U.S. patent number 3,622,422 [Application Number 04/863,273] was granted by the patent office on 1971-11-23 for process for producing a nonwoven fabric.
This patent grant is currently assigned to The Kendall Company. Invention is credited to Nicholas S. Newman.
United States Patent |
3,622,422 |
Newman |
November 23, 1971 |
PROCESS FOR PRODUCING A NONWOVEN FABRIC
Abstract
A major portion by weight of an unbonded fibrous fleece is
combined by heat and pressure with a minor portion of a
thermoplastic film to form soft, conformable, air-permeable
nonwoven fabrics suitable for use as disposable clothing.
Inventors: |
Newman; Nicholas S. (West
Newton, MA) |
Assignee: |
The Kendall Company (Boston,
MA)
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Family
ID: |
27504511 |
Appl.
No.: |
04/863,273 |
Filed: |
October 2, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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563238 |
Jul 6, 1966 |
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530734 |
Feb 28, 1966 |
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514079 |
Dec 15, 1965 |
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Current U.S.
Class: |
156/309.6;
156/279; 156/282; 427/180 |
Current CPC
Class: |
B29C
66/7294 (20130101); B29C 65/48 (20130101); D04H
1/62 (20130101); B32B 27/00 (20130101); B29C
66/83413 (20130101); D04H 1/60 (20130101); B29C
66/83415 (20130101); B29C 66/45 (20130101); B29C
66/1122 (20130101); B29K 2023/06 (20130101); B29K
2023/12 (20130101); B29K 2033/12 (20130101); B29K
2033/08 (20130101); B29K 2027/06 (20130101); B29C
66/71 (20130101); B29C 66/71 (20130101); B29C
66/71 (20130101); B29C 66/71 (20130101); B29C
66/71 (20130101); B29C 66/71 (20130101) |
Current International
Class: |
B32B
27/00 (20060101); B29C 65/48 (20060101); D04H
1/58 (20060101); D04H 1/60 (20060101); D04H
1/62 (20060101); C09j 005/00 () |
Field of
Search: |
;156/231,306,622,624,279 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Epstein; Reuben
Parent Case Text
This application is a continuation-in-part of my copending
application, Ser. No. 563,238, filed July 6, 1966, which is a
continuation-in-part of my application, Ser. No. 530,734, filed
Feb. 28, 1966, which in turn is a continuation-in-part of my
application Ser. No. 514,079, filed Dec. 15, 1965, Ser. Nos.
563,238, 530,734 and 514,079 being now abandoned.
Claims
Having thus described my invention, I claim:
1. A process for producing an air-permeable nonwoven fabric which
comprises,
assembling an array of unspun and unwoven textile length
fibers,
superimposing said array of fibers upon an imperforate undrawn and
unoriented thermoplastic film,
and subjecting said fibrous array and said film to heat and
pressure,
more heat being applied to the film surface than to the fibrous
surface,
the temperature applied to the film surface being sufficient to
soften the film but not to melt said film,
the combined effect of heat and pressure being sufficient to cause
said film substance to flow around and encapsulate substantially
all of said fibers,
said film substance constituting not over 35 percent of the total
weight of the product.
Description
This invention relates to a process for the manufacture of
air-permeable nonwoven fabrics suitable for use as disposable
clothing and allied uses, and to certain products of said process.
More specifically, it relates to a process for combining an organic
polymeric film which is unoriented and which may be heated without
undergoing substantial shrinkage with an unbonded fleece of textile
length fibers.
It is known to combine polymeric films with various substrates such
as paper, cloth and nonwoven fabrics, the latter being either
adhesively bonded or needled to provide handling strength. Such a
combination may be brought about by the use of adhesives, or by the
use of heat and pressure. These combinations, however, partake of
the nature of laminations, in that the tensile properties of the
film and the tensile properties of the substrate are individually
distinguishable, as explained below, on a stress-strain diagram.
Prior art film-to-substrate combinations of the layered or laminate
type do not develop the maximum strength possible considering the
potential tensile strength which the combination of components is
capable of developing in accordance with the present invention.
Additionally, it has been found particularly difficult in the past
to develop fiber-film combinations which were air permeable --i.e.,
breathable, as desired for such uses as for comfortable
interlinings and disposable clothing. So far as I am aware, the
preparation of such air-permeable materials has been accomplished
mainly by dusting a particular binder onto a fibrous web, by the
incomplete consolidation of an impregnating latex, by stretching or
otherwise manipulating a fiber-film combination, or by swelling or
dissolving some of the fibers from such a combination. It is an
important element of the present invention that an air-permeable
product can be made from a fibrous web and an impermeable
thermoplastic film by a simple process.
In addition, prior art laminations made from such substrates, where
the various yarns or fibers of the substrate are interconnected and
incapable of free and independent movement, suffer from what may be
called planar instability. That is, the elongation strains set up
in the film and in the substrate during processing, and the
recoveries after processing, are different for the two species,
with the result that such laminates tend to curl markedly at the
edges. This curling, which is very undesirable in many
applications, is even accentuated by humidity changes, because
although the film and the substrate are adherent to each other,
each of these elements reacts more or less independently to
humidity changes, and each tries to react in its characteristic
fashion because each is present essentially in a continuous
phase.
It is also known to combine fibers and film substance to make
substitutes for artificial leather, weighing up to a pound or more
per square yard and 20 to 40 mils thick. Examination of such
products fails to reveal the widespread and uniform dispersion of
fibers through film substance which is characteristic of the
product of this invention. In general, the nonwoven clothing
fabrics of the present invention are realized with combinations of
fiber and film which do not weigh in excess of 50 to 70 grams per
square yard, and which are not over 5 or 6 mils thick in final
form.
It is therefore a primary object of this invention to develop
breathable and conformable nonwoven fabrics of improved tensile
strength and an improved degree of planar stability. It is a
further object of this invention to prepare such nonwoven fabrics
from a thermoplastic film, as defined below, and an unbonded array
of textile-length fibers.
It is an additional object of this invention to prepare nonwoven
fabrics from a thermoplastic film and an unbonded array of
textile-length fibers in which the stress-strain curve is
characterized by a low elongation and a single inflection
point.
A further object of this invention is to prepare air-permeable
nonwoven fabrics of the above type from an impermeable polymeric
continuous film and an unbonded array of textile-length fibers.
Other objects of the invention will appear more fully from the
following description and drawings, in which:
FIG. 1 is a cross-sectional view of a prior art laminate comprising
a film and a nonwoven fabric.
FIG. 2 is a cross-sectional view of another prior art product, both
FIGS. 1 and 2 representing air-impermeable products.
FIG. 3 is a cross-sectional view of a typical product of this
invention.
FIG. 4 is a stress-strain diagram of the prior art laminate of FIG.
1.
FIG. 5 is a stress-strain diagram of the product of FIG. 3, on a
scale which is three-fourths of the scale of FIG. 4.
FIG. 6 is a schematic representation of an apparatus suitable for
carrying out the process of this invention.
FIG. 7 is a schematic representation of an alternative apparatus
suitable for carrying out the process of this invention.
The principal embodiment of my invention is a nonwoven fabric
comprising fibers and a bonding film, the bonding film being
present in continuous phase, with substantially all of said fibers
embedded in said bonding film in discontinuous phase and
distributed substantially throughout the entire body of said film,
said nonwoven fabric deriving its integrity essentially from said
film. The term "continuous phase" does not herein signify that the
film substance is impermeable. Actually, the film has sufficient
air porosity to render it breathable and comfortable when the
fabrics are fashioned into disposable garments. The term
"continuous" signifies that the film is not dispersed into
disconnected particles or fragments, and that if the fiber
substance were to be dissolved out of the combined product, a
unitary and manipulatable film would remain. In the products of my
invention the fibers are held in position essentially by the
softened and resolidified film substance. The starting fibrous
array should be so open, and the fibers so free to move with
relation to each other, that the film-bonding material can
penetrate between and surround substantially all of the fibers. In
the preferred form of my invention, the fibrous array component
which is used as a starting material has little or no integrity
before combination with the film-bonding material component and the
fibers are not felted, interengaged or bonded to more than a casual
degree so that there is minimal interference with the bonding of
fibers to film substance which it is desired to develop.
The products of this invention differ from most prior art
combinations in several important ways. First, the fibrous
substrate is not a needled or otherwise bonded nonwoven fabric, but
is an unbonded array of intermingled textile fibers such as is
delivered by a card, garnett, air-lay machine, or the like, in
which the only restraint to the free movement of the fibers is the
casual frictional contact of one fiber with another. Therefore, the
eventual bond between fibers and film substance, after the process
of the invention has been carried out, is the operative bond in the
product, and is not obscured or altered by any prebonding residing
in the substrate.
This has the dual advantage of allowing the maximum amount of
cooperative bonding between film and fibers, and of producing a
final product in which film and fibers coact as a unitary
reinforced material with a stress-strain diagram which is not
characteristic of either component tested separately or combined in
a normal laminating procedure.
It has been found that a desirable degree of air porosity, ranging
from about 10 to as high as over 90 cubic feet of air per minute at
0.5 inch pressure drop (Frazier Tester) can be realized if the film
portion of the product does not constitute more than 10 percent to
about 45 percent of the total assembly, by weight, and if the
process is so conducted that the fibers are distributed
substantially uniformly throughout the film substance, from one
face to the other. It has been found that if the film portion
constitutes 50 percent or more of the weight of the product, and
especially if the fibers are distributed in a nonuniform manner,
impermeable products are liable to result.
The process of this invention involves a combination of heat and
pressure applied to the film-substrate combination sufficient to
cause the heat-softened film to penetrate substantially uniformly
through the entire depth of the unbonded fibrous substrate, as
explained more fully below.
Referring to FIG. 1, representing in cross section a prior art
film-nonwoven fabric laminate, an array of textile fibers 10 is
shown as bonded by an adhesive binder 14 to form a nonwoven fabric,
which in turn has been laminated by heat and pressure to a
thermoplastic film 12. The film 12 may extend to a slightly greater
depth into the nonwoven substrate than shown, particularly if the
interfiber spaces in the substrate are incompletely filled with
binder, but essentially the product is a two-component laminate of
film and substrate.
The two-component nature of such prior art products is illustrated
by the stress-strain diagram of FIG. 4, representing the typical
behavior of such products when tested on an Instron machine, using
a 1-inch wide strip on the 50-pound scale with the crosshead speed
and chart speed both 12 inches per minute. From the initiation of
the extension to the point B, the tensile properties of the
nonwoven substrate are being tested, and are found to reach a
maximum of 11.7 pounds at point A. From point B on, the long
vertical extension of the curve represents the elongation of the
film portion 12 of the laminate. The stress-strain diagram of a
product of this type, therefore, is a composite curve, indicating
that the nonwoven fabric substrate and the film, although
superficially unified, really act independently when the laminate
is subjected to tensile stress.
Apparatus suitable for carrying out the process of the invention is
shown at FIGS. 6 and 7. A convenient source of heat and pressure
for continuous production of the product of FIG. 3 is represented
in FIG. 6 by a three-roll calender, with a cotton, husk, or
fiber-filled roll 26 mounted between two steel rolls 24 and 28, the
steel rolls being capable of being heated, as by gas-fired burners
mounted axially therein. The calender should be capable of
operating at a pressure of at least 500 pounds per inch of nip
width through pressure loading on the journals, said pressure
devices and journals being conventional and not shown.
A continuous sheet of film 20, together with a fibrous web 22, from
any desired source such as card, garnett, air-lay machine or the
like, not shown, is fed to the nip formed by the lower and heated
steel roll 24 and the cotton roll 26. The temperature and pressure
requirements of the process will vary with the nature of the film,
as set forth in the discussion below. For utmost penetration of the
film substance into and amalgamation with the fibrous web, to
produce the product of FIG. 3, it is convenient to have the film
contact the heated steel roll directly. Alternatively, the product
of FIG. 3 may be made by employing a four-roll calender, consisting
of two cotton rolls 26,26, mounted between heated steel rolls 24
and 28, the calender being equipped with pressurized journals, not
shown. In the preferred routing shown in FIg. 7, a continuous sheet
of film 20 is sandwiched between two fibrous webs 22--22 and is
subjected to heat and pressure first in the nip formed by heated
steel roll 28 and a cotton roll 26, and then in the nip formed by
the bottom heated steel roll 24 and the lower cotton roll, heat
thus being applied to alternate surfaces of the combination.
As films suitable for the practice of this invention I have found
that it is preferable to utilize cast or flat-extruded films,
because of the lower degree of shrinkage which such films undergo
during heating in comparison with uniaxially or biaxially oriented
films of the same chemical composition. Although the latter types
of film have higher strength, their utilization in this invention
necessitates special tensioning devices to hold the film to full
width as it passes through the hot nip. Films made from acrylic
polymers, polyethylene, polypropylene, polyvinyl chloride and the
like are characteristic thermoplastic films suitable for use in
this invention, with polypropylene particularly preferred.
A wide variety of textile fibers may be used in this process, the
selection of a particular fiber or blend of fibers depending on the
particular tensile and elongation characteristics desired in the
final product. Fibers which are substantially straight yield
products with a total elongation of 15 to 25 percent; fibers of
similar chemical composition, but highly crimped, yield products
with a total elongation of around 30 to 70 percent. Cotton, rayon,
(including polynosics), acetate, polyester fibers, polyacrylic and
modified polyacrylic fibers, and a variety of other natural and
synthetic fibers may be used.
Operating conditions during the calendering operation will vary
with the particular film employed, a general guide being that the
temperature should be high enough to soften, but not to melt, the
film. In general, this means that the process is carried out with
the steel roll or rolls heated to the softening temperature of the
film, but preferentially below the melting point of the film. In
the case of polyethylene, the temperature range between softening
point and melting point is rather narrow, and calendering
temperatures are critical. For this reason, when a fiber-reinforced
polyolefine film is desired, I prefer to use polypropylene, with a
working range of around 40 F. between softening point and melting
point. In the case of films where there is a wide range between
softening point and melting point, considerably more latitude may
be employed in calender temperatures.
The invention will be illustrated by the following examples.
EXAMPLE 1
A soft, thermoplastic polymeric film was cast from a copolymer
consisting of 95 parts of ethyl acrylate, 5 parts of butyl
acrylate, 5 parts of acrylonitrile, and 2 parts of glycidyl
acrylate. The dried film was about 1 mil thick and weighed about 15
grams per square yard.
A carded web, with the fibers predominantly oriented in the
lengthwise direction, was prepared from a blend of 80 percent
3-denier nylon and 20 percent 3-denier viscose rayon. It weighed 20
grams per square yard, and has substantially no tensile strength,
being less than 0.5 pounds per inch-wide strip in the machine
direction.
The fibrous web was completely encapsulated into the film by
passing the combination through the apparatus of FIG. 6, with the
steel roll heated to 300.degree. F. and the cotton roll to
200.degree. F. by transfer of heat from the steel roll. The
pressure was 800 pounds per inch of nip width.
After processing, the resultant nonwoven fabric had a strength of
18 pounds in the machine direction, 3 pounds in the cross
direction. It was very soft and conformable, and had an air
porosity of 95 cubic feet of air per minute per square foot of
fabric at one-half inch hydrostatic head as measured on the Frazier
Tester.
The rigidity of the fabric was measured according to Federal
Specification CCCT-191b, Method 5206-2, on the Fabrics Research
Laboratory Cantilever Tester. The flexural rigidity G, expressed in
inch-pounds was 0.00005, or 58 milligram-centimeters. In general,
the flexural rigidities, average of machine direction and cross
direction, will range from 40 to 200 milligram centimeters.
By comparison, the flexural rigidity of prior art impermeable
fiber-film combinations normally ranges from tenfold to several
hundredfold greater.
EXAMPLE 2
A random web of crimped nylon fibers, 3 denier and 11/2 inches
long, was prepared on a Rando-Webber machine. It weighed 25 grams
per square yard.
The fibrous web was combined with a film of cast polypropylene 0.5
mils thick, weighing 10 grams per square yard, by passing both
materials through the apparatus of FIG. 6, with the fiber layer
next to the steel roll, heated to 350.degree. F., and the film
against the cotton roll, heated to 50.degree. F. The pressure was
850 pounds per inch of nip.
The final product weighed 35 grams per square yard and consisted of
28 percent film substance and 72 percent fiber. It had an air
permeability of 82 cubic feet of air per minute per square foot of
product at 1/2 inch hydrostatic head.
The products of the above examples of this invention have related
to fibers combined with truly thermoplastic film, that is, films
which can be repeatedly softened and resolidified without
substantial degradation. There exists another class of films which
have a temperature range within which they are tacky and adhesive,
but which contain cross linking reactants so that on heating or
curing at elevated temperatures, the film becomes irreversibly set
and cannot be reverted to a plastic condition. Such films at room
temperature or slightly above partake of the nature of
thermoplastic films, and are considered within the scope of
thermoplastic films as defined in this invention.
One type of such films, particularly useful for the production of
the fabrics of this invention, is a modified acrylic film supplied
by Rohm and Haas under the name Oroform. This film is soft and
plastic at room temperature, flowing readily under modest heat and
pressure. If heated to 300.degree. F. or more, the film cross-links
internally and becomes thermoset in nature. Subsequent to such a
heat-setting or curing process, the film is quite thermostable,
withstanding prolonged exposure to temperatures of 300.degree. F.
and over. It will yellow slightly in 1 minute at 400.degree. F.,
considerably at 500.degree. F., but does not melt or decompose to
an adverse degree at those temperatures.
In processing what will for convenience be herein termed
transiently thermoplastic films, a single-nip process is generally
used, similar to the apparatus of FIG. 6. If the acrylic film 20 is
adhesive at room temperatures, it may be supplied on a roll of
release paper, from which it is separated just prior to being
combined with the chosen fibrous web 22. Interlinings for films of
this sort, and devices for separating film and interlining, are
well known in the art and are not shown. In order to postcure the
film and convert it to a thermoset condition, any convenient
secondary heating arrangement may be used, as an oven, heated dry
cans, infrared lamps, and the like.
The preparation of thermally resistant air-permeable nonwoven
fabrics will be illustrated by the following example.
EXAMPLE 3
Using the apparatus of FIG. 6 and the general procedure of example
1 a random web of 3-denier Kodel 11 Eastman polyester) fibers
weighing 25 grams per square yard was combined with a 1-mil thick
Oroform film (Rohm and Haas) type C-23. The calender pressure was
1,200 pounds per inch of nip width, with the steel roll heated to
255.degree. F., and the cotton roll to 175.degree. F. The material
was then heated to 325.degree. F. for 1 minute to complete the
transformation of the film to a thermoset condition. The product
resembled the product of FIG. 3, and had a stress-strain curve
resembling that of FIG. 5. The tensile strength of the product per
inch-wide strip was 7.6 pounds machine direction, 7.7 pounds
crossdirection; elongations were between 40 percent and 50 percent
in each direction. The air porosity was 19 cubic feet of air per
minute on the Frazier Tester. The product, consisting of 67 percent
fiber and 33 percent film, was soft and conformable, with a
flexural rigidity G of 0.00007 inch pounds or 81
milligram-centimeters.
The above procedure was repeated using a web of Nomex (duPont's
polyimide) fibers, weighing 25 grams per square yard. After
calendering, the tensile strengths were 16.5 pounds in the machine
direction, 6.6 pounds in the crossdirection. The corresponding
elongations were 34.6 percent and 76.3 percent. After heat-curing
for one minute at 325.degree. F., the figures were 17.5 pounds, 8.2
pounds, 24.8 percent and 27.2 percent respectively.
Both of the above products have a stress-strain curve characterized
by a single inflection point, typical of the products of this
invention, and were suitable for use as fabrics for use as
disposable clothing and the like, particularly where
high-temperature conditions need to be met.
If very high porosity is desired in such film-fiber combinations,
one expedient method is to agitate the acrylic polymer solution
while the film is being cast, so that air bubbles are incorporated
into the cast film said bubbles collapsing during the calendering
operation and leaving minute scattered discontinuities in the
film.
In general, the products of this invention may be differentiated
from prior art laminated or otherwise bonded nonwoven fabrics by
their air permeability, their enhanced planar stability, and their
exceptionally low rigidity per unit weight of bonding film
employed. Additionally, the ratio of wet strength to dry strength
in the products of this invention is very high, reaching 90 percent
or more. Since the film substance is in a continuous phase, the
internal cohesive strength of the product is excellent, with no
internal splitting or delamination.
The weight ratio of film to fiber will vary with the
characteristics to be incorporated into the product. My preferred
range is to have between 10 and 45 percent of the product composed
of film substance, with the balance fiber. Below about 10 percent
film substance, the product is liable to develop a fuzzy and
essentially fibrous surface: above about 50 percent the products
are liable to be impermeable to air, and the synergistic effect of
the fiberfilm combination becomes smaller.
* * * * *