초록 ▼

A high loft, low density, nonwoven fibrous web is provided comprising a plurality of irregularly arranged, intersecting, overlapping, mechanically interengaged, loosely assembled fibers including both thermoplastic synthetic wood pulp fibers and other fibers, segments of the thermoplastic synthetic

A high loft, low density, nonwoven fibrous web is provided comprising a plurality of irregularly arranged, intersecting, overlapping, mechanically interengaged, loosely assembled fibers including both thermoplastic synthetic wood pulp fibers and other fibers, segments of the thermoplastic synthetic wood pulp fibers being heat fused at a plurality of junctures with segments of other thermoplastic synthetic wood pulp fibers and with segments of fibers of other types, with additional binder distributed throughout the web. The web is prepared by air-laying a blend of thermoplastic synthetic wood pulp fibers and other fibers applying heat without pressure to the air-laid blend to fuse at least some of the thermoplastic synthetic wood pulp fibers to each other and to some of the other fibers to form a self-supporting fibrous web, introducing a latex binder into the web and drying and curing the binder. This application relates to a high loft, low density, nonwoven fibrous material, such as an air-laid web or fabric, containing synthetic wood pulp fibers as one constituent thereof, and to a method of producing the same.

대표청구항 ▼

A high loft, low density, nonwoven fibrous material containing thermoplastic synthetic wood pulp fibers, as one constituent thereof and fibrous material other than thermoplastic synthetic wood pulp fibers, said synthetic wood pulp fibers having a length and denier generally similar to natural wood p

A high loft, low density, nonwoven fibrous material containing thermoplastic synthetic wood pulp fibers, as one constituent thereof and fibrous material other than thermoplastic synthetic wood pulp fibers, said synthetic wood pulp fibers having a length and denier generally similar to natural wood pulp fibers, which comprises: a plurality of irregularly arranged, intersecting, overlapping, mechanically interengaged, loosely assembled fibers including both thermoplastic synthetic wood pulp fibers and fibers other than synthetic wood pulp fibers, said fibrous material contains generally in the range of about 10 percent to about 30 percent by weight of said synthetic wood pulp fibers, said other fibers having a melting point above that of the synthetic wood pulp fibers, the general orientation and arrangement of the fibers of said material being substantially the same in all directions across the material and substantially uniform from one boundary surface of the material to the other; segments of said synthetic wood pulp fibers having been heat fused in the absence of pressure at a plurality of junctures with segments of both said synthetic wood pulp fibers and said other fibers to form a self-supporting fibrous web in the absence of any additional binder; and said web having an additional binder distributed therein to bond fiber segments in contact with each other, whereby a stable bonded fibrous material is provided having good wet strength and delamination resistance, with substantially lower density and less shrinkage stiffness, harshness and evidence of web collapse than would be exhibited by a fibrous web formed of said other fibers alone and with its fibers bonded only by said additional binder. In a diaper structure comprising a facing layer, an adsorbent batt and an impervious backing layer in which said facing layer and said backing sheet are outermost layers and said batt is positioned between said facing layer and said backing sheet, the improvement wherein said facing layer comprises the high loft, low density, nonwoven fibrous material of claim 1. A method of producing a high loft, low density, nonwoven fibrous material containing thermoplastic synthetic wood pulp fibers as one constituent thereof and fibrous material other than thermoplastic synthetic wood pulp fibers, said thermoplastic synthetic wood pulp fibers having a length and denier generally similar to natural wood pulp fibers, which comprises: applying heat in the absence of pressure to a starting layer of irregularly arranged, intersecting, overlapping, mechanically interengaged, loosely assembled fibers including both said synthetic wood pulp fibers and fibers other than synthetic wood pulp fibers, said fibrous material contains generally in the range of about 10 percent to about 30 percent by weight of said synthetic wood pulp fibers, the general orientation and arrangement of the fibers of said material being substantially the same in all directions across the material and substantially uniform from one boundary surface of the material to the other, said other fibers having a melting point, or degradation temperature, above that of the temperature of the synthetic wood pulp fibers, to fuse at least some of said synthetic wood pulp fibers to each other and to some of said other fibers and thereby form a self-supporting fibrous web in the absence of any additional binder which is resistant to web collapse during the subsequent bonding step; introducing a liquid binder into said fibrous web; and drying and curing said binder to bond fiber segments in contact with each other throughout the web to form a stable bonded fibrous material of good wet strength, abrasion resistance and delamination resistance with substantially lower density and less shrinkage stiffness and harshness than would be exhibited by a fibrous web formed of said other fibers alone and with its fibers bonded only by said binder.