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WO1992016361A1 - Non-tisses presentant des gradients de quantite de fibres - Google Patents

Non-tisses presentant des gradients de quantite de fibres Download PDF

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Publication number
WO1992016361A1
WO1992016361A1 PCT/US1991/006282 US9106282W WO9216361A1 WO 1992016361 A1 WO1992016361 A1 WO 1992016361A1 US 9106282 W US9106282 W US 9106282W WO 9216361 A1 WO9216361 A1 WO 9216361A1
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WO
WIPO (PCT)
Prior art keywords
fibers
fiber
fibrous
web
intermingled
Prior art date
Application number
PCT/US1991/006282
Other languages
English (en)
Inventor
Reinhardt N. Sabee
Original Assignee
Sabee Reinhardt N
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sabee Reinhardt N filed Critical Sabee Reinhardt N
Publication of WO1992016361A1 publication Critical patent/WO1992016361A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres

Definitions

  • the present invention pertains to non-woven fabrics, and particularly to non-woven fabrics of the multilayered type having controlled intermingling of a portion of the fibers of each of the respective ad ⁇ joining or contacting fibrous layers in the formation of an intertwined coherent matrix of fibers.
  • the known composite non-woven fibrous fab ⁇ rics formed to date are fabrics which are formed by the deposition and formation of fibers onto a previ- ously formed web, which precludes any appreciable in depth penetration of the deposition fibers into the formed web. This severely limits the quality of the joining due solely to entanglement of the individual deposition fibers with the individual fibers of the previously formed web.
  • melt blow ⁇ ing techniques for forming fibers.
  • These melt blowing techniques for forming from thermoplastic resins, elastomeric fibers and non-elastic but elongateable fibers can be prepared by known techniques as de ⁇ scribed in an article by Van A. Wente entitled "Super ⁇ fine Thermoplastic Fibers” appearing in Industrial and Engineering Chemistry, Vol. 48, No. 8, pp. 1342 to 1346.
  • the fiber diameters may vary from 0.5 to 250 or more microns depending upon the combination of gas flow rates, polymer flow rate, die temperature and polymer molecular weight.
  • melt blowing process comprises heating a fiber forming resin to a molten state and extruding it through a plurality of fine orifices into a high ve ⁇ locity heated gas stream which attenuates the extrud- ate to form the melt blown fibers. This process is further described in U.S. Patent No. 3,849,241 to Butin et al., the disclosure of which is incorporated herein in its entirety by reference and relied upon.
  • the gathered fibrous non-woven web is separated from the non-woven elastic web and rolled up.
  • Morman '487 is an example of a method of fiber deposition onto an already formed fabric and is directed to the formation of a separably joined fi ⁇ brous non-woven gatherable web onto the surface of a non-woven elastic web while the non-woven elastic web is maintained at its extended stretched biased length. It is also there stated that the separable joining is achieved by the entanglement of the individual fibers of the fibrous non-woven gatherable web with the non- woven elastic web. It is further stated in Morman • 487 that the separable joining of the fibrous non- woven gatherable web to the fibrous non-woven elastic web is achieved by entanglement of the individual fi ⁇ bers of the fibrous gatherable web with the individual fibers of the fibrous non-woven elastic web.
  • Morman U.S. Patent No. 4,657,802 discloses several methods of joining a fibrous non-woven gather ⁇ able web to the non-woven elastic web.
  • a method of heat bonding involving fusion, wherein the melt temperature of at least one of the materials is about 50* below at least one of the materials utilized to form at least one of the two webs, to about the melt temperature of at least one of the materials utilized to form at least one of the two webs.
  • Morman '802 goes on to state that the heat bonding may also be performed under conventional pres- surized conditions. Morman '802 further states that conventional sonic bonding techniques may be substi ⁇ tuted for the heat bonding steps.
  • the joining of the two webs is achieved by forming the non-woven elastic web out of a tacky elastic material.
  • bodiments of the process of joining the two webs there disclosed may be enhanced by applying pressure to the two webs after the gatherable web has been formed on the surface of the elastic web.
  • Morman '802 also states that the joining of the two webs may be further improved by applying an adhesive material to the upper surface of the non-woven elastic web prior to forma ⁇ tion of the fibrous non-woven gatherable web thereon. This, of course, increases the stiffness of the fabric with a deleterious effect on the feel and hand.
  • melt blown elastic fibers are depos ⁇ ited on a foraminous collecting screen and as they are deposited upon the moving collecting screen, they en ⁇ tangle and cohere to form a cohesive fibrous non-woven elastic web while simultaneously being cooled by air movement through the collecting screen.
  • the non-woven elastic web is subsequently stretched and followed by a direct deposition of melt blown fibers onto the - 5 -
  • nates have been formed by depositing two or more fi ⁇ brous layers onto each other to build up a multiple laminate, having relatively sharp lines of demarcation between the contacting surfaces of the layered fabric.
  • the bonding that takes place between layer surfaces consists mainly of the fibers of a subsequently depos ⁇ ited web being embedded in the crevices and interstic ⁇ es of the surface of a previously deposited fibrous web.
  • This type of bonding or joining in the formation 10 of laminates is readily separated and the separated webs wound into rolls as taught in Morman '487. Any repetitive stretching and relaxing forces, if applied to this laminate, would have an adverse effect upon the fabric coherence and integrity such as the stress- 5 es applied to disposable garments.
  • This invention relates to improvements to the fabrics and processes described above, and to so- lutions to some of the problems raised or not solved thereby. Summary of the Invention
  • two sided fab ⁇ ric is used herein to describe a fabric having out ⁇ side surfaces with different physical or other charac- teristics.
  • the fiber quan ⁇ tity gradient across the depth of the fabric is easily changed by varying the amount of gas-fiber stream overlap.
  • This gradient is shallow if the gas-fiber stream overlaps are small and can be of considerable depth if the gas-fiber stream overlaps are large.
  • This increased depth of fiber quantity gradient may reach almost to the opposite side, yet the outside surfaces may have different characteristics which re- late to the respective fiber characteristics of the fibers contained in the gas-fiber streams.
  • the joining of two or more adjacent layers of non-woven fabric is ob ⁇ tained by the high velocity intermingling of fiber laden hot gas streams as they travel between the melt blown orifice and the deposition surface.
  • the fiber bonding can range from fusion bonding of molten or heat softened bonds solely to intermingling or entan ⁇ gling to a predetermined depth of cooled, solidified fibers rather than the deposition of fibers onto an already formed and solidified web.
  • the quality and tenacity of the surface joining of directly deposited melt blown fibers onto a previously formed, cooled and stretched fibrous non- woven elastic layer or web is in sharp contrast to the superior quality and tenacity of the simultaneous sur ⁇ face or boundary joining of fibrous layers or webs wherein the fibrous stratified webs of the various fabrics are formed and joined simultaneously and wherein portions or depths of the fibers of each of - 9 -
  • the two joining boundaries or gas-fiber mixtures are intimately intermingled and intertwined prior to or at their deposition onto a collecting surface.
  • This si ⁇ multaneous joining by intermingling in depth of two or more types of fibers and/or filaments between the extrudate orifices and the collection surfaces allow the intermingling to be accomplished in temperatures which range from molten to softened to solidified which in turn allows bonding of one or more types of fibers, to range between full fusion bonds, to stick bonds, to release bonds and finally, to the joining of solidified fibers or filaments by sole entanglement of two or more types of fibers.
  • a more complete descrip ⁇ tion of these types of bonding is given in Sabee, U.S. Patent No.
  • the predetermined, boundary or gas-fiber mixture, depth joining of simultaneous depositions of two or more melt blown fiber and gas streams of like or dissimilar materials facilitates the homogeneous distribution of the two or more types of fibers, thereby forming an indepth boundary or gas-fiber mix ⁇ ture junction which is unseparable without damaging or rupturing the fabric.
  • Extremely low basis weight webs of exceptional strength are obtained due to the inti- mate fiber indepth intermingling in the forming of the coalesced fabric.
  • the tenacity of the boundary or gas-fiber mixture "in-depth" joining by simultaneous fiberizing and mingling of various streams of air- or gas-borne fibers varies with the amounts or the size of the por- - lo ⁇
  • This simultaneous intermingling of two or more types of fibers and/or filaments between the extrudate orifices and the collecting surfaces allow the intermingling to be accomplished at fiber tempera ⁇ tures which range from molten to softened to solidi ⁇ fied in the various gas-fiber entangling streams.
  • the temperature range of the intermingled fibers permits the bonding or joining of fibers ranging from full fusion to entangling of fibers having no bonding at their intersections.
  • Suitable fibers for use in forming indepth joined stratified elasticized webs are elastomeric fibers of all kinds and types, self-adhering elastic fibers such as Fullastic self- adhering elastic materials from the H.B. Fuller Co. of St. Paul, Minnesota or pressure sensitive adhesive - 11 -
  • the melt blowing of adhesive fibers is per ⁇ formed by the same technique as in the previously dis- cussed article by Van A. ente, and forms diameters ranging from less than 0.5 microns to more than about 250 microns.
  • These adhesive fibers are made by ex ⁇ truding a molten thermoplastic adhesive material through a plurality of fine die capillaries as a mol- ten extrudate of filaments into a high velocity gas stream which attenuates the filaments of molten adhe ⁇ sive material to reduce their diameter to the above stated range in the formation of microfibers or fila ⁇ ments.
  • Any fiberizable hot melt adhesive material is suitable in the formation of adhesive fibers to be used in the intermingling and the joining of strati ⁇ fied fibrous fabrics.
  • Elastomeric adhesives are some of the adhesives suitable for forming adhesive fibers, but again it is to be understood that the present in ⁇ vention is not to be limited to these specific adhe ⁇ sives.
  • the melt blown adhesive fibers do not stiffen the fibrous stratified fabrics as do the roller applied or coated adhesives. These latter adhesives fill crevices and interstices between the fibers of the fibrous layer or web, and after solidification can bind groups of fi- - 12 -
  • melt blown adhesive fibers act as do the fibers of the layered fibrous web, and not as sprays such as paint sprays, wherein small droplets of paint are emitted from the gun.
  • the melt blown fibers being flexible and of small diameter, are tur- bulently entangled with the fibrous web fibers and form bonds at their intersections with these fibers. These intersectional adhesive bonds behave similarly to fusion bonds with no noticeable stiffness of the composite fabric. They have the additional feature that the elastomeric adhesive fibers stretch or elon ⁇ gate under stress.
  • the high velocity gas and fiber intermin ⁇ gling of two or more fiber types takes place in the overlapped portions of two or more deposition spray zones.
  • Each of the spray zones is the shape of the intersection of two planes, with the apexes of the dihedral angles at the extrusion spinnerets, and the dihedral angle openings between the intersections of the planes being at the deposition surface.
  • the smaller the overlap of the fiber deposition zones the shallower will be the depth of the simultaneously in- termingled fibers of the overlapped deposition spray zones. That is, as the deposition zone overlap is reduced, the simultaneous intermingling depth becomes less. Finally as the overlap of the deposition zones is reduced to zero, any simultaneous intermingling of boundary fibers takes place on the deposition surface.
  • the process then becomes one wherein the fibers of a first spray zone are deposited on a deposition surface, thereby forming a cooled fi- - 13 -
  • the present invention over ⁇ comes the delamination or web separation problem, with its accompanying loss of integrity upon application of a stretching force by providing a method or process for making low cost layered sandwiches, stratified fabrics or laminates wherein the various web or layer boundary fibers of one layer or web are intermingled to a predetermined depth with the adjacent boundary fibers of a second layer or web via turbulent mixing of the two sets of fibers in fiber laden gas streams. That is, a predetermined portion or depth of the - 14 -
  • boundary fibers and/or filaments of a first fibrous layer or web are intermingled or blended with a prede ⁇ termined portion or depth of the boundary fibers and/or filaments of a second layer or web.
  • This tur- bulent mixing of the adjacent boundary fibers of two fibrous webs in a high temperature, high velocity gas stream prior to deposition onto a collection surface attains a homogeneous distribution of the two differ ⁇ ent surface or boundary fibers at the joining site, forming an intertwined, coherent high tenacity matrix of these two types of fibers to a predetermined depth.
  • This intermingling and entangling begins at a distance from the die tip which is determined by the type of entangling and fiber joining desired. Fusion bonding of molten fibers occurs closer to the die tip than does the mechanical entanglement of solidified filaments.
  • the velocities of gas and fibers are the highest and where the entangling process is the most efficient.
  • the gas-fiber mixture approaches the deposition surface which may consist of a foraminous belt or drum over a vacuum chamber, the fibers are cooled and solidified by aspirated air or gas above the foraminous belt and the ambient air which is drawn through the belt by the vacuum from the vacuum cham ⁇ ber.
  • This fabric is comprised of 100% fibers of a first material at one outer surface of the fabric and 100% fibers of a second material at the second outer surface of the web with the central portion of the fibrous fabric comprised of an entan ⁇ gled mixture of fibers from the first and second mate ⁇ rials having fiber quantity gradients across its depth at the joining site.
  • the resultant fabric is a strat- ified two fibrous layered fabric of different fibrous materials having no sharp line of demarcation at the joining site of the two layers but rather having a fiber quantity gradient across the depth of the join ⁇ ing site.
  • elasticized fab ⁇ rics are formed wherein the elastomeric or elastic fibers are intertwined with the non-elastic fibers throughout the fabric in a predetermined manner which is suitable for extremely light weight, low basis weight elasticized fabrics.
  • An important object of the present invention is to provide a low cost, light weight, stratified fabric comprising two or more fibrous webs wherein the joining of various fibrous webs or layers is accom- plished by an indepth intermingling and entangling of the fibers of the joining surfaces to a predetermined depth while the fibers are at temperatures wherein they vary from the molten to the cooled solidified states and wherein the junction ranges from fusion bonding of entangled fibers to only the physical tur ⁇ bulent entanglement of the solidified fibers.
  • the range of bonding includes release or stick bonds which are more fully described in Sabee '064.
  • tion to provide a fabric comprising three stratified fibrous layers or webs wherein at least a portion of the fibers of all three layers or webs are entangled and intermingled with each other. It is yet another object of the present in ⁇ vention to provide a stratified fabric wherein at least the surface fibers of adjacent fibrous webs are joined to each other by fiber entanglement and wherein the fiber entanglement of adjacent webs with each oth- er occurred prior to deposition onto a collection sur ⁇ face.
  • Yet another general object of the present invention is to provide a stratified fabric comprising fibrous layers in which at least one of the fibrous layers consists of adhesive fibers and in which prede ⁇ termined portions of the adhesive fibers are entangled and intermingled with predetermined portions of fibers of at least one adjacent layer or web boundary to form a predetermined fiber quantity gradient of the adhe ⁇ sive fibers in the depth direction of the adjacent layer or web.
  • These non-woven elasticized fabrics may vary from ex- tremely light weight webs of about 10 grams or less per square meter to heavy weight webs of more than 300 grams per square meter and may comprise one or more layers of elastomeric fibrous webs alternating between layers of elongateable but non-elastic fibrous webs.
  • Another object of the present invention is to provide a process which does not require heat, ad ⁇ hesives or sonic bonding in the forming of non-woven elasticized webs. Another object is to provide a process not requiring the necessity of having a relaxing and cool ⁇ ing step as used in the stretch bonded process.
  • Fig. l is an isometric view of an apparatus constructed to practice one embodiment of the method of the invention, and to produce one embodiment of the product of the invention.
  • Fig. 2 is a bottom view, looking up, of a number of extrusion heads for a melt blowing device as employed in the practice of the invention.
  • Fig. 3 is a side view of the apparatus shown - 20 -
  • Fig. 4 is a side view of an apparatus con ⁇ structed to practice an alternative embodiment of the invention incorporating a creping function.
  • Fig. 5 is a side view of an apparatus con ⁇ structed to practice the invention by use of a drum- type collector.
  • Fig. 6 is a side view of an apparatus con ⁇ structed to practice an alternative to that shown in Fig. 5.
  • Fig. 7 is a side view of an apparatus con ⁇ structed to practice another alternative to that shown in Fig. 5.
  • Fig. 8 is a side view of an apparatus con- structed to practice an embodiment which is a slight modification from that shown in Fig. 6.
  • Fig. 9 is a side view of a number of extru ⁇ sion heads for a melt blowing device as employed in the practice of the invention, including orifice ex- trusion tips which are specially angled and posi ⁇ tioned. Description of the Preferred Embodiments
  • boundary joining refers to the joining of the broad surfaces, not the ends or sides, of the various fibrous layers or webs being joined, and to the turbulent intermingling or intertangling of the two respective surface fibers with each other prior to or at their simultaneous de ⁇ position onto a collecting surface.
  • This intermin- gling of the respective layer surface fibers of two fibrous layers prior to or at their simultaneous depo ⁇ sition onto a collection surface forms a far superior joining than does the joining obtained by the deposi ⁇ tion of fibers onto a previously deposited solidified fibrous web, wherein the newly deposited fibers lie - 21 -
  • depth boundary fibers is herein meant to be the joining fibers of two or more fibrous layers which have been intermingled in the distance between the extrusion fiberizing die and the collection surface, and may consist of thermoplastic fiberized materials, pulp fibers or any of the staple fibers.
  • gas-fiber spray gas or air- • fiber spray
  • gas-fiber stream gas-fiber mixture
  • fiber fiber
  • gaseous stream deposition spray zone
  • melt blown adhesive fibers do not stiffen the fibrous stratified fabrics as do the roller applied or coated adhesives. These latter adhesives often fill crevices and interstices between the fibers of the fibrous lay- - 22 -
  • melt blown adhesive fibers on the other hand act as do the fibers of the layered fibrous web and not as sprays such as paint sprays, wherein small droplets of paint are emitted from a gun.
  • the melt blown fibers being flexible and of small diameter, are turbulently entangled with the fibrous web fibers and form bonds at their intersections with these fibers. These in- tersectional adhesive bonds behave similarly to fusion bonds with no noticeable stiffness of the composite fabric. They also provide the additional feature that the elastomeric adhesive fibers stretch or elongate under stress.
  • polyolefins such as polypropylene, polyethylene, polybutane, polymethyldentene, ethylene- propylene co-polymers
  • polyamides such as polyhexa- methylene adipamide, poly-(o ⁇ -caproa ide) , polyhexa- methylene sebacamide
  • polyvinyls such as polystyrene
  • thermoplastic elastomers such as polyurethanes, other thermoplastic polymers such as polytrifluorochloroeth- ylene and mixtures thereof; as well as mixtures of these thermoplastic polymers and co-polymers
  • ethylene vinyl acetate polymers synthetic polymers comprising 40% or more of polyurethane; polyetheresters; poly- etherurethane; polyamide elastomeric materials; and polyester elastomeric materials S-EB-S Kraton "G" Block co-polymers and Kraton
  • viscoelastic hot melt pressure sensitive adhesives such as "Fullastic” supplied by H.B. Fuller and Compa ⁇ ny and other hot melt adhesives including pressure sensitive adhesives.
  • thermo ⁇ plastic polymers including fiber forming hot melt ad- hesives, pressure sensitive adhesives, and viscoelas ⁇ tic hot melt pressure sensitive adhesives can be used for stabilizing the web or bonding the stabilized web to one or more cellulose webs, wood pulp webs, melt blown fibrous mats, or for laminating and bonding two or more stabilized webs to from laminates.
  • the in ⁇ stant invention is not limited by the above polymers, for any thermoplastic polymer, co-polymer or mixture thereof capable of being melt blown into fibers or filaments is suitable.
  • thermoplastic elas- tomers which are capable of being melt blown or melt spun are suitable for the manufacture of stretchable fabrics.
  • fabric forming apparatus 10 for forming stratified fi ⁇ brous melt-blown fabrics having boundary joinings or junctions of fiber-to-fiber quantity gradients across - 24 -
  • the apparatus 10 includes a number of extruders 12a, 12b and 12c, each having a respective die head 14, 16 and 18.
  • each die head 14, 16, 18, 19 includes a plurality of orifice extru ⁇ sion tips 20, 22 and 24, preferably arranged in one or more rows, wherein the longitudinal and lateral spac- ings and the angles or directions of extrudate emis ⁇ sion as shown in Fig. 2 are varied to obtain various indepth entanglements or various fiber quantity gradi ⁇ ents across the depth of the joined fabric at the site of the junction.
  • the amount of gas-fiber spray overlap onto the adjacent gas-fiber spray determines the depth of the fiber quantity gradient of the two or more entangled fibers.
  • the individual extrusion tips 20, 22, 24 may be spaced and positioned at angles such that fibrous emissions from extrusion tips 24 in the last row of melt blown die 16 are directed between the fibrous emissions from extrusion tips 20 in the first row of melt blown die 18, and so on. This allows the intermeshing of fi- brous emissions from extrusion tips 24 of melt blown die 16 and the fibrous emissions from extrusion tips 20 of melt blown die 18. This intermeshing of the various fiber streams with one another facilitates deeper penetration of two or more types of entangling fibers.
  • a collection or de ⁇ position surface 26 comprising a foraminous belt 28 moving over a vacuum chamber 30 equipped for indepen- dent vacuum pressures under each die head.
  • Each die head 14, 16, 18 may extrude one or more fiberizable materials and be posi- tioned at various angles to each other as determined by the angles of polymer emission at which the orifice extrusion tips 20, 22, 24 are to be set.
  • the extrudate As the extrudate is emitted from the extrusion tips 20, 22 and 24 into high velocity gas streams, they form fiberized turbulent gas-fiber mixtures or fibrous sprays 32, 34 and 36 in their travel from the orifices to the deposition surface 26 to form a .layered or stratified fibrous non-woven fabric 38 by being drawn onto the deposition belt 28 with vacuum from chamber 26.
  • the various melt blown gas-fiber sprays 32, 34, 36 are deposited simultaneously onto the foraminous belt 28 in partially overlapping orientations of their respective portions, subsequent to turbulent intermin ⁇ gling and entangling before reaching the foraminous belt.
  • the overlapping of the gas-fiber sprays 32, 34, 36 is variable and is accomplished by varying the dis ⁇ tance between the die heads 14, 16 and 18 and the foraminous belt 28 and the distances between each of the die heads themselves.
  • the gas-fi ⁇ ber mixture 32 and the gas-fiber mixture 34 are com ⁇ bined to form the gaseous mixture of fibers 40 and 42 at joining site 46, while simultaneously combining the gas-fiber mixture 34 and the gas-fiber mixture 36 to form the gaseous mixture of fibers 42 and 44 at join ⁇ ing site 48.
  • the air or gas is withdrawn from the gaseous mixture, thereby compacting all the fibers and mixtures of fi ⁇ bers into the stratified fibrous fabric 38.
  • the fabric 38 contains the indepth - 26 -
  • the stratified fi ⁇ brous fabric 38 contains the indepth intermingled fi- brous boundary 50 comprising fibrous layers or webs 54 and 56 and the indepth intermingled fibrous boundary 52 of fibrous layers or webs 56 and 58.
  • This indepth intermingling processing of fibers 40 and 42 forms this fiber quantity gradient 50 at joining site 46 and deposited onto collecting site 60.
  • Both the die spac- ings and the distances between the die orifices and the deposition surfaces are adjustable to facilitate the setting of predetermined fiber gradient depths and surface characteristics.
  • the process of forming strat ⁇ ified fibrous fabrics having predetermined fiber in ⁇ depth entanglements of the various layer boundaries with one another during fabric formation includes the following steps.
  • the polymeric material after pas- sage through the heated extruder 12, die heads 14, 16, 18 and extrusion tips 20, 22, 24, is emitted from the extrusion tips as molten extrudate in the form of fil ⁇ aments or fibers 40, 42, 44 and injected into a high velocity heated gas stream.
  • the gas stream may be air, nitrogen or some other inert gas which attenuates the molten filaments 40, 42, 44 at fiberizing veloci ⁇ ties to form gas-fiber sprays 32, 34, and 36 respec ⁇ tively.
  • a first portion of the fibers 40 of gas-fiber spray 32 are deposited directly onto foraminous belt 28.
  • a second portion of the fibers 40 of gas-fiber spray 32 are then intermingled with a first portion of the fibers 42 of gas-fiber spray 34 and deposited onto the previously deposited fibers 40. This is followed by a deposition of a second portion of fibers 42 of gas-fiber spray 34 onto the previously deposited in- - 27 -
  • the third remaining portion of fibers 42 of gas-fiber spray 34 are then intermingled with a first portion of fibers 44 of gas- fiber spray 36 and deposited onto the previously de- posited second portion of fibers 42 of gas-fiber spray 34.
  • the second and remaining portion of fiber 44 of gas-fiber spray 36 is deposited onto the previ ⁇ ously deposited intermingled fibers 40 and 42, thereby completing the forming and emergence of a three layer stratified fibrous fabric 38 having two boundary junc ⁇ tions of fiber to fiber quantity gradients 50 and 52 across their depths.
  • the first fiber quantity gradi ⁇ ent 50 occurs at site 46 with an intermediate of fi ⁇ bers 40 and 42, the second fiber quantity gradient 52 occurring at site 48 with an intermingling of fibers 42 and 44.
  • the lower surface of the stratified fi ⁇ brous fabric 38 adjoining the foraminous belt 28 is comprised of fibers 40, with the upper surface 58 be ⁇ ing comprised of fibers 44 and the central layer or web 56 comprising fibers 42.
  • er dies 14 and 18 form elongateable but non-elastic fibers 40 and 44. Portions of each type of fiber are intermingled before deposition onto collection surface 26 wherein the collected fibers form a three layer stratified elastomeric fibrous fabric 38 with boundary junctions having fiber quantity gradients across their depths.
  • the elasticized fabric 38 may be subsequent ⁇ ly passed through squeeze rolls 64, stretch-and-draw rolls 66 and/or corrugated crimp rolls 68 to stretch the inner elastomeric fibrous layer 56 and elongate and molecularly orient the two outer elongateable but non-elastic fibrous layers 54 and 58.
  • the fabric 38 may be relaxed, whereupon gathers are formed in the two outer non-elastic layers 54 and 58 by the inner elastomeric layer 56.
  • the relaxed elasticized fabric 38 may then be wound into a roll 70 conventionally on a two drum winder 72.
  • elongateable but non- elastic fibers do not necessarily require high perma- nent elongation to effectively vary surface character ⁇ istics of fibrous webs having fibrous quantity gradi ⁇ ents across their depths. This allows the use of low cost materials in the forming of fibrous fabrics hav ⁇ ing unique surface characteristics.
  • the predetermined intermingling of at least two types of polymeric fi ⁇ bers can take place in a narrow portion of the fabric depth wherein one side of said fabric is comprised of substantially all of a first type of fiber with the opposite side of the said fabric being comprised of substantially all of a second type of fiber.
  • the predetermined entanglement of at least two types of polymeric fibers may take place throughout a major portion of the fabric wherein one side of the said fabric may be comprised of an intermingled ix- ture of a large portion of a first type of fiber and a small portion of a second type of fiber with the opposite side comprising a large portion of a second type of fiber intermingled with a small portion of a first type of fiber.
  • fibrous materials to those disclosed herein, because any polymeric fiberiz ⁇ able material will suffice. This includes all fiber ⁇ izable polymeric thermoplastic materials ranging from elastomeric to non-elastic materials including adhe- sive materials ranging from elastomeric pressure sen ⁇ sitive adhesives to hot melt polymeric adhesives.
  • FIG. 5 illustrates one application of this concept.
  • a stratified elastomeric fibrous fabric 78 having fiber quantity gradients across the depth of the fabric is formed on a drum-type collector 74 hav- - 30 -
  • a first extrusion die 80 is positioned above the clockwise-rotating deposition drum 76.
  • a first gaseous stream 82, containing elas- tomeric fibers 84, is emitted, the fibers being depos ⁇ ited onto drum 76.
  • Adjacent to and downstream from first die 80 is a second die 86 from which a second gaseous stream 88 containing non-elastic polymeric fibers 90 is emitted.
  • the second die 86 is positioned with respect to the first die 80 so that the fibers 90 are deposited onto drum 76 in a partially overlapped and intermingling mixture with a portion of the elas ⁇ tomeric fibers 84.
  • the unlapped portion of fibers 90 is deposited and joined indepth to the previously de- posited mixture of fibers 84 and 90 to form fibrous layer or web 92.
  • the surface of the formed fabric 78 adjacent to the drum 76 is comprised of elastomeric fibers 84 with a rubbery feel and a high degree of slip resis- tance. This is because first gas-fiber stream 82 con ⁇ taining elastomeric fibers 84 is deposited onto the drum 76 prior to the deposition of the intermingled elastomeric and non-elastic polymeric fibers, that is, prior to the fibrous quantity gradient deposition area 94 at the joining site 96.
  • the fiber quantity gradi ⁇ ent 98 comprising elastomeric fibers 84 and non-elas ⁇ tic polymeric fibers 90 lies between the elastomeric fibrous layer 100 and the non-elastic polymeric layer 102 comprising the outer layer on the drum 76.
  • the outer surface of layer 102 will have characteristics related to the fibrous material forming layer 102.
  • the gas-fiber stream 88 is increased in size so as to overlap a greater area or portion of the gas-fiber stream 82, the less rubbery and less slip resistant will be the outer surface of layer 100.
  • Fig. 6 illustrates a case wherein the melt blown fiber dies 80 and 86 are positioned so that the second gas-fiber stream 88 containing non-elastic but elongateable polymeric fibers 90 completely envelopes the first gas-fiber stream 82 containing elastomeric fibers 84.
  • the surface of the fabric 78 adjacent to collecting drum 76 comprises an intermingled mixture of elastomeric fibers 84 and non-elastic polymeric fibers 90.
  • surface of the fabric 78 has a decreased rubbery feel and a lower slip resistance level.
  • This lower slip resistance can be reduced further by reducing the throughput of the melt blown elastomeric fiber 84. This reduction can be accomplished by merely reducing the extruder screw velocity, adjusting the polymer temperatures, changing the fiberizing air pressures and temperatures, or some combination of these adjust ⁇ ments.
  • non-slip resistance can be varied by increasing or decreasing the extruder screw velocity which in turn varies the throughput of extruders 80 and 86.
  • Fig. 7 illustrates a drum type collector 104.
  • the rotating deposition drum 106 of the collec- tor 104 may be foraminous and include a fixed vacuum chamber 108, and may have a surface ranging from smooth to patterned, on which to collect fibers which, in combination with various fiber materials, will form various surface characteristics of a formed non-woven stratified fibrous fabric 110.
  • the gas- fiber sprays 118, 120 and 122 are extruded and emitted from dies 124, 126 and 128, respectively.
  • the fibers 130, 132 and 134 of these sprays are turbulently en ⁇ tangled with each other to form the gaseous mixture of the fibers at site 136.
  • the stratified fibrous fabric 110 is formed, containing fiber quantity gradient 138 across the depth of the web is formed.
  • Fabric 110 is thus comprised of fibrous layers or webs 112, 114 and 116 having a common fiber quantity gradient 138 of fi ⁇ bers 130, 132 and 134 at joining site 136.
  • an added extrusion die 140 may be used to form elastomeric filaments for the elasticizing of the fab ⁇ ric 78 by extruding elastomeric filaments 142 through extrusion die 140, cooling and solidifying the molten filaments 142 on temperature controlled chill roll 144 and depositing the solidified filaments on foraminous deposition drum 76.
  • the drum 76 is traveling at a higher surface velocity than the sur- face velocity of chill roll 144. This difference in - 33 -
  • Another alternative is to deposit another web 150 from parent roll 152 onto drum 76 pri ⁇ or to the deposition of adhesive fibers 146. This again is followed by a turbulent mixture of adhesive fibers 146 and fibers 90 and the final deposition of only fibers 90, thereby forming a high strength lami ⁇ nated fabric comprising web 150, fibers 146 and fibers 90.
  • the web 150 from parent roll 152 may be any suit ⁇ able prefabricated web including but not limited to dry or wet laid webs, spun bonded webs, melt blown webs, air laid webs, hydroentangled webs, film, spun laced webs, fibrillated films, needle punched webs, high loft fabrics, and stabilized, non-random laid, continuous filament webs as described in Sabee '064.
  • Fig. 9 shows three die heads 154, 156, 158 in end view, and corresponding rows of extrusion tips, in an arrangement modified from that shown in Fig. 2.
  • each die head 154, 156, 158 in ⁇ cludes a plurality of rows of orifice extrusion tips 160, 162 and 164. Tips 160 are straight, tips 162 are angled to one side and tips 164 are angled in the op- - 34 -
  • the lat ⁇ eral spacings and the angles or directions of extrud ⁇ ate emission are arranged so that the angled tips 162, 164 actually extrude fibers closer to the adjacent head than to the head to which the respective tip is attached.
  • This embodiment further assures the turbu ⁇ lent intermixing of the fibers from the different die heads to obtain indepth entanglements and fiber quan ⁇ tity gradients across the depth of the joined fabric at the site of the junction, and facilitates deeper penetration of two or more types of entangling fibers.
  • fibers 40, 42 and 44 of lengths varying from about li inches to substantially continu- ous are cooled to solidification between the orifice extrusion tips 20, 22, 24, and the deposition surface 26, and in so doing these fibers are frozen and set in spiraled, convoluted, twisted and bent shapes of all sizes.
  • the resultant web 38 consists of these turbulently entangled, springy, bulky, resil ⁇ ient and thick high loft fibers and/or filaments.
  • this fabric 38 resists matting or packing down, and upon the relaxation of the compres- sive force it expands and tends to return to substan ⁇ tially its original precompressed height. Applicant has found that the greater the overlap of the gas-fi ⁇ ber streams 32, 34, 36, the greater will be the in depth intermingling of the entangled boundary surface fibers and the greater will be the strength of the joined webs at their boundary.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

Procédé selon lequel la jonction (50, 52) des limites d'au moins deux couches fibreuses (54, 56, 58) est effectuée par l'entremêlement turbulent des fibres limites de jets ou de projections gaz-fibres adjacents (40, 42, 44) composés de fibres d'au moins deux types, au cours du passage des fibres de leurs orifices d'extrusion vers une surface de ramassage. On décrit aussi le tissu (38) ainsi produit. On fabrique ce tissu en amenant simultanément les jets gaz-fibres chauffés et qui vont s'élargissant (40, 42, 44), sur la surface de dépôt (28) en une configuration de dépôt à recouvrement partiel (46, 62), de sorte que des parties prédéterminées d'un jet de fibres sont entremêlées avec des parties prédéterminées d'un second jet de fibres pour produire un gradient de quantité de fibres dans les deux jets de fibres sur la profondeur de la zone frontière. Les parties restantes des deux jets de fibres forment les couches stratifiées composées des premier et second types de fibres respectifs.
PCT/US1991/006282 1991-03-20 1991-09-03 Non-tisses presentant des gradients de quantite de fibres WO1992016361A1 (fr)

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US67254091A 1991-03-20 1991-03-20
US672,540 1991-03-20

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WO1999027875A1 (fr) * 1997-12-01 1999-06-10 Minnesota Mining And Manufacturing Company Bandage cohesif non tisse
WO1999028539A1 (fr) * 1997-12-01 1999-06-10 Minnesota Mining And Manufacturing Company Fibres copolymeres acryliques
WO1999040952A1 (fr) * 1998-02-11 1999-08-19 Minnesota Mining And Manufacturing Company Renfort imper-respirant pour article adhesif
EP1331297A1 (fr) * 2001-12-20 2003-07-30 AAF-McQuay Inc. Arrangement en série pour la formation de mats composés de couches de fibres différentes et contrôle des surfaces
EP2022878A4 (fr) * 2006-05-31 2010-03-31 Kao Corp Tissu non tisse extensible
WO2010098792A1 (fr) * 2009-02-27 2010-09-02 Exxonmobil Chemical Patents Inc. Stratifiés in situ non tissés multicouches et leur procédé de fabrication
DE102013006212A1 (de) 2012-04-11 2013-10-17 Ap Fibre Gmbh Feinstfaservliese und papierähnliche Produkte sowie Verfahren zu deren Herstellung
WO2013182296A1 (fr) * 2012-06-04 2013-12-12 Irema-Filter Gmbh Procédé de fabrication d'un non-tissé
US9168718B2 (en) 2009-04-21 2015-10-27 Exxonmobil Chemical Patents Inc. Method for producing temperature resistant nonwovens
US9168471B2 (en) 2010-11-22 2015-10-27 Irema-Filter Gmbh Air filter medium combining two mechanisms of action
US9175428B2 (en) 2012-04-30 2015-11-03 Chen-Cheng Huang Method of making a double-sided embossed non-woven fabric
US9498932B2 (en) 2008-09-30 2016-11-22 Exxonmobil Chemical Patents Inc. Multi-layered meltblown composite and methods for making same
DE102016223571A1 (de) * 2016-11-28 2018-05-30 Adidas Ag Herstellung von Vliesstoffen einschließlich einer Komponente
US10161063B2 (en) 2008-09-30 2018-12-25 Exxonmobil Chemical Patents Inc. Polyolefin-based elastic meltblown fabrics
US10273611B2 (en) 2006-03-28 2019-04-30 Irema-Filter Gmbh Pleatable nonwoven material and method and apparatus for production thereof
US10668424B2 (en) 2014-11-28 2020-06-02 Irema-Filter Gmbh Filter medium having large fold spacing
DE102019203986A1 (de) * 2019-03-22 2020-09-24 Adidas Ag Vliesstoffartikel
US20220162787A1 (en) * 2018-05-29 2022-05-26 Nike, Inc. Method for nonwoven textiles with variable zonal properties
US11571645B2 (en) 2013-05-16 2023-02-07 Iremea-Filter Gmbh Fibrous nonwoven and method for the production thereof
US12435454B2 (en) * 2022-02-14 2025-10-07 Nike, Inc. Method for nonwoven textiles with variable zonal properties

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US4604313A (en) * 1984-04-23 1986-08-05 Kimberly-Clark Corporation Selective layering of superabsorbents in meltblown substrates
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AU729676B2 (en) * 1997-12-01 2001-02-08 Minnesota Mining And Manufacturing Company Nonwoven cohesive wrap
WO1999027875A1 (fr) * 1997-12-01 1999-06-10 Minnesota Mining And Manufacturing Company Bandage cohesif non tisse
US6083856A (en) * 1997-12-01 2000-07-04 3M Innovative Properties Company Acrylate copolymeric fibers
US6133173A (en) * 1997-12-01 2000-10-17 3M Innovative Properties Company Nonwoven cohesive wrap
WO1999028539A1 (fr) * 1997-12-01 1999-06-10 Minnesota Mining And Manufacturing Company Fibres copolymeres acryliques
WO1999040952A1 (fr) * 1998-02-11 1999-08-19 Minnesota Mining And Manufacturing Company Renfort imper-respirant pour article adhesif
US6107219A (en) * 1998-02-11 2000-08-22 3M Innovative Properties Company Breathable backing for an adhesive article
AU734971B2 (en) * 1998-02-11 2001-06-28 Minnesota Mining And Manufacturing Company Breathable backing for an adhesive article
EP1331297A1 (fr) * 2001-12-20 2003-07-30 AAF-McQuay Inc. Arrangement en série pour la formation de mats composés de couches de fibres différentes et contrôle des surfaces
US10273611B2 (en) 2006-03-28 2019-04-30 Irema-Filter Gmbh Pleatable nonwoven material and method and apparatus for production thereof
EP2022878A4 (fr) * 2006-05-31 2010-03-31 Kao Corp Tissu non tisse extensible
US8053074B2 (en) 2006-05-31 2011-11-08 Kao Corporation Stretch nonwoven fabric
US10161063B2 (en) 2008-09-30 2018-12-25 Exxonmobil Chemical Patents Inc. Polyolefin-based elastic meltblown fabrics
US9498932B2 (en) 2008-09-30 2016-11-22 Exxonmobil Chemical Patents Inc. Multi-layered meltblown composite and methods for making same
KR101348060B1 (ko) * 2009-02-27 2014-01-03 엑손모빌 케미칼 패턴츠 인코포레이티드 다층 부직 동일-공정계 라미네이트 및 이의 제조 방법
JP2012519242A (ja) * 2009-02-27 2012-08-23 エクソンモービル・ケミカル・パテンツ・インク 多層不織ｉｎｓｉｔｕラミネートおよびその製造方法
WO2010098792A1 (fr) * 2009-02-27 2010-09-02 Exxonmobil Chemical Patents Inc. Stratifiés in situ non tissés multicouches et leur procédé de fabrication
JP2015004158A (ja) * 2009-02-27 2015-01-08 エクソンモービル・ケミカル・パテンツ・インク 多層不織ｉｎｓｉｔｕラミネートおよびその製造方法
CN102333644B (zh) * 2009-02-27 2015-07-22 埃克森美孚化学专利公司 多层非织造原位层压体及其制备方法
US9168720B2 (en) 2009-02-27 2015-10-27 Exxonmobil Chemical Patents Inc. Biaxially elastic nonwoven laminates having inelastic zones
US9168718B2 (en) 2009-04-21 2015-10-27 Exxonmobil Chemical Patents Inc. Method for producing temperature resistant nonwovens
US9168471B2 (en) 2010-11-22 2015-10-27 Irema-Filter Gmbh Air filter medium combining two mechanisms of action
DE102013006212A1 (de) 2012-04-11 2013-10-17 Ap Fibre Gmbh Feinstfaservliese und papierähnliche Produkte sowie Verfahren zu deren Herstellung
WO2013152858A1 (fr) 2012-04-11 2013-10-17 Ap Fibre Gmbh Nappes de microfibres et produits similaires au papier et leur procédé de fabrication
US9175428B2 (en) 2012-04-30 2015-11-03 Chen-Cheng Huang Method of making a double-sided embossed non-woven fabric
WO2013182296A1 (fr) * 2012-06-04 2013-12-12 Irema-Filter Gmbh Procédé de fabrication d'un non-tissé
US11571645B2 (en) 2013-05-16 2023-02-07 Iremea-Filter Gmbh Fibrous nonwoven and method for the production thereof
US10668424B2 (en) 2014-11-28 2020-06-02 Irema-Filter Gmbh Filter medium having large fold spacing
DE102016223571A1 (de) * 2016-11-28 2018-05-30 Adidas Ag Herstellung von Vliesstoffen einschließlich einer Komponente
US10975500B2 (en) 2016-11-28 2021-04-13 Adidas Ag Method of non-woven fabrics including a component
DE102016223571B4 (de) * 2016-11-28 2020-08-13 Adidas Ag Herstellung von Vliesstoffen einschließlich einer Komponente
US20220162787A1 (en) * 2018-05-29 2022-05-26 Nike, Inc. Method for nonwoven textiles with variable zonal properties
DE102019203986A1 (de) * 2019-03-22 2020-09-24 Adidas Ag Vliesstoffartikel
DE102019203986B4 (de) 2019-03-22 2022-07-07 Adidas Ag Vliesstoffartikel
US12435454B2 (en) * 2022-02-14 2025-10-07 Nike, Inc. Method for nonwoven textiles with variable zonal properties

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