High cellulose layer nonwoven fabric and its manufacturing method

专利摘要:
High cellulose layer nonwoven fabric and its method of manufacture The present invention provides a high cellulose layer nonwoven fabric suitable for use in wipes, absorbent articles and other applications, and a method for making the same. The nonwoven layered comprises three layers joined together, where the outer layers are lightweight solidified sheets by rotation and the intermediate layers are composed primarily of cellulose fibers. each of the first (3), second (2) and third (4) nonwoven layers are preferably first formed separately and individually to be self-supporting blankets, after which the three self-supporting blankets are assembled essentially just prior to joining. them. When used as a substrate for wet wipes, the inventive fabric exhibits a combination of several useful properties; good smoothness and wet and dry mass, good wet abrasion resistance and low wet lint propensity, and where most of the raw material is cellulose.
公开号:BR112012001275B1
申请号:R112012001275-4
申请日:2010-07-20
公开日:2019-11-12
发明作者:Nortman Brian；Meikle Gordon；Escaffre Pascale
申请人:Suominen Corp；
IPC主号:

专利说明:

Descriptive Report of the Invention Patent for NON-WOVEN FABRIC IN HIGH-CELLULOSE CONTENT LAYERS AND ITS MANUFACTURING METHOD.
FIELD OF THE INVENTION [001] The present invention relates to layered composite nonwoven fabrics and a method for making layered composite nonwoven fabrics.
BACKGROUND OF THE INVENTION [002] Nonwoven fabrics have been around for many years and today there are a number of different nonwoven production technologies being used commercially. An important area of application for non-woven fabrics is in the field of cleaning materials, also known as handkerchief or cleaner. Wipes are used for a wide range of purposes in industrial, domestic, institutional and personal cleaning environments. Within these applications, a common requirement is that the tissue be absorbent to water and aqueous solutions or to certain solvents in the case of industrial tissues. Handkerchiefs are often sold and packaged in a pre-moistened state as baby wipes. Other common tissue requirements include the ability to remove and retain dirt, smoothness, volume, and strength appropriate for the intended use, and a low propensity to release lint (loosens fibers and / or particles). When the tissue is intended for use in the wet state, the properties mentioned above are usually measured as wet properties after the nonwoven fabric has been properly moistened. Many wipes are intended to be for single use (for example, baby wipes and personal hygiene) or limited reuse items (for example, some types of kitchen wipes). Current trends in the field of consumer wipes (baby wipes, personal hygiene wipes and household cleaning wipes, including design wipes
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2/85 section), place the emphasis on cleaning performance, economy and concern for the environment. The consumer demands a high level of cleaning performance, that is, mainly the removal of dirt, leaving little or no residual lint or streaks on the clean surface. Reducing the weight of a tissue needed to perform a specific cleaning task will consume less raw materials per tissue and will be more economical. The weight of baby wipes and personal hygiene is generally about 40 gsm to about 65 gsm, and the weight of wipes for consumption of household cleaning and disinfection is generally from 40 gsm to about 55 gsm . There is growing public concern about the use of natural resources to be used in the manufacture of cleaning articles, the use of which is of limited duration. Therefore, there is a growing consumer demand for scarves produced with less environmental impact, for example, scarves made from a high percentage of renewable and sustainable materials, and preferably, scarves that are biodegradable after use.
[003] Cellulose is used in various types of nonwoven fabrics made by different technologies. Although nonwoven fabrics made of cellulose fibers are known to be absorbent, nonwoven fabrics made entirely of cellulose fibers may be undesirable for some cleaning applications due to the lack of adequate strength and abrasion resistance, and are prone to loosening. cellulose fibers during use. The handkerchief is often used to clean a surface by rubbing the handkerchief over the surface. The rubbing action wears off the surface of the scarf. If the material used to make the scarf has a low abrasion resistance, this results in the scarf having relatively poor durability and an excessive number of fibers or other particles tend to come off the scarf and contaminate the clean surface. This is particularly the case when the substrate of
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3/85 cleaning contains cellulose. In the past, non-woven fabrics with a high cellulose content have been strengthened by applying chemical binders and / or using bonding techniques, such as hydroentanglement. Each of these approaches has disadvantages. For example, the use of synthetic chemical binder dispersions increases the cost, generally increases energy consumption during manufacture due to the need for additional drying of the blanket, and can cause unwanted stripes when the handkerchief is used to clean a hard surface like glass . Due to the short length of cellulose fibers (generally less than 4 mm, and often about 2 mm), the 100% w / w hydro-interlacing of cellulose blankets with high pressure water jets has only a limited effect. Generally, longer fibers or filaments should be mixed with the cellulose pulp fibers, or conversely, supplied in such a way that the cellulose pulp fibers can wrap around the longer fibers or filaments during the hydroentanglement process. Examples of hydro-entanglement of cellulose fibers in the presence of longer fibers are disclosed in Canadian patent 841938 and US patent 5009747. Hydro-entanglement with high pressure water jets is a high energy process, and another consequence is densification of the non-woven fabric, that is, reduction of the blanket thickness and volume during the hydro-interlacing. Non-woven fabrics with a high content of hydroentangled cellulose pulp can still release lint to an unacceptable degree, and require further treatment, such as the addition of a chemical binder.
[004] A number of spin solidification technologies have been used to manufacture nonwoven fabrics. Spin solidified nonwovens can be made from a variety of thermoplastic resins, including (but not limited to) polymers and / or
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4/85 copolymers of olefins, esters, amides, urethanes, and vinyl compounds such as vinyl chloride, vinyl alcohol and vinyl acetate. The resin (s) may include those made from sustainable sources, such as poly (lactic acid) and other thermoplastics derived from plants. The spunbond continuous spinning process produces multiple polymer filaments, essentially continuous, which are placed on a foraminous moving surface to form a loose blanket, which are then commonly connected by means of heated calender rolls. Spunbond blankets are generally strong and porous. US patent 3802817 describes the spunbond process and equipment. The meltblown melted and blown process was first developed in the 1950s to provide advanced filtration materials, as described in Van A. Wente in Industrial and Engineering Chemistry, Volume 48, No. 8 (1956). US patents 3379811, 3634573 and 3849241 describe the process. Meltblown blankets are generally weaker than the equivalent weight of the spunbond blanket, but have smaller pores, and as such are often used in filtration applications. The two technologies can be combined to produce composite fabrics, such as 3-layer spunbondmeltblown-spunbond or 'SMS' composite fabric, which combines the strength of the spunbond with the filterability of meltblown blankets. The product of another hybrid technology is the so-called high-strength meltblown non-woven fabric whose method of manufacture is described in US patents 4731215 and 6013223. Although the use of 100% w / w of synthetic spin solidified blankets as cleaning materials has been described in US patent 6315114 B1 and in US patent application 2005 / 133174A1, such wipes are more commonly used in professional and industrial applications, rather than as consumer wipes. The blankets solidified by rotation were combined with cellulose, usually through hydro-interlacing, for
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5/85 to make non-woven fabrics suitable for use as cleaning materials. US patents 4442161, 4808467 and 4939016 describe such cellulose-solidified blanket composites by rotation.
[005] The nonwoven technologies used today to make cleaning materials with a high percentage content of cellulose pulp include co-formed compounds, formed by airflow and hydro-interlaced.
[006] A co-formed nonwoven is a sheet comprising a deep mixture of meltblown filaments (usually polypropylene filaments) and cellulose fibers (usually cellulose pulp fibers). In the co-formation process, the fibers of the cellulose pulp (usually about 70% by weight of the fabric) are individualized, transported in an air stream that is combined with a second meltblown filament carried by the air stream. The combined air stream deposits the fibrous material on a foraminous surface. Co-formation-like processes and fabrics are described in US patents 4100324 and 5350624. Co-formed non-woven fabrics are generally bulky and soft, but generally have relatively poor wet abrasion resistance, resulting in a greater propensity to release lint.
[007] In the formation process by air, the cellulose pulp fibers (usually 70% or more by weight of the fabric) are individualized, using, for example, a hammer mill transported in an air stream to a distribution that distributes substantially uniform fibers in the cross direction of the production machine. After passing through the distribution device, the fibers are deposited on a moving foraminous surface by means of an air flow created by vacuum boxes below the surface. Other materials, such as synthetic fibers, powder or particles can be mixed with the cellulose pulp fibers. The air-formed blanket can be connected by a number of methods, including
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6/85 binders activated by heat and / or application of liquid binders. US patent 3,575,749 describes the process for airlaid airflow (formed by air) and US patent 4494278 describes a fiber distribution device used to make the blankets mentioned above. When blankets formed by air are used to make cleaning substrates, the strength of the mat is enhanced by spraying or applying a liquid binder, typically an aqueous dispersion of synthetic latex, to one or both surfaces of the mat that must be dried and healed. Through the application of the liquid binder, mainly on the surfaces of the mat, the detachment of fibers (also known as dispersing or loosening lint) from the substrate surfaces is reduced. A recent modality of the airflow process for the production of cleaning materials is the so-called multiple bond airflow process (MBAL). In the MBAL process, the binding thermoplastic fibers (usually about 30% by weight of the fabric) are mixed with cellulose pulp fibers. Binder fibers are typically of a coating: bicomponent core configuration, where the coating polymer has a lower melting point than the polymer that makes up the fiber core. After depositing the mixture of cellulose pulp fibers and binder fibers on a foraminous surface to form a blanket, the blanket passes through an oven where the fibers bond with neighboring fibers, thus reinforcing the blanket. In addition, a light application of a liquid binder, usually an aqueous dispersion of synthetic latex, is applied to one or both surfaces of the mat to reduce the number of fibers coming off during its use as a handkerchief. Airflow blankets, including multiple connection airflow blankets, are generally bulky, can be smooth, depending on the choice of binder (s), but have poor resistance to wet abrasion, resulting in greater proPetition 870190030328, of 03/29/2019, p. 10/100
7/85 pension for loose hair.
[008] The hydro-interweaving of cellulose pulp non-woven compounds and other fibers or filaments has long been known. US patents 3485706 and 3560326 describe hydro-interlacing of cut polyester fiber compounds and cellulose pulp. US patents 4442161 and 4808467 describe hydroentangled compounds of spunbond blankets and cellulose pulp. Such nonwoven compounds generally contain less than about 70% by weight of cellulose pulp fibers. US patent 5284703 describes a composite fabric made from hydro-interwoven cellulose pulp in a spunbond blanket, and where the cellulose pulp content of the non-woven compound is at least 70% by weight. Depending on the choice of raw materials, such as cellulose paste containing hydro-interlaced blankets, it may have good resistance to wet abrasion, but they are not very soft or bulky, and are normally used for industrial or hard surface cleaning.
[009] Tests of commercial tissue samples made from the nonwoven technologies described above demonstrate that they have either good wet abrasion resistance or good wet volume, or a low propensity to release lint, but not all of these desirable properties together. It is an object of the present invention to provide an improved nonwoven cleaning material with the combination of good wet volume, good resistance to wet abrasion and a low propensity to release lint and with a high cellulose paste content of at least 50% in Weight.
DEFINITIONS [0010] As used here, the term Formation by air or by airflow must mean the well-known process by which a layer of fibrous nonwoven can be formed. In the process of formation by air, the bundles of small fibers having lengths
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Typical 8/85 ranging from 1 to 50 mm are separated and drawn into an air supply and then deposited on a forming screen, usually with the aid of a vacuum source. The fibers deposited at random may, if desired, be bonded together using, for example, a chemical adhesive and / or thermal bond. The terms airflow formation and airway formation are used interchangeably throughout this document.
[0011] As used here, the term attenuation means the act of pulling or stretching a hot thermoplastic filament in its long direction. In meltblown and spunbond processes, attenuation or elongation is usually effected by a gas (usually air) that flows at high speed in the same direction and, essentially, parallel to the movement of the filaments. The attenuation has the simultaneous effects of reducing the diameter of the filament, increasing the alignment of the polymer molecules along the length of the filament, and increasing the tenacity of the filament.
[0012] As used here, the term weight must mean the weight of a sheet material per unit area, for example, in grams per square meter (gsm or g / m2) or ounces per square yard (osy). Note: the conversion factor is 1 osy = 33.91 gsm.
[0013] As used here, the term bicomponent fiber is understood to mean a fiber that was formed from two different polymers. At the beginning of the filament production process, the two polymers are melted and transformed using separate equipment, before being taken to each hole in the die to be braided in a pre-arranged configuration to form a single filament or fiber. Typically, two separate polymers are extruded, although a two-component fiber can cover extrusion of the same polymeric material from separate extruders. Extruded polymers
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9/85 data are arranged in distinct zones positioned substantially constant within the cross section of the bicomponent fibers and extend substantially continuous along the length of the bicomponent fibers. Various types of cross-sectional configurations of bicomponent fibers are known, non-limiting examples include coating: central, side by side, multi-segment cake and fibril matrix. The transverse configuration of the bicomponent fibers can be symmetrical (for example, coating, concentric and core, or side by side of equal proportions), or it can be asymmetrical (for example, offset core within the coating, or side-by-side segments of proportions uneven). The two polymers can be present in proportions of, for example, (but not exclusively), 75/25, 50/50 or 25/75. Three-component fibers, made from three polymers, are also known.
[0014] As used here, the term fiber or bicomponent filament should be understood as a fiber or filament that was formed from a mixture of two or more extruder extruded polymers as a mixture. The bicomponent fibers or filaments do not have the various polymer components arranged in distinct relatively constant zones positioned over the entire cross-sectional area of the fiber and the various polymers are normally non-continuous along the entire length of the fiber or filament, in instead, usually forming fibrils that start and end randomly.
[0015] As used here, the term binder should be understood as an adhesive material used to attach a fiber mat or to connect one mat to the other. The main properties of a binder are adhesion and cohesion. The binder can be in solid form, for example, a powder, a film, or a fiber, in liquid form, for example, a solution, a dispersion, or an emulsion or in
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10/85 foam form.
[0016] As used here, the term volume should be understood as the opposite of density applied to non-woven fabrics. Volume (in cubic centimeters per gram, cc / g) is calculated from the thickness of the nonwoven fabric (in microns) divided by the weight of the nonwoven fabric (in grams per square meter, gsm). The wet and dry volume is calculated from the wet and dry thickness of the non-woven fabric, respectively.
[0017] As used here, the term calendering should be understood as the process of smoothing the surface of paper, non-woven fabric or textile sheet, pressing it between the opposite surfaces. Opposite surfaces include flat plates and rollers. One or both of the opposite surfaces can be heated.
[0018] As used here, the term card means a machine designed to separate the individual fibers from a mass of unordered fibers, to align the fibers and distribute the aligned fibers like a cover or blanket. The fibers in the mat can be aligned randomly or essentially parallel to each other and predominantly in the direction of the machine. The card consists of a series of rollers and drums that are covered with a plurality of threads or the projected metal teeth.
[0019] As used here, the term carded blanket means a blanket of non-woven fibers produced by carding.
[0020] As used here, the term carding means a process for making nonwoven blankets on a card.
[0021] As used here, the term cellulose fiber means a fiber composed substantially of cellulose. Cellulosic fibers from artificial sources (for example, regenerated cellulose fibers or lyocell fibers) or natural sources, such as cellulose fibers or cellulose pulp from woody and non-woody plants
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11/85 sas. Woody plants include, for example, deciduous and coniferous trees. Non-woody plants include, for example, cotton, flax, esparto, kenaf, sisal, abaca, asclepias, straw, jute, hemp, and mulch.
[0022] As used herein, the term cellulose material means a material composed substantially of cellulose. The material can be a fiber or a film. Cellulosic materials come from artificial sources (for example, regenerated cellulose films and fibers) or natural sources, such as fibers or pulp from woody and non-woody plants.
[0023] As used here, the term co-formed material means a sheet material comprising a deep mixture of meltblown filaments and cellulose fibers, formed by combining air currents carrying each type of material and forming a sheet material when depositing said materials on a foraminous surface. Other materials, such as fibers, flakes or particles can be added to the air stream (s), and are incorporated into the sheet material co-formed by this means.
[0024] As used herein, the term comprising means the various components, ingredients or steps that can be employed together in the practice of the present invention. Thus, the term comprising encompasses the most restrictive terms consisting essentially of and consisting of.
[0025] As used here, the term conventional meltblown process means the well-known process for making meltblown filaments (see separate definition) described by Van A. Wente in Industrial and Engineering Chemistry, Volume 48, No. 8 (1956). One of the main objectives of the conventional meltblown process is the production of thin polymer filaments for use in high efficiency filter media and, in this case, the need for
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12/85 producing strong filaments is a minor consideration.
[0026] As used here, the term conjugated fiber means a fiber that was formed by extruding polymer sources from separate extruders and twisted to form a single fiber. A conjugated fiber encompasses the use of two or more separate polymers each supplied by a separate extruder. The extruded polymers are arranged in distinct zones positioned substantially constant on the other side of the cross section of the conjugated fiber and extended substantially continuously along the length of the conjugated fiber. The shape of the conjugated fiber can be any shape that is convenient for the producer for the intended purpose, for example, round, trilobal, triangular, dog-shaped, flat or hollow.
[0027] As used here, the term cross direction of the machine (CD) is understood to be the direction perpendicular to the direction of the machine.
[0028] As used here, the term denier means a unit used to indicate the fineness of a filament given by the weight in grams per 9,000 meters of filament. A 1 denier filament has a mass of 1 gram per 9,000 meters in length.
[0029] As used here, the term embossing means the process of creating a three-dimensional image or design on paper, nonwovens, or other ductile materials. In the field of nonwovens, the equipment used is typically a two-roll calender, at least one roll of which has the desired relief pattern. The two-roll calender rotates in reverse at about the same speed, one or both of the rollers can be heated, and there is usually a mechanism to press one roll against the other in a controlled manner. The nonwoven blanket is passed between the rollers and comes with a pattern in relief on at least one of its surfaces.
[0030] As used here, the term fabric means a material
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13/85 in non-woven sheet, generally permeable to air, made of fibers and / or filaments. The terms fabric and blanket are used here interchangeably.
[0031] As used here, the term fiber means a material shape characterized by a high proportion between length and diameter. The fibers are generally not continuous in length and can be of natural or artificial origin. The fibers can be designated as short or long (see separate definitions).
[0032] As used here, the term filament means a material shape characterized by a very high ratio between length and diameter. The filaments are produced from a variety of polymers by extruding a polymer material melted through a die. During the production of filaments, it is generally intended that the filaments are substantially continuous in length, but occasionally some filaments may break, reducing their length.
[0033] As used here, the term non-woven fabric composed of high cellulose content means a fabric, composed substantially of natural cellulose fibers. Natural cellulose fibers comprise at least 50% by weight of the composite nonwoven fabric.
[0034] As used here, the term high-strength meltblown filament means meltblown filaments made by a meltblown process that is intermediate between the conventional meltblown process and the conventional spunbond process. The description of the process and apparatus used is given in US patent 6013323. In the high strength meltblown process, a polymer class with a relatively high average molecular weight (similar to the polymer class used in the spunbond process) is used in contrast to the class of lower average molecular weight polymers, with a higher rate of
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14/85 melt flow, normally used in the production of conventional meltblown filaments. The use of such a class of polymer with a generally relatively high average molecular weight produces meltblown filaments with greater toughness.
[0035] As used here, the term high strength meltblown means a nonwoven sheet material made from high strength meltblown filaments and which is stronger when produced than a nonwoven sheet of the same weight and the same polymer made by the conventional meltblown process. Note that this comparison is based on there being no additional bonding processes, for example, thermal bonding point.
[0036] As used here, the terms non-woven in layers and non-woven in layers mean a non-woven fabric made by bringing together two or more layers of sheet materials, followed by a bonding process in which there is little mixing of materials on the interface between layers.
[0037] As used here, the term long fiber means a fiber having an average length of at least 25 mm and up to about 200 mm or more.
[0038] As used here, the term lyocell means an artificial cellulose material obtained by directly dissolving cellulose in an organic solvent, without forming an intermediate compound and later extruding the cellulose solution and an organic solvent in a coagulant bath.
[0039] As used here, the term male-female embossing means a embossing process using two counter-rotating metal calender rolls, one of which (the male roll) is engraved so that raised areas (overhang points) protrude from the roll surface and another roll (the female roll) is engraved with impressions or machined cavities on the roll surface that are complementary and
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15/85 correspond exactly to the shape and spacing of the recorded male points. The size of the female prints is usually slightly larger than the corresponding male engraved dots. It is also possible for each roll to incorporate both the male projection points and female impressions - when two rolls are joined, the male projection points and the female impressions of each roller exactly match the complementary characteristics of the other rolls. The two rollers rotate opposite in register and at the same speed. One or both rolls can be heated. When a sheet material is fed between the two rotating rollers, the sheet material is pressed into the female impressions by means of the corresponding male projection points. The sheet material resulting in relief is said to be male-female in high relief. US patent 4333979 illustrates a male-female engraving process and equipment. Alternative terms for this process include off-plane and 3-dimensional (3-D) embossing.
[0040] As used here, the term machine direction (MD) means the direction of displacement of the forming surface on which the fibers are deposited during the formation of a non-woven mat material.
[0041] As used here, the term melt additive means a material added and mixed with a polymer in its molten state after which, for example, the molten mixture is extruded into a film or twisted to form filaments or fibers. The melting additive generally gives some functionality or additional attributes to the article made of polymer, non-exclusive examples of which include: it makes the article hydrophilic or hydrophobic and / or colored and / or increases opacity and / or reduces gloss surface and / or makes the article less prone to static charge buildup.
[0042] As used here, the term fluidity index (MFR) means
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16/85 is the rate at which a polymer flow fused under standard measurement conditions, as described in the ASTM D1238 test method. In the case of polypropylene, the melting temperature of the polymer is 230 ° C and the molten resin is extruded through a hole of defined dimensions, under a load of 2.16 kg. The amount of polymer (in grams) extruded through the orifice in 10 minutes is measured.
[0043] As used here, the term meltblown filament means a filament or fiber formed by the extrusion of a fused thermoplastic material like filaments from a plurality of thin, usually circular, capillary arrays in a high-speed, generally hot gas stream, (for example, air), which attenuates the filaments of the molten thermoplastic material to reduce its diameter. Thereafter, the meltblown filaments are carried by the high-speed gas flow and are deposited on a collection surface to form a blanket of randomly dispersed meltblown filaments. The meltblown process includes the meltspray process. In a blanket of meltblown filaments there may be short meltblown fibers and / or long meltblown fibers and / or substantially continuous meltblown filaments depending on the parameters of the meltblown process.
[0044] As used here, the term non-woven solidified by rotation means a collective term for non-woven blanket materials produced from artificial filaments. Most commonly this includes spunbond nonwoven and meltblown nonwoven, and combinations of these, for example, laminated spunbond-meltblown-spunbond. An alternative term with a similar meaning is spunmelt nonwoven.
[0045] As used here, the term natural cellulose fiber means a cellulose fiber produced by nature. A non-exhaustive list of these fibers includes wood fiber (commonly referred to as cellulose pulp), linen, cotton, jute and sisal. Included in this definition are fibers that have not received any chemical treatment
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17/85 co and also the fibers that have been chemically treated. A non-exhaustive list of the latest chemical treatments includes the use of pulp chemicals to delignify wood to produce cellulose pulp, bleach chemicals and detaching chemicals used in the production of fluff pulp and the like.
[0046] As used here, the term non-thermoplastic polymer means any polymer material that does not fall under the definition of thermoplastic polymer.
[0047] As used here, the term fabric, sheet and non-woven blanket means a sheet material having a structure of individual fibers or filaments that are interspersed, but not identifiable as in a textile fabric or mesh. Nonwoven materials have been formed from many processes, such as, for example, meltblown processes, spunbond fusion processes, carding processes, air processes, and wet processes. As used here a nonwoven sheet includes a sheet of damp paper.
[0048] As used here, the term attachment point means a thermal or ultrasonic attachment technique. Typical thermal point bonding equipment uses at least two calender rolls, at least one of which has a plurality of raised points (protrusion) on its surface. US patent 3855046 describes typical thermal connection point equipment and process. A specific type of connection point is called pin-by-pin embossing where both rollers have an identical pattern of raised projection points and where the heated rollers rotate opposite to the projection points in perfect register such that the blanket is connected by heat and compression between the raised projection points. The ultrasonic connection point uses a grooving calender roll with a plurality of raised projections and an ultrasonic horn
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18/85 (see definition of ultrasonic connection for more details). When a blanket of fibers or filaments is thermally or ultrasonically bonded with such a standard calender, the fibers or filaments are bonded by temperature and pressure in localized areas corresponding to the place where the protruding points make contact with the blanket. The ridges are usually arranged (but not necessarily) in a regular geometric pattern. The individual projections can have different shapes - square, round, oval, etc. and, normally, each individual projection can have an area of up to about 10 mm ² , although larger projection points are possible. The percentage of the surface of the calender roll covered by protruding points, called the bonding area, generally ranges from about 5% to about 50%. For spunbond nonwoven fabric, a bonding area of about 20% is common. Connection point of a fibrous blanket generally gives strength to the blanket while maintaining some flexibility and draping.
[0049] As used here, the term polymer means a chain of repeated structural units. It generally includes, for example, homopolymers, copolymers, such as, for example, block, grafted, random and alternate copolymers, terpolymers, etc., and mixtures and modifications thereof. In addition, unless specifically limited, the term polymer includes all possible geometric configurations. These configurations include, for example, isotactic, syndiotactic and atactic or random symmetries. Alternative terms for polymers include resin.
[0050] As used here, the term regenerated cellulose means the artificial cellulose material obtained by chemical treatment of natural cellulose to form a soluble chemical derivative or intermediate compound and subsequent decomposition of the derivative to regenerate cellulose. Regenerated cellulose includes spun ray and cell film
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19/85 fane. The regenerated cellulose processes include the viscose process, the cupro-ammoniacal process and saponification of cellulose acetate.
[0051] As used here, the term self-supporting blanket means a fibrous or filamentary blanket that has sufficient integrity and strength for it to be treated (for example, rolled or unrolled from a roll) without requiring any additional support, for example example, without the need to be supported by a carrier sheet.
[0052] As used here, the term short fiber means a natural or artificial fiber that has been formed or cut to a length of up to 25 mm. It is observed that natural fibers, such as cellulose, generally do not need to be cut, as they are formed to an adequate length.
[0053] As used here, the term short cut fiber means a natural or artificial fiber that has been formed or cut to a length of up to 10 millimeters. It is observed that natural fibers, such as cellulose, generally do not need to be cut, as they are formed to an adequate length.
[0054] As used here, the term side nonwoven fabric means a sheet of nonwoven material having different fiber compositions and / or different average lengths of fibers on its two opposite surfaces.
[0055] As used herein, the term entanglement means a method of attaching a carded nonwoven web by interweaving the web fibers over adjacent fibers using a plurality of high pressure fluid streams. The fluid can be water. The non-woven blanket is supported on a porous or mesh surface to allow fluid to pass through it. Negative pressure (vacuum) is applied on the side of the surface opposite the non-woven blanket to draw water from the blanket
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20/85 across the surface.
[0056] As used here, the term spunbond filament means a filament formed by extruding a fused thermoplastic material like filaments from a plurality of thin, generally circular capillaries from a die. Shortly after being spun, the filaments are partially cooled and then attenuated, for example, by eductive drawing and / or other well-known spunbonding mechanisms. The attenuation has the simultaneous effect of reducing the filament diameter, increasing the alignment of the polymer molecules in the direction of the filament length and increasing the filament's toughness. Spunbond filaments are generally substantially continuous with deniers within the range of about 0.1 to 10.
[0057] As used herein, the term non-woven spunbond means a non-woven web formed (generally) in a single process by extruding at least one thermoplastic material melted as filaments from a plurality of thin capillaries, usually circular, from a die . After being partially erased and attenuated, the substantially continuous filaments are placed on a collection surface as a filamentous layer. The cover is then connected by one or more techniques, including (but not limited to) thermal bonding, including bonding point, needle, chemical bonding and / or hydro-interlacing.
[0058] As used here, the term "cut fiber" means a fiber that has been formed by, or cut into, a length generally 1 to 8 inches (25.4 mm to 203.2 mm).
[0059] As used here, the term synthetic fiber means a fiber composed of artificial material, for example, glass, polymer, combination of polymers, metal, carbon, regenerated cellulose or lyocell. The terms synthetic fibers and artificial fiber are used interchangeably here.
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21/85 [0060] As used here, the term substantially continuous means: in reference to the polymeric filaments of a non-woven web the majority of the filaments formed by extrusion through holes remain as continuous, unbroken filaments as they are extracted and collected on a moving surface or other device. Some filaments can be broken during the fading or drawing process, with a substantial majority of the remaining continuous filaments.
[0061] As used here, the term Tex means a unit used to indicate the fineness of a filament given by the weight in grams per 1,000 meters of filament. A tex filament has a mass of 1 gram per 1,000 meters in length. A unit most commonly used is decitex (abbreviated as dtex), which is the mass of the filament in grams per 10,000 meters.
[0062] As used here, the term thermal bonding means the technology of bonding process by heating the materials to be bonded. Optionally, pressure can be used in combination with the application of heat. In the field of nonwovens, numerous thermal bonding techniques are available, including (but not limited to) thermal point bonding, thermal calendering, furnace heating and through air connection using hot air.
[0063] As used here, the term thermoplastic polymer means a polymer or copolymer that is fusible, softened when exposed to heat and generally returning to its hardened state when cooled to room temperature. Thermoplastic materials include, for example (but are not limited to), polyvinyl chlorides, some polyesters, polyamides, polyfluorocarbons, polyolefins, some polyurethanes, polystyrenes, polyvinyl alcohol, ethylene copolymers and at least one vinyl monomer, for example poly ( ethylene vinyl acePetition 870190030328, of 03/29/2019, page 25/100
22/85 touch) and acrylic resins.
[0064] As used here, the term thermoset polymer means a polymer or copolymer that permanently hardens when heated and / or cross-linked.
[0065] As used here, the term ultrasonic bonding means the bonding of fibers and / or filaments using ultrasonic energy. In the field of nonwovens, ultrasonic devices are normally used to make the point of attachment of the nonwoven. Typically, the equipment used consists of an engraved rotating metal roller that can be temperature controlled. Mounted above the surface of the roller is an ultrasonic horn that is caused to vibrate at about 20,000 cycles / second or more. A fibrous blanket is fed between the roller and the ultrasonic horn. The space between the horn and the surface of the roller is adjusted so that the blanket is compressed, especially in the vicinity of raised areas on the engraved surface of the roller. Where the vibrating horn makes contact with the blanket, the fibers and / or filaments in the vicinity of the horn are caused to vibrate in relation to the other, which in turn generates localized heating by friction of the fibers and / or filaments, which together with the compression of the mat results in the thermal bonding of the fibers and / or filaments to each other.
[0066] As used here, the term blanket means a non-woven sheet material, usually permeable to air, made of fibers and / or filaments. The terms blanket and fabric are used here interchangeably.
[0067] As used here, the term wettable means that the contact angle of a drop of water on the surface of a sheet material is less than 90 degrees. In practical terms, it means that the nonwoven blanket will be considered wettable if the nonwoven blanket spontaneously absorbs a drop of water placed on the
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23/85 non-woven surface within about 5 seconds at room temperature.
[0068] SUMMARY OF THE INVENTION [0069] The various embodiments of the present invention meet the needs discussed above, providing a nonwoven composite fabric with a high content of improved cellulose and a method for making such a fabric. The composite fabric contains at least about 50 weight percent cellulose fibers. The layered composite fabric comprises three layers, each of which is preferably separated and individually formed, and the three layers are thermally or ultrasonically bonded or glued together. The outer layers of the laminate comprise light non-woven blankets solidified by rotation, while the middle layer is a sheet material comprising mainly cellulose pulp fibers with a smaller amount of thermoplastic material (s).
[0070] The inventive laminated non-woven fabric is well suited for the preparation of soft and bulky wipes, especially wet wipes. The inventive nonwoven gives wet wipes a particularly advantageous combination of properties, that is, good dry and wet softness and wet volume, good resistance to wet abrasion and low wet propensity to release lint, along with at least 50% by weight of fiber natural cellulose content, for example, cellulose content.
[0071] The lightweight spin-solid nonwoven blanket material used for the outer layers of a laminate may comprise a spunbond nonwoven, or a meltblown nonwoven. Currently, the lightest weight of polypropylene spunbond nonwoven widely available on the market is 12 gsm. In the design of a 3-layer laminated nonwoven made with two outer layers
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24/85 in 12 gsm spunbonds and an intermediate layer made of a mixture of short cut fibers, ie cellulose pulp and about 15% by weight of thermoplastic fibers, then by means of a mathematical calculation can be shown that only 3-layer laminates with a weight of at least 58.3 gsm will have a total cellulose pulp content of 50% or more. That is, in this particular product design, an intermediate layer with a weight of at least 34 gsm (of which 85% or about 29 gsm is cellulose) is necessary to ensure the total cellulose content of the compound which is 50% or more .
[0072] Table A illustrates a number of product design scenarios. The Table shows the minimum compound weight required to design products with (a) 50% or more of the total cellulose content, or (b) 65% or more of the total cellulose content, when taking into account the weight of the external layers solidified by rotation (5, 8, 10 or 12gsm), and the non-cellulose binder fiber content of the intermediate layer (15% or 25%).
Table A
TABLE A
DESIGN SCENARIOS PRODUCTS
Weight of each layer Content of the binder fiber Minimum weight of the external compound (gsm) solidified by rotation of the intermediate layer containing at least (gsm) (%)
50% cellulose 65% cellulose
12 15 58.3 102.0 10 15 48.6 85.0 8 15 38.9 68.0 5 15 24.3 42.5 12 25 72.0 180.0 10 25 60.0 150.0 8 25 48.0 120.0 5 25 30.0 75.0
[0073] In order to produce a laminated compound with 65% or more cellulose in the normal weight range of 40 to 65gsm for cleaning substrates, the only design within this criterion in Table A is the only one with two outer layers of 5 gsm solidified by rotation, and an intermediate layer containing 15% of binder fibers.
Petition 870190030328, of 03/29/2019, p. 28/100
25/85 [0074] The use of meltblown blankets as the outer layers of the 3-layer product design has a special advantage in cleaning or absorbent article applications. These meltblown blankets generally have a relatively small pore size and are therefore widely used in filtration applications. The two meltblown blankets on the outside of the 3-layer laminate act as a filter to reduce the number of cellulose pulp fibers or cellulose fragments being released from the laminate, that is, the meltblown layers reduce their propensity to release lint.
[0075] Currently, the only non-woven spin solidified available with a weight of less than 10gsm, preferably 5gsm or less, are meltblown non-woven blankets made by the conventional meltblown process. In such low weights, conventional polypropylene meltblown blankets have low physical strength and therefore their use in the inventive 3-layer laminate would result in a material with low strength.
[0076] Unexpectedly, it was found that high strength, low weight, meltblown polypropylene blankets produced by a process that is intermediate between the conventional meltblown and spunbond processes, is particularly suitable for use as the outer layers of the inventive composite nonwoven. High-strength meltblown blankets of this type, with a weight of less than 10 gsm, are currently not commercially available. The high-strength, low-weight meltblown blankets used in the present invention were produced on a pilot line. Surprisingly, it was discovered that self-sufficient, high-strength, polypropylene meltblown blankets could be produced with a weight as low as 3 gsm. Although it is possible to make a self-sufficient, high-strength, polypropylene, 3 g / m ² meltblown blanket, such a light blanket is a limit for resistance, and a blanket with
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26/85 gram weight of about 5gsm is currently more practical. The development of equipment, process and / or materials may allow the production of even less weight blankets in the future [0077] When compared to equivalent nonwoven blankets made by the conventional meltblown process, the high strength meltblown material is superior in a series physical properties, including tensile and tear strength. For blankets of similar weight, the wet tensile strength of the high-strength polypropylene meltblown blanket is approximately three times greater than that of a conventional polypropylene meltblown blanket, as shown in Table C. It was found that when the non-woven composite in Inventive layers are made using high-strength meltblown blankets as outer layers, the laminate has superior strength and wet abrasion resistance when compared to laminates made with outer layers made from conventional meltblown blankets. For similar weights, high strength polypropylene meltblown blankets have at least twice the dry tensile strength, MD and CD, of conventional meltblown blankets.
[0078] The two outer layers solidified by rotation can be of the same weight, or can be of different weight. The outer layers can be made by different technologies, for example, a high-strength meltblown mat as an outer layer, and a spunbond mat as the second outer layer, an example of which is shown in Table H. The material used to make the non-woven solidified by rotation can be any polymer and / or copolymer solidifiable by rotation, such as, for example, polypropylene, polyethylene, polyester or polyamide. The two outer layers can be made of the same material or they can be made of different materials. The spin-solidified filaments comprising the outer layer non-woven blankets can be composed of a single
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27/85 polymer, or can be composed of two different polymers in a bicomponent or biconstituent configuration. In an advantageous embodiment of the invention, the polymer is that derived from sustainable plant-based materials, for example, poly (lactic acid).
[0079] Spin-solidified nonwovens made from poly (lactic acid) (PLA) are known, including thermo-sealed spunbond blankets manufactured using bicomponent filaments. An example of the latter is grade 50003C and 18gsm PLA spunbond non-woven fabric made by Ahlstrom Chirnside Ltd., Duns, United Kingdom. The heat-sealing characteristic is given by the coating production: bicomponent core spunbond filaments in which the core is formed from a PLA class with a melting point of about 165 ° C, and the coating is made from a PLA class with a melting point of around 130 ° C. Both PLA classes were provided by NatureWorks LLC in Blair, Nebraska, USA.
[0080] In the course of the work that led to this invention, the PLA meltblown blankets were made on a pilot line by the high strength meltblown process. The meltblown matrix was of several lines of orifice design generally described in US patent 6013223 to Biax-Fiberfilm Corp. The die was 12.5 inches (31.8 centimeters) wide and comprised of several individual holes arranged in 12 rows, each hole being about 0.01 inches (0.25 mm) in diameter. A mixture of two PLA resins was used - about 80% by weight of class 6204, and about 20% by weight of class 3251, both supplied by NatureWorks LLC. The temperature of the resin cast in the matrix was about 500 ° F (260 ° C), and the transfer rate of the resin was about 105 grams per minute. The meltblown PLA blanket produced by this process was self-contained, and could easily be rolled up in rolls. Several samples of meltblown PLA blankets were made with a weight ranging from about
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28/85 from 40 gsm to about 5 gsm.
[0081] Located between the two outer layers solidified by rotation is a sheet material of intermediate layer formed by formation by wet or formation by air or by a co-formation process and containing both cellulose fibers and a thermoplastic material. Cellulose fibers may include (but are not limited to) cellulose pulp, cotton, abaca, sisal, linen and / or jute. In a preferred embodiment the cellulose fibers are cellulose pulp fibers. In particular, chemically detached fluff cellulose pulp fibers are preferred, as the resulting composite nonwoven fabric has good wet and dry volume, absorption and softness. The thermoplastic material can be of various forms, non-limiting examples, including thermoplastic fibers or filaments, synthetic cellulose paste (SWP), thermoplastic films, thermoplastic powders, pastilles, flakes or granules, and / or as a dispersion in a liquid . The intermediate layer sheet material may contain one or more types of thermoplastic material. The thermoplastic material can be made of the same or similar polymers and / or copolymers, as used to make the spin solidified blankets used for the outer layers. It is preferable that the thermoplastic material is compatible with the outer layers solidified by rotation to ensure a good thermal bond between the layers. In a preferred embodiment the thermoplastic material (s) comprises filaments of thermoplastic fiber or fiber (s). In those modalities where the thermoplastic material comprises fibers or filaments, these can be of a single-component or two-component configuration. Non-limiting examples of two-component coating: core binder fibers include PE coating: PET core, or PE coating: PP core, or PP coating: PET core. Where the intermediate layer is formed by a process of formation via air, the fibers or filaments
Petition 870190030328, of 03/29/2019, p. 32/100
29/85 thermoplastics can be straight or wavy, have a fineness between 0.1 and 20 denier, and are generally less than about 10 millimeters in length. Where the intermediate layer is formed by a wet process, the thermoplastic fibers or filaments can be straight or wavy, have a fineness between 0.1 and 20 denier, and are generally less than about 20 millimeters in length. Where the intermediate layer is formed by a co-formation process, thermoplastic filaments usually have a diameter of less than 10 microns and are generally more than 10 cm in length. The sheet material of the intermediate layer may contain one or more types of thermoplastic fibers or filaments. In addition to fibrous materials, other non-fibrous materials can be added to the sheet material of the intermediate layer, more particularly in the case of a co-formed or air-formed sheet material. These other materials include powders, granules, flakes, beads, seeds or other particles, non-limiting examples of which include superabsorbent polymers (including, but not limited to, polymers made using acrylic chemicals, alginate and / or carboxymethylcellulose), activated carbon, encapsulated spheres containing materials such as perfumes or essential oils, abrasive particles, bleaching powder, anti-microbial agents, soap flakes, detergent flakes or granules and the like. Those skilled in the art will recognize that there are numerous other non-fibrous materials that can optionally be included in the intermediate layer sheet material.
[0082] The structure of the interlayer sheet material can be a substantially homogeneous mixture of cellulose pulp and thermoplastic material (s) and other additives, or it can be a layered or stratified structure where one or more component ( s), for example, the thermoplastic material (s), is / are more concentrated (s) near the upper and / or lower surface of the bed sheetPetition 870190030328, of 03/29/2019, p. 33/100
30/85 of the intermediary.
[0083] Optionally, the sheet material of the intermediate layer can be standardized. There are several standardization techniques that can be employed, non-limiting examples of which include hot or cold stamping, printing, needle punching, and techniques that cause relatively thin and thick regions to be formed on the sheet. The non-limiting examples of the latter, particularly applicable to wet-formed sheet materials, are described in US 4666390 and GB 1102246. An advantage of using a standardized sheet with relatively thin and thick regions is that it is possible, with due registration , thermally or ultrasonically connect the two outer layers solidified by rotation through the relatively thin regions of the intermediate layer, especially when using a complementary connection point pattern.
[0084] The three layers of the compound are advantageously formed separately and individually and then brought together and grouped before bonding. The three layers can be thermally connected using a calender with two heated rollers. The heated calender can include a flat steel anvil cylinder and a roller engraved with a connection point pattern, ie a pin-anklet connection point. Alternatively, the heated calender can include two steel rollers engraved with the same connection point pattern and that rotate with the combined patterns and in the register, that is, pin-to-pin connection point. Alternatively, the heated calender may include two rolls of steel engraved with male-female combination patterns for the purpose of male-female embossing. Alternatively, the three layers can be ultrasonically joined using a bonding point pattern. By using a particular relief pattern, as shown in figure 11, it is possible to create a so-called cushion effect
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31/85 soft, which visually accentuates the volume of the product. Alternatively the three layers can be bonded together, for example, using a hotmelt adhesive.
[0085] It will be noted that in this product design and manufacturing method there is a well-defined interface between each of the layers, with little fiber mixed between the layers. Thus, the boundary between any two adjacent nonwoven layers is distinct in that the fibers on or near the surface of such adjacent layers are not significantly mixed.
[0086] In a preferred embodiment, where the two outer layers of the compound comprise a non-woven blanket made of high-strength meltblown filaments, the use of this blanket material gives particular advantages to the composite fabric. Due to its relatively small average pore size, the meltblown blanket acts as a filter or a barrier for the fibers of the sheet material of the intermediate layer, reducing the propensity of the lint-free composite material. The process by which high strength meltblown filaments are formed produces a high strength nonwoven mat material (as shown in Table C). The use of 5gsm high-strength polypropylene meltblown blankets as the two outer layers of the inventive laminate, produces a composite nonwoven with better moisture and dry tensile strength, tear strength and greater Mullen burst resistance (comparison shown in Table G ), and which are comparable to these properties with other high-cellulose pulp cleaning substrates such as nonwovens formed by air flow, formed by multiple bond air flow and co-formed (comparison shown in Table I) . Conversely, if the inventive laminate is made using two outer layers of the conventional 5gsm polypropylene meltblown blanket, it would have insufficient strength to function effectively as
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32/85 a handkerchief.
[0087] In a preferred embodiment, the present invention contemplates the outer layers each being a non-woven mat solidified by rotation of about 5 gsm or less, the sheet material of the intermediate layer being a non-woven mat formed by air comprising a mixture of detached fluff paste and thermoplastic fibers and the three layers are connected by thermal or ultrasonic connection point. This preferred embodiment results in a soft composite non-woven fabric with properties well suited for use as a range of consumer products, including wet wipes, in particular with the advantageous combination of high wet volume, good resistance to wet abrasion and low propensity to loosen. lint. In an advantageous embodiment, the composite non-woven fabric has a dry weight between 40 gsm and 65 gsm.
[0088] The present invention also contemplates the treatment of composite non-woven fabric with small amounts of materials, such as, but not limited to, surfactants, moisturizing agents, anti-static agents, lubricants and / or pigments to provide additional or different functionalities . These treatments can be applied both to the blankets comprising the individual layers and / or to the laminated bound fabric. In the case of outer layers solidified by rotation, these materials can be added as meltable additive (s) to the melted polymer prior to filament production and / or the materials made are added as a topical treatment for the filaments or spun blankets.
[0089] The intermediate layer and the outer layers are thermally, ultrasonically bonded or glued together to form a non-woven composite of high cellulose content. Thermal and ultrasonic bonding requires that, in each of the layers that are linked together, some thermoplastic fibers are present, having a softening
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33/85 similar and / or melting temperature and are compatible in the sense that when thermally fused, they form a reasonably strong bond. Such thermoplastic fibers when at least partially melted in a thermal and ultrasonic bonding process allows the intermediate layer and the outer layers to be joined. When using a glue to join the layers, it is not necessary to have thermoplastic fibers in each of the layers to be joined.
[0090] The non-woven intermediate layer and the non-woven outer layers are first formed separately and individually to be self-supporting blankets, after which the three self-supporting blankets are brought together essentially just before joining them to form the nonwoven high cellulose content. When these three separately fabricated, self-supporting layers are linked by thermal, ultrasonic or bonding, the boundary between any two adjacent non-woven layers is distinct in that the fibers on or near the surface of such adjacent layers are not significantly mixed.
[0091] In recent years there has been a growing focus on raw materials from renewable and / or sustainable sources. Cellulose fibers, such as cellulose pulp, cotton, pineapple, sisal, linen, jute and the like, have been widely used in the manufacture of paper and similar products. Such fibers have the additional advantage of being biodegradable and compostable. Today, the majority of cellulose pulp is produced from wood from managed forests, with new trees being planted to replace the harvested ones. As such, the cellulose pulp meets the requirements of being sustainable and renewable. Another research yielded polymeric materials of vegetable origin. For example, poly (3-hydroxybutyrate) (PHB) and poly (lactic acid) (PLA), both of which can be made from plant sugar or starch. Advantageously each first, second and third ca
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34/85 layers comprise the same solidifiable material by rotation, sustainable and renewable, derived from plant materials, such as, for example, poly (3-hydroxybutyrate) (PHB) or poly (lactic acid) (PLA). Such a composition can be thermally bonded, for example, to form a renewable and / or sustainable non-woven fabric.
BRIEF DESCRIPTION OF THE DRAWINGS AND FIGURES [0092] The invention will be more easily understood by a detailed explanation of the invention, including the drawings. Consequently, the drawings that help explain the invention are attached here. It should be understood that such drawings are intended to assist explanation only and are not necessarily dimensioned. The drawings are briefly described as follows:
[0093] Figure 1 is a diagrammatic cross-sectional view of the inventive fabric in layers before the point of attachment.
[0094] Figure 2 is a diagrammatic cross-sectional view of the inventive tissue in layers after the pin-anvil connection point. [0095] Figure 3 is a diagrammatic cross-sectional view of the inventive fabric in layers after the pin-to-pin connection point.
[0096] Figure 4 is a diagrammatic cross-sectional view of the inventive layered fabric after embossing with rolls engraved with male-female pattern.
[0097] Figure 5 is a diagrammatic cross-sectional view of the inventive fabric in layers after the pin-to-pin connection point, using an intermediate layer with the thin and thick regions and where the laminate connection point takes place predominantly through the thin regions of the middle layer.
[0098] Figure 6 shows a diagrammatic view of side elevation of a first preferred embodiment for making the inventive fabric. [0099] Figure 7 shows a diagrammatic view of side elevation of a second preferred embodiment for making the inventive fabric.
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35/85 [00100] Figure 8 shows a diagrammatic side elevation view of a third preferred embodiment for making the inventive fabric.
[00101] Figure 9 shows a diagrammatic view of lateral elevation of a fourth preferred embodiment for making the inventive fabric.
[00102] Figure 10 is a photograph of the inventive laminate after thermal bonding with the embossing pattern used to produce all the Examples. The ruler in the photo is in the transversal direction, showing both scales based on millimeters and inches.
[00103] Figure 11 is a photograph of the inventive laminate after embossing with an alternating embossing pattern. The ruler in the photo is in the transversal direction, showing both scales based on millimeters and inches.
DETAILED DESCRIPTION OF THE INVENTION [00104] Reference will now be made in detail to preferred embodiments of the invention, examples of which are illustrated in the Examples section below. For the sake of simplicity and clarity, the following text assumes that the blankets solidified by rotation that comprise the outer layers are made of polypropylene. This does not exclude the use of spin solidified blankets made from other materials being used to produce the inventive laminate.
[00105] To achieve the object of the invention of providing an improved non-woven substrate with a high content of cellulose paste to be used in the manufacture of soft cleaning materials, the present inventors have discovered that the use of a meltblown nonwoven blanket lightweight, high-strength outer layers of a laminated mat structure unexpectedly provide a non-woven cleaning material with various advantageous properties and combinations thereof, including good wet volume, good wet abrasion resistance and a low lint-prone.
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36/85 [00106] Figure 1 shows a diagrammatic cross section of the inventive layered nonwoven fabric 1 before the point of attachment. Nonwoven fabric 1 is made from three precursor layers. The two outer layers, the second layer 2 and the third layer 4 comprise lightweight high-strength meltblown non-woven blankets. The mat 2 may or may not be of the same weight and / or composition as the mat 4. The first layer 3, which is the intermediate layer, comprises a sheet material made from cellulose pulp fibers and thermoplastic fibers or filaments and, optionally, other materials, such as particles. Thermoplastic fibers or filaments can form up to 40% w / w of the sheet material of the intermediate layer. The three layers 2, 3 and 4 are each formed separately and individually, and then brought together and grouped, before being linked to form the composite nonwoven 1. The inventive composite nonwoven fabric 1 contains at least 50% p / w cellulose, for example, cellulose pulp fibers, preferably more than 65% w / w and have a dry weight of less than 200gsm, preferably less than 100 gsm and, advantageously, between 40 to 65gsm.
[00107] The requirement for the two outer layers of nonwoven 2 and 4 is that they comprise essentially fibers solidifiable by rotation.
[00108] The three layers of the inventive layered non-woven fabric may be bonded by an adhesive bond or using ultrasonic bond or thermal bond, both latter processes preferably using at least one calender. The thermal energy transmitted to the blanket by the latter techniques connects the layers together by means of the thermoplastic material contained in each layer. In a preferred embodiment, a connection point pattern is used, either in connection with the ultrasonic connection or with the
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37/85 thermal connection. As the bonding point technique creates bond between the layers in localized areas only, the bonded laminate retains a high degree of softness, flexibility, draping and volume, while the bond between the layers is suitable for its intended application as a substrate from which wet and / or dry wipes are made. In an advantageous embodiment, the embossing pattern is chosen to create a pillow effect as illustrated in figure 11.
[00109] Figure 2 shows a diagrammatic cross section of the inventive layered non-woven fabric 1 after the pin-anvil connection point, using ultrasonic or thermal energy. The layer 2 that was in contact with the steel roller engraved with the connection point pattern shows a embossing pattern, while layer 4 that was in contact with the soft anvil roller remains essentially flat. The intermediate layer 3 is compacted in areas located by the connection point pattern roller. Between the connection points, layer 3 is poorly compacted.
[00110] Figure 3 shows a diagrammatic cross section of the inventive layered composite non-woven fabric 1 after the pin-to-pin connection point. Layers 2 and 4 both show a embossing pattern due to the bonding point pattern engraved on both rollers. While the connection point pattern on both rolls is identical and the two rolls rotate with the patterns matched in the register, the embossing patterns that communicate with the outer layers 2 and 4 are symmetrical images of each other. The intermediate layer 3 is compacted in areas located by the standard connection point rolls. Between the connection points, layer 3 is poorly compacted.
[00111] In another embodiment, the three layers of the non-woven composite in inventive layers can be linked, using a calan
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38/85 dra equipped with embossing rolls engraved with heated male-female patterns. Figure 4 shows a diagrammatic cross-section of the inventive composite non-woven fabric 1 after embossing with heated male-female pattern rollers. The outer layers 2 and 4 both show a embossing pattern due to the combined and complementary male-female patterns engraved on the two calender rolls.
[00112] Figure 5 shows a diagrammatic cross section of the inventive layered non-woven fabric 1 after the pin-to-pin connection point, but using a sheet material of intermediate layer 3, which has thin and thick regions and where the point of attachment of the three layers 2, 3 and 4 happens predominantly through the thin regions of the intermediate layer 3. Alternatively, using the same concept of employing a sheet material of intermediate layer that has thin and thick regions, a laminated material of 3 layers can be done using pinobigorn connection point.
[00113] It will be noted that in figures 2, 3, 4 and 5 at least the outer surface of the composite fabric is non-planar, that is, it has surface characteristics giving it a textured surface. When the nonwoven is converted into a handkerchief, the textured surface (s) assists in the cleaning process, helping to remove tough dirt and assisting in the collection and removal of surface debris such as crumbs , hair, fibers and / or other particles.
[00114] Figure 6 illustrates a preferred first process for producing the inventive layered composite non-woven fabric, in which the intermediate layer sheet material is produced by an air-forming process. The first self-supporting solidified blanket 23 is produced using a meltblown matrix 21 and a vacuum rotary collecting drum 22. A second solid blanket
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39/85 determined by self-sustaining rotation 26 is produced using a meltblown matrix 24 and a rotary vacuum collecting drum 25. For each blanket solidified by rotation 23 and 26, adjusting the combination of resin transfer rate and circumferential velocity of the collecting drum, a blanket solidified by rotation of desired weight is obtained. Alternatively, one or both of the blankets solidified by rotation can be replaced by a prefabricated blanket, for example, a spunbond blanket, which is unrolled from a roll mounted on an unwinder platform. The sheet material sheet of the intermediate layer 30 is formed by means of one or more air forming heads 27, which is fed with a controlled proportion of fibrarized fluff cellulose paste and artificial fibers. One or more vacuum boxes 29 are located within a continuous foraminous collecting surface 28. The vacuum box (s) are located directly below the air former 27. The (s) vacuum box (s) creates an air current that pulls the fibers deposited by the air former 27 down to the moving collecting surface. By adjusting the fiber transfer rate of the air-forming head (s) 27 and the linear speed of the collecting surface 28, a sheet material of intermediate layer 30 of desired weight can be obtained. The sheet material 30 passes through a heating element 31, for example (but not exclusively), a hot air oven, where the blanket formed by air is heated. The heating element 31 can also be used to fuse some or all of the thermoplastic fibers contained in the sheet material to neighboring fibers. The blankets comprising the three layers 23, 26 and 30 are then gathered and grouped between the rollers 32 and 33, before moving on to the tightening of a thermal calender where the three layers are connected. The distance between bundling rollers 32 and 33 is adjustable to suit the thickness of the composite structure
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40/85 is layered. Figure 6 illustrates a thermal calender comprising an embossed connection point roller 34 along with a flat anvil roller 35, producing thermally dot-woven nonwoven fabric 1. Alternatively, the calender rolls 34 and 35 can be engraved with patterns of complementary male-female embossing or both can be engraved with the same connection point pattern combined to allow pin-to-pin embossing. Alternatively, the three layers can be joined together using an ultrasonic bonding device as shown in figure 8. After bonding, laminated fabric 1 can be rolled up or processed.
[00115] Figure 7 illustrates a second preferred process for producing the inventive layered composite non-woven fabric, in which the sheet material of the intermediate layer is made by a wet process. The layers of the self-sustaining rotation solidified blanket 39 and 42 are made as previously described for figure 6. Alternatively, one or both blankets solidified by rotation can be replaced by a prefabricated non-woven blanket, for example, a blanket of continuous spinning, which is unrolled from a roll mounted on an unwinder platform. The sheet material of the intermediate layer 48 is produced by a wet process. Any conventional papermaking equipment can be used or, as figure 7 illustrates, a wet inclined former can be used. The latter is preferred if it processes a mixture of cellulose pulp and artificial fibers, as in the present invention, because a more diluted fiber suspension can be used, thus allowing better sheet formation particularly when using longer artificial fibers. A diluted dispersion of the fiber mixture in water is provided to the endbox 43, which applies the fiber in water suspension to a moving foraminous surface 44 where a wet fibrous sheet 46 is formed on top of the
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41/85 foraminous surface. Vacuum boxes 45 located below the foraminous surface are used to collect and remove water from the fiber in water suspension applied to the foraminous surface. Vacuum boxes 45 also help to reduce the amount of residual water in the wet sheet 46. Optionally, a machine with two or three inlet boxes can be used. Having multiple inboxes present allows fiber suspensions with different fiber mixtures, for example, different cellulose pulp for the proportion of thermoplastic fiber, to be supplied to each inbox, allowing for a stratified or layered sheet structure are formed, for example, with a higher percentage of thermoplastic fibers located near the top and / or bottom surfaces of the wet sheet. The blanket is dried by means of a heating element 47, which can include any conventional equipment, such as dryer cans heated by oil or steam, through air dryers, hot air ovens, hot air impact driers, infra dryers red and the like. The heating element 47 can also be used to fuse some or all of the thermoplastic fibers contained in the sheet material to neighboring fibers. The dry mat 48 and the layers of the mat solidified by rotation 39 and 42 are then brought together and grouped between the rolls 49 and 50, before going through the tightening of a thermal calender where the three layers are connected to form the composite nonwoven. 1. The distance between bundling rollers 49 and 50 is adjustable to suit the thickness of the layered composite structure. Figure 7 illustrates a thermal calender comprising an embossed binding point roll 51 along with a flat anvil roll 52, producing a thermally stitched non-woven fabric 1. Alternatively, the calender rolls 51 and 52 can be embossed with patterns complementary male-female embossing methods or can both be engraved with the
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42/85 same connection point pattern combined to allow pin-to-pin embossing. Alternatively, the three layers can be connected together using an ultrasonic connection device. After bonding, laminated fabric 1 can be rolled up or processed.
[00116] Figure 8 illustrates a third preferred process for producing the inventive layered composite non-woven fabric, in which the sheet material of the intermediate layer is made by an air-forming process. The illustrated process is similar to that shown and described in figure 6, except that the bonding of the three layers is carried out using an ultrasonic bonding process. Figure 8 illustrates that the outer layers 55 and 58 of the layered compound are self-sustaining rotation-solidified blankets, produced as previously described for figure 6. Alternatively, one or both of the rotation-solidified blankets can be replaced by a non-woven blanket. prefabricated fabric, for example, a continuous spinning blanket, which is unrolled from a roll mounted on an unwinder platform. An ultrasonic horn 66 is mounted in close proximity to an engraved rotating calender roll 67. After combining the three layers between bundling rollers 64 and 65, the layered compound is ultrasonically bonded as it passes between the ultrasonic horn 66 and the engraved roller 67.
[00117] Figure 9 illustrates a fourth preferred process for producing the inventive layered composite non-woven fabric, in which the sheet material of the intermediate layer is made by an air-forming process. The illustrated process is similar to that shown and described in figure 6, except that the bonding of the three layers is carried out using an adhesive. When considering adhesive bonding, there are many possible techniques. Figure 9 illustrates a technique using a hot melt adhesive. Those skilled in the art will recognize which other adhesive bonding techniques may be employed.
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43/85 of. Figure 9 illustrates that the outer layers 70 and 73 of the layered compound are self-sustaining rotation-solidified blankets, produced as previously described for figure 6. Alternatively, one or both of the rotation-solidified blankets can be replaced by a blanket prefabricated non-woven fabric, for example, a continuous spinning blanket, which is unrolled from a roll mounted on an unwinder platform. The binder fibers contained in the air-formed mat 77 are activated by heating the mat in the heating element 78 to create a self-sustaining mat. Using a hot melt adhesive applicator 79, a small amount (less than 10 gsm, preferably less than 5 gsm) of the hot melt adhesive is applied to one side of the mat 70 so that the hot melt adhesive will also come into contact with a blanket layer of the intermediate layer 77 when the three layers are combined. Likewise, using a hot melt adhesive applicator 80, a small amount (less than 10 gsm, preferably less than 5 gsm) of the hot melt adhesive is applied to one side of the mat 73 so that the melt adhesive the hot one will also come in contact with a blanket layer of the intermediate layer 77 when the three layers are combined. The blankets 70 and 73 are combined with the blanket formed by air 77 between two rollers 81 and 82, the distance between these rollers being adjustable. The resulting laminated mat 83 is a flat, unglazed sheet structure. If embossing is desired, the non-embossed mat 83 is then passed through the tightening of two rolls of an embossing calender which can optionally be heated. Figure 9 illustrates a embossing calender comprising an embossed roller 84 along with a flat anvil roller 85, producing an embossed nonwoven fabric 1. Alternatively, the calender rolls 84 and 85 can be embossed with embossing patterns
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44/85 complementary male-female or can both be engraved with the same combined connection point pattern to allow pin-to-pin embossing. Alternatively, the layered composite nonwoven can be patterned using an ultrasonic patterning device. After bonding, laminated fabric 1 can be rolled up or processed.
[00118] The following paragraphs provide a detailed description of the production and characteristics of the three precursor layers. High strength meltblown mat [00119] The meltblown filaments that form the high strength meltblown mat are produced using a meltblown matrix that comprises a plurality of rotating filament nozzles arranged in multiple rows, as described in US patent 6013223. The raw material selected is fed in a controlled manner to a heated screw extruder, which melts and mixes the polymer. The molten polymer is then measured in the meltblown matrix body under pressure using one or more volumetric gear pumps. If necessary, melting additive (s) can be mixed with the polymer resin prior to melting and mixing inside the heated screw extruder. The molten polymer is extruded through multiple rotating nozzles to form polymer streams that are attenuated in filaments by being accelerated by hot air flowing at high speed in a direction essentially parallel to the rotating nozzles. The filaments are simultaneously accelerated and cooled below their melting point by the high-speed air flow (also known as the attenuation air). The resulting filaments are at least partially drawn and have a degree of molecular orientation and toughness. US patent 6013223 describes the use of a wire drawing jet to attenuate the filaments. However, when making the meltblown blankets used in the present invention, the use of a wire drawing
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45/85 was not necessary. The filaments are collected on a moving foraminous surface, which in figure 6 is shown as a rotating cylinder 22 which is covered with an endless foraminous surface. Alternatively, the filaments can be collected on a moving foraminous flat surface. The rotating cylinder has one or more vacuum boxes contained within its structure. The vacuum created in this way helps to draw the meltblown filaments on the foraminous surface of the cylinder, where the meltblown filaments form a self-supporting blanket, without any additional treatment, bonding or other intervention. The formation of a self-supporting non-woven blanket is believed to be due, at least in part, to self-interlacing on the meltblown filaments on the collection surface combined with the residual heat in the filaments. Meltblown self-sustaining polypropylene blankets with a weight as low as 3 gsm have been made by this method.
[00120] As shown in figure 6, a second meltblown blanket 26 is produced using a second meltblown matrix 24 and a second collection drum 25 in a similar manner as described above. In the present invention, the second meltblown blanket 26 may or may not be of the same weight and may or may not be of the same composition as the first meltblown blanket 23.
[00121] Alternatively, one or both meltblown blankets can be replaced with a different type of nonwoven, for example, a conventional meltblown blanket or a spunbond blanket. In this case, the alternative nonwoven is supplied as a roll of prefabricated fabric that is unwound, combined with the other layers, and then all the layers are thermally or ultrasonically bonded.
[00122] In the inventive non-woven layered compound, meltblown filaments can be composed of a single resin, or can
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46/85 be composed of two resins in the form of two-component filaments. The cross section of a bicomponent filament can include configurations, such as core-coating (center or offset core), side-by-side, multi-segment pizza and other configurations known to those skilled in the art.
[00123] The production of high strength meltblown filaments varies from the production of conventional meltblown filaments in several ways. To illustrate the differences, polypropylene (PP) meltblown will be used as an example.
Raw materials [00124] Conventional PP meltblown filaments are produced by extruding a molten polymer of relatively low viscosity through the rotating nozzles. A low viscosity polymer melt is produced by (a) selecting a PP resin class with a high melt flow rate (MFR), examples of which are PP3746G class available from ExxonMobil which has an MFR of around 1475 grams / 10 minutes at 230 ° C; and Metocene of class MF650Y available from LyondellBasell which has an MFR of about 1800 grams / 10 minutes at 230 ° C, and (b) keeping the polymer melted at an elevated temperature before filament spinning, typically about 240 - 250 ° C in order to further reduce the melt viscosity of the polymer. In order to achieve such high melt flow rates, peroxide compounds can be added to the PP resin. When the polymer and peroxide are fused together, the peroxide forms free radicals that interact and split the polypropylene polymer chains, thus reducing the average molecular weight of the resin. The reduction in the molecular weight of the resin causes a reduction in the toughness of the filaments formed in the solidification process by rotation. When meltblown filaments are used to form filtration media, especially when used as part of a compos
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47/85 to SMS, this reduction in filament resistance is relatively irrelevant as the main function of meltblown filaments is to form a filtration layer. However, in the present invention, the strength of the meltblown filaments and the strength of the nonwoven web they form is important for a cleaning application. [00125] By way of contrast, in the spunbond process the objective is to produce high tenacity filaments, which, after bonding, form a high resistance non-woven blanket. The polypropylene resin used to produce the spunbond filaments has a low melt flow rate, typically about 35 grams / 10 minutes at 230 ° C (commonly referred to as 35 MFR). Such resin is of the PP3155 class available from ExxonMobil. Peroxides are not usually added to these resins. To minimize thermal degradation of the resin during processing, the molten polymer is kept at a lower temperature before filament spinning, typically about 230 ° C. The combination of high molecular weight PP resin, less thermal degradation during the filament spinning process and effective attenuation of filaments after spinning allows high resistance spunbond filaments to be formed.
Process conditions [00126] High strength meltblown filaments are produced by a process that is intermediate between (or a hybrid of) the spunbond process and the conventional meltblown process. A typical polypropylene spunbond resin (35 MFR) can be used to produce the high strength meltblown filaments. During the filament spinning the temperature of the melted polymer is about 285 to 290 ° C. These factors result in a polymer melted within the meltblown matrix with a much higher viscosity compared to the polymer melted in the conventional meltblowing process. In order to achieve a sufficient transfer rate of the molten polymer of
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48/85 high viscosity, it is necessary to pressurize the polymer melted in the matrix at pressures up to 1200 psi (8274 kPa). This pressure is much greater than that used in the conventional meltblowing process and exceeds the pressure handling capacity of a conventional meltblown matrix, but is within the pressure handling capacity of the meltblown matrix described in US patent 6013223, due to its design and its different construction.
[00127] Table B shows a comparison of materials and typical process conditions used to produce conventional polypropylene meltblown filaments, polypropylene spunbond, and high strength polypropylene meltblown.
TABLE B
Typical processing conditions
Process: Conventional Meltblown Spunbond High strength meltblown Raw material resin flow rate at 230 ° C (g / 10 min) Melting temperature of the polymer in the matrix (deg C)Polymer melting pressure in the matrix (psi) Attenuated air temperature (deg C) PP resin1800240 - 25040 - 50250 PP resin352301000 - 1500 environment PP resin35285 - 2901000 - 1200225
[00128] Table C shows a comparison of the properties of non-woven polypropylene blankets produced by the conventional meltblown process and the high strength meltblown process
TABLE C
COMPARISON OF CONVENTIONAL MELTBLOWN BLANKET PROPERTIES AND HIGH RESISTANCE
Conventional MeltblownEx. A Conventional MeltblownEx. B Conventional MeltblownEx. C High strength meltblownEX. D Meltblown's3 high strengthEx. E High strength meltblownEx.F Weight (gsm) 4.65 6.07 11.10 4.83 5.32 7.70 Dry tensile strength, MD (N / m) 26.5 27.8 55.2 65.3 80.3 102.3 Dry tensile strength, CD (N / m) 8.5 7.5 22.3 35.0 31.0 55.8 Geometric mean of R.T. dry (N / m) 15.0 14.4 35.1 47.8 49.9 75.6 Dry elongation stress, MD (%) 6 6 2 39 51 91 Dry elongation stress, CD (%) 12 6 3 106 109 96 Dry toughness. MD (J) 0.003 0.003 0.002 0.053 0.099 0.245 Dry toughness. CD (J) 0.001 0.037 0.002 0.087 0.078 0.128 Wet attraction resistance, MD (N / m) 25.8 30.5 58.8 80.2 77.5 112.5 Wet tensile strength, DC (N / m) 9.0 9.8 25.8 38.8 36.0 64.5 Geometric mean of R.T. UCD14 ^ N / m) 15.2 17.3 39.7 55.8 52.8 85.2 geometric mean index R.T. wet (N / m pero ^ xu) 3.3 2.8 3.6 11.5 9.9 11.1 Wet stretching stress, MD (%) 4 6 2 49 36 84 Wet stretching stress, DC (%) 7 6 3 117 95 109 Wet toughness. MD (J) 0.002 0.003 0.002 0.102 0.059 0.221 Wet toughness, CD (J) 0.001 0.001 0.001 0.107 0.08C 0.169 Dry Elmendorf rupture, MD (ccjN.) 160 160 200 440 520 540 Wet Elmendorf Rupture, MD (rnfjJ.) 160 160 160 600 750 720 Wet thickness (microns) 95 88 142 82 101 129 Wet volume (cc / g) 20.7 14.5 12.8 15.9 18.9 16.7 Air permeability (l / min / dcm) 4598 3235 1750 2128 208E 1188 Average filament diameter (microns) 5.35 3.56 Average pore size (microns) 46 27
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49/85 [00129] For almost similar weights, high-strength polypropylene meltblown blankets have a geometric average of the dry tensile strength of at least twice that of conventional meltblown blankets. The geometric mean index of wet tensile strength is about three times higher than conventional meltblown blankets of a similar weight. The wet and dry MD and CD toughness and wet and dry MD breaking strength are all substantially improved in the case of high-strength meltblown blankets. The thickness and wet volume are very similar for the two types of the meltblown blanket. The average filament diameter of the high-strength meltblown blanket is less than that of the conventional meltblown blanket, which is also reflected in the relative air permeability. It is observed that due to the very light weight of these meltblown blankets, the abrasion resistance of the individual blankets could not be measured. However, since 3-layer laminates are formed from these meltblown blankets, the abrasion resistance of the laminate can be easily measured.
[00130] Meltblown blankets can be subjected to additional bonding by a number of techniques, of which thermal bonding is the most common. The thermal bonding point is widely used to create strong non-woven blankets from spunbond filaments. To evaluate the modification of the properties of the mat after the connection point, high strength PP meltblown mat sampling rolls were subjected to the thermal connection point using 2 calender rolls using the conditions shown below:
[00131] Connection point pattern in engraved steel roller: connection points in the shape of a diamond arranged in a regular geometric pattern, 18% connection area. Anvil roll: smooth steel roll [00132] Roll surface temperature: engraved roll 103 ° C, anvil roll 105 ° C (measured using a conPetition temperature probe 870190030328, 29/03/2019, p. 53 / 100
50/85 surface touch) [00133] Pressure load on the rollers: 200 pounds per linear inch (35.8 kg per linear cm) [00134] Blanket speed: 100 feet / minute (30.5 meters / minute) [00135] Table D shows a comparison of the properties of high strength polypropylene meltblown blankets before and after the connection point.
TABLE D
CONNECTION POINT EFFECT
Connecting point Ex. DAt the Ex. EAt the Ex. GYes Ex. HYes Weight (gsm) 4.83 5.32 4.01 4.34 Resistance to dry traction. MD (N / m) 65.3 80.3 100.3 100.3 Resistance to dry traction. CD (N / m] 35.0 31.0 24.3 32 Geometric mean of R.T. dry (N / m] 47.8 49.9 49.4 56.7 Dry elongation stress, MD (%] 39 51 21 22 Dry elongation stress, CD (¾) 106 109 74 68 Dry toughness, MD (1] 0.063 0.099 0.043 0.043 Dry toughness, CD (1) 0.087 0.078 0.037 0.046 Wet tensile strength, MD (N / m] 80.2 77.5 105.0 94.0 Wet tensile strength, CD (N / m] 38.8 36.0 29.8 29.5 Geometric mean of R.T. wet (N / m) 55.8 52.8 55.9 52.7 Wet stretching stress, MD (%) 49 36 21 12 Wet stretching stress, DC (%] 117 95 65 66 Wet toughness, MD (J) 0.102 0.069 0.046 0.021 Wet toughness, CD (J) 0.107 0.080 0.041 0.041 Elmendorf Dry Break, MD (ijjM 440 520 48 23 Elmendorf wet break, MD (niN.) 600 760 28 45 Wet thickness (microns) 82 101 79 90 Wet volume (cc / g) 16.9 18.9 19.6 20.7
[00136] It will be noted that while the thermal bonding point increased the wet and dry tensile strength MD, the other properties tested were lower after the bonding point or changed little. Thus, with a small increase in property to be acquired when stitching the high-strength meltblown mat, all subsequent production of the inventive laminated nonwoven was carried out using high-strength meltblown blankets that were not subjected to any deliberate bonding process prior to final combination and bonding of the multi-layer laminate.
[00137] When considering laminated compounds made using a
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51/85 middle layer formed by air, the advantage of using high strength webs solidified by rotation can be clearly seen. Even after fusing the binder fibers to create a self-sustaining mat, the mat formed by air has relatively low dry and wet strength. Much of the strength, particularly the wet strength, of the inventive laminated compound comes from the outer layers solidified by rotation. When a composite laminate is produced with outer layers of low-weight spin solidified blankets, for example, about 5 gsm, it is advantageous to use high-strength solidified polypropylene blankets that have significantly higher tensile strength than blankets of conventional meltblown polypropylene of a similar weight. For example, the geometric mean index of wet tensile strength of polypropylene blankets solidified by high-strength rotation is about three times higher than that of conventional polypropylene meltblown blankets. Table I shows that the wet strength of the resulting laminated compound made using high strength spin solidified outer layers (Example 1) is similar to the wet strength of other commercial cleaning substrates with a high cellulose paste content based on forming technologies airway, multi-connection airway formation and co-formation. Whereas Table G shows that a three-layer laminate with a similar weight made using outer layers of the conventional polypropylene meltblown blanket (Example 7) has a significantly lower wet tensile strength when compared to substrates made using airborne forming technologies, formation multi-link airway and co-formation. It is doubtful whether a material (Example 7) with such low wet strength can function satisfactorily as a cleaning substrate.
[00138] In the present invention, it is advantageous that the outer layers
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52/85 in the non-woven composite are hydrophilic so that the non-woven composite can quickly and completely absorb the aqueous solution of surfactants, perfumes, biocides and stabilizers (the so-called 'lotion') applied by the wet wipe converter or manufacturer. The amount of lotion applied to the substrate is typically about 300% by weight. A number of techniques for imparting hydrophilicity to spin-solidified blankets are known, including (but not limited to) melting additives and applying topical treatments to the surface of the meltblown filaments and / or the blanket itself. As will be shown in the Examples, in the present invention both techniques have been evaluated.
[00139] Hydrophilic fusion additives typically contain a hydrophilic molecule as the active agent, examples of which include (but are not limited to) linear and / or branched poly (ethylene oxide) (PEO) and fatty acid glyceride esters, both having a relatively low molecular weight. The hydrophilic fusion additive is generally composed as a master batch using a similar type of polymer resin as it will be mixed with, in this case, polypropylene. The main hydrophilic additive batch is intimately mixed at the desired rate of addition with the polypropylene resin granules before entering the heated screw extruder at the beginning of the filament spinning process. Immediately after spinning the filaments, the hydrophilic additive is distributed more or less evenly throughout the filament. The hydrophilic molecules then slowly diffuse to the filament surface creating a thin hydrophilic layer on the filament surface. The diffusion process can take several days before the filaments and the nonwoven web are sufficiently hydrophilic or 'wettable'. In one embodiment of the present invention, a hydrophilic fusion additive, class TPM12713 (available from Techmer PM of Clinton, TN, USA), was mixed with a
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53/85 rate of about 2% by weight, with 35 MFR polypropylene resin granules. The mixture of polypropylene and granules of additives was then fed through a hopper into the heated screw extruder at the beginning of the meltblown filament spinning process. The resulting meltblown mat when initially made did not absorb any drops of water placed on the mat surface within 30 seconds. However, after seven days of storage at room temperature, a drop of water placed on the surface of the blanket was absorbed in less than 1 second.
[00140] Another common technique for making a blanket solidified by hydrophilic rotation is the topical application of treatment chemicals, applied to the filament solidified by rotation before the formation of the blanket and / or to the non-woven blanket solidified by rotation. There are a number of known techniques for applying topical treatment, including (but not limited to) foaming, spraying, filling and coating the Kiss roller. In these techniques, an aqueous solution of the treatment chemical is first prepared at an appropriate concentration and this solution is applied by foam, spray, filler or Kiss roller to the filaments and / or the spin solidified mat. The treatment agents are hydrophilic chemicals, most commonly in the surfactant class. These include (but are not limited to) anionic surfactants such as sodium lauride sulfate, sodium dioctyl sulfosuccinate and fatty acid salts (soaps); cationic surfactants such as benzalkonium chloride and cetylpyridinium chloride; nonionic surfactants such as poly (ethylene oxide), polysorbates and fatty alcohols. An active area of research in recent years has been the development of topical treatments for non-woven solidified by rotation used as components of personal hygiene articles (disposable diapers, incontinence products, feminine hygiene products)
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54/85 na and the like). The hydrophilically treated spin solidified blanket must meet certain ethical requirements, for example, it should not cause irritation or sensitization in prolonged contact with the user's skin. Depending on how long the personal care article will be in service, there is a need for temporary, semi-durable or durable hydrophilic topical treatments. In the case of the present invention, the meltblown blankets on the outside of the nonwoven compound have only a temporary hydrophilic effect to allow absorption of the aqueous lotion that is applied to the nonwoven compound during the wet cleaning conversion process. Subsequently, a hydrophilic nature is imparted to the moistened wipe by the aqueous lotion which generally contains one or more chemical surfactants. In one embodiment of the present invention, an aqueous solution was prepared using Unifroth 1387, a surfactant containing dioctyl sodium sulfosuccinate (available from Unichem Inc. of Haw River, NC, USA). In two experiments this solution was sprayed onto fresh meltblown polypropylene filaments spun under controlled conditions to produce two levels of added surfactants (a) about 0.5% surfactant by weight on the filaments and (b) about 1% surfactant by weight on the filaments. The treatment was applied to the meltblown filaments before being collected in the rotation collection drum. In both experiments, the resulting polypropylene meltblown nonwoven blanket was made wettable, so that it absorbed a drop of water placed on its surface in less than 1 second. A similar result can be obtained by spraying an aqueous solution of this surfactant under controlled conditions on one or both surfaces of a previously untreated polypropylene meltblown nonwoven mat. The blanket can be subsequently dried, if necessary, by applying heat, and / or by blowing air along and / or through its surface, and / or allowing
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55/85 for the blanket to air dry under ambient conditions. By this method, the levels of the added surfactant (a) about 0.5% of surfactant by weight on the mat and (b) about 1% of surfactant by weight on the mat, resulted in a wettable non-woven mat so that when a drop of water placed on its surface is absorbed in less than 1 second. It will be understood by those skilled in the art that similar wettability results can be obtained by application techniques alternating with this or other surfactants.
Middle layer sheet material [00141] An intermediate layer sheet material formed by air was prepared from the combination of selected cellulose pulp and selected thermoplastic fibers. With regard to cellulose pulp, there are several types that can be used. Typically, they are kraft or sulfite pastes, can be bleached or unbleached, can contain some recycled pulp fibers or be 100% virgin pulp and they can optionally be treated with a chemical bonding agent to reduce inter-bonding. fibers. In a preferred embodiment of the present invention, the cellulose pulp is treated with a detached chemical agent to provide a nonwoven compound with improved smoothness and volume.
[00142] Chemical peeling agents are well known in the manufacture of paper products and non-woven materials. Cellulose pastes treated with chemical peeling agents are particularly used in the manufacture of absorbent articles such as diapers, incontinence products, feminine hygiene products, spill control items and the like. The peeling agents are mixed with the cellulosic fibers to inhibit the formation of bonds between the fibers after wet or dry formation. Peeling agents are described and disclosed in US patents 4482429, 4144122 and
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56/85
4432833. The peeling agents also help in the process of defibration of the cellulose pulp sheets by means of hammer mills and the like, by reducing the amount of energy required per kg of pulp to separate and individualize the pulp fibers.
[00143] Peeled fluff pastes are available from several manufacturers. The paste used in the Examples section is class NF405, a kraft paste made from southern pine wood, available from Weyerhaeuser Inc. Other suitable detached fluff pastes can be used in place of class NF405, including a class designated as Golden Isles 4822 , available from Georgia-Pacific Inc.
[00144] The thermoplastic fibers present with the cellulose paste in the sheet material of the intermediate layer are necessary to allow (a) thermal or ultrasonic bonding of adjacent layers and (b) if desired, the formation of a sheet material self-sustaining by thermal fusion of some or all of the thermoplastic fibers using a hot air oven, or air dryer, or the like. Thermoplastic fibers can be composed of a single resin or they can be composed of two resins in the form of bicomponent fibers. The cross section of a bicomponent fiber can include configurations, such as core-coating (central or offset core), side-by-side, multi-segment pizza and other configurations known to those skilled in the art. A mixture of two or more types of thermoplastic fiber can be used, including, but not limited to, mixtures of fibers with different lengths and / or diameters and / or shapes or configuration and / or material construction. As a general principle, thermoplastic fibers must be chemically compatible with the material (s) that comprise the outer layers. For example, when the outer layers comprise a high-strength meltblown non-woven fabric made of
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57/85 lamellas of polypropylene, it is preferable that the thermoplastic fibers are also made of polypropylene. In the case where the thermoplastic fibers have a bicomponent configuration, for example, core coating, it is preferable that the coating component is made of polypropylene. In the case of a mixture of two or more thermoplastic fibers, it is preferable that at least one type of fiber is polypropylene or has a polypropylene coating, in the case of a bicomponent fiber. Thermoplastic fibers are generally short cut having a length of 10 mm or less and must have a denier between 0.1 and 10 denier, and can be folded or not. For ease of handling and dispersion in air or wet systems, a chemical finish can be applied to the thermoplastic fibers.
[00145] Another advantage of adding thermoplastic fibers to the intermediate layer is to improve the clarity and definition of the pattern provided to the composite non-woven when connected to a thermal embossing or ultrasonic calender. Figure 10 illustrates the clarity of the embossed pattern, which can be achieved with the inventive laminate.
[00146] In the formation of the blanket by air, the equipment can be configured to provide (a) a substantially uniform mixture of cellulose pulp and thermoplastic fibers or (b) a layered or stratified structure where the concentration of thermoplastic fibers is larger near the top and bottom surface of the sheet material and, consequently, the center of the sheet material has a relatively high concentration in percentage of cellulose pulp fibers. The latter stratified structure may be desirable in order to achieve a better thermal bond between the sheet material of the intermediate layer and the outer layers solidified by rotation. The degree of stratification is, to some extent, controllable.
[00147] The equipment for the production of blankets formed via
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Aviation 58/85 is available through a number of suppliers, including (but not limited to) M & J (Denmark, a subsidiary of Oerlikon Neumag), Dan-Web (Denmark) and Celli S.p.A. (Italy). In the following Examples, the intermediate layer formed by air was made on a pilot machine provided by Dan-Web.
[00148] The equipment for the production of wet-formed blankets has long been known. In the wet formation of a mixture of cellulose pulp and thermoplastic fibers, the use of an inclined Fourdrinier wire former is preferable, because it allows the fiber mixture to be prepared as a suspension highly diluted in water before forming the sheet, resulting in on a more uniform sheet. US patent 2045095 describes the general principles of operation of an inclined Fourdrinier wire machine. The cellulose pulp fibers generally used to produce wet formed paper or nonwoven sheets are kraft and / or sulfite pulp and are not normally treated with chemical peeling agents before the wet formation process begins. However, it has been found that certain chemically detached fluff pastes, including NF405 grade Weyerhaeuser kraft pulp, can be used successfully to produce a uniform moist formed mat, although the resulting mat has less strength than an equivalent matte mat made of from a non-chemically detached southern pine kraft paste. The choice of thermoplastic fiber (s) for use in the wet formation of the intermediate layered sheet material is substantially similar to that described above for the airway formation method. A shorter fiber length may be desirable to facilitate fiber dispersion and wet formation, for example, 12 millimeters or less. The chemical finish applied to the fibers is chosen to allow easy dispersion in water and uniform formation in the sheet formed by the wet route.
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59/85 [00149] When using a wet forming machine with more than one inlet box, a layered or stratified sheet structure can be produced, similar in concept to that described above for blankets formed by air, so that the concentration of thermoplastic fibers is higher near the top and / or the bottom surface of the wet-formed sheet material and that the center of the wet-formed sheet has a relatively high concentration in percentage of cellulose pulp fibers.
[00150] The fabric of the invention finds applications, for example, as wet and dry wipes for consumption in domestic and industrial use, medical wipes (low propensity to release lint), filter media of various types, absorbents, low propensity medium lint free for medical use, for example, around draped surgical fenestrations, absorbent meat fillers (to absorb meat juices), absorbent products for leak control (chemical spills, oil spills, etc.) and how a component of incontinence products or feminine hygiene fillers.
[00151] The following non-limiting examples serve to illustrate the product and process of the present invention and do not limit the invention in any way.
EXAMPLES [00152] In the description above and in the following non-limiting Examples, the following test methods were employed to determine various characteristics and properties reported. ASTM refers to the American Society for Testing and Materials, INDA refers to the Association of the Nonwovens Fabrics Industry and IEST refers to the Institute of Environmental Sciences and Technology.
[00153] The test was generally carried out in accordance with the test methods recommended by INDA; any deviation from one
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60/85 INDA's test method is noted in the text. Before testing the dry properties, the samples were conditioned for 24 hours in a controlled environment at about 20 ° C and 50% relative humidity, unless otherwise specified.
[00154] The weight (in grams per square meter or g / m ² ) was measured by a test method that generally follows the INDA 1ST 130.1 (1998) test method. The samples were cut in a matrix at 8 inches by 8 inches (20.3 centimeters by 20.3 centimeters) and weighed in grams to four decimal places on a digital scale. The weight is calculated by dividing the sample weight (in grams) by the sample area (in square meters). In the case of pre-packaged tissue samples, the tissue dimensions were measured to the nearest millimeter and its area in square meters was calculated. In the case of pre-packaged wet tissue samples, the sample sheets were left to air dry and were then conditioned in a controlled environment before weighing. Usually measurements were made on 4 or more samples and an average value was calculated.
[00155] The tensile strength test (T.S.) was performed using a tensile test instrument, model 5500R, supplied by Instron Inc. The samples were cut into wide one-inch (2.54 cm) strips. Normally, both MD and CD directions have been tested. The initial separation between the claws of the samples was five inches (12.7 centimeters) and the strain rate was 30 cm / minute. The instrument provides a report of tensile strength, elongation and toughness (absorption of tensile energy) at the sample's breaking point. Measurements on wet samples were performed by pre-immersing the sample strips in deionized water. At least 4 individual test strips were tested per sample and an average value was calculated. The geometric mean of tensile strength MD and CD was
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61/85 calculated from the square root of the MD and CD tensile strength product. The geometric mean index of tensile strength (in N / m per gsm) was calculated by dividing the geometric mean of tensile strength (in N / m) by the weight (in gsm) of the test sample. [00156] Elmendorf rupture strength was measured by a test method that generally follows the method of ASTM D 5734, using an Elmendorf rupture tester, model 1653, provided by H.E. Messmer of London. The device is equipped with a pendulum model 60-8, capable of measuring up to 7840 mN. Measurements on wet samples were performed by pre-immersing the test pieces in deionized water. Usually measurements were made on 4 or more test pieces and an average value was calculated.
[00157] The thickness of the tissue was measured by a test method that generally follows the test method of INDA IST 120.1 (1998). The equipment used was a Thwing-Albert ProGage (Thwing-Albert, West Berlin, NJ, USA), equipped with a 2.54 cm diameter presser foot (area of 506 mm ² ) exerting a pressure of 4.1 kPa in the sample test, 6.3 cm diameter anvil, maximum range 1000 microns and 0.1 micron screen resolution. At least 10 measurements were made at random positions in each sample and an average value was calculated.
[00158] The volume (in cubic centimeters / gram, or cc / g) is calculated by dividing the thickness of the fabric (in microns) by the weight of the fabric (in gsm). The latter properties are measured by the test methods described above. The wet and dry volume is calculated from the wet and dry thickness of the non-woven fabric, respectively. A high volume value indicates a high low density material.
[00159] Overflow resistance was measured by a test method that generally follows the ASTM D-774 method. The equipment
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62/85 used was a Mullen type hydraulic diaphragm burst tester manufactured by BF Perkins & Sons Inc., and supplied by HE Messmer of London. Measurements on wet samples were performed by pre-immersing the test sample pieces in deionized water. Usually measurements were made on 4 or more test pieces and an average value was calculated.
[00160] Absorption capacity was measured using the following test method. After conditioning, the test pieces of 100 mm by 100 mm were cut in a matrix from the sample to be tested and weighed individually to the nearest 0.001 g. The test pieces were immersed in a bath of deionized water at about 20 ° C. After 60 seconds, the test pieces were individually removed from the bath, and a paper tail (approximately 3 mm by 25 mm) was loosely attached to a corner of the test piece, pressing the tail lightly against a corner of the sample. Each test piece was then suspended vertically downward from a horizontal bar using an alligator clip to secure the corner of the test piece opposite the paper tail. Excess water was allowed to drain from the test piece, the drops being directed away from the test piece through the paper tail. After 5 minutes the test piece (minus the paper tail) was weighed again to the nearest 0.001 g. The absorption capacity was calculated as follows,
Absorption Capacity (%) = 100% x [final weight - initial weight initial weight [00161] Normally measurements were made on 4 or more test pieces and an average value was calculated.
[00162] Abrasion resistance was measured by a test method that generally follows ASTM D 4966. The apparatus used was a Martindale abrasion tester supplied by James H. Heal & Co. Ltd. of Halifax, England. The abrasive wool cloth used was supplied by James H. Heal Ltd. and complies with the requirements of the owner.
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63/85 age specified in Table 1 of EN ISO 12947-1. Felt pads were also provided by James H. Heal Ltd. The pressure applied to the samples during the test was 12 kPa. To improve consistency, all samples were tested by the same operator. To determine resistance to wet abrasion, the test samples were moistened with deionized water. The test was completed when the sample was rubbed sufficiently that a hole appeared in the sample and the number of polishes observed. Usually measurements were made on 4 or more test pieces and an average value was calculated. A high number of polishes is indicative of an abrasion resistant material.
[00163] The softness or hand of non-woven cleaning substrates is a somewhat subjective property, especially when evaluating wet samples. Generally, the hand of a wet non-woven sample is considerably softer and more flexible than that of the corresponding dry sample. While there is no widely recognized instrumental method for measuring wet hand or softness, there are test methods for measuring dry tissue flexibility. The Handle-O-Meter instrument was used, using a test procedure that generally follows ASTM D2923. The nonwoven to be tested is deformed through a slot opening by a blade-shaped plunger and the required force (in grams of force) is measured. This force is a measure of both the flexibility and the friction of the nonwoven surface. The instrument used was a Thwing Albert Handle-o-Meter, model 211-300, with a maximum scale reading of 100 grams-force. A low scale reading is indicative of a soft and flexible material. The slot width was adjusted to 0.5 inch (12.7 mm) and the test pieces were cut to 6 inches by 6 inches (152.4 x 152.4 mm). The samples were left to condition in an air-conditioned room (at about 23 ° C, 50%
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HR) for about 24 hours before measurements are taken. Four test pieces were tested per sample, on both MD and CD, and also turning the test piece in order to test both faces and the average values were calculated. Samples of packaging purchased from the wet wipes store were allowed to air dry, and were then conditioned in an air-conditioned room before testing. As a result of the conversion and packaging process, such samples are usually folded and / or pleated and wrinkled, which generally results in artificially low test values.
[00164] The cellulose content of a sample was determined by dissolving the cellulose fraction in concentrated sulfuric acid, as follows. The test sample was cut into 32 pieces of approximately 25 x 25 mm, dried in an oven at 105 ° C, and the collection of 32 pieces weighed to 0.1 mg closest. The 32 sample pieces were placed in a 500 ml Erlenmeyer flask and 320 g of 72% sulfuric acid was added to the flask. The flask contents were stirred at room temperature for 24 hours. The contents of the flask were then diluted by shaking them with 4 liters of distilled water. The liquid and non-cellulose residue was filtered through a glass fiber filter disc, which had been pre-weighed after drying in an oven. The filtration disc plus the residue was dried in an oven at 105 ° C until very dry and then weighed to the nearest 0.1 mg. The weight of the non-cellulose residue on the filter disc was calculated from the weights before and after the filter disc. The percentage of cellulose in the sample was calculated from _. . . .... [weight of initial sample - weight of waste]
Cellulose content (%) = 100% x —-------------------------------- ¹ weight of the initial sample [00165 ] Pore size measurements were performed by the University of Tennessee non-woven research laboratory. The pore size was measured using an automated capillary flow porometer model # PCP-110-AEX. Test to moisten and dry was
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65/85 performed using Galwick fluid having a surface tension of 15.6 dynes / cm.
[00166] The filament diameter measurements were made by the University of Tennessee non-woven research laboratory. Using a scanning electron microscope, the diameter of at least 100 filaments was measured and averaged.
[00167] Wet lint (loosen particles and fibers of sample tissue in water) - gravimetric method. Test method that generally follows the INDA IST 160.3 (1998) test method was used. 10 ± 0.1 grams of dry sample were accurately weighed and placed in a clean, dry 500 ml glass bottle with plastic screw cap. 400 ± 1 ml of deionized water at room temperature was added to the flask. After ensuring the closure of the bottle, the bottle and contents were manually shaken vigorously for 60 ± 1 seconds. The test sample was immediately removed using a clean glass rod and the liquid filtered through a Whatman pre-weighed glass fiber filtration disc. The filter disc was dried in a laboratory oven at 105 ° C for about 2 hours, and then weighed to four decimal places on an analytical balance. The amount of lint released into the water (in parts per million, or ppm) is calculated from {change in the weight of the filtration disc (g) x weight 1,000,000 / original weight of the sample (g)}. Usually measurements were made on 4 or more test pieces and an average value was calculated.
[00168] Wet lint (drop particles and fibers from sample tissues in water) - particle counting method. The biaxial agitation test described in the IEST test method IEST-RP-CC004.3, section 6.1.3 was used. These test procedures measure readily released particles (present on the surfaces of the tissue) and particles generated by mechanical agitation of the tissue in water. The tes
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66/85 te of the samples was performed by RTI International, 3040 Cornwallis Road, Research Triangle Park, North Carolina, USA. The results are expressed as the number of particles released and generated per square meter of cleaning. Two sets of measurements were made on each test piece and the average values calculated.
[00169] The materials of the invention can be used dry or after moistened with water or aqueous solutions. If the intended application requires the fabric to be used in the wet state, for example, wet wipes, measuring wet test properties is generally more relevant. In the following Examples, a number of wet test properties were measured.
Manufacture of high-strength meltblown blankets [00170] A high-strength meltblown blanket was prepared from polypropylene resin Basell Profax class PH835, which has a melt flow rate of 34 g / 10 minutes (34 MFR). In another experimental work, the high-strength meltblown blankets were also produced from ExxonMobil polypropylene resin class PP3155 (36 MFR), and these blankets had properties very similar to blankets made from Profax resin. The equipment used was a pilot line of 25 inches of nominal width (63 cm) operated by Biax Fiberfilm Corporation located in Quality Drive, Greenville, Wisconsin, USA. The pilot line equipment consists of five main elements in a row - a screw extruder, two gear pumps, a meltblown die, a collection drum and a winding machine. The meltblown matrix is the multiple line of holes (at least 10 lines) designed as generally described in US patent 6013223 to Biax-Fiberfilm Corp. The screw extruder is used to melt the polypropylene resin (and mix it with a melting additive, if used) and delivered an essentially uniform melt of resin at a temperature under pressure
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67/85 of about 550 ° F (288 ° C) for the two gear pumps. The two gear pumps operate in parallel and run at the same low speed, typically about 12 revolutions / minute, each gear pump delivers about 30 cm ³ of resin cast per revolution to the meltblown matrix. At this gear pump speed, the resin transfer rate is about 32.4 kg / hour, or about 0.108 grams / minute through each orifice. The molten resin is maintained at about 550 ° F (288 ° C) as it passes under pressure through the gear pumps and into the meltblown matrix. The meltblown die is equipped with approximately 5000 holes arranged in multiple rows, each hole having an internal diameter of 0.015 inches (0.38 millimeters). The pressure inside the die body was about 1200 psi (8276 kPa) and the molten resin was forced through the holes as thin filaments. The still-fused filaments that emerge from the holes have been attenuated by high-speed hot air currents (about 430 ° F, 221 ° C) that flow essentially parallel and in the same direction as the filaments. US patent 6013223 describes the use of a wire drawing jet to further attenuate the filaments. However, when making the meltblown blankets used in the present invention, the use of a wire drawing jet was not found to be necessary. A fine mist of water spray was used to cool the filaments between the meltblown matrix and the collection drum. The mist spray was applied approximately perpendicular to the direction of movement of the filaments. The attenuated filaments were blown and collected in a rotary vacuum drum covered with foraminous material. The distance between the meltblown matrix and the drum surface was about 14 inches (35 cm). The meltblown filaments thus collected on the rotating drum formed a self-supporting, non-woven sheet material, which could easily be removed from the drum and rolled into a roll without
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68/85 the need for an additional bonding process, even with weights as low as about 3 gsm. For a transfer rate of the supplied resin, by varying the speed of the collection drum surface, the weight of the meltblown filament blanket could be changed. A blanket of approximately 5 gsm was made at a drum surface speed of 535 feet / minute (163 meters / minute). To minimize any loss in the width of the mat, it was found to be preferable to locate the winding machine close to the rotation collection drum, in order to reduce the drawing forces on the mat.
[00171] As shown in Table C, a 7.7 gsm sample had an average filament diameter of 3.56 microns and an average pore size of 27 microns.
[00172] A hydrophilic version of the above blanket was produced using a fine mist spray of an aqueous solution of a surfactant to cool the filaments in place of a fine mist spray of water. In some experiments, the surfactant used was Cytec Aerosol GPG (general purpose class), a dioctyl sodium sulfosuccinate solution. In other experiments, the surfactant used was Unifroth class 1387 (a dioctyl sodium sulfosuccinate solution), supplied by Unichem Inc. The surfactant solution was applied to the filaments using a spray bar consisting of seventeen types of MTP-1510 nozzles (available American Nozzle Co.). About 8.8 US gallons / hour (33.3 liters / hour) of the surfactant solution was applied through the spray nozzles. In the case of both surfactants, the concentration of the surfactant solution was adjusted in such a way that the surfactant application rate for filaments was approximately 1% by weight of solids. In the following Examples, the high-strength meltblown blankets were treated by this method.
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69/85 [00173] Alternatively, hydrophilic meltblown polypropylene filaments were produced using a hydrophilic fusion additive, class TPM 12713, available from Techmer PM, Clinton, Tennessee, USA. The active ingredient is confidential and is not disclosed. The melting additive, 2% by weight, was added to the polypropylene resin at the beginning of the melted screw extruder and was mixed with the molten polypropylene resin. Subsequently, the molten mixture was transformed into meltblown filaments and a non-woven blanket as described above. In common with some other fusion additives, the hydrophilic active ingredient gradually diffuses to the surface of the filaments. As a result, the wettability of the mat improved after several days of aging at room temperature.
Manufacture of polypropylene blankets by the conventional meltblown process [00174] The polypropylene blankets, made by the conventional meltblown process, used in the present invention were prepared on the 20 inch (0.51m) wide pilot line owned and operated by the research laboratory of University of Tennessee non-woven fabric. The polypropylene resin used was Metocene class MF650Y supplied by LyondellBasell, with a melt flow rate of around 1800 g / minute at 230 ° C. The resin transfer rate was about 120 grams / minute. The meltblown matrix temperature was about 450 ° F (232 ° C) and the attenuating air temperature was about 500 ° F (260 ° C). Blankets weighing up to 20gsm were produced. A nominal 5gsm meltblown blanket was produced at a line speed of around 47 meters / minute. The blankets were not treated with any chemicals. As shown in Table C, an 11gsm sample had an average filament diameter of 5.4 microns and an average pore size of 46 microns.
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Manufacture of blankets by air [00175] The blankets produced by air were made on a pilot line operated by Marketing & Technology Services (MTS), located in Kalamazoo, Michigan, USA. The pilot line is about 60 cm wide and is of Danweb design with five molding stations by air. The cellulose pulp used in all the tests was Weyerhaeuser class NF405, a chemically detached cellulose pulp called 'fluff paste'. The cellulose pulp, supplied as a roll-shaped sheet, was shredded into large individual fibers using one or more hammer mills. Several types of synthetic binder fibers were used in the tests, including a 1.5 denier and 6 mm polyethylene coating: two-component polyester core fiber (Celbond type T-255 from Invista), a 2.0 denier polypropylene coating and 6 mm: bicomponent fiber of polyester core, and 2.2 denier polypropylene fibers and 5 mm of FiberVisions. Binder fibers can be used alone or as a mixture. In addition, for the preparation of blankets by air with different weights and / or different types and / or the percentage content of binding fiber, it is possible to create an air blanket with an essentially uniform mixture of pastes and binding fibers or, alternatively, structure in the stratified or gradient Z direction. The latter type of structure is created, for example, by providing a mixture of paste-binder fiber with a relatively high percentage of binder fiber for the first and last air forming stations (numbers 1 and 5), and providing a second mixture of paste-agglutinant fiber with a lower percentage of agglutinating fiber for the other forming stations. In this example, the resulting air mat has a relatively high binder fiber content near its top and bottom and a relatively high cellulose paste content near the middle of the thickness.
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71/85 of the blanket.
[00176] In terms of thermally bonding a polypropylene meltblown blanket to an airway blanket made of fluff pulp and binder fiber, it was found that a stronger bond resulted when binder fibers containing polypropylene were used. The use of binder fibers containing polyethylene (for example, the Celbond T-255 type) produced a weaker thermal bond to the polypropylene meltblown blanket. It is generally known that polyethylene and polypropylene have limited compatibility with respect to the thermal bond between them.
[00177] The MTS pilot line is equipped with a hot air oven, which can be used to melt or partially melt the binder fibers in the air mat in order to produce a self-sustaining mat. In making the pilot scale of the air blankets used in these Examples, the air blankets were melted in the oven sufficiently to produce self-supporting blankets to facilitate later handling. It should be noted that melting in the oven is not a necessary element of the intended manufacturing process. Manufacture of wet blankets [00178] The wet formed blankets used in the present invention were produced in an inclined wet wire former pilot scale owned and operated by Ahlstrom USA Inc. in Windsor Locks, Connecticut, USA. The cellulose pastes used were (a) Weyerhaeuser NF405 chemically detached fluff paste delivered in roll form or (b) Weyerhaeuser Grand Prairie kraft pulp delivered in sheet form. In preparing the fiber blend, a heavy amount of cellulose paste was first added to a measured amount of water in a Hollander mixer where it was circulated and lightly brushed to defibrate it. At the end of the brushing cycle, a heavy amount of the selected binder fiber was added to the paste suspension, and the fibrous mass circulates
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72/85 of (but not brushed) for about 10 minutes to mix and melt the paste and binder fibers, before the entire contents of the mixer are pumped into a holding tank equipped with a stirrer. No wet strength agents or other chemicals were added to the fibrous mixture. The fibrous suspension was pumped into the humid former's inbox along with an appropriate amount of diluted water to produce a sheet of desired weight. The wet sheet formed in this way was dried in can rotary dryers and rolled. The sheet formed from the fluff paste was considerably weaker than that formed from the kraft paste, but it had a good formation and was strong enough to be handled.
Production of laminates [00179] The three layers of laminates were connected to each other by means of a thermal connection point using a pilot scale embossing calender, with an engraved steel roller and a flat steel anvil roller. The engraved connection point pattern used is shown in figure 10. The engraved pattern consists of a multiplicity of approximately round connection points, the majority being about 1.25 mm in diameter, the rest being about 1 mm in diameter. diameter. The depth of the pattern engraved on the roll is about 1.25 mm and the bonding area is about 8.5%.
[00180] Both calender rolls have been heated. Before connecting a series of samples, the surface temperature of both rolls was measured using a digital temperature gauge (model HH802U from Omega Engineering, Stamford, CT), equipped with a surface contact thermocouple probe (model 98226 from Omega Engineering).
[00181] Before the thermal connection, a 3 to 4 meter long sandwich was collected manually by spreading on a lon table
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73/85 g the length of each of the precursor blankets in such a way that the blanket formed via air was in the middle and a blanket solidified by rotation was on each side of the blanket formed by air. The precursor blankets were used in the width in which they were made, that is, about 60 cm. After adjusting the temperature, the pressing pressure and the rotational speed of the embossing rolls to the desired values, the grouped sandwich was passed through the tightening of the embossing calender at a constant linear speed of about 20 meters / minute.
[00182] During this hot embossing process on a pilot scale the blanket materials were unrestricted on both MD and CD. A small amount of dimensional shrinkage occurred during thermal embossing, typically about 3% in MD and about 2% in CD, which resulted in the final laminate having a higher weight than the nominal target value. It is expected that in an industrial process with adequate blanket restriction this thermal shrinkage will be reduced.
Examples 1-3 [00183] Examples 1 to 3 illustrate the manufacture and properties of 3-layer laminates with a high cellulose pulp content, along with other desirable properties. The composition and properties of these Examples are summarized in Table E.
[00184] In Examples 1 - 2, the two outer layers were taken from a roll of high strength polypropylene blanket of weight of about 5 gsm, prepared as described above from the polypropylene resin Basell Profax class PH835. In Example 3, the two outer layers were taken from a high strength polypropylene blanket roll weighing about 8 gsm, prepared as described above from polypropylene resin Basell Profax class PH835. The filaments
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74/85 meltblown were treated topically in the manner described above with an aqueous solution of Cytec Aerosol GPG surfactant. The concentration of the solution was adjusted to give a surfactant addition of about 1% by weight.
[00185] The intermediate layer of the laminate was a blanket formed by air of a weight of about 45 gsm and is composed of a mixture of defibrated fluff paste and synthetic binder fibers. The percentage and type of binder fiber used in each Example is shown in Table E. In Example 2, a mixture of two types of binder fiber was used. In Examples 1 to 3, and all of the following examples, employing an intermediate layer formed by air, the blanket formed by air had a gradient structure in which the upper and lower surfaces of the blanket had a proportionally higher percentage of fibers. binders in relation to the center of the blanket. And, conversely, the center of the air-formed mat had a proportionally higher percentage of fluff pulp compared to the top and bottom surfaces of the mat. Examples 1 and 3 contained about 65% or more of cellulose pulp.
TABLE E
Μ A HIGH RESISTANCE MELTBLOWN / FORMED BY AIR / HIGH RESISTANCE MELTBLOWN
Ex. 1 Ex. 2 Ex. 3 Construction nomination (gsm) 5/45/5 5/45/5 8/45/8 Binder fiber content of airway blanket,%, type 20% PP: bicomponent PET 15% pp _ 15% PE: PET bicomp. 10% PE: bicomponent PET Nominal cellulose pulp content,% 65.5 57.3 66.4 Weight, (gsm) 59.5 55.1 63.8 Dry tensile strength, MD (N / m) 357 293 463 Wet attraction resistance, MD (N / m) 300 248 426 Wet tensile strength, CD (N / m) 165 126 212 Geometric mean of R.T. wet (N / m) 222 177 301 Wet toughness, MD (J) 0.132 0.127 0.251 Wet toughness, CD (J) 0.080 0.081 0.213 Resistance to wet Elmendorf, MD (qjN) 1,120 1,160 1,240 Dry thickness (microns ^ 641 693 725 Dry volume (cc / g) 10.8 12.6 11.4 Wet thickness (microns) 501 439 516 Wet volume (cc / g) 8.4 8.0 8.1 Absorption capacity (%) 1,007 1,140 1,035 Handle-o-Meter, Seco, MD (g.f) 67 66 74 Handle-o-Meter, Dry, CD (g.f) 55 54 62 Abrasion resistance Martindale dry (polished) 70 69 87 Abrasion resistance Martindale wet (polished) 51 49 42 Wet lint, gravimetric method (pp.mJ 35 13 18
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75/85 [00186] The grouping on a pilot scale and the lamination process described above were followed. Approximately 4 meters of each blanket material were grouped annually on a flat surface to give the necessary laminated structure, that is, {meltblown blanket by air 45gsm - meltblown}. The surface temperature of the engraved calender roll was adjusted to about 113-115 ° C and the surface temperature of the anvil calender roll was adjusted to about 108-110 ° C (both rolls were checked and measured by the thermocouple thermocouple). surface contact). Squeeze pressure was about 450 pounds / linear inch (79 N / mm), and the line speed was about 20 meters / minute. The grouped sandwich was fed by squeezing the embossing calender and collected on the other side. [00187] The resulting laminates were soft and drape, especially in the wet state, and had a pleasant hand. The clarity of the embossing pattern was good and was similar to that shown in figure 10. The test properties of the three Examples are shown in Table E. The laminated compounds quickly absorbed water and the absorption capacity was over 1000% for all three Examples. The Handle-O-Meter test values for Examples 1 to 3 are broadly comparable to the test values for other commercial cleaning products, as shown in Table I. The inventive laminates were bulky in both wet and dry conditions. , and had very good wet and dry abrasion resistance. The tensile strength and resistance to rupture were sufficient to allow the use of laminated inventions as hard surface wipes or personal hygiene wipes. The amount of wet lint measured for these laminated materials is low, probably due to the relatively small pore size of the meltblown outer layers reducing the loss of pulp fibers across the laminate faces.
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Examples 4 and 5 [00188] Examples 4 and 5 illustrate the fabrication and properties of 3-layer laminates made using a wet-produced intermediate layer. The composition and properties of these Examples, together with Example 1 as a comparison, are shown in Table F. Examples 4 and 5 contained about 65% or more of cellulose pulp.
TABLE F
HIGH-RESISTANCE MELTBLOWN BLANKET / FORMED BY AIR OR MOIST / HIGH-RESISTANCE MELTBLOWN
Nominal Construction (osm)Middle layer paste formation method, twda pasteBinder fiber content of the airway blanket,%, typeNominal cellulose pulp content,% Ex. 15/45/5Pasta fluff, by air20% two-component PElPET65.5 Ex. 45/45/5Fluff paste, wet20% two-component PElPET65.5 Ex. 55/45/5Loft folder via wet10% one-component PP73.6 Weight, (gsm) 59.5 55.4 53.4 Dry tensile strength, MD (N / m) 357 565 1235 Wet tensile strength, MD (N / m) 300 232 183 Wet tensile strength, CD (N / m) 165 126 97 Geometric mean of R.T. wet (N / m) 222 171 133 Wet toughness. MD (J) 0.132 0.064 0.09S Wet toughness, CD (J) 0.080 0.060 0.116 Resistance to wet Elmendorf, MD (ujW.) 1,120 1,120 600 Dry thickness (microns) 641 431 350 Dry volume (cc / g) 10.8 7.8 6.6 Wet thickness (microns) 501 366 355 Wet volume (cc / g) 8.4 6.6 6.6 Mullen. Burst resistance, wet (JsRaJ 6955 Absorption capacity (%) 1,007 428 461 Handle-o-Meter, Seco, MD (g, f) 67 > 100 > 100 Handle-o-Meter, Dry, CD (g.f) 55 71 72 Resistance to dry Martindale abrasion (polished) 70 106 59 Abrasion resistance Martindale unique (polished) 51 26 37 Wet lint, gravimetric method (cucei) 35 15 21
[00189] The pilot scale grouping and lamination process described later were followed.
[00190] The intermediate layer of Example 4 was a wet mixture formed of Weyerhaeuser NF405 fluff paste (80% by weight) and 20% by weight of 6 mm Celbond PE: PET binder fiber. The intermediate layer of Example 5 was a wet mixture formed from Weyerhaeuser Grand Prairie paste (90% by weight) and 10% by weight of 6 mm HERCULON T153 polypropylene fiber.
[00191] Examples 4 and 5 were soft and drapeable, especially in the wet state, but not as soft as those of Examples made with an intermediate layer by air, such as Examples
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77/85 from 1 to 3. This is demonstrated in the Handle-O-Meter values for Examples 4 and 5 which are higher than for Example 1 - the MD values have exceeded the capacity of the instrument. They were bulky, but not as bulky as Examples 1 through 3. They had good resistance to abrasion when used as a tissue, on the skin or on hard surfaces. Example 5 (intermediate layer of kraft paste) had very high dry tensile strength, but this was very low in the wet state. In fact, both Examples with an intermediate layer formed via wet had lower wet strength, compared to Example 1 (intermediate layer of fluff paste formed via air). Tear resistance and resistance to delamination were suitable for use as hard surface wipes or personal hygiene wipes. The amount of wet lint measured for laminated materials made with intermediate layers via wet is less than the equivalent laminates made with an intermediate layer via air. The absorption capacity of Example 1 (intermediate layer of fluff paste formed by air) is more than double that of Examples 4 and 5 made with intermediate layers via wet.
[00192] Therefore, for a given product design, replacing an intermediate wet layer with an intermediate air layer produces a less soft, less bulky laminate with less absorption capacity.
Examples 6 and 7 [00193] Examples 6 and 7 illustrate the improvement in the properties of the laminate caused by the use of high strength polypropylene meltblown outer layers, compared to the use of a conventional polypropylene meltblown blanket of similar weight. The composition and properties of these examples are summarized in Table G.
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TABELAG
MELTBLOWN / AIRWAY / MELTBLOWN
Ex, 6 Ex. 7 Nominal construction (gsm) 5/45/5 5/45/5 Meltblown blanket type High resistance conventional Binder fiber content of airway blanket,%, type 20% PPiPET bicorn ponente 20% bicomponent Nominal cellulose pulp content. % 65.5 65.5 Weight, (gsm) 56.6 59.7 Dry tensile strength .. MD (N / m) 402 103 Wet attraction resistance, MD (N / m) 363 93 Wet attraction resistance, DC (N / m) 228 91 Geometric mean of R.T. wet (N / m) 288 92 Wet toughness, MD (J) 0.184 0.024 Wet toughness, CD (3) 0.100 0.030 Resistance to wet Elmendorf, MD (rxiNj 1,400 96C Dry thickness (microns) 620 666 Dry volume (cc / g) 10.9 11.2 Wet thickness (microns) 472 454 Vol wet me (cc / g) 8.3 7.6 Mullen burst resistance, wet (kPa) 75 51 Absorption capacity (%) 996 952 Handle-o-Meter, Seca, MD (g.f) 55 54 Handle-o-Meter, Dry, CD (g.f) 45 40 Abrasion resistance Martindale dry (polished) 61 60 Abrasion resistance Martindale wet (polished) 43 48 Wet lint, gravimetric method (pptxi) 28 38
[00194] In both examples, the outer layers were made of approximately 5gsm of meltblown polypropylene - high strength meltblown blanket, in the case of Example 6, conventional meltblown blanket, in the case of Example 7. The intermediate layer formed by air was same in both examples. Example 7 was difficult to group and laminate due to the very low strength of the conventional meltblown mat. In contrast, Example 6 was easy to group and laminate.
[00195] Table G details the lower strength of the laminate, Example 7, made with conventional meltblown mat - wet and dry tensile strength, wet toughness, wet tear resistance and wet burst resistance are all substantially lower. The geometric mean of the wet tensile strength of Example 6 is more than three times greater than that of Example 7. The thickness, volume, absorbency, abrasion resistance, and flexibility
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79/85 Handle-o-Meter are very similar for the two Examples. Examples 8-10 [00196] Examples 8-10 illustrate the versatility of the inventive product design, including asymmetric product constructions (Examples 8 and 9). 3-layer laminates were made using one or two layers of spunbond polypropylene, and with intermediate layers formed by air or wet, the latter using fluff paste or kraft paste. The composition and properties of these examples are summarized in Table H.
[00197] The polypropylene spunbond nonwoven used in these Examples was a class commercially supplied by First Quality Nonwovens, of Great Neck, New York, USA. The average filament diameter of this spunbond blanket was found to be 16.8 microns, as opposed to about 3.5 microns for the high-strength polypropylene meltblown blanket. The average pore size of the spunbond blanket was found to be 51.5 microns, versus about 27 microns for the high-strength polypropylene meltblown blanket.
[00198] In Example 8, the intermediate layer was a 35gsm overlay blanket of fluff paste and comprising about 20% two-component PE: PET binder fiber. In Example 9, the intermediate layer was a wet blanket formed of 35gsm comprising Weyerhaeuser NF405 fluff paste and about 20% bicomponent binder fiber PE: PP overlay: core. In Example 10, the intermediate layer was a wet blanket formed of 35gsm comprising Grand Prairie kraft pulp and about 10% Herculon T153 polypropylene fiber. Due to the use of one or two 13gsm layers of spunbond nonwoven in these Examples, the cellulose pulp content of these laminates was less than in the previous Examples, but still greater than 50%.
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TABLE Η
MELTS PUN / BLANK FORMED BY AIR OR WET / MELTSPUN
Ex. 8 Ex. 9 Ex. 10 Nominal construction (aau) 5/35/13 5/35/13 13/35/13 Outer layer materials (gstq) high strength PP meltblown (5) / PP spunbond (13) high strength PP meltblown (5) / FP spunbond (13) PP spunbond (13] /PP spunbond (13) Paste formation method of the intermediate layer, Pasta fluff, by air Fluff paste, wet Kraft paste, wet ÜHflde folderBinder fiber content of the airway blanket,%, type 20% PE: bicomponent PET 20% PE: Two-component PP 10% PPsingle component Nominal cellulose pulp content,% 52.8 52.8 51.5 Weight, (gsm) 55.3 51.8 62.7 Dry tensile strength, MD (N / m) 532 592 1093 Wet attraction resistance, MD (N / m) 552 499 933 Wet tensile strength, CD (N / m) 247 223 442 Geometric mean of R.T. wet (N / m) 369 334 642 Wet toughness, MD (J) 0.400 0.258 0.514 Wet toughness, CD (J) 0.216 0.186 0.316 Elmendorf wet tear strength, MD GW) 2,640 1,840 2,320 Dry thickness (microns) 663 422 464 Dry volume (cc / g) 12.0 8.1 7.4 Wet thickness (microns) 434 364 406 Wet volume (cc / g) 7.9 7.0 6.5 Mullen burst resistance, Dr / (KE &) 91 97 108 Absorption capacity (%) 1,159 544 346 HandIe-o-Meter, Seco, MD (g.f) 66 > 94 > 100 Handle-o-Meter, Dry, CD (g.f) 48 43 > 100 Abrasion resistance Martindale dry (polished) > 150 > 150 > 150 Abrasion resistance Martindale wet (polished) 23 > 150 > 150 Wet lint, gravimetric method (pptn) 52 31 79
[00199] The use of one or two spunbond outer layers, together with the use of wet intermediate layers, resulted in laminates that were reasonably soft and flexible, especially in the wet state, but generally less soft and flexible than the examples described earlier. The Handle-O-Meter MD test values for Examples 9 and 10 were both very high. The Handle-O-Meter MD and CD test values for Example 10, with two outer layers of spunbond, were both> 100 gf (ie, exceeded the full scale capacity of the instrument). Example 8 with an intermediate layer via air and only an outer spunbond layer was more flexible, as indicated by the lower Handle-O-Meter values.
[00200] As expected, the use of one or two layers of non-woven spunbond significantly increases the strength properties of these Examples. The dry volume of the laminate is influenced
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81/85 by choosing the intermediate layer - Example 8 with an intermediate layer by air has the largest volume. The use of spunbond outer layers greatly increases abrasion resistance - in Example 9, the spunbond face of the laminate was tested both wet and dry, while in Example 8 it was the high-strength meltblown face that was tested wet. The absorption capacity is higher when the detached fluff paste is used in the intermediate layer, instead of the kraft paste, and greater absorption capacity was obtained when the intermediate layer contained the fluff paste via air. When spunbond is used as one or both of the outer layers of the laminate, the amount of lint released into the water (gravimetric method) is higher, particularly Example 10 with two spunbond outer layers, compared to Examples 1 to 3 made with two meltblown outer layers. Spunbond nonwovens generally have a more open pore structure, compared to similarly weighted meltblown nonwovens. Therefore, the higher amount of lint released by Examples 8-10 is probably due to the larger pore size of outer layers of spunbond nonwoven of the laminate.
Comparison with competitor materials [00201] In Table I the test properties of Examples 1, 3 and 6 are compared with commercially purchased wet wipes whose substrate is made by four different airborne technologies (resin bonded), multi - connection via air (MBAL), co-formation and interlacing (blanket carded by hydro-interlacing).
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TABLE I
COMPARISON WITH COMPETING CLEANING MATERIALS
Sample description CVS * Baby wipes MembersMark * MoistPop-ups Huggies * Natural Care Walmart Equate * Popups Ex. 1 Ex. 6 Ex.3 Non-woven substrate technology By air Multi-link airway Co-formation Spunlace 5/45/5 laminate 5/45/5 laminate S / 45/8 laminated Laminate structure No No No No Yes Yes Yes Cellulose pulp content,% > 95 65 75 0 65 65 66
Weight, (gsm) 43.5 64.8 66.0 50.8 59.5 56.6 63.8 Dry tensile strength, MD (N / m) 631 342 243 1353 357 402 463 Wet tensile strength, MD (N / m) 210 208 264 1668 300 363 426 Wet tensile strength, CD (N / m) 180 130 84 435 165 228 212 Geometric mean of R.T. wet (N / m) 194 164 149 852 222 288 301 Wet toughness, MD (J) 0.082 0.085 0.117 1,070 0.132 0.184 0.251 Wet toughness, CD (J) 0.072 0.085 0.115 0.705 0.080 0.100 0.213 Resistance to wet Elmendorf rupture. MD (ojM) 600 1,160 840 5,880 1,120 1,400 1,240 Dry thickness (microns) 273 492 550 426 641 620 725 Dry volume (cc / g) 6.3 7.6 8.3 8.4 10.8 10.9 11.4 Wet thickness (microns) 256 421 488 411 501 472 516 Wet volume (cc / g) 5.9 6.5 7.4 8.1 8.4 8.3 8.1 Absorption capacity (%) 351 640 875 708 1,007 996 1,035 Handle-o-Meter, Seco, MD (g.f) 27 50 35 23 67 55 74 Handle-o-Meter, Dry, CD (g.f) 19 38 18 4 56 45 62 Abrasion resistance Martindale dry (polished) 17 32 9 93 70 61 87 Martindale abrasion resistance (polished) 11 5 5 52 51 43 42 Wet lint, gravimetric method (ppeo) 13 64 197 35 35 28 18
[00202] It is recognized that handkerchiefs purchased in stores have already been converted from roll products to packaged handkerchiefs, and that the conversion process can affect some properties, such as thickness. In our experience, dry thickness is more impacted by the conversion process than wet thickness. Typically the dry thickness can be reduced by 20 - 25% due to the compaction of the sheet in some stages of the conversion process, while the wet thickness can be reduced by a smaller percentage. However, other properties, such as strength and abrasion resistance, should be largely affected by the conversion process. The dry properties of commercial handkerchiefs were measured after allowing the individual leaves to be air-dried, after which they were placed in a conditioned room. The wet properties were measured on the wet wipes as received.
[00203] The cellulose paste content of commercial wipe substrates was determined using the sulfuric acid dissolution procedure described above. All cleaning substrates, with the exception of the interlaced sample, contain a high percentage of cellulose paste. Upon microscopic examination, the interlaced substrate does not contain cellulose.
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83/85 [00204] When comparing tensile strength and wet toughness MD and CD, Examples 1, 3 and 6 are similar or better than samples formed by air, multi-bonded air and co-formed. The Elmendorf MD wet tear strength is comparable to the multi-bond airborne substrate and Examples 1, 3 and 6; co-formed and particularly formed substrates by air have less resistance to rupture. As expected, the interlaced sample has high resistance to traction and rupture, due to its nature (fibers of cut length hydro-interlaced) - proven to be stronger than necessary to function as a cleaning substrate.
[00205] The thickness and wet and dry volume of Examples 1, 3 and 6 are similar or better than commercial wipes formed by multi-bonded airway, co-formed and particularly formed by air, even taking into account the impact of the conversion process.
[00206] As expected due to its construction, the interlaced substrate has the best wet and dry Martindale abrasion resistance. Of the cellulose paste containing substrates, Examples 1, 3 and 6 have the highest wet and dry Martindale abrasion resistance, just slightly below the test results for the interlaced substrate, and are substantially better than samples formed by air , multi-link and co-formed airways.
[00207] The flexibility of the inventive laminates depends, to a certain extent, on the construction materials and the embossing pattern chosen. Example 3 with 8 gsm rotation solidified outer layers is less flexible (larger Handle-O-Meter reading) than Examples 1 and 6 with 5gsm rotation solidified outer layers. An embossing pattern alternated with, for example, a lower bonding area will likely produce a more flexible laminate.
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In general, the Handle-O-Meter values for inventive laminates are broadly similar to those of other substrates with a high cellulose pulp content listed in Table I.
[00208] The inventive laminates, Examples 1, 3 and 6, have the highest measured absorption capacity, and almost the lowest level of wet lint, the exception being the wet formed sample bound to latex.
[00209] The propensity to release lint from substrates containing cellulose paste was investigated using the IEST test method IEST-RPCC004.3, section 6.1.3, which measures the number of particles released into water. The test method also categorizes the particles released by size (in microns), for example, in the range of 0.5 to 1 micron, 1 to 2 microns, etc. Table J summarizes the results of measurements made using the IEST protocol. The airborne substrate attached to latex released the fewest particles in the water. Conversely, the co-formed substrate released the largest number of particles in the water and was particularly notable for releasing a number of particles in the largest particle size categories. By comparison, the substrate formed by air multi-bonding and Examples 1 and 3 show intermediate results, with at least 90% of the released particles being 2 microns or less, a particle size practically invisible to the human eye. As expected, Example 3 with two 8 gsm meltblown outer layers releases fewer particles than Example 1, which has two 5 gsm meltblown outer layers.
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TABLE J
RESULTS OF THE WET LABEL TEST BY THE PARTICLE COUNTING METHOD
Sample description CVS ^s Baby Wipes Members Mark ³ Moist Pop-ups Huggies ³ Natural Care Ex. 1 Ex.3 Non-woven substrate technology By air Multi-link airway Co-formed 5/45/5laminate 8/45/8laminate Cellulose pulp content,% > 95 55 75 65 66 Number of particles 0,5 - lu (particles x10 ^s ) 304 1570 438C 1810 129C Particle number 1 - 2u (x10 ^s particles) 55 497 142C 305 128 Particle number 2 - 5u (x10 ^s particles) 12 151 480 71 22 Number of particles 5 - 10 (particles 10 x ⁵ ) 2 28 120 13 4 Number of particles> 10 (particles x 10 ^s ) 1 15 109 8 2 Total number of particles (particles x10 ^s ) 374 2272 6509 2207 1446
[00210] Those skilled in the art will understand that a new product design generally needs to go through one or more optimization steps or processes to achieve a satisfactory balance of properties for the intended application of the product. It should be recognized that the properties of the previous Examples have not been fully optimized.
[00211] In summary, inventive laminates exhibit a unique combination of valuable features useful in applications such as wipes or absorbent articles. Namely, (a) a high content of cellulose pulp (> 50%), and (b) high thickness and wet and dry volume, and (c) high absorption capacity, and (d) high resistance to wet Martindale abrasion and dry, and (e) low propensity to release lint, together with good softness and fold, and resistance to traction and breakage suitable for the purpose of a wet or dry wipe. None of the competing substrates offers the same useful and valuable characteristics and combinations with similar or better test values as various modalities of the invention.

权利要求:
Claims (27)
[1]
1. Method for making layered non-woven fabrics (1), comprising:
- at least one first layer of non-woven fabric (3),
- on both sides of said first layer (3), a second (2) and a third (4) layer of nonwoven fabric, which the second (2) and third (4) layers of nonwoven comprise, essentially, meltblown fibers and each second (2) and third layers of nonwoven (4) have a weight of 12 g / m ² or less and,
- non-woven fabric composed of at least 50% by weight of natural cellulose,
- the first layer (3) is formed by an air formation process, characterized by the fact that
- the first layer (3) comprises natural cellulose fibers and thermoplastic fibers,
- the first layer is prepared using short cuts of bicomponent fibers,
- the second (2) and third (4) layer of non-woven fabric are formed separately and individually to be a self-supporting blanket with a geometric average of wet tensile strength / weight ratio of at least 7N / m per g / m ² , and
- the three blankets (2, 3, 4) are joined with at least one method from the following group:
- ultrasonic bonding or thermal bonding or adhesive bonding.
[2]
2. Method, according to claim 1, characterized by the fact that both second (2) and third (4) nonwoven layers have a weight of 12 g / m ² or less, preferably 10 g / m ² or less, and advantageously 6 g / m ² or less.
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[3]
Method according to claim 1 or 2, characterized by the fact that the cellulose fiber content of the non-woven fabric is at least 65%.
[4]
Method according to any one of claims 1 to 3, characterized in that at least one of the second (2) or third (4) layer of nonwoven and, preferably, both second (2) and third (4) layers of nonwoven are manufactured by a high-strength meltblown process.
[5]
Method according to any one of claims 1 to 4, characterized in that the three layers of nonwoven (2, 3, 4) are produced separately in such a way that the edge between any two adjacent layers of non -fabric is distinct, as the fibers on the surfaces or close to the surfaces of such adjacent layers are not significantly mixed.
[6]
Method according to any one of claims 1 to 5, characterized in that the weight of the layered non-woven fabric is less than 200 g / m ² , preferably less than 100 g / m ² and, advantageously , between 40 and 65 g / m ² .
[7]
Method according to any one of claims 1 to 6, characterized in that the non-woven fabric is produced comprising in the first non-woven layer (3) more than 75% w / w, preferably 80% w / w or more, and advantageously between 85% w / w and 90% w / w of cellulose fibers and less than 25% w / w, preferably less than or equal to 20% w / w, advantageously between 10 and 15% w / w thermoplastic material.
[8]
Method according to any one of claims 1 to 7, characterized in that both the second (2) and the third (4) layers of nonwoven are formed separately and individually to be self-supporting blankets after which the three blankets are gathered essentially just before joining them together to
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3/6 form the composite non-woven fabric (1).
[9]
Method according to any one of claims 1 to 8, characterized in that the fabric is manufactured comprising in each first, second and third layer the same material solidified by rotation, the material of which is advantageously a sustainable and renewable material, derived from plant materials, such as, for example, poly (3-hydroxybutyrate) (PHB) or poly (lactic acid) (PLA).
[10]
Method according to any one of claims 1 to 9, characterized in that the first layer (3) is formed by a co-formation method.
[11]
Method according to any one of claims 1 to 10, characterized in that the first nonwoven layer (3) is shaped before the three blankets (3,2,4) are joined.
[12]
Method according to any one of claims 1 to 11, characterized in that the first (3), the second (2) and the third non-woven layer (4) are thermally, ultrasonically or by gluing to form a layered nonwoven fabric (1) and that the edge between any two adjacent layers of nonwoven is distinct, with the fibers on or near the surfaces of such adjacent layers not being significantly mixed.
[13]
13. Method according to any one of claims 1 to 12, characterized in that the first layer (3) is formed as an essentially homogeneous monolayer.
[14]
Method according to any one of claims 1 to 13, characterized in that the first layer (3) is formed as a stratified or layered structure, with the thermoplastic material, for example, the fibers, being concentrated near the upper and lower surfaces of the first nonwoven layer (3).
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[15]
15. Layered non-woven fabric, comprising:
- at least one first layer of non-woven fabric (3),
- on both sides of said first layer (3), a second (2) and a third (4) non-woven layer, which the second (2) and third (4) non-woven layer essentially comprise , meltblown and blown fibers and each second (2) and third layer of nonwoven (4) has a weight of 12 g / m ² or less, and
- non-woven fabric composed of at least 50% by weight of cellulose, characterized by the fact that
- the first layer (3) is formed by the air formation process,
- the first layer (3) comprises natural cellulose fibers and short-cut two-component thermoplastic fibers,
- the second (2) and third (4) layer of non-woven fabric are formed separately and individually to be a self-supporting blanket with a geometric average of wet tensile strength / weight ratio of at least 7N / m per g / m ² , and
- the three blankets (2, 3, 4) are joined with at least one method from the following group:
- ultrasonic bonding or thermal bonding or adhesive bonding.
[16]
16. Fabric according to claim 15, characterized in that both the second (2) and the third (4) layers of nonwoven have a weight of 12 g / m ² or less, preferably 10 g / m ² or less and advantageously 6 g / m ² or less.
[17]
17. Fabric according to either of claims 15 or 16, characterized in that both the second (2) and the third (4) layers of nonwoven are manufactured using a high-strength meltblown process.
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[18]
18. Fabric according to any one of claims 15 to 17, characterized in that the first (3), second (2) and third (4) non-woven layer are thermally, ultrasonically or glued to form a layered non-woven fabric (1), the edge between any two adjacent layers of non-woven fabric being distinct, with the fibers on or near the surfaces of such adjacent layers not being significantly mixed.
[19]
19. Fabric according to any one of claims 15 to 18, characterized in that the weight of the layered non-woven fabric is less than 200 g / m ² , preferably less than 100 g / m ² and, advantageously between 40 and 65 g / m ² .
[20]
20. Fabric according to any one of claims 15 to 19, characterized in that the first non-woven layer (3) comprises more than 75% w / w, preferably 80% w / w or more and advantageously between 85% w / w and 90% w / w of cellulose fibers and less than 25% w / w, preferably less than or equal to 20% w / w, advantageously between 10 and 15% w / w of thermoplastic material.
[21]
21. Fabric according to any one of claims 15 to 20, characterized by the fact that each first, second and third layer comprise the same meltblown material, said material being advantageously a sustainable and renewable material , derived from plant materials, such as, for example, poly (3-hydroxybutyrate) (PHB) or poly (lactic acid) (PLA).
[22]
22. Fabric according to any one of claims 15 to 21, characterized in that the layered non-woven fabric has an absorption capacity of more than 900% by weight.
[23]
23. Fabric according to any one of claims 15 to 22, characterized in that the non-woven fabric with
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6/6 comprises at least 65% w / w cellulose fibers, preferably between 70 and 80% w / w cellulose fibers.
[24]
24. Fabric according to any of the claims
15 to 23, characterized by the fact that the dry weight of the composite nonwoven fabric is between 40 g / m ² and 65 g / m ² and the outer layers of non-woven fabric (2.4) each being a non-woven blanket. high-strength meltblown polypropylene fabric of about 6 g / m ² or less, the first non-woven layer (3), that is, the sheet material of the intermediate layer being a non-woven blanket formed by air comprising a mixture of long-fiber take-off cellulose and a mixture of short polypropylene fibers and short polyethylene coating / two-component polypropylene core fibers, with the amount of long-fiber take-off cellulose being between 70 and 90% w / p in the first layer of nonwoven (3), the three layers being joined by thermal or ultrasonic bonding point, the edge between any two adjacent layers of nonwoven being distinct, and the fibers being on or near the surfaces of such layers Adjacent s are not significantly mixed.
[25]
25. Fabric according to any one of claims 15 to 24, characterized in that the first layer of nonwoven (3) is shaped before the three blankets (3,2,4) are brought together.
[26]
26. Fabric according to any one of claims 15 to 25, characterized in that the first layer (3) is essentially a homogeneous monolayer.
[27]
27. Fabric according to any one of claims 15 to 26, characterized in that the first layer (3) is a stratified or layered structure, with the thermoplastic material, for example, the fibers, being concentrated close to the upper and lower surfaces of the first non-woven layer (3).

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同族专利:

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公开号 | 公开日

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RU2012105927A|2013-08-27|

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BR112012001275A2|2016-02-10|

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US9296176B2|2016-03-29|

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ES2429498T3|2013-11-15|

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EP2456585B1|2013-07-03|

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FI20095800A0|2009-07-20|

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EP2456585A2|2012-05-30|

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WO2011009997A3|2011-05-26|

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ES2429498T5|2018-04-13|

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WO2011009997A2|2011-01-27|

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EP2456585B2|2017-12-20|

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RU2534534C2|2014-11-27|

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US20120177888A1|2012-07-12|

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法律状态:
2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-02-05| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|

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2019-05-28| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2019-09-10| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2019-11-12| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 20/07/2010, OBSERVADAS AS CONDICOES LEGAIS. (CO) 20 (VINTE) ANOS CONTADOS A PARTIR DE 20/07/2010, OBSERVADAS AS CONDICOES LEGAIS |

优先权:

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申请号 | 申请日 | 专利标题

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FI20095800A|FI20095800A0|2009-07-20|2009-07-20|Nonwoven composite product with high cellulose content|

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PCT/FI2010/050603|WO2011009997A2|2009-07-20|2010-07-20|High cellulose content, laminiferous nonwoven fabric|

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