U.S. patent number RE35,621 [Application Number 08/473,917] was granted by the patent office on 1997-10-07 for cardable hydrophobic polypropylene fiber, material and method for preparation thereof.
This patent grant is currently assigned to Hercules Incorporated. Invention is credited to A. Chandler Schmalz.
United States Patent |
RE35,621 |
Schmalz |
October 7, 1997 |
**Please see images for:
( Certificate of Correction ) ** |
Cardable hydrophobic polypropylene fiber, material and method for
preparation thereof
Abstract
A method for placing hydrophobic polyolefin fiber in condition
for cutting, carding and production of nonwoven material without
substantial sacrifice in desired hydrophobic properties in the
corresponding nonwoven, by utilization of a sequential treatment of
the fiber with a neutralized phosphoric acid ester and a
polysiloxane of defined classes.
Inventors: |
Schmalz; A. Chandler (Conyers,
GA) |
Assignee: |
Hercules Incorporated
(Wilmington, DE)
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Family
ID: |
27000280 |
Appl.
No.: |
08/473,917 |
Filed: |
June 7, 1995 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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909188 |
Jul 6, 1992 |
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Reissue of: |
358985 |
May 30, 1989 |
04938832 |
Jul 3, 1990 |
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Current U.S.
Class: |
156/308.8;
156/296; 156/305; 252/8.81; 427/393.1; 428/369; 428/391; 442/359;
524/274 |
Current CPC
Class: |
D06M
7/00 (20130101); D06M 13/292 (20130101); D06M
15/643 (20130101); D06M 2200/40 (20130101); Y10T
442/635 (20150401); Y10T 428/2922 (20150115); Y10T
428/2962 (20150115) |
Current International
Class: |
D06M
15/37 (20060101); D06M 15/643 (20060101); D06M
13/00 (20060101); D06M 13/292 (20060101); B05D
003/02 (); D06M 013/00 (); B32B 009/00 () |
Field of
Search: |
;156/296,305,308.2,308.6,308.8 ;428/288,290,369,391
;252/8.6,8.7,8.61,8.81,8.84 ;524/274 ;427/389.9,393.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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0010764 |
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May 1980 |
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EP |
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0400622 |
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Dec 1990 |
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EP |
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0486158 |
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May 1992 |
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EP |
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2259938 |
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Aug 1975 |
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FR |
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2351152 |
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May 1977 |
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FR |
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1494751 |
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Jul 1964 |
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DE |
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828735 |
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Feb 1960 |
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GB |
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999199 |
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Dec 1963 |
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GB |
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1246134 |
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Sep 1971 |
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GB |
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1533359 |
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May 1976 |
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GB |
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Other References
Derwent Abstract of JP 87 052072. .
Derwent Abstract of JP 87 047989. .
Derwent Abstract of JP 82 002828. .
Kirk-Othmer, Encyclopedia of Chemical Technology, Third Edition,
vol. 22, 1983 (John Wiley & Sons) pp. 359-361. .
Zimmerman et al., Supplement IV to the 1953 Edition of Handbook of
Material Trade Names, p. 126. .
George A. Goulston Company, Technical Data Report, entitled
"Lurostat AS-Y Anionic Antistatic Agent"..
|
Primary Examiner: Griffin; Steven P.
Attorney, Agent or Firm: Greenblum & Bernstein,
P.L.C.
Parent Case Text
.Iadd.This application is a continuation of application Ser. No.
07/909,188, filed Jul. 6, 1992, now abandoned. .Iaddend.
Claims
I claim:
1. A method for preparing essentially hydrophobic
polyolefin-containing spun fiber or filament for cutting and
carding steps in the production of hydrophobic nonwoven material,
comprising
A. initially treating corresponding continuous spun fiber or
filament with an effective amount .Iadd.for fiber or filament
processing to avoid difficulties generated by friction and
accumulated static charge .Iaddend.of a first modifier composition
comprising
(a) about 70%-100% by weight of modifier composition of at least
one neutralized phosphoric acid ester represented by the formula
##STR3## wherein Alk is individually defined as a lower alkyl
group,
R is defined as an amino group or an alkali metal,
n and m are individually defined as positive numbers of not less
than .[.about.]. 1, the sum of which is about 3; and
(b) up to about 30% by weight of modifier composition of at least
one polysiloxane represented by the formula ##STR4## wherein X and
Y are defined as hydrophobic chemical end groups,
R' is individually defined as a lower alkyl group, and
o is defined as a positive number .[.within the range.]. of
.Iadd.at least .Iaddend.about 10 .[.-50 or higher.].;
B. crimping the resulting continuous fiber or filament in a
crimper;
C. applying to said fiber or filament an effective amount .Iadd.for
fiber or filament processing to avoid difficulties generated by
friction and accumulated static charge .Iaddend.of a second
modifier composition comprising
(a) about 70%-100%, by weight of second modifier composition, of at
least one polysiloxane represented by formula (2) and
(b) up to about 30%, by weight of second modifier composition, of
at least one neutralized phosphoric acid ester represented by
formula (1);
D. processing the resulting modifier-treated fiber or filament to
obtain one or more webs for bonding; and
E. bonding the resulting web to obtain a desired hydrophobic
nonwoven material.
2. The method of claim 1 wherein initial treatment of said
continuous spun fiber or filament is effected using about 100%, by
weight of first modifier composition, of at least one neutralized
phosphoric acid ester represented in formula (1).
3. The method of claim 1 wherein the Alk-O group of the neutralized
ester is defined as a straight 1-4 carbon alkoxy group; n is 2; and
m is 1.
4. The method of claim 1 wherein the second modifier composition is
topically applied upstream of said crimper.
5. The method of claim 1 wherein the second modifier composition is
topically applied to an at least partially crimped continuous spun
fiber or filament.
6. The method of claim 1 wherein the "D" processing step comprises
a fiber cutting and carding operation.
7. The method of claim 1 wherein the "D" "E" steps comprise a spun
bonding operation.
8. A .[.Crimped.]. .Iadd.crimped .Iaddend.essentially hydrophobic
polyolefin-containing fiber obtained by
A. initially treating corresponding continuous spun fiber or
filament with an effective amount .Iadd.for fiber or filament
processing to avoid difficulties generated by friction and
accumulated static charge .Iaddend.of a first modifier composition
comprising
(a) about 70%-100% by weight of modifier composition of at least
one neutralized phosphoric acid ester represented by the formula
##STR5## wherein Alk is individually defined as a lower alkyl
group,
R is defined as an amino group or an alkali metal, n and m are
individually defined as positive numbers of not less than
.[.about.]. 1, the sum of which is about 3; and
(b) up to about 30% by weight of modifier composition of at least
one polysiloxane represented by the formula ##STR6## wherein X and
Y are defined as hydrophobic chemical end groups,
R' is individually defined as a lower alkyl group, and
o is defined as a positive number .[.within the range.]. of
.Iadd.at least .Iaddend.about 10 .[.-50 or higher.].;
B. crimping and applying to said fiber or filament an effective
amount .Iadd.for fiber or filament processing to avoid difficulties
generated by friction and accumulated static charge .Iaddend.of a
second modifier composition comprising
(a) about 70%-100%, by weight of second modifier composition, of at
least one polysiloxane represented by formula (2), and
(b) up to about 30%, by weight of second modifier composition, of
at least one neutralized phosphoric acid ester represented by
formula .[.(I).]. .Iadd.(1).Iaddend..
9. The fiber of claim 8 wherein initial treatment of said
continuous spun fiber or filament is effected using about 100%, by
weight of first modifier composition, of at least one neutralized
phosphoric acid ester represented in formula (1).
10. The fiber of claim 8 wherein the Alk-O group of the neutralized
ester is defined as a straight 1-4 carbon alkoxy group; n is 2; and
m is 1.
11. The fiber of claim 10 wherein the second modifier composition
is topically applied upstream of said crimper.
12. The fiber of claim 9 wherein the second modifier composition is
topically applied to an at least partially crimped continuous spun
fiber or filament.
13. A nonwoven material .[.obtained in accordance with.].
.Iadd.produced by the method recited in .Iaddend.claim 1.
14. A nonwoven material .[.obtained in accordance with.].
.Iadd.produced by the method recited in .Iaddend.claim 2.
15. A nonwoven material .[.obtained in accordance with.].
.Iadd.produced by the method recited in .Iaddend.claim 3.
16. A nonwoven material .[.obtained in accordance with.].
.Iadd.produced by the method recited in .Iaddend.claim 4.
17. A nonwoven material .[.obtained in accordance with.].
.Iadd.produced by the method recited in .Iaddend.claim 5.
18. A nonwoven material .[.obtained in accordance with.].
.Iadd.produced by the method recited in .Iaddend.claim 6.
19. A nonwoven material .[.obtained in accordance with.].
.Iadd.produced by the method recited in .Iaddend.claim 7.
.Iadd.
20. The method of claim 1, wherein o is defined as a positive
number of about 10 to 50. .Iaddend..Iadd.21. The fiber of claim 8,
wherein o is
defined as a positive number of about 10 to 50. .Iaddend..Iadd.22.
The method for preparing essentially hydrophobic
polyolefin-containing fiber or filament, comprising:
treating continuous polyolefin-containing fiber or filament with a
first composition comprising at least one neutralized phosphoric
acid ester represented by the formula ##STR7## wherein Alk is
individually defined as a lower alkyl group, R is defined as an
amino group or an alkali metal, n and m are individually defined as
positive numbers of not less than 1, the sum of which is about
3;
crimping the polyolefin-containing fiber or filament subsequent to
treatment with the first composition; and
treating the crimped polyolefin-containing fiber or filament with a
second composition comprising at least one neutralized phosphoric
acid ester represented by the formula ##STR8## wherein Alk is
individually defined as a lower alkyl group, R is defined as an
amino group or an alkali metal, n and m are individually defined as
positive numbers of not less than 1, the sum of which is about
3.
.Iaddend..Iadd.23. The method according to claim 22, wherein said
first composition further comprises at least one polysiloxane.
.Iaddend..Iadd.24. The method according to claim 23, wherein said
at least one polysiloxane comprises at least one polysiloxane
represented by the formula ##STR9## wherein X and Y are defined as
hydrophobic chemical end groups,
R' is individually defined as a lower alkyl group, and
o is defined as a positive number of at least about 10.
.Iaddend..Iadd.25. The method according to claim 24, wherein o is
defined as a positive
member of about 10 to 50. .Iaddend..Iadd.26. The method according
to claim 24, wherein the treating comprises applying from about
0.09% to 0.5% of the first composition based on the weight of the
fiber or filament. .Iaddend..Iadd.27. The method according to claim
22, wherein said second composition further comprises at least one
polysiloxane. .Iaddend..Iadd.28. The method according to claim 27,
wherein said at least one polysiloxane comprises at least one
polysiloxane represented by the formula ##STR10## wherein X and Y
are defined as hydrophobic chemical end groups,
R' is individually defined as a lower alkyl group, and
o is defined as a positive number of at least about 10.
.Iaddend..Iadd.29. The method according to claim 28, wherein the
treating the continuous polyolefin-containing fiber or filament
with a first composition comprises applying from about 0.09% to
0.5% of the composition based on the weight of the fiber or
filament, and the treating the crimped polyolefin-containing fiber
or filament with a second composition comprises applying from about
0.05% to 0.20% of the second composition based on the weight of the
fiber or filament. .Iaddend..Iadd.30. The method according to claim
27, further comprising processing the polyolefin-containing fiber
or filament subsequent to treatment with the second composition to
obtain at least one web, and bonding the at least one web to obtain
a hydrophobic nonwoven material. .Iaddend..Iadd.31. The method
according to claim 22, further comprising processing the
polyolefin-containing fiber or filament subsequent to treatment
with the second composition to obtain at least one web, and bonding
the at least
one web to obtain a hydrophobic nonwoven material.
.Iaddend..Iadd.32. The method according to claim 22, wherein the
treating comprises applying from about 0.09% to 0.5% of the first
composition based on the weight of the fiber or filament.
.Iaddend..Iadd.33. The method according to claim 22, wherein the
treating the continuous polyolefin-containing fiber or filament
with a first composition comprises applying from about 0.09% to
0.5% of the composition based on the weight of the fiber or
filament, and the treating the crimped polyolefin-containing fiber
or filament with a second composition comprises applying from about
0.05% to 0.20% of the second composition based on the weight of the
fiber or filament.
.Iaddend..Iadd.34. An essentially hydrophobic polyolefin-containing
fiber or filament, comprising:
polyolefin-containing fiber or filament including a coating
comprising at least one neutralized phosphoric acid ester
represented by the formula ##STR11## wherein Alk is individually
defined as a lower alkyl group, R is defined as an amino group or
an alkali metal, n and m are individually defined as positive
numbers of not less than 1, the sum of which is about 3.
.Iaddend..Iadd.35. The fiber or filament according to claim 34,
wherein said coating further comprises at least one
polysiloxane.
.Iaddend..Iadd. . The fiber or filament according to claim 35,
wherein said at least one polysiloxane comprises at least one
polysiloxane represented by the formula ##STR12## wherein X and Y
are defined as hydrophobic chemical end groups,
R' is individually defined as a lower alkyl group, and
o is defined as a positive number of at least about 10.
.Iaddend..Iadd.37. The fiber or filament according to claim 36,
wherein o is defined as a positive number of about 10 to 50.
.Iaddend..Iadd.38. The fiber or filament according to claim 35,
wherein said fiber or filament is crimped.
.Iaddend..Iadd.39. A nonwoven material comprising the fibers of
claim 35. .Iaddend..Iadd.40. The fiber or filament according to
claim 34, wherein said fiber or filament is crimped.
.Iaddend..Iadd.41. A nonwoven material
comprising the fibers of claim 34. .Iaddend..Iadd.42. A method for
preparing essentially hydrophobic polyolefin-containing spun fiber
or filament for cutting and carding steps in the production of
hydrophobic nonwoven material, comprising
A. initially treating corresponding continuous spun fiber or
filament with from about 0.09% to 0.5% based on the weight of the
fiber or filament of a first modifier composition comprising
(a) about 70%-100% by weight of modifier composition of at least
one neutralized phosphoric acid ester represented by the formula
##STR13## wherein Alk is individually defined as a lower alkyl
group, R is defined as an amino group or an alkali metal, n and m
are individually defined as positive numbers of not less than 1,
the sum of which is about 3; and
(b) up to about 30% by weight of modifier composition of at least
one polysiloxane represented by the formula ##STR14## wherein X and
Y are defined as hydrophobic chemical end groups,
R' is individually defined as a lower alkyl group, and
o is defined as a positive number of at least about 10;
B. crimping the resulting continuous fiber or filament in a
crimper;
C. applying to said fiber or filament from about 0.05% to 0.20%
based on the weight of the fiber or filament of a second modifier
composition comprising
(a) about 70%-100%, by weight of second modifier composition, of at
least one polysiloxane represented by formula (2), and
(b) up to about 30%, by weight of second modifier composition, of
at least one neutralized phosphoric acid ester represented by
formula (1);
D. processing the resulting modifier-treated fiber or filament to
obtain one or more webs for bonding; and
E. bonding the resulting web to obtain a desired hydrophobic
nonwoven
material. .Iaddend..Iadd.43. A crimped essentially hydrophobic
polyolefin-containing fiber obtained by
A. initially treating corresponding continuous spun fiber or
filament with from about 0.09% to 0.5% based on the weight of the
fiber or filament of a first modifier composition comprising
(a) about 70%-100% by weight of modifier composition of at least
one neutralized phosphoric acid ester represented by the formula
##STR15## wherein Alk is individually defined as a lower alkyl
group, R is defined as an amino group or an alkali metal, n and m
are individually defined as positive numbers of not less than 1,
the sum of which is about 3; and
(b) up to about 30% by weight of modifier composition of at least
one polysiloxane represented by the formula ##STR16## wherein X and
Y are defined as hydrophobic chemical end groups,
R' is individually defined as a lower alkyl group, and
o is defined as a positive number of at least about 10;
B. crimping and applying to said fiber or filament from about 0.05%
to 0.20% based on the weight of the fiber or filament of a second
modifier composition comprising
(a) about 70%-100%, by weight of second modifier composition, of at
least one polysiloxane represented by formula (2), and
(b) up to about 30%, by weight of second modifier composition, of
at least one neutralized phosphoric acid ester represented by
formula (1). .Iaddend .
Description
The present invention relates to a method utilizing topically
applied modifier compositions arranged in sequence and in a unique
arrangement whereby polyolefin-containing hydrophobic fiber or
filament is made receptive to interim cutting and carding
operations without loss of hydrophobicity in the resulting fiber or
nonwoven product.
BACKGROUND
While the manufacture of polyolefin-based fiber, webs and
corresponding nonwoven materials are well known in the textile art,
attempts to broadly apply such knowledge to produce products in the
area of personal hygiene, such as catamenial devices, disposable
diapers, incontinence pads and the like, have met with serious
technical problems.
In general, such products must have a fluid-absorbent core, usually
comprising one or more layers of absorbent material such as wood
pulp, rayon, gauze, tissue and the like and, in some cases,
synthetic hydrophilic material such as a hydrophilic polyurethane
foam.
Such fluid-absorbing core is most generally fabricated in the form
of a thermally bonded pad, of wood pulp, fiber and conjugate fiber,
having a rectangular or somewhat oval shape. To protect a wearer's
clothing, and surrounding areas from stain or wetting by fluids
already absorbed in such a core, a fluid-impervious barrier sheet
is usually required. In general, the absorbent device is positioned
against the body of the user with hydrophilic material facing and
contacting the body and the fluid impervious barrier sheet
positioned on the outside or opposite side.
A particularly troublesome technical problem arises when a high
degree of hydrophobicity is desired in a nonwoven component
produced substantially from conventionally bonded webs of
hydrophobic fiber such as polyolefin-containing staple or
spun-bonded webs.
In general, untreated hydrophobic fiber quickly becomes unworkable
due to friction and accumulated static charge generated during
conventional spinning, cutting and carding operations. For this
reason, the art has long recognized and used a variety of topically
applied antistatic agents which change fiber surface properties
sufficiently to permit such conventional fiber processing. In
effect, however, such treatment also produces fiber, web and
nonwoven product which is substantially more hydrophilic than the
untreated spun fiber.
Because of the nature of commercial high speed operations, and the
somewhat unpredictable affinity of such agents to individual
batches or bales of hydrophobic fiber, it becomes very difficult to
maintain adequate control over bonding steps and over the wetting
characteristics of the final nonwoven product.
It is an object of the present invention to prepare a hydrophobic
polyolefin-containing spun fiber or filament for processing such as
intermediate cutting and carding steps without unduly interfering
with subsequent bonding steps or sacrificing needed hydrophobic
characteristics in the nonwoven product.
THE INVENTION
The above objects are obtained in accordance with the present
invention by preparing polyolefin-containing spun fiber or filament
in accordance with the steps of
A. initially treating the corresponding continuous spun fiber or
filament with an effective amount, varying from about0.09%-0.5%
based on fiber weight, of a first modifier composition
comprising
(a) about 70%-100% by weight of modifier composition of at least
one neutralized phosphoric acid ester represented by the formula
##STR1## wherein Alk is individually defined as a lower alkyl
group, such as a 1-8 carbon alkyl and preferably a 1-4 carbon alkyl
group;
R is defined as an amino group or an alkali metal,
n and m are individually defined as positive numbers of not less
than about 1, the sum of which is about 3; and
(b) up to about 30% by weight of modifier composition of at least
one polysiloxane represented by the formula ##STR2## wherein X and
Y are individually defined as a hydrophobic chemical end group such
as a lower alkyl group;
R' is individually defined as a lower alkyl such as a methyl group,
and
o is defined as a positive number within the range of about 10-50
or higher;
B. crimping the resulting continuous fiber or filament in a
crimper;
C. applying to said continuous fiber or filament preferably at a
point proximate to said crimper an effective amount, varying from
about 0.05%-0.20% by fiber weight, of a second modifier composition
comprising
(a) about 70%-100%, by weight of second modifier composition, of at
least one polysiloxane represented by formula (2), and
(b) up to about 30%, by weight of second modifier composition, of
at least one neutralized phosphoric acid ester represented by
formula (1);
D. processing the resulting modifier-treated continuous fiber or
filament, for spun bonding or for staple web bonding purposes, to
obtain position one or more webs for bonding; and
E. bonding the resulting web in a conventional manner to obtain a
desired hydrophobic nonwoven material.
For present purposes the term "polyolefin-containing spun fiber or
filament" includes continuous as well as staple melt spun fibers
which are obtainable from conventionally blended isotactic
polypropylene as well as art-recognized hydrophobic copolymers
thereof with ethylene, 1-butene, 4-methylpentene-1 and the like.
The resulting blended .[.an.]. .Iadd.and .Iaddend.extruded spun
melt conveniently has a weight average varying from about
3.times.10.sup.5 to about 5.times.10.sup.5, a molecular weight
distribution of about 5.0-8.0, a melt flow rate of about 2.5 to
about 4.0 g/10 minutes, and a spin temperature conveniently within
a range of about 220.degree. C.-300.degree. C.
Also includible within the spun melt are various art-recognized
fiber additives, including pH stabilizers such as calcium stearate,
antioxidants, pigments, including whiteners and colorants such as
TiO.sub.2 and the like. Generally such additives vary, in amount,
from about 0.5%-3% by weight of spun melt.
The present invention is found particularly applicable to high
speed production of a variety of nonwoven materials utilizing webs
obtained, for instance, from spun bonded or carded staple and may
also comprise additional web components such as .[.fabricated.].
.Iadd.fibrillated .Iaddend.film and the like. In each case, the
fiber-handling difficulties generated by friction and accumulated
static charge can be avoided, without unacceptable sacrifice in
bonding characteristics (i.e. strength) or loss of hydrophobic
properties of the final nonwoven product.
In this regard, the term "processing" as applied in process step
"D" is inclusive of art recognized web formation techniques
applicable to continuous as well as crimped, cut and carded staple
fiber, the crimping step in the former case being optional with
respect to webs formed solely of fiber or filament.
Continuous spun fiber or filaments used to form webs within the
scope of the present invention preferably comprise topically
treated spun melt staple fiber, filament or fibrillated film of
bicomponent or monofilament types, the above-defined modifier
compositions being conventionally drawn over a feed wheel partially
immersed in a bath of the above-defined modifier composition,
dipped therein, or sprayed in effective amount for fiber
processing, and dried.
For present purposes, webs used to form nonwovens within the scope
of the present invention can be formed by spun bonded, melt blown
or conventional "Dry" carded Process using staple fiber and bonded
together using techniques employing adhesive binders (U.S. Pat. No.
4,535,013), calender rolls, hot air, sonic, laser, pressure
bonding, needle punching and the like, known to the art.
Webs used to fabricate nonwoven material can also usefully comprise
conventional sheath/core or side-by-side bicomponent fiber of
filament, alone or combined with treated or untreated homogeneous
type fiber or filament and/or fibrillated film.
Also within the scope of the present invention is the use of
nonwovens comprised of one or more bonded webs of modifier-treated
polyolefin fiber and/or fiber-like (fibrillated film) components
having a mixed fiber denier of homogeneous and/or bicomponent types
not exceeding about 40 dpf. Such webs preferably utilize fiber or
filaments within a range of about 0.1-40 dpf.
In addition, the resulting nonwoven material can be embossed and/or
calender printed conventionally with various designs and colors, as
desired, to increase loft, augment wet strength, and provide easy
market identification.
In addition, webs used in forming nonwovens within the scope of the
present invention are produced from one or more types of
conventionally spun fibers or filaments having, for instance,
round, delta, .[.trifocal.]. .Iadd.trilobal.Iaddend., or diamond
cross sectional configurations.
Nonwoven cover stock of the above defined types can usefully vary
in weight from about 10-45 gm yd.sup.2 or higher.
The invention is further illustrated but not limited by the
following Examples and Tables:
EXAMPLE 1
A. Polypropylene in flake form and characterized as follows:
(crystallinity 60% M.sub.w 3.5.times.10.sup.5, molecular weight
distribution 6.4, and melt flow 3.2 g/10 minutes) is mixed in an
impact blender. After thorough blending, the mixture is fed into a
11/2 extruder and spun through a 210 hole spinnerette at
280.degree. C., air quenched, and stretched at 115.degree. C.
(4.times.) to obtain a 2 dpf circular filament which is then passed
over a feed or kiss wheel partly immersed in a tank of first
modifier composition consisting of a 50% aqueous solution of
Lurol.RTM. AS-Y.sup.(*1), a neutralized phosphoric acid/alcohol
ester, contact being of sufficient duration and speed to topically
apply about 0.6 wt. % of the dried composition. The resulting
continuous filament is crimped at about 100.degree. C. and spray
coated (0.10 wt %) with a second modifier composition consisting of
a 20:1 mixture by weight of a 60% polydimethyl siloxane emulsion
commercially available as LE-458HS.sup.(*2) and a 50% aqueous
solution of Lurol AS-Y. After air drying, the coated 2.0 dpf fiber
is chopped to 1.5" length staple and set aside for conventional
ASTM Sink Time tests in which a given weight of fiber is loosely
packed into a mesh basket and the sink time measured in seconds.
The remainder is carded into webs weighing about 20 g/yd.sup.2, two
webs being calender bonded at 162.degree. C. to obtain test
nonwoven material. The test nonwoven is cut into strips of
convenient dimensions for carrying out conventional strength and
run off tests using syn urine.sup.(*3) as the wetting fluid. Test
results, are summarized and reported in Tables I and II.
TABLE I
__________________________________________________________________________
STAPLE PROPERTIES Color Degree of Percent Finish Tenacity
Elongation Spin Fin. Over Fin. Sample # Type Hydrophobicity*.sup.4
MFR Tow Staple DPF gms % CPI Type/AMT Type/AMT
__________________________________________________________________________
S-1 195 5 17.6 0.77 0.41 2.6 2.05 308.7 28.9 263/0.6 262/0.3 S-2
187 5 35.7 0.31 0.49 2.0 -- -- -- 263/0.2 262/0.3 S-3 195 5 24.3
0.15 -- 2.2 263/0.2 262/0.15*.sup.5 S-4 187 5 21.7 0.48 0.48 2.43
1.68 402.0 25.1 263/0.2 262/0.3 Lt. Blue S-5 187 5 22.2 0.25 0.38
2.54 1.72 424.8 28.5 263/0.2 262/0.3 Med. Blue S-6 195 5 21.0 0.5
0.53 2.28 1.91 375.1 26.0 263/0.4 262/0.3 S-7 195 5 21.0 0.5 0.51
2.38 1.86 373.8 21.5 263/0.4 262/0.3*.sup.6 S-8 195 5 21.0 0.5 0.48
2.45 2.10 411.4 22.8 263/0.4 262/0.3*.sup.7 S-9 195 5 21.0 0.5 0.60
2.43 1.91 363.0 22.1 263/0.4 262/0.3*.sup.8 S-10 195 5 21.0 0.5
0.61 2.50 1.93 361.5 20.5 263/0.4 262/0.3*.sup.9 S-11 187 5 0.42 --
-- -- -- 30.8 263/0.4 262/0.3 Lt. Blue S-12 187 5 0.45 -- -- -- --
30.8 263/0.4 262/0.3 Med. Blue S-13 195 5 22.3 0.35 0.4 2.42 1.87
273.9 27.5 263/0.4 262/0.15 S-14 187 5 19.8 0.47 0.52 2.36 21.3
263/0.4 262/0.3 Blue S-15 187 5 20.9 0.56 0.53 2.42 1.80 297.0 27.8
263/0.4 262/0.3 Blue 225 S-16 187 5 20.8 0.44 0.48 2.13 1.92 347.0
26.3 263/0.4 262/0.3 Blue 275
__________________________________________________________________________
*.sup.4 1 = Fully Hydrophilic 5 = Fully Hydrophobic based on Fiber
Sink Test. *.sup.5 Added Finish No. 262 to tow with kim roll to
reduce static. Total 262 addon not known. *.sup.6 Finish No. 262 +
0.08 Lurol ASY; *.sup.7 Extra (0.24) Lurol ASY: *.sup.8 Extra 0.32
Lurol ASY. *.sup.9 Extra 0.72 Lurol ASY
TABLE II
__________________________________________________________________________
THERMOBONDED WEB Bond Bond Line Speed Strength g/in.*.sup.10
Elongation %*.sup.10 Run-Off Rewet Strike Time Staple Temp.
.degree.C. Press. Pli ft./min. MD CD MD CD % gms. sec.
__________________________________________________________________________
S-1 165 160 250 930 271 43 86 98.3 *.sup.11 *.sup.11 S-2 160 160
250 892 288 27 70 99.3 *.sup.11 *.sup.11 S-3 157.5 160 100 1294 325
30 77 97.3 *.sup.11 *.sup.11 S-4 160 160 250 1716 339 50 101 91.2
*.sup.11 *.sup.11 S-5 155 160 100 1500 423 37 87 94.7 *.sup.11
*.sup.11 S-6 155 160 100 1463 310 27 70 95.9 0.105 *.sup.11 S-7 155
160 100 1345 292 27 76 95.0 0.120 *.sup.11 S-8 155 160 100 1188 285
23 78 97.1 0.111 *.sup.11 S-9 155 160 100 1325 255 28 70 94.1 0.102
*.sup.11 S-10 155 160 100 1391 220 29 73 98.8 0.147 *.sup.11 S-11
152.5 160 100 1244 257 31 71 93.0 *.sup.11 *.sup.11 S-12 152.5 160
100 1389 294 37 80 95.2 *.sup.11 *.sup.11 S-13 150 160 100 *.sup.12
*.sup.12 *.sup.12 *.sup.12 91.5 *.sup.11 *.sup.11 S-14 157.5 160
100 1944 533 34 78 95.0 *.sup.11 *.sup.11 S-15 157.5 160 --
*.sup.12 *.sup.12 *.sup.12 *.sup.12 94.9 *.sup.11 *.sup.11 S-16
157.5 160 100 1347 392 26 80 >90.0 *.sup.11 *.sup.11
__________________________________________________________________________
*.sup.10 20 g/yd.sup.2 Wet *.sup.11 Could not test. Solution
remained on surface of fabric in Run Of Test (fully hydrophobic)
*.sup.12 No determination run.
* * * * *