Full-surface bonded multiple component melt-spun nonwoven web
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
D04H-001/00
D04H-013/00
D04H-003/03
D04H-003/02
D04H-005/00
출원번호
US-0007980
(2004-12-09)
등록번호
US-7452832
(2008-11-18)
발명자
/ 주소
Bansal,Vishal
Lim,Hyun Sung
Laura, Jr.,David Matthews
출원인 / 주소
E.I. du Pont de Nemors and Company
인용정보
피인용 횟수 :
13인용 특허 :
10
초록▼
A full-surface bonded multiple component nonwoven fabric is provided that has an improved combination of tear strength and tensile strength at lower thicknesses than known in the art. The full-surface bonded multiple component webs have a void percent between about 3% and 56% and a Frazier permeabil
A full-surface bonded multiple component nonwoven fabric is provided that has an improved combination of tear strength and tensile strength at lower thicknesses than known in the art. The full-surface bonded multiple component webs have a void percent between about 3% and 56% and a Frazier permeability of at least 0.155 m3/min-m2. The full-surface bonded multiple component nonwoven fabrics can be prepared in a smooth-calendering process.
대표청구항▼
What is claimed is: 1. A full-surface bonded multiple component nonwoven fabric comprising a full-surface bonded nonwoven sheet consisting of melt-spun multiple component fibers selected from the group consisting of multiple component staple fibers, multiple component continuous fibers, and combina
What is claimed is: 1. A full-surface bonded multiple component nonwoven fabric comprising a full-surface bonded nonwoven sheet consisting of melt-spun multiple component fibers selected from the group consisting of multiple component staple fibers, multiple component continuous fibers, and combinations thereof, the multiple component fibers having a cross-section and a length, and comprising a first polymeric component and a second polymeric component, the first and second polymeric components being arranged in substantially constantly positioned distinct zones across the cross-section of the multiple component fibers and extending substantially continuously along the length of the multiple component fibers, wherein the second polymeric component has a melting point that is at least about 10�� C. lower than the melting point of the first polymeric component and wherein at least a portion of the outer peripheral surface of the multiple component filaments comprises the second polymeric component, a ratio of average strip tensile strength to basis weight of at least 1.05 N/gsm, and a ratio of average trap tear strength to basis weight of at least 0.329 N/gsm. 2. The full-surface bonded multiple component nonwoven fabric of claim 1 which has a void percent between about 3% and 56%. 3. The full-surface bonded multiple component nonwoven fabric of claim 1 which has a Frazier air permeability of at least 0.155 m3/ min-m2. 4. The full-surface bonded multiple component nonwoven fabric of claim 1 wherein the melt-spun multiple component fibers consist of multiple component continuous spunbond fibers. 5. The full-surface bonded multiple component nonwoven fabric of claim 4 wherein the multiple component continuous fibers have a cross-section selected from the group consisting sheath-core and side-by-side configurations. 6. The full-surface bonded multiple component nonwoven fabric of claim 5 wherein the continuous multiple component continuous fibers have a sheath-core cross-section wherein the first polymeric component forms the core and the second polymeric component forms the sheath. 7. The full-surface bonded multiple component nonwoven fabric of claim 6 wherein the first polymeric component comprises a polymer selected from the group consisting of poly(ethylene terephthalate) and poly(hexamethylene adipamide), and the second polymeric component comprises a polymer selected from the group consisting of poly(ethylene terephthalate) copolymers, poly (1,4-butylene terephthalate), poly(1,3-propylene terephthalate), and polycaprolactam. 8. The full-surface bonded multiple component nonwoven fabric of claim 7 wherein the first polymeric component comprises poly(ethylene terephthate) and the second polymeric component comprises a poly(ethylene terephthalate) copolymer. 9. The full-surface bonded multiple component nonwoven fabric of claim 8 wherein the poly(ethylene terephthalate) copolymer is selected from the group consisting of poly(ethylene terephthalate) copolynmers comprising between about 5 and 30 mole percent di-methyl isophthalio acid based on total diacid units in the copolymer and poly(ethylene terephthalate) copolymers comprising between about 6 and 60 mole percent 1,4-cyclohexanedimethanol based on total glycol units in the copolymer. 10. The full-surface bonded multiple component fabric of claim 1 wherein the melt-spun multiple component fibers consist of multiple component staple fibers. 11. The full-surface bonded multiple component nonwoven fabric of claim 1 wherein the void percent is between about 35% and 55%. 12. A multi-layer composite sheet comprising at least one full-surface bonded multiple component nonwoven fabric according to claim 1 adhered to at least one sheet layer selected from the group consisting of nonwoven webs and films. 13. The multi-layer composite sheet of claim 12 wherein the full-surface bonded multiple component nonwoven fabric consists of multiple component continuous fibers and the sheet layer comprises a meltblown web. 14. The multi-layer composite sheet of claim 13 further comprising a second full-surface bonded multiple component nonwoven fabric according to claim 1 consisting of multiple component continuous fibers, wherein the meltblown web is sandwiched between and adhered to the first and second full-surface bonded multiple component nonwoven fabrics. 15. A process for preparing a thermally bonded multiple component nonwoven fabric comprising the steps of: a. providing a multiple component nonwoven fabric having a first outer surface and an opposing second outer surface, the multiple component nonwoven fabric consisting of multiple component melt-spun fibers selected from the group consisting of multiple component staple fibers, multiple component continuous fibers, and combinations thereof, the multiple component fibers having a cross-section and a length, and comprising a first polymeric component and a second polymeric component, the first and second polymeric components being arranged in substantially constantly positioned distinct zones across the cross-section of the multiple component fibers and extending substantially continuously along the length of the multiple component fibers, wherein the second polymeric component has a melting point, Tm, that is at least about 10�� C. lower than the melting point of first polymeric component and at least a portion of the outer peripheral surface of the multiple component filaments comprises the second polymeric component; b. pre-heating the first and second outer surfaces of the multiple component nonwoven fabric to a temperature between 35�� C. and (Tm-40)�� C.; c. full-surface bonding the first outer surface of the nonwoven fabric by passing the pre-heated nonwoven fabric through a first nip formed by first and second smooth-surfaced calender rolls wherein the second roll is unheated and the first roll contacts the first outer surface of the nonwoven fabric and is maintained at a temperature no greater than (Tm-40)�� C., while applying a nip pressure between about 17.5 to about 70 N/mm; and d. full-surface bonding the second outer surface of the nonwoven fabric by passing the nonwoven fabric through a second nip formed by third and fourth smooth-surfaced calender rolls wherein the fourth roll is unheated and the third roll contacts the second outer surface of the nonwoven fabric and is maintained at a temperature no greater than (Tm-40)�� C. while applying a nip pressure between about 17.5 to about 70 N/mm. 16. A process for preparing a thermally bonded multiple component nonwoven fabric comprising the steps of: a. providing a multiple component nonwoven fabric having a first outer surface and an opposing second outer surface, the multiple component nonwoven fabric consisting of multiple component melt-spun fibers selected from the group consisting of multiple component staple fibers, multiple component continuous fibers, and combinations thereof the multiple component fibers having a cross-section and a length, the multiple component fibers comprising a first polymeric component and a second polymeric component, the first and second polymeric components being arranged in substantially constantly positioned distinct zones across the cross-section of the multiple component fibers and extending substantially continuously along the length of the multiple component fibers, wherein the second polymeric component has a melting point, Tm, that is at least about 10�� C. lower than the melting point of first polymeric component and at least a portion of the outer peripheral surface of the multiple component filaments comprises the second polymeric component; b. pre-heating the first outer surface of the multiple component nonwoven fabric to a temperature between 35�� C. and (Tm-40)�� C.; c. full-surface bonding the first outer surface of the multiple component nonwoven fabric by passing the pre-heated nonwoven fabric through a first nip formed by first and second smooth-surfaced calender rolls wherein the second roll is unheated and the first roll contacts the first outer surface of the nonwoven fabric and Is maintained at a temperature no greater than (Tm-40)�� C.;, while applying a first nip pressure between about 17.5 to about 70 N/mm; d. pre-heating the second outer surface of the multiple component nonwoven fabric to a temperature between 35�� C. and (Tm-40)�� C.; and e. full-surface bonding the second outer surface of the nonwoven fabric by passing the twice pre-heated nonwoven fabric through a second nip formed by third and fourth smooth-surfaced calender rolls wherein the fourth roll is unheated and the third roll contacts the second outer surface of the nonwoven fabric and is maintained at a temperature no greater than (Tm-40)�� C., while applying a second nip pressure between about 17.5 to about 70 N/mm. 17. A full-surface bonded nonwoven fabric prepared according to the process of either of claims 15 or 16 wherein the full-surface bonded nonwoven fabric has a void percent between 3% and 56%. a ratio of average strip tensile strength to basis weight of at least 1.05 N/gsm, a Frazier air permeability of at least 0.155 m3/ min-m2 , and a ratio of average trap tear strength to basis weight of at least 0.329 N/gsm. 18. The full-surface bonded nonwoven fabric of claim 17 wherein the void percent is between about 35% and 55%. 19. The full-surface bonded nonwoven fabric of either of claims 1 or 18 wherein the Frazier air permeability is at least 0.310 m3/ min-m2.
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