WO2024165178A1

WO2024165178A1 - Filled nonwoven textile systems

Info

Publication number: WO2024165178A1
Application number: PCT/EP2023/053396
Authority: WO
Inventors: Martin Hottner
Original assignee: W. L. Gore & Associates Gmbh
Priority date: 2023-02-10
Filing date: 2023-02-10
Publication date: 2024-08-15

Abstract

The present disclosure relates to a nonwoven article comprising an intumescent material, activated carbon, sorbents, super absorbent polymers or a combination thereof. These articles can be useful for a number of articles including fire retardant laminates, filter layers, and absorbing wipes.

Description

TITLE

Filled Nonwoven Textile Systems

TECHNICAL FIELD OF THE DISCLOSURE

[0001] The present disclosure relates to nonwoven articles comprising additives that can provide one or more of flame retardancy, high liquid absorbency or high absorbency of volatile organic compounds.

BACKGROUND OF THE DISCLOSURE

[0002] Flame retardant compositions are commonly used in textiles. However, the use of some flame retardant materials, for example, additive materials can require the use of solvents, binders or both to incorporate the additive materials on the surface of the textile. The additive materials may be applied over that surface in a manner that results in non-homogenous coverage and may impact the performance of an article comprising the nonwoven and the additive material.

SUMMARY OF THE DISCLOSURE

[0003] The present disclosure relates to an article comprising a nonwoven of one or more polymeric or thermoplastic filaments and one or more additive materials, wherein the one or more additive materials, wherein the additive materials are incorporated in the one or more polymeric or thermoplastic filaments and/or the additive materials are incorporated into the nonwoven article in between the one or more polymeric or thermoplastic filaments of the nonwoven article forming a nonwoven composite of polymeric or thermoplastic filaments and additive materials.

[0004] In another embodiment, the additive material is an intumescent material, activated carbon, a sorbent, a super absorbent polymer or a combination thereof. [0005] In any of the previous embodiments, the additive materials have an average particle size in the range of from 10 micrometers to 1000 micrometers.

[0006] In any previous embodiments, the additive material is an intumescent material and the intumescent material is expandable graphite.

[0007] In any of the previous embodiments, the additive materials are present on a surface of one or more of the filaments.

[0008] In any of the previous embodiments, the additive materials are present as a filler in the one or more filaments.

[0009] In any of the previous embodiments, the article comprises in the range of from 5 to 75% by weight of the additive materials, based on the total weight of the article.

[0010] In any of the previous embodiments, the one or more polymeric or thermoplastic filaments is polyester, copolyester, polyamide, copolyamide, polycarbonate, polyether, polyurethane, melamine, a copolymer thereof, a blend thereof, or a multicomponent mixture thereof.

[0011] In any of the previous embodiments, the article comprises a meltblown nonwoven, a spunbond nonwoven, a stitchbonded nonwoven, needlepunch nonwoven, or a wet-laid nonwoven.

[0012] In any of the previous embodiments, the additive material is a super absorbent polymer and the super absorbent polymer is one or more of polyacrylic acid, polyacrylic acid, sodium polyacrylate, acrylamide, amylopectin, cyclodextrin, gelatin, cellulose, silica gel, com cob granulate, and/or polyurethane coated com cob granulate.

[0013] In any of the previous embodiments, the article further comprises a flame retardant agent.

[0014] The present disclosure also relates to a laminate comprising i) the nonwoven of the previous embodiments, wherein the nonwoven comprises a layer having a first side and a second side; ii) a second layer attached to the first side or the second side of the nonwoven; and iii) a layer of an adhesive between the nonwoven layer and the barrier layer. The present disclosure also relates to a garment comprising the laminate. The present disclosure also relates to the article, wherein the article is an adhesive layer in a multiplayer laminate. [0015] The present disclosure also relates to a process of forming the nonwoven wherein the process comprises the steps of forming a melt or a solution of the thermoplastic polymer, extruding the melt through orifices to form one or more filaments, drawing and entangling the filaments using a high velocity gas, laying down the entangled filaments on a moving surface to form a nonwoven, distributing the additive materials across at least a portion of the width of the nonwoven, wherein the addition of the additive particles is free from any added gas stream.

BRIEF DESCRIPTION OF THE FIGURES

[0016] Fig. 1 shows an SEM of the article.

DETAILED DESCRIPTION

[0017] The disclosures of all cited patent and non-patent literature are incorporated herein by reference in their entirety.

[0018] As used herein, the term "embodiment" or "disclosure" is not meant to be limiting, but applies generally to any of the embodiments defined in the claims or described herein. These terms are used interchangeably herein.

[0019] Unless otherwise disclosed, the terms "a" and "an" as used herein are intended to encompass one or more (i.e. , at least one) of a referenced feature.

[0020] The features and advantages of the present disclosure will be more readily understood, by those of ordinary skill in the art from reading the following detailed description. It is to be appreciated that certain features of the disclosure, which are, for clarity, described above and below in the context of separate embodiments, may also be provided in combination in a single element. Conversely, various features of the disclosure that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. In addition, references to the singular may also include the plural (for example, "a" and "an" may refer to one or more) unless the context specifically states otherwise.

[0021] The use of numerical values in the various ranges specified in this application, unless expressly indicated otherwise, are stated as approximations as though the minimum and maximum values within the stated ranges were both proceeded by the word "about". In this manner, slight variations above and below the stated ranges can be used to achieve substantially the same results as values within the ranges. Also, the disclosure of these ranges is intended as a continuous range including each and every value between the minimum and maximum values.

[0022] As used herein, the term ‘filament’ means a thin thread having an essentially endless length. The filament may be several hundred to thousands of meters long. [0023] A ‘fiber’ is intended to mean a thin thread having a finite length, for example, from a few millimeters to about 30 centimeters in length.

[0024] Described herein is an article comprising a) a nonwoven of one or more polymeric or thermoplastic filaments, wherein the polymeric or thermoplastic filaments have a discrete length or are essentially endless; and b) one or more additive materials, wherein the additive materials are incorporated in the one or more thermoplastic fibers and/or the additive materials are incorporated into the nonwoven article in between the one or more thermoplastic fibers of the nonwoven article forming a nonwoven composite of thermoplastic fibers and additive materials.

[0025] In embodiments, the term “thermoplastic” within the scope of this disclosure is used to describe both thermoplastic polymers as well as solutions of non-meltable polymers, for example, melamine.

[0026] The nonwoven can be made using any known process and can be, for example, a melt blown nonwoven, a spun bond nonwoven, a stitch bonded nonwoven, needle punch nonwoven, or a wet-laid nonwoven. Nonwovens can be made from thermoplastic materials and from non-meltable polymeric materials, using known processes. For the purpose of this disclosure, the nonwoven formation processes will be generically described in terms of melt-blowing thermoplastic polymers. In some embodiments, the nonwoven is produced by a melt blown or a spun bond process. In the melt blown or spun bond processes, a thin stream of a melt of the thermoplastic material of the nonwoven is extruded through small nozzles. The thin continuous stream of melted thermoplastic material are then drawn and subjected to a high velocity gas (usually air or nitrogen), wherein the high velocity gas extends the thin streams and randomly deposits the thermoplastic material on a substrate to form the nonwoven. The high velocity gas can break up the thin continuous stream of thermoplastic material causing the filaments to form smaller fibers. Since the thin streams of thermoplastic material are generally in the melt at the time they are deposited onto the substrate, they entangle and may flow into one another, forming an essentially endless sheet of fibers and filaments. As used herein, the material making up the nonwoven will be referred to as a filament although it should be understood that some fibers may be present. Depending on the process conditions, the nonwoven layer can be made in various widths, thicknesses and lengths. Depending on the thermoplastic material used to form the article, the article can be an elastic and/or flexible article. The article may have an elasticity that has a stretch of at least 5% and up to about 200%, based on the original length and/or width of the article.

[0027] The material used to form the nonwoven can be a thermoplastic or other polymeric material. In some embodiments, the thermoplastic material can be a polyester, copolyester, polyamide, copolyamide, polycarbonate, polyether, polyurethane, melamine (for example, smartMELAMINE, available from smartMELAMINE d.o.o., Slovenia), a copolymer thereof, a blend thereof, or a multicomponent mixture thereof. In some embodiments, the thermoplastic is a polyester. In other embodiments, the thermoplastic can be a polyamide. In other embodiments, the thermoplastic can be a polyurethane. In other embodiments, the thermoplastic can be a copolyester and a polyurethane, for example, a polyesterurethane. In other embodiments, the thermoplastic can be a copolymer of a polyether and a polyurethane, for example, a polyetherurethane. In still further embodiments, the thermoplastic can be a copolyamide. In still further embodiments, the polymeric material can be a melamine. In some embodiments, the nonwoven is produced from a thermoplastic polymer that is meltable and flammable. A meltable and flammable polymer can be determined by subjecting the nonwoven material to the Melting and Thermal Stability test as provided herein.

[0028] Depending upon the choice of the thermoplastic polymeric material and the method for incorporating the additive material into the nonwoven, the additive material or the thermoplastic material may require a dispersing agent or other additive to prevent agglomeration of the intumescent materials. In some embodiments, the article is free from or essentially free from agglomerations of the additive materials.

[0029] In some embodiments, the additive material can be incorporated into the nonwoven by forming a melt or a solution of the thermoplastic material and adding the additive material to the melt. In some embodiments, the additive materials can be present on the surface of one or more of the polymeric or thermoplastic filaments during or after the formation of the nonwoven. In an embodiment incorporating the additive materials during the formation of a melt blown nonwoven, the intumescent materials can be added as a separate component before, during, or just after the lay down of the filaments. For example, melt blown nonwovens are typically formed on a moving air- permeable substrate (a conveyor, a take-up screen, a rotating drum, or another substrate), wherein the moving substrate is able to release the nonwoven after formation, or wherein the moving substrate acts as a carrier for the nonwoven and becomes a part of the nonwoven. In either case, the desired amount of additive material can be added to the moving substrate and the nonwoven can be formed so that the additive material becomes adhered to the filaments as they are laid down onto the moving substrate. A melt blown process typically uses a stream of high velocity gas to blow or direct the molten stream of thermoplastic polymer onto the moving substrate. The additive materials can be entrained in this high velocity gas stream to deposit the additive materials during the formation of the nonwoven on the moving substrate. In other embodiments, the additive materials can be added to the nonwoven after the nonwoven has been laid down on the moving substrate while at least a portion of the filaments of the nonwoven are still in the melt. At least a portion of the filaments can be at least partially in the melt, so that the melt is able to at least partially coat and/or adhere to the additive material, thus providing a bond between the filaments and the additive materials so that the additive materials cannot be easily removed from the nonwoven after the thermoplastic material has cooled to below its melting temperature. In some embodiments, the article is free from an added adhesive or an added binder adhering the additive material to the surface of one or more of the nonwoven filaments. Minimizing or excluding the use of adhesives or binders to adhere the additive materials to a nonwoven can help to minimize the weight of the article and/or can maximize the permeability of the article. In other embodiments, a blend of the additive material and an adhesive material can be used to help bond the additive material to the nonwoven. For example, a blend of a super absorbent polymer and an adhesive powder may be used when forming the nonwoven.

[0030] In other embodiments, the additive material can be an intumescent material and the intumescent material can be present as a filler in the one or more polymeric or thermoplastic filaments. To produce these embodiments, the intumescent materials can be incorporated into the melt of the thermoplastic material and extruded as a part of the filament, becoming a final part of the filament itself during the formation of the nonwoven. In this embodiment, the intumescent materials are present as a filler in the thermoplastic polymer. It is important that the temperature of the thermoplastic melt is lower that the temperature that initiates expansion of the intumescent material. It is also important that the particle size of any intumescent material is small enough to pass through the extruder nozzles without clogging or blocking the extruder nozzles and blocking or impeding filament formation. Other additive materials can also be added in this manner.

[0031] Typical nonwoven formation processes use a stream of high velocity air to entangle the filaments. It has been found that adding the additive materials into the high velocity air can results in a low percentage of the additive materials, which are often relatively small particles, being entrained into the forming nonwoven. In some embodiments, the disclosure relates to a process of forming the nonwoven wherein the process comprises the steps of forming a melt or a solution of the thermoplastic polymer, extruding the melt through orifices to form one or more filaments, drawing and entangling the filaments using a high velocity gas, laying down the entangled filaments on a moving surface to form a nonwoven, distributing the additive materials across at least a portion of the width of the nonwoven, wherein the addition of the additive particles is free from any added gas stream.

[0032] The additive materials can be an intumescent material, activated carbon, sorbents, a super absorbent polymer, or a combination thereof. In some embodiments, the intumescent material is expandable graphite. In some embodiments, the additive material is activated carbon. In some embodiments, the additive material is a super absorbent polymer (SAP), and the super absorbent polymer is one or more of polyacrylic acid, sodium polyacrylate, acrylamide, amylopectin, cyclodextrin, gelatin, cellulose, silica gel, com cob granulate, and/or polyurethane coated com cob granulate. [0033] in some embodiments, the article comprises a nonwoven and one or more intumescent materials. The intumescent materials can be any of those known in the art. The intumescent material should begin to initiate expansion at a temperature between 180°C and 350°C. At expansion initiation temperatures below 180°C, the intumescent material may begin to expand as it is placed on or in the melted or partially melted thermoplastic filaments of the nonwoven, making formation of the article problematic. At expansion initiation temperatures above 350°C, the article may not be able to protect a wearer from injury from heat evolved during an exposure to a high thermal energy incident.

[0034] In some embodiments, the intumescent materials can be expandable graphite. An expandable graphite suitable for use with the nonwovens and methods disclosed herein has an average expansion rate of at least 9 micrometer/°C (pm/°C) between 180°C and 280°C. Depending on the desired properties of the article, it may be desirable to use an expandable graphite having an expansion rate greater than 9 pm/°C between 180°C and 280°C, or an expansion rate greater than 12pm/°C between 180°C and 280°C, or an expansion rate greater than 15pm/°C between 180°C and 280°C. One expandable graphite suitable for use in certain embodiments expands by at least 900 micrometers (pm) in a thermo-mechanical analysis (TMA) expansion test described herein when heated to 280°C. Another expandable graphite suitable for use in certain embodiments expands by at least 400 pm in TMA expansion test described herein when heated to 240°C. If tested using the Furnace Expansion Test described herein, expandable graphite suitable for use in the articles have an average expansion of at least 9 cc/g at 300°C. In one example, expandable graphite B (3626 available from Asbury Graphite Mills, Inc) has an average expansion of about 19 cc/g at 300°C, whereas expandable graphite E (3538 available from Asbury Graphite Mills. Inc.) has an expansion of only about 4 cc/g at 300°C, when tested according to the Furnace Expansion Test as described herein. [0035] In some embodiments, the article can be formed comprising expandable graphite, wherein the expandable graphite has an endotherm of at least about 100 Joules/gram (J/g) when tested according to the DSC Endotherm Test method described herein. In other embodiments, it may be desirable to use expandable graphite with an endotherm greater than or equal to about 150 J/g greater than or equal to about 200 J/g or an endotherm greater than or equal to about 250 J/g. In some embodiments, an article having a nonwoven and an expandable graphite wherein the expandable graphite has an expansion greater than 900 micrometers (pm) at 280°C and an endotherm greater than 100 J/g is formed having an average afterflame value of less than 20 seconds, an average char length of less than 20 centimeters (cm) or both, when tested according to the Edge Ignition Test described herein. In other embodiments, articles can be formed comprising nonwovens and expandable graphite wherein the article has an average afterflame of less than 10 seconds, or less than 2 seconds; and/or the articles may have an average char length less than 15 cm or less than 10 cm, when tested according to the Edge Ignition Test.

[0036] The expandable graphite can have an average particle diameter in the range of from 10 to 500 pm. In other embodiments, the average diameter of the expandable graphite can be in the range of from 20 to 400 pm or from 30 to 300 pm or from 40 to 250 pm or from 50 to 275 pm or from 50 to 250 pm or from 50 to 200 pm. As used herein, average particle size means the average particle size of the particles after the particles are incorporated into the article and can be determined using a Coulter Counter. The average size of the expandable graphite can depend upon the method used to make the article. For example, if the article is made by blending the expandable graphite with a melt of the thermoplastic and then extruding a blend of the thermoplastic and the expandable graphite into filaments, then the expandable graphite particles should of sufficiently small size so that they can fit through the extrusion nozzles without clogging the nozzles. On the other hand, if the expandable graphite is added to the melt blown or spun bond nonwoven before, during or shortly after the manufacture of the nonwoven, then an expandable graphite can be used that has a relatively larger average particle size as the expandable graphite particles are not required to pass through the extrusion nozzles. Figure 1 shows an SEM of the article 10, comprising thermoplastic filaments 20 and expandable graphite 30.

[0037] The article can comprise in the range of from 5 to 75% by weight of the intumescent materials, based on the total weight of the article. In other embodiments, the article can comprise in the range of from 10 to 70% by weight or from 10 to 60% by weight or from 10 to 50% by weight of the intumescent materials, based on the total weight of the article.

[0038] The article comprises a nonwoven and one or more additive materials. Optionally, the article can further comprise one or more flame retardant agents. Suitable flame retardant agents can include, for example, chlorinated compounds, brominated compounds, antimony oxide, organic phosphorous-based compounds, phosphate esters, resorcinol bis(diphenyl phosphate), zinc borate, ammonium polyphosphate, melamine cyanurate, melamine polyphosphate, molybdenum compounds, alumina trihydrate and magnesium hydroxide, or a combination thereof. In some embodiments, the flame retardant agents can be added to the thermoplastic material as a filler. In other embodiments, the flame retardant agent can be added during the formation of the nonwoven during the addition of the intumescent material. [0039] The flame retardant agent can comprise in the range of from 1 to 10% by weight, based on the total weight of the article. In other embodiments, the article can comprise in the range of from 1 to 7% by weight or from 1 to 5% by weight of the flame retardant agent, based on the total weight of the article.

[0040] In some embodiments, the article comprises a nonwoven and an additive material, wherein the additive material is activated carbon. The activated carbon can have an average particle size in the range of from 1 pm to 1000 pm. In other embodiments, the activated carbon can have an average particle size in the range of from 5 pm to 750 pm or from 5 pm to 500 pm or from 5 pm to 350 pm or from 10 pm to 350 pm or from 20 pm to 325 pm. The activated carbon can be present in the article in the range of from 1 to 75% by weight, based on the total weight of the article. In other embodiments, the activated carbon can be present in the range of from 1 to 50% by weight or from 2 to 30% by weight, based on the total weight of the article. [0041] Suitable activated carbons are commercially available from, for example, Donau Carbon, Cabot Corporation, Necatec AG and others. Articles comprising a nonwoven and activated carbon can be useful at absorbing gases and in liquid filtration, for example, absorbing organic contaminants from water or aqueous liquids.

[0042] In some embodiments, the article comprises a nonwoven and a super absorbent polymer. Super absorbent polymers (SAP) are a class of polymers that are able to absorb many times their own weight of another material, generally another liquid or fluid substance. Suitable super absorbent polymers can include one or more of, for example, polyacrylic acid, sodium polyacrylate, acrylamide, amylopectin, cyclodextrin, gelatin, cellulose, silica gel, com cob granulate, and/or polyurethane coated com cob granulate.

[0043] Suitable super absorbent polymers can have an average particle size in the range of from 100 pm to 2 millimeters (mm). In other embodiments, the super absorbent polymers can have an average particle size in the range of from 100 pm to 1.5 mm or from 200 pm to 1 mm or from 300 pm to 1 mm or from 400 pm to 1 mm or from 500 pm to 1 mm. The super absorbent polymer can be present in the range of from 10 to 75% by weight, based on the total weight of the article. In other embodiments, the super absorbent polymer can be present in the range of from 10 to 70% or from 10 to 60% or from 20 to 50% by weight, based on the total weight of the article. Articles comprising the nonwoven and super absorbent polymers can be used as tissues and/or wipes for absorbing liquids. The absorbed liquids may be water, chemicals and/or oils. The articles comprising super absorbent polymers can also be used in hygienic articles, for example, diapers.

[0044] The article can be used in a laminate. The article comprising the nonwoven and the additive material is in the form of a nonwoven layer having a first side and a second side. The nonwoven layer will generally have a length and a width which are much greater than the thickness of the nonwoven layer. In some embodiments, the width, the length, or both will be at least 10 times greater than the thickness. In other embodiments, the width, the length, or both will be at least 20 times, or at least 50 times, or at least 100 times greater than the thickness. The laminate comprises i) the nonwoven described herein in the form of a layer and having a first side and a second side; ii) a second layer attached to the first side or the second side of the nonwoven layer; and iii) a layer of an adhesive between the nonwoven layer and the second layer. The laminate comprising the nonwoven layer and the second layer, adhered to one another by an adhesive layer is called a 2-layer laminate.

[0045] The second layer can be a film, a textile, or a combination thereof. In some embodiments, the second layer is a film comprising a thermoplastic film, a thermoset film or a multilayer laminate thereof. In other embodiments, the second layer is a textile comprising a knit, a woven, a nonwoven or a multilayer laminate thereof.

[0046] In some embodiments, the second layer can be a film. The film can be a thermoplastic or a thermoset film. Suitable examples of these films can include, EVOH, EVAc, PVC, PVdC, polyvinyl fluoride, polyvinylidene fluoride, fluoropolymers, polyurethanes, polyesters, polyamides, polyethers, polyacrylates and polymethacrylates, copolyetheresters, and copolymers or multilayer laminates thereof. In some embodiments, the film can be a fluoropolymer film comprising polytetrafluoroethylene (PTFE) or expanded polytetrafluoroethylene (ePTFE). In some embodiments, the film can be a waterproof breathable film comprising ePTFE, polyurethane, polyester, or a combination or a multilayer laminate thereof. In some embodiments, the second layer can be a thermally stable film, for example, PTFE or ePTFE. In some embodiments, the second layer can be a barrier layer. As used herein, the phrase ‘barrier layer’ means a layer that is impervious to one or more of liquids and/or gases. In some embodiments, the barrier layer can be a microporous membrane or a monolithic membrane that is impermeable to liquid water, but is permeable to water vapor. Suitable barrier layers can include, for example, ePTFE, polyurethanes, or combinations thereof. The film can be relatively lightweight, for example, the weight may be in the range of from 5 g/m² to about 100 g/m². In other embodiments, the textile layer can have a weight in the range of from 10 g/m² to 90 g/m², or from 150 g/m² to 80 g/m².

[0047] In other embodiments, the second layer can be a textile layer. The textile layer can be a textile layer produced from natural fibers, from synthetic fibers or filaments, or a combination thereof. In some embodiments, the textile layer can be a woven, a knit or a nonwoven textile layer. Examples of natural fibers can include, for example, cotton, wool, silk, cellulose, jute, flax, bamboo, or hemp. Synthetic fibers can include for example, nylon, polyester, acrylic, polyolefin, aramid, PBI, PBO, viscose, flame retardant viscose, or rayon. If desired, many of the natural and synthetic fibers are or can be made flame resistant using any of the known flame retardant treatment methods. In some embodiments, the textile layer can be a flame retardant textile layer comprising one or more flame retardant natural or synthetic fibers or filaments.

[0048] The textile layer can be a woven, knit or a nonwoven textile. In some embodiments, the textile is a relatively lightweight textile produced from one or more synthetic fibers, for example, a knit comprising a blend of cotton and polyester. In some embodiments, the second layer can be a textile layer wherein the textile layer is a thermally stable textile layer, for example, a textile made from an aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), flame retardant viscose or a combination thereof. In other embodiments, the textile layer can be an inherently flame retardant layer comprising flame retardant fibers or filaments. In one embodiment, the textile layer can be a woven textile comprising a blend of aramid, flame retardant viscose and an anti-static additive. The textile layer can be relatively lightweight, for example, the textile weight may be in the range of from 30 g/m² to about 120 g/m². In other embodiments, the textile layer can have a weight in the range of from 40 g/m² to 110 g/m², or from 50 g/m² to 100 g/m².

[0049] In some embodiments, that laminate can be a multilayer laminate, for example, a 3-layer or a 4-layer laminate. For these multi-layer laminate embodiments, one or more additional layers can be added to the previously described 2-layer laminate. The one or more additional layers can be adhered to the 2-layer laminate on one side, the other side or both sides of the 2-layer laminate. In other embodiments, the laminate can comprise layers that include a film layer and a textile layer, wherein the textile layer is attached to the second layer on a side opposite the nonwoven layer. If more than one additional layers are used, each additional layer can be chosen independently of each other. An adhesive can be used to adhere the additional layer. The adhesive can be any of the known adhesives. In some embodiments, the adhesive can be a polyurethane, an epoxy, an epoxy amine, an epoxy acid, a polyester, an acrylic, a polyvinyl alcohol, a polyvinyl acetate adhesive or a combination thereof. [0050] In some embodiments, the 2-layer laminate can be formed by placing an adhesive on the nonwoven layer, on the second layer or on both and adhering the nonwoven layer and the second layer together, wherein the adhesive layer is between the nonwoven layer and the second layer. The adhesive can be placed on one or both of the nonwoven layer or the second layer in a continuous or a discontinuous manner. In a continuous manner, the adhesive can cover essentially the entire width, for example, greater than or equal to 90% of the width of the nonwoven layer or the second layer. The adhesive can also be applied to the nonwoven layer or the second layer or both in a discontinuous manner. For example, the adhesive may be applied to one or more of the surfaces in a series of lines, grids, or dots. In some embodiments with discontinuous coverage, the average distance between adjacent areas of the discontinuous pattern is less than 5 millimeters (mm), or preferably less than 3.5 mm, 2.5 mm, 1 .5 mm, or 0.5 mm. The average distance between adjacent areas can be measured by measuring the spacing between adjacent lines, grids or dots. While dots are mentioned, it should be understood that any regular or irregular shape of dot can be used. For example, a dot can be round, square, star-shaped or any polygon shape as well as any irregular shape. In some embodiments, the adhesive can be applied using gravure printing, screen printing, ink jet printing or any other known printing technique. In embodiments where properties such as hand, breathability, and/or laminate weight are important, a surface coverage of less than 90%, or less than 80%, or less than 70%, or less than 60%, or less than 50%, or less than 40%, or less than 30% may be used. The percent coverage may be calculated by measuring the geometry of a gravure cell or a screen printing masks, depending on which application method is used. One method for achieving a coverage of less than 100% comprises applying the adhesive by printing the mixture onto a surface of the nonwoven layer or the second layer by, for example, gravure printing.

[0051] In some embodiments, the adhesive may be a heat reactive material. The heat reactive material can be a mixture of a polymer resin and expandable graphite. The polymer resin may have a melt or softening temperature of less than about 280°C. The polymer resin may be sufficiently flowable or deformable to allow the expandable graphite to expand substantially upon heat exposure at or below about 300°C. The polymer resin may be sufficiently flowable or deformable to allow the expandable graphite to expand substantially upon heat exposure at or below about 280°C. The polymer resin may allow the expandable graphite to sufficiently expand at temperatures below the pyrolysis temperature of the meltable outer textile. The extensional viscosity of the polymer resin may be low enough to allow for the expansion of expandable graphite and high enough to maintain the structural integrity of the heat reactive material after expansion of the mixture of polymer resin and expandable graphite. These factors can be quantified by the storage modulus and tan delta of the polymer resin.

[0052] The polymer resin may have a storage modulus of at least about 10³ dyne/cm². The polymer resin may have a storage modulus from 10³ to 10⁸ dyne/cm². The polymer resin may have a storage modulus from 10³ to 10⁷ dyne/cm². The polymer resin may have a storage modulus from 10³ to 10⁶ dyne/cm². The polymer resin may have a storage modulus from 10³ to 10⁵ dyne/cm². The polymer resin may have a storage modulus from 10³ to 10⁴ dyne/cm². Storage modulus is a measure of a polymer elastic behavior and can be measured using Dynamic Mechanical Analysis (DMA). The polymer resin may have a Tan delta from about 0.1 to about 10 at 200°C. Tan delta is the ratio of the loss modulus to the storage modulus and can also be measured using DMA techniques.

[0053] The polymer resins may have a modulus and elongation at around about 300°C or less, suitable to allow the expandable graphite to expand. The polymer resins may be elastomeric. The polymer resins may be cross-linkable, such as crosslinkable polyurethane. The polymer resins may be thermoplastic. Thermoplastic polymer resins may have a melt temperature from 50°C to 250°C.

[0054] The polymer resin may comprise polymers which include but are not limited to polyesters, polyether, polyurethane, polyamide, acrylic, vinyl polymer, polyolefin, silicone, epoxy or a combination thereof.

[0055] The heat reactive material and/or the polymer resin may comprise a flame retardant material. The flame retardant material may comprise melamine, phosphorous, metal hydroxides such as alumina trihydrate (ATH), borates, or a combination thereof. The flame retardant material may comprise brominated compounds, chlorinated compounds, antimony oxide, organic phosphorous-based compounds, zinc borate, ammonium polyphosphate, melamine cyanurate, melamine polyphosphate, molybdenum compounds, magnesium hydroxide, triphenyl phosphate, resorcinol bis- (diphenylphosphate), bisphenol-A-(diphenylphosphate), tricresyl phosphate, organophosphinates, phosphonate esters or a combination thereof. If present, the flame retardant materials may be used in a proportion of from 1 percent to 50 percent by weight, based on the total weight of the polymer resin.

[0056] In some embodiments, the laminate can be a 2-layer laminate comprising a nonwoven layer with an expandable graphite additive material, a second layer of expanded polytetrafluoroethylene and a layer of heat reactive material bonding the nonwoven layer and the expanded polytetrafluoroethylene layers.

[0057] The article can also be used as an adhesive layer in a laminate. The article can be used to adhere two of the layers of the above described laminate, wherein the article is the middle layer. Ultrasonic heating or calendaring the laminate can cause at least a portion of the nonwoven article to melt, thereby forming a bond between the layers. In some embodiments, the laminate can comprise a first layer comprising a film or a textile, a middle layer comprising the article, and a second layer independently comprising a film or a textile layer, wherein the article is sandwiched in between the first and the second layers. The article acts as the adhesive, bonding at least portions of the first and second layer together.

[0058] The present disclosure also relates to a garment comprising the laminate or the article as previously described. The garment can be a shirt, a jacket, a hat, gloves, pants, overalls, coveralls, footwear or a combination thereof.

[0059] The garment can be used as a protective garment for a wearer wherein the garment protects the wearer from serious injury as a result of an exposure to a high thermal or electrical energy exposure. If a garment comprising the article or laminate comprising the nonwoven and the intumescent material is exposed to high thermal energy, the thermoplastic material of the nonwoven can melt and the intumescent material, for example, the expandable graphite, can expand forming a plurality of tendrils comprising expanded graphite. The total surface area of the expandable graphite increases significantly when compared to the same material prior to expansion. In some embodiments, the surface area of the expandable graphite increases at least 5 times, or at least 10 times or at least 20 times. The expansion of the expandable graphite can absorb the melting thermoplastic material of the nonwoven to prevent it from dripping. If the heat exposure is high enough, the thermoplastic material can decompose and together with the expanding expandable graphite, for a char that can act as a thermal insulation, further protecting the wearer of injury. The protective ability of the garment can be increased if the barrier layer is a thermally stable barrier layer, for example, a thermally stable film or a thermally stable textile.

[0060] When used as a protective garment, the nonwoven layer comprising the intumescent material is typically the outermost layer, exposed to the outside of the exterior and a barrier layer is placed on the nonwoven layer on an interior portion of the garment closer to the wearer.

[0061] The present disclosure also relates to a nonwoven article that can be used as filter layer. The nonwoven articles can have high air permeability and can also block particulate matter from passing though. Nonwoven articles comprising activated carbon can also filter and trap vapor phase organic molecules efficiently, thus providing excellent filtering capabilities.

[0062] The present disclosure also relates to a nonwoven article that can be used in a hygienic article or as an absorbent wipe. Nonwoven articles comprising a super absorbent polymer can have high water or other liquid absorbency and can function as a wipe or as a liquid absorbing layer in a diaper, an incontinency product or a feminine hygiene product.

EXAMPLES

[0063] Melting and Thermal Stability test

[0064] The test was used to determine the thermal stability of textile materials. This test was based on thermal stability test as described in section 8.3 of NFPA 1975, 2004 Edition. The test oven was a hot air circulating oven as specified in ISO 17493. The test was conducted according to ASTM D 751 , Standard Test Methods for Coated Fabrics, using the Procedures for Blocking Resistance at Elevated Temperatures (Sections 89 to 93), with the following modifications:

[0065] Borosilicate glass plates measuring 100 mm x100 mm x 3 mm were used.

Y1 [0066] A test oven set to a temperature of 300°C, plus or minus 5 degrees centigrade was used. The specimens were allowed to cool a minimum of 1 hour after removal of the glass plates from the oven.

[0067] Any sample side sticking to glass plate, sticking to itself when unfolded, or showing evidence of melting or dripping was considered as meltable. Any sample side lacking evidence of meltable side was considered as thermally stable.

[0068] Thermo-mechanical analysis (TMA) expansion test

[0069] TMA (Thermo-mechanical analysis) was used to measure the expansion of expandable graphite particles. Expansion was tested with TA Instruments TMA 2940 instrument. A ceramic (alumina) TGA pan, measuring roughly 8 mm in diameter and 12 mm in height was used for holding the sample. Using the macroexpansion probe, with a diameter of roughly 6 mm, the bottom of the pan was set to zero. Flakes of expandable graphite about 0.1 -0.3 mm deep, as measured by the TMA probe, were put in the pan. The furnace was closed and initial sample height was measured. The furnace was heated from about 25°C to 600°C at a ramp rate of 10°C/minute. The TMA probe displacement was plotted against temperature; the displacement was used as a measure of expansion.

[0070] Furnace Expansion Test

[0071] A nickel crucible was heated in a hot furnace at 300°C for 2 minutes. A measured sample (about 0.5 g) of expandable graphite was added to the crucible and placed in the hot furnace at 300°C for 3 minutes. After the heating period, the crucible was removed from the furnace and allowed to cool and then the expanded graphite was transferred to a measuring cylinder to measure expanded volume. The expanded volume was divided by the initial weight of the sample to get expansion in cc/g units. [0072] DSC Endotherm Test

[0073] Tests were run on a Q2000 DSC from TA Instruments using T-ZERO T™ hermetic pans. For each sample, about 3 milligrams (mg) of expandable graphite were placed in the pan. The pan was vented by pressing the corner of a razor blade into the center, creating a vent that was approximately 2 mm long and less than 1 mm wide. The DSC was equilibrated at 20°C. Samples were then heated from 20°C to 400°C at 10°C/min. Endotherm values were obtained from the DSC curves. [0074] Edge Ignition Test

[0075] Samples of textiles and textile composites were tested in accordance with ASTM D6413 test standard. Samples were exposed to flame for 12 seconds. Afterflame time and char length for an average of five (5) samples were recorded. A textile composite is considered as having "no melt-drip" when no falling droplets or melt dripping is observed during or after the completion of the test.

[0076] Comparative Example A

[0077] An extruder equipped with a spinning pump and a nozzle bar (1 nozzle per mm, nozzle diameter 0.5 millimeter) and having three heating zone set at 171 °C, 189°C and 200°C was used to extrude Borealis PP granulate (available from Borealis AG, Vienna, Austria) having a melt flow index of 800. The pressure at the extruder was 4 bar and the pressure after the spinning pump was 7 bar. The polymer filament was laid down on a conveyor belt having and speed of 4 meters per minute. The distance from the nozzle to the belt was 300 mm. No additive materials were added to the nonwoven.

[0078] Example #1

[0079] An extruder equipped with a spinning pump and a nozzle bar (1 nozzle per mm, nozzle diameter 0.5 millimeter) and having three heating zone set at 171 °C, 189°C and 200°C was used to extrude Covestro Thermoplastic polyurethane granulate (available from Covestro AG, Leverkusen, Germany). The pressure at the extruder was 4 bar and the pressure after the spinning pump was 7 bar. The polymer filament was laid down on a conveyor belt having and speed of 4 meters per minute. The distance from the nozzle to the belt was 300 mm.

[0080] Particles of intumescent graphite (part number GHL PX 96/-1 , available from Georg H. Luh GmbH, Walluf, Germany) were scattered onto the nonwoven web using a brush scattering device feeding into the lay down of the nonwoven web in order to get a theoretical lay down of the particles of 30 grams/minute.

[0081] The nonwoven web was determined to have a particle content of 38 grams/meter², which was reduced to 36 grams/meter² after strong shaking, indicating that the majority of the particles were strongly entrapped into the fibers of the nonwoven web.

Claims

1. An article comprising; a) a nonwoven of one or more polymeric or thermoplastic filaments, wherein the polymeric or thermoplastic filaments have a discrete length or are essentially endless; and b) one or more additive materials, wherein the additive materials are incorporated in the one or more polymeric or thermoplastic filaments and/or the additive materials are incorporated into the nonwoven in between the one or more polymeric or thermoplastic filaments of the nonwoven forming a nonwoven composite of polymeric or thermoplastic filaments and additive materials.

2. The article of claim 1 , wherein the one or more additive material comprises intumescent material, activated carbon, sorbents, a super absorbent polymer (SAP), or a combination thereof.

3. The article of claim 2, wherein the intumescent material is expandable graphite

4. The article of any one of claims 1 to 3, wherein the additive material has an average particle size in the range of from 10 micrometers to 1000 micrometers.

5. The article of any one of claims 1 to 4, wherein the additive materials are present on the surface of the filaments.

6. The article of any one of claims 1 to 5, wherein the additive materials are present as a filler in the filaments.

7. The article of any one of claims 1 to 6, wherein the polymeric or thermoplastic filament is polyester, copolyester, polyamide, copolyamide, polycarbonate, polyether, polyurethane, melamine, a copolymer thereof, a blend thereof, or a multicomponent mixture thereof.

8. The article of any one of claims 1 to 7, wherein the nonwoven article is a meltblown nonwoven, a spunbond nonwoven, a stitchbonded nonwoven, needlepunch nonwoven, or a wet-laid nonwoven.

9. The article of any one of claims 1 to 8, wherein the article comprises in the range of from 5 to 75% by weight of the intumescent materials, based on the total weight of the article.

10. The article of any one of claims 2 or 4 to 8, wherein the additive materials are super absorbent polymers comprising one or more of polyacrylic acid, polyacrylic acid, sodium polyacrylate, acrylamide, amylopectin, cyclodextrin, gelatin, cellulose, silica gel, com cob granulate, and/or polyurethane coated com cob granulate.

11 . The article of any one of claims 1 to 10, wherein the article further comprises a flame retardant agent.

12. A laminate comprising; i) the article of any one of claims 1 to 11 , in the form of a nonwoven layer having a first side and a second side; ii) a second layer attached to one of the first side or the second side of the nonwoven layer; and iii) a layer of adhesive between the nonwoven layer and the barrier layer.

13. The laminate of claim 12, wherein the laminate further comprises a textile layer adjacent to the nonwoven layer that is opposite the second layer or wherein the textile layer is attached to the second layer on a side that is opposite the nonwoven layer.

14. The laminate of claim 11 or 12, wherein the layer of adhesive is a heat reactive material.

15. A garment comprising the article of any one of claims 1 to 11 .

16. A garment comprising the laminate of claims 12 or 13.