruded from a
homogeneous melt blend of polymeric materials. However, any of the
distinct polymers used to form the multiple component fibers
disclosed herein may comprise a blend of polymeric materials.
Multiple component fibers useful in practicing the current
invention include sheath-core and side-by-side fibers. Preferably
the multiple component fibers are bicomponent fibers in which the
two distinct polymers are arranged in a side-by-side
configuration.
[0017] The term "multiple component web" as used herein refers to a
nonwoven web comprising multiple component fibers. The term
"bicomponent web" as used herein refers to a nonwoven web
comprising bicomponent fibers. The term "single component meltblown
web" is used herein to refer to meltblown webs which are formed
from a single polymer or a substantially homogeneous polymer blend
as opposed to being formed from distinct zones of polymers arranged
along the length of the fibers.
[0018] The term "poor-spinning polymer" as used herein refers to a
polymer which forms poor quality single component meltblown webs
using short die-to-collector distances at high polymer throughput.
Poor quality meltblown webs are highly fused, stiff, rough feeling,
with large fused fibers and usually contain significant amounts of
"shot". Poor-spinning polymers generally have a specific heat of
greater than about 1.6 kJ/kg/K and a glass transition temperature
(T.sub.g) less than about 25.degree. C. Poor-spinning polymers may
have a glass temperature of less than about 0.degree. C. Examples
of poor-spinning polymers include polyolefins such as polyethylene
(heat capacity=1.86 kJ/kg/K; T.sub.g=-130.degree. C.) and
polypropylene (heat capacity=1.8 kJ/kg/K; T.sub.g=-10.degree.
C.).
[0019] The term "good-spinning polymer" as used herein refers to a
polymer which forms good quality single component meltblown webs at
short die-to-collector distances and high polymer throughput. A
meltblown web is generally considered to be a good quality web if
it is characterized by low levels or the substantial absence of
"shot", and being drapeable with a relatively soft hand as a result
of the fibers not being over-fused, etc. Generally good-spinning
polymers form webs at short DCD's (e.g. less than about 15.2 cm)
and high throughput that have similar properties to webs formed at
the same throughput at more conventional, higher DCD's (e.g. 30+
cm). Good-spinning polymers generally have a specific heat of less
than about 1.6 kJ/kg/K and a glass transition temperature of
greater than about 25.degree. C. Examples of good-spinning polymers
include polyesters such as poly(ethylene terephthalate) (heat
capacity=1.1 kJ/kg/K; T.sub.g=70.degree. C.), polyamides such as
poly(.epsilon.-caprolactam) (nylon 6, heat capacity=1.4 kJ/kg/K;
T.sub.g=50.degree. C.) and poly(hexamethylene adipamide) (nylon 66,
heat capacity=1.59 kJ/kg/K; T.sub.g=40.degree. C.), and polystyrene
(heat capacity=1.2 kJ/kg/K; T.sub.g=100.degree. C.).
[0020] FIG. 1 is a schematic lateral cross-sectional view of a
conventional side-by-side bicomponent meltblowing die 10 useful in
practicing the method of the present invention. Two different
polymers, one of which is a poor-spinning polymer and the other of
which is a good-spinning polymer, are melted in separate extruders
(not shown) and metered separately by gear pumps (not shown) to
conduits 12 and 14 which are divided from each other by a plate 16.
The polymer components are fed to a line of spin orifices 18 and
are combined just prior to exiting the spin orifice. Alternately,
plate 16 can be removed and the bicomponent meltblown fibers can be
made by extruding a the polymer components as a layered molten mass
through a row of side-by-side orifices as described in Krueger et
al. U.S. Pat. No. 6,057,256, which is hereby incorporated by
reference. A post-coalescent die, as disclosed in copending
provisional application No. 60/223,040, filed Aug. 4, 2000, now
U.S. Ser. No. ______, incorporated herein by reference, in which
the distinct polymeric components are extruded through separate
extrusion orifices and are contacted and fused after exiting the
capillaries to form multiple component meltblown fibers, can also
be used. Other die configurations are also suitable, for example
the die tip may be recessed with respect to the die face or may
extend a short distance beyond the die face.
[0021] The polymer components are preferably fed to the spin
orifices at a total polymer throughput per orifice of greater than
about 0.5 g/orifice/min, more preferably greater than about 0.6
g/orifice/min. If a post-coalesecent spin configuration is used,
the total polymer throughput "per orifice" is the combined polymer
flows through the pairs or groups of orifices that form each
extruded multiple component melt stream.
[0022] The skilled artisan will recognize that the configurations
and shapes of the extrusion capillaries can be modified in numerous
ways for various reasons. For example, by machining pie-slice
shaped cross-sections in the die tip, the process is able to
accommodate delivering more than two polymer components into the
fibers to form fibers having a substantially circular cross-section
with pie-shaped component cross-sections. Likewise, those skilled
in the art will recognize that on a production scale, it can be
necessary to use many extruder/die apparatuses ("spin blocks") in
order to obtain full coverage of the collection surface so as to
produce an acceptable nonwoven web or fabric.
[0023] As the polymer components exit the die through spin orifice
18 they form multiple component polymeric melt streams which are
contacted by high velocity jets of attenuating gas exiting through
channels 20. Preferably the attenuating gas is a heated gas having
a temperature that is within about 30.degree. C., and more
preferably within about 10.degree. C. of the temperature of the
molten polymer components as they exit the spin capillaries. The
attenuating gas is generally heated air, however other inert gases
may be used. The extruded polymer melt streams are pneumatically
drawn by the attenuating gas to form meltblown fibers having an
average effective diameter of less than about 10 microns, and
generally in the range of 0.5 to 10 microns. As used herein, the
"effective diameter" of a fiber with an irregular cross section is
equal to the diameter of a hypothetical round fiber having the same
cross sectional area. The average effective diameter of the
meltblown fibers is preferably between about 1 and 6 microns, and
most preferably between about 2 and 4 microns. A plurality of
gas-borne meltblown fiber streams, formed by attenuating a
plurality of molten polymer streams extruded through the plurality
of extrusion orifices in the meltblowing die, form a curtain of
meltblown fibers extending across the width of moving collecting
surface 22, such as a foraminous belt, screen, or scrim, located at
a distance "h" below the meltblowing die. Distance "h" is the DCD,
the distance between the die face and the collector surface. The
DCD is preferably less than about 6 inches (15.2 cm), more
preferably between about 3 to 5.5 inches (7.6 to 14.0 cm), and most
preferably between about 4.5 to 5.5 inches (11.4 to 14.0 cm).
Optionally, a relatively cool quench gas may impinge upon the
curtain of fibers downstream of the attenuating gas jet.
[0024] Composite materials may be formed by collecting the
meltblown fibers on a different sheet material such as another
nonwoven layer, woven fabric, or foam, or bonding a previously
formed meltblown web to such sheet materials or a polymer film. For
example the meltblown fibers can be deposited between two spunbond
nonwoven layers using methods known in the art to form a SMS
(spunbond-meltblown-spunbond) fabric. The layers may be joined
using methods known in the art such as by thermal, ultrasonic,
and/or adhesive bonding. The meltblown layer and other sheet layer
preferably each include polymeric components which are compatible
so that the layers can be thermally bonded, such as by thermal
point bonding. For example, in a preferred embodiment, the
composite laminate comprises a meltblown web and spunbond web, each
of which include at least one substantially similar or identical
polymer. Alternatively, the layers of the composite sheet can be
produced independently and later combined and bonded to form the
composite sheet.
[0025] Collecting surface 22 may be fitted with one or more vacuum
chambers located beneath the collecting surface on which the
meltblown web is collected, the vacuum functioning to conduct the
attenuating gas stream through the collecting surface and away from
the fibers deposited thereon. At very short die-to-collector
distances, it may be desirable to provide additional quenching
means for cooling of the meltblown fibers such as providing a
cooled air flow to the fibers as they exit the die, by spraying the
fibers with a water mist as they are carried to the collector or by
cooling the collector surface.
[0026] The web may be passed through a nip formed by a pair of
rolls to press the meltblown fibers together, however this is
optional since meltblown fibers generally form a cohesive meltblown
web as they are deposited on the collecting surface. The multiple
component meltblown web preferably has a basis weight between about
2 and 40 g/m.sup.2, more preferably between 5 and 30 g/m.sup.2, and
most preferably between 10 and 35 g/m.sup.2. The meltblown webs are
useful for forming spunbond-meltblown-spunbond fabrics having good
barrier properties and useful in end uses such as medical gowns and
drapes. Preferably the spunbond-meltblown-spunbond fabrics have a
hydrostatic head greater than about 30 cm H.sub.2O, more preferably
greater than about 60 cm H.sub.2O.
[0027] It has been found that multiple component fibers comprising
both a poor-spinning polymer component and a good-spinning polymer
component can be spun at high polymer throughput and short
die-to-collector distances, for example less than about 6 inches
(15.2 cm), to obtain multiple component meltblown webs having
improved uniformity and barrier properties compared to similar webs
formed at higher, more conventional die-to-collector distances. In
addition, it has been found that good quality multiple component
webs can be formed from a combination of poor-spinning polymer and
good-spinning polymer under spinning conditions (low DCD and high
throughput) that would normally result in unacceptable properties
for single component meltblown webs made from the poor spinning
polymer alone.
[0028] In a preferred embodiment of the current invention, the
ratio of the die-to-collector distance (cm) divided by the total
polymer throughput per orifice (g/orifice/min), referred to herein
as the formation ratio, is less than about 30
cm.multidot.orifice.multidot.min/g- , preferably less than about 20
cm.multidot.orifice.multidot.min/g. In a preferred embodiment, the
formation ratio is in the range of about 10 to 20
cm.multidot.orifice.multidot.min/g, most preferably in the range of
about 14 to 18 cm.multidot.orifice.multidot.min/g. If a
post-coalesecent spin configuration is used, the formation ratio is
calculated using the combined flows through the pairs or groups of
orifices that form each multiple component melt stream as the total
polymer throughput "per orifice".
[0029] As polymer throughput is increased, it becomes increasingly
difficult to form good quality meltblown webs at short
die-to-collector distances from poor-spinning polymers. In a
preferred embodiment of the current invention, good-quality
multiple component meltblown webs comprising a poor-spinning
polymeric component and a good-spinning polymeric component are
formed using a die-to-collector distance less than about 8 inches
(20.3 cm), preferably less than about 6 inches (15.2 cm) and a
formation ratio less than about 30 cm.multidot.orifice.multidot-
.min/g, preferably less than about 20
cm.multidot.orifice.multidot.min/g. Under these conditions of
die-to-collector distance and formation ratio, it is not possible
to form good-quality meltblown single component webs from the
poor-spinning polymeric component alone.
[0030] One example of a combination of polymers for forming
bicomponent meltblown webs according to the present process is
polyethylene and poly(ethylene terephthalate), where polyethylene
is the poor-spinning component and poly(ethylene terephthalate) is
the good-spinning component. Preferably the polyethylene is a
linear low density polyethylene having a melt index of at least 10
g/10 min (measured according to ASTM D-1238; 2.16 kg@190.degree.
C.), an upper limit melting range of about 120.degree. to
140.degree. C., and a density in the range of 0.86 to 0.97 gram per
cubic centimeter. Meltblown webs comprising bicomponent
polyethylene/poly(ethylene terephthalate) meltblown fibers are
especially useful in nonwoven fabrics for medical end uses since
they are radiation sterilizable. The bicomponent
polyethylene/poly(ethylene terephthalate) meltblown webs can be
bonded to spunbond layers typically used in such end uses to
provide composite laminates having a good balance of strength,
softness, breathability, and barrier properties. According to a
preferred embodiment of the invention, a low intrinsic viscosity
polyester polymer and polyethylene are combined to make a meltblown
bicomponent web in the meltblown web production apparatus. The low
viscosity polyester preferably comprises poly(ethylene
terephthalate) having an intrinsic viscosity of less than about
0.55 dl/g, preferably from about 0.17 to 0.49 dl/g, more preferably
from about 0.20 to 0.45 dl/g, most preferably from about 0.22 to
0.35 dl/g (measured using ASTM D 2857, using 25 vol. %
trifluoroacetic acid and 75 vol. % methylene chloride at 30.degree.
C. in a capillary viscometer). Other preferred polymer combinations
include polypropylene/poly(ethylene terephthalate),
polypropylene/poly(hexamethylenediamine adipamide), and
polyethylene/poly(hexamethylenediamine adipamide).
Test Methods
[0031] In the description above and in the examples that follow,
the following test methods were employed to determine various
reported characteristics and properties. ASTM refers to the
American Society for Testing and Materials, and AATCC refers to the
American Association of Textile Chemists and Colorists.
[0032] Fiber Diameter was measured via optical microscopy and is
reported as an average value in microns. For each meltblown sample
the diameters of about 100 fibers were measured and averaged.
[0033] Basis Weight is a measure of the mass per unit area of a
fabric or sheet and was measured using a custom-made instrument
that uses beta-radiation to determine the mass over a circular area
having a diameter of 0.4 inches (1.02 cm) [i.e. a sample area of
0.126 in.sup.2 (0.81 cm.sup.2)]. Methods using beta-radiation for
measurement of basis weight are well known in the art. The
instrument measured basis weight in a manner similar to
commercially available on-line devices such as the
Honeywell-Measurex Da Vinci Precision Measurement system.
Measurements were taken across the width of a sheet, the sheet was
indexed forward, another set of measurements were taken across the
sheet width, etc. For the examples below, about 40 measurements
were taken across the sheet width for about 100 different locations
along the length of the sheet which corresponds to about 4000 data
points per sample. Standard statistics were used to calculate the
mean basis weight and variability in basis weight for each data
set. The variability in basis weight is reported as the standard
deviation (.sigma.) for a total of between about 3000 to 4000
individual basis weight measurements. This method has been found
suitable for characterizing the variability of small
non-uniformities in the sheet by making measurements on small
sample areas. Other methods known in the art for measuring basis
weight may also be used provided they are capable of accurately
measuring the basis weight for sample areas of about 0.126 in.sup.2
(0.81 cm.sup.2).
[0034] Hydrostatic Head is a measure of the resistance of the sheet
to penetration by liquid water under a static pressure. The test
was conducted according to AATCC-127-1989, which is hereby
incorporated by reference, and is reported in centimeters of water.
Because meltblown webs generally have low strength, they may fail
during the hydrostatic head measurement if they are unsupported.
Therefore, the values reported herein are obtained from
measurements made on spunbond-meltblown-spunbond (SMS) composite
fabrics. SMS fabrics suitable for use in measuring the hydrostatic
head are prepared by thermally point bonding a spunbond layer on
each side of the meltblown web with about 10-30% bond area. Any
spunbonded fabric is suitable so long as it has sufficient strength
to survive the test method without failing.
[0035] The Specific Heat of a polymer is a fundamental physical
property of the polymer that relates to the amount of heat per mass
required to raise the temperature of the polymer one degree Kelvin
at a constant pressure. Tabulated values for numerous materials can
easily be found in technical publications. Specific heat is a
function of the temperature at which it is measured. The specific
heat values reported herein are measured at 25.degree. C.
[0036] The Glass Transition Temperature (T.sub.g) of a polymer is a
fundamental physical property of the polymer and is a second order
transition that relates to the temperature above which it is
possible to soften and potentially crystallize the amorphous
portion of the polymeric material. Glass transition temperatures
can be measured by many techniques, such as by differential thermal
analysis and differential scanning calorimetry. Since the measured
value of T.sub.g is rate dependent, glass transition temperatures
reported herein are measured using very slow rate methods or are
obtained by extrapolating the data from faster, non-equilibrium
techniques to zero rates. This is a fairly common practice, in
order that the glass transition temperature can be considered as a
characteristic only of the polymer and not of the measuring method.
Tabulated values of T.sub.g for numerous materials can be readily
found in technical publications.
EXAMPLES 1-3
[0037] A meltblown bicomponent web was made with a polyethylene
component and a poly(ethylene terephthalate) component. The
polyethylene component was made from linear low density
polyethylene with a melt index of 135 g/10 minutes (measured
according to ASTM D-1238, 2.16 kg@190.degree. C.) available from
Equistar as GA594. The polyester component was made from
poly(ethylene terephthalate) with a reported intrinsic viscosity of
0.53 dl/gm available from DuPont as Crystar.RTM. polyester (Merge
4449). The polyethylene polymer was heated to 260.degree. C. and
the polyester polymer was heated to 305.degree. C. in separate
extruders. The polyester was hydrolytically degraded in the melt
system using approximately 1500 ppm moisture in the resin which
results in an intrinsic viscosity of less than about 0.35 dl/g. The
two polymers were separately extruded and metered to two
independent polymer distributors. The planar melt streams exiting
each distributor were independently filtered and then combined in a
bicomponent meltblown die to provide a side-by-side filament cross
section. The die was heated to 305.degree. C. and had 645 capillary
openings arranged in a 54.6 cm line. The polymers were spun through
the each capillary at a polymer throughput rate of 0.80
g/orifice/min. Attenuating air was heated to a temperature of
305.degree. C. and supplied at a pressure of 5.5 psi through two
1.5 mm wide air channels. The two air channels ran the length of
the 54.6 cm line of capillary openings, with one channel on each
side of the line of capillaries set back 1.5 mm from the capillary
openings. A forced entrainment air flow of 1200 m/min at about
13.degree. C. was provided on both sides of the fibers through a
duct that was 2 inches (5 cm) high and extended beyond the edges of
the fiber zone. The polyethylene was supplied to the spin pack at a
rate of 6.2 kg/hr and the polyester was supplied to the spin pack
at a rate of 24.8 kg/hr to produce a bicomponent meltblown web that
was 20 weight percent polyethylene and 80 weight percent polyester.
In Example 1, the filaments were collected at a die to collector
distance of 11.4 cm (4.5 in) on a moving forming screen to produce
a meltblown web a basis weight of 18.8 g/m.sup.2 which was
collected on a roll.
[0038] In Example 2, a meltblown sheet was formed according to the
procedure of Example 1 except that the distance from the die tip
exit to the collection belt was 14 cm (5.5 in).
[0039] In Example 3, a meltblown sheet was formed according to the
procedure of Example 1 except that the distance from the die tip
exit to the collection belt was 16.5 cm (6.5 in).
[0040] Composite SMS sheets for use in hydrostatic head
measurements were fabricated by thermally bonding a layer of
spunbond on each side of the melblown web. Each spunbond layer was
a 20 g/m.sup.2 bicomponent web formed from 80 weight % polyester
and 30 weight % polyethylene, where the polyethylene formed a
concentric sheath around the polyester core. The spunbond fibers
were about 1.3 dpf and were created with a direct, high speed beam
spinning process. The composite SMS web was thermally bonded
between an engraved oil-heated metal calender roll and a smooth oil
heated metal calender roll. Both rolls had a diameter of 466 mm.
The engraved roll had a chrome coated non-hardened steel surface
with a diamond pattern having a point size of 0.466 mm.sup.2, a
point depth of 0.86 mm, a point spacing of 1.2 mm, and a bond area
of 14.6%.
[0041] It can be seen from the meltblown web properties reported in
Table 1 below that as the DCD, and therefore the formation ratio
decreases, all other process variables remaining constant, the
variability of the basis weight of the sheet decreases. A lower
Basis Weight variability results in better composite sheet barrier
properties as is shown in the Hydrostatic Head values given in
Table 1.
1TABLE 1 MELTBLOWN FABRIC PROPERTIES Formation Ratio Basis Basis
Composite DCD (cm .multidot. orifice .multidot. Weight Weight
.sigma. Hydrostatic Example (cm) min/g) (g/m.sup.2) (g/m.sup.2)
Head (cm) 1 11.4 14.2 18.8 0.85 82.8 2 14.0 17.5 19.1 1.15 72.7 3
16.5 20.6 19.0 1.43 71.1
[0042] Attempts to meltblow a single component polyethylene web at
the same conditions of throughput and DCD, and thus the same
formation ratio, yielded fused fiber, shot, fly and a web that
would stick and adhere to the collection belt such that it was not
possible to collect samples. The web that was removed from the belt
by scraping with a metal blade felt very rough and had clearly lost
the properties characteristic of a fibrous meltblown web.
* * * * *