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Kafe 바로가기국가/구분 | United States(US) Patent 등록 |
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국제특허분류(IPC7판) |
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출원번호 | US-0966483 (2010-12-13) |
등록번호 | US-8444895 (2013-05-21) |
발명자 / 주소 |
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출원인 / 주소 |
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대리인 / 주소 |
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인용정보 | 피인용 횟수 : 13 인용 특허 : 379 |
Disclosed are water-dispersible fibers derived from sulfopolyesters having a Tg of at least 25° C. The fibers may contain a single sulfopolyester or a blend of a sulfopolyester with a water-dispersible or water-nondispersible polymer. Also disclosed are multicomponent fibers comprising a water dispe
Disclosed are water-dispersible fibers derived from sulfopolyesters having a Tg of at least 25° C. The fibers may contain a single sulfopolyester or a blend of a sulfopolyester with a water-dispersible or water-nondispersible polymer. Also disclosed are multicomponent fibers comprising a water dispersible sulfopolyester having a Tg of at least 57° C. and a water non-dispersible polymer. The multicomponent fibers may be used to produce microdenier fibers. Fibrous articles may be produced from the water-dispersible fibers, multicomponent fibers, and microdenier fibers. The fibrous articles include water-dispersible and microdenier nonwoven webs, fabrics, and multilayered articles such as wipes, gauze, tissue, diapers, panty liners, sanitary napkins, bandages, and surgical dressings. Also disclosed is a process for water-dispersible fibers, nonwoven fabrics, and microdenier webs. The fibers and fibrous articles have further applications in flushable personal care and cleaning products, disposable protective outerwear, and laminating binders.
1. A process for producing water-dispersible fibers comprising: I. heating at least one water-dispersible polymer composition to a temperature above its flow point, wherein said water-dispersible polymer composition comprises: (A) at least one sulfopolyester having a glass transition temperature (Tg
1. A process for producing water-dispersible fibers comprising: I. heating at least one water-dispersible polymer composition to a temperature above its flow point, wherein said water-dispersible polymer composition comprises: (A) at least one sulfopolyester having a glass transition temperature (Tg) of at least 25° C., said sulfopolyester comprising: (i) residues of one or more dicarboxylic acids;(ii) about 4 to about 40 mole %, based on the total repeating units, of residues of at least one sulfomonomer having 2 functional groups and one or more metal sulfonate groups attached to an aromatic or cycloaliphatic ring wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;(iii) one or more diol residues wherein at least 20 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2—CH2)n—OHwherein n is an integer in the range of 2 to about 500;(iv) 0 to about 25 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;(B) optionally, at least one water-dispersible polymer blended with said sulfopolyester; and(C) optionally, at least one water-nondispersible polymer blended with said sulfopolyester to form a blend with the proviso that said blend is an immiscible blend; andII. melt spinning said water-dispersible polymer composition to produce said water-dispersible fibers; wherein said water-dispersible fiber contains less than 8 weight percent of at least one pigment or filler, based on the total weight of said water-dispersible fiber. 2. A process for producing at least one water-dispersible, nonwoven fabric, comprising: I. heating at least one water-dispersible polymer composition to a temperature above its flow point, wherein said water-dispersible polymer composition comprises: (A) at least one sulfopolyester having a glass transition temperature (Tg) of at least 25° C., said sulfopolyester comprising: (i) residues of one or more dicarboxylic acids;(ii) about 4 to about 40 mole %, based on the total repeating units, of residues of at least one sulfomonomer having 2 functional groups and one or more metal sulfonate groups attached to an aromatic or cycloaliphatic ring wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;(iii) one or more diol residues wherein at least 20 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2-CH2)n-OHwherein n is an integer in the range of 2 to about 500;(iv) 0 to about 25 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;(B) optionally, at least one water-dispersible polymer blended with said sulfopolyester; and(C) optionally, at least one water-nondispersible polymer blended with said sulfopolyester to form a blend with the proviso that said blend is an immiscible blend;II. melt spinning said water-dispersible polymer composition to produce water-dispersible fibers; wherein said water-dispersible fibers contain less than 8 weight percent of at least one pigment or filler, based on the total weight of said water-dispersible fibers; and III. overlapping and collecting said water-dispersible fibers of Step II to form said water-dispersible nonwoven fabric. 3. A process for producing at least one multicomponent fiber having a shaped cross section comprising spinning at least one water dispersible sulfopolyester having a glass transition temperature (Tg) of at least 57° C. and at least one water-nondispersable polymer immiscible with said sulfopolyester into said multicomponent fiber, said sulfopolyester comprising: (i) residues of one or more dicarboxylic acids;(ii) about 4 to about 40 mole %, based on the total repeating units, of residues of at least one sulfomonomer having 2 functional groups and one or more sulfonate groups attached to an aromatic or cycloaliphatic ring wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;(iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2—CH2)n—OHwherein n is an integer in the range of 2 to about 500; and(iv) 0 to about 25 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;wherein said multicomponent fiber has a plurality of segments comprising said water-nondispersable polymer and said segments are substantially isolated from each other by said sulfopolyester intervening between said segments and wherein said multicomponent fiber contains less than 8 weight percent of at least one pigment or filler, based on the total weight of said multicomponent fiber. 4. The process according to claim 3 wherein said sulfopolyester comprises: (i) about 50 to about 96 mole % of one or more residues of isophthalic acid or terephthalic acid, based on the total acid residues;(ii) about 4 to about 30 mole %, based on the total acid residues, of a residue of sodiosulfoisophthalic acid;(iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2—CH2)n—OHwherein n is an integer in the range of 2 to about 500; and(iv) 0 to about 20 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof. 5. The process according to claim 3 wherein said shaped cross section is an islands-in-the-sea or segmented pie. 6. The process according to claim 3 further comprising quenching said multicomponent fiber thereby solidifying said multicomponent fiber. 7. The process according to claim 6 further comprising applying at least one finish to said multicomponent fiber. 8. The process according to claim 7 wherein said finish further comprises at least one additive. 9. The process according to claim 8 wherein said additive is at least one selected from the group consisting of emulsifiers, antistatics, antimicrobials, antifoams, lubricants, thermostabilizers, and UV stabilizers. 10. The process of claim 6 further comprising drawing said multicomponent fiber. 11. The process according to claim 10 further comprising texturizing said multicomponent fiber. 12. A process for producing at least one microdenier fiber comprising: A. spinning at least one water dispersible sulfopolyester having a glass transition temperature (Tg) of at least 57° C. and at least one water-nondispersable polymer immiscible with said sulfopolyester into at least one multicomponent fiber, wherein said sulfopolyester comprises: (i) residues of one or more dicarboxylic acids;(ii) about 4 to about 40 mole %, based on the total repeating units, of residues of at least one sulfomonomer having 2 functional groups and one or more sulfonate groups attached to an aromatic or cycloaliphatic ring wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;(iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2—CH2)n—OHwherein n is an integer in the range of 2 to about 500; and(iv) 0 to about 25 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;wherein said multicomponent fiber has a plurality of segments comprising said water-nondispersable polymer wherein said segments are substantially isolated from each other by said sulfopolyester intervening between said segments; and wherein said multicomponent fiber contains less than 8 weight percent of at least one pigment or filler, based on the total weight of said multicomponent fiber; andB. contacting said multicomponent fiber with water to remove said sulfopolyester thereby forming said microdenier fiber. 13. The process of claim 12 wherein said sulfopolyester comprises: (i) about 50 to about 96 mole % of one or more residues of isophthalic acid or terephthalic acid, based on the total acid residues;(ii) about 4 to about 30 mole %, based on the total acid residues, of a residue of sodiosulfoisophthalic acid;(iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2—CH2)n—OHwherein n is an integer in the range of 2 to about 500; and(iv) 0 to about 20 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof. 14. The process of claim 12 wherein said contacting with water is conducted at a temperature in the range of about 25° C. to about 100° C. 15. The process of claim 14 wherein said contacting with water is conducted at a temperature in the range of about 50° C. to about 80° C. 16. The process of claim 12 wherein said contacting with water is conducted for a time ranging from about 10 to about 600 seconds. 17. The process according to claim 12 wherein said water-nondispersible polymer is at least one selected from the group consisting of polyolefins, polyesters, polyamides, polylactides, polycaprolactones, polycarbonates, polyurethanes, polyvinyl chlorides, cellulose esters, and combinations thereof. 18. The process according to claim 12 wherein said water-nondispersible polymer is biodistintegratable as determined by DIN Standard 54900 or biodegradable as determined by ASTM Standard Method, D6340-98. 19. The process according to claim 16 wherein said water-nondispersible polymer is an aliphatic-aromatic polyester. 20. A process for producing at least one microdenier fiber web, comprising: A. spinning at least one water dispersible sulfopolyester having a glass transition temperature (Tg) of at least 57° C. and at least one water-nondispersable polymer immiscible with said sulfopolyester into at least one multicomponent fiber, said sulfopolyester comprising:(i) residues of one or more dicarboxylic acids;(ii) about 4 to about 40 mole %, based on the total repeating units, of residues of at least one sulfomonomer having 2 functional groups and one or more sulfonate groups attached to an aromatic or cycloaliphatic ring wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;(iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2—CH2)n—OHwherein n is an integer in the range of 2 to about 500; and(iv) 0 to about 25 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof; wherein said multicomponent fiber has a plurality of segments comprising said water-nondispersable polymer wherein said segments are substantially isolated from each other by said sulfopolyester intervening between said segments; and wherein said multicomponent fiber contains less than 8 weight percent of at least one pigment or filler, based on the total weight of said multicomponent fiber;B. overlapping and collecting said multicomponent fiber of Step A to form at least one nonwoven web; andC. contacting said nonwoven web with water to remove said sulfopolyester thereby forming said microdenier fiber web. 21. The process of claim 20 wherein said sulfopolyester comprises: (i) about 50 to about 96 mole % of one or more residues of isophthalic acid or terephthalic acid, based on the total acid residues;(ii) about 4 to about 30 mole %, based on the total acid residues, of a residue of sodiosulfoisophthalic acid;(iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2—CH2)n—OHwherein n is an integer in the range of 2 to about 500; and(iv) 0 to about 20 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof. 22. A process for dispersing at least one fibrous article in water, said process comprising: A. spinning at least one water dispersible sulfopolyester having a glass transition temperature (Tg) of at least 57° C. and at least one water-nondispersable polymer immiscible with said sulfopolyester into at least one multicomponent fiber, said sulfopolyester comprising: (i) residues of one or more dicarboxylic acids;(ii) about 4 to about 40 mole %, based on the total repeating units, of residues of at least one sulfomonomer having 2 functional groups and one or more sulfonate groups attached to an aromatic or cycloaliphatic ring wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;(iii) one or more diol residues wherein at least 25 mole %, based on the total diol residues, is a poly(ethylene glycol) having a structure H—(OCH2—CH2)n—OHwherein n is an integer in the range of 2 to about 500; and(iv) 0 to about 25 mole %, based on the total repeating units, of residues of a branching monomer having 3 or more functional groups wherein said functional groups are hydroxyl, carboxyl, or a combination thereof;wherein said multicomponent fiber has a plurality of segments comprising said water-nondispersable polymer wherein said segments are substantially isolated from each other by said sulfopolyester intervening between said segments; and wherein said multicomponent fiber contains less than weight percent of at least one pigment or filler, based on the total weight of said multicomponent fiber;B. overlapping and collecting said multicomponent fiber of Step A to form at least one fibrous article; andC. contacting said fibrous article with water to remove said sulfopolyester thereby dispersing said fibrous article.
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