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WO2024102390A1 - Bandes non tissées fabriquées à partir de filaments multicomposants et procédé de formation de bandes non tissées - Google Patents

Bandes non tissées fabriquées à partir de filaments multicomposants et procédé de formation de bandes non tissées Download PDF

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Publication number
WO2024102390A1
WO2024102390A1 PCT/US2023/037000 US2023037000W WO2024102390A1 WO 2024102390 A1 WO2024102390 A1 WO 2024102390A1 US 2023037000 W US2023037000 W US 2023037000W WO 2024102390 A1 WO2024102390 A1 WO 2024102390A1
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WO
WIPO (PCT)
Prior art keywords
nonwoven web
polymer containing
less
containing component
polymer
Prior art date
Application number
PCT/US2023/037000
Other languages
English (en)
Inventor
Laura E. Keck
Jeffrey Krueger
Original Assignee
Kimberly-Clark Worldwide, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly-Clark Worldwide, Inc. filed Critical Kimberly-Clark Worldwide, Inc.
Publication of WO2024102390A1 publication Critical patent/WO2024102390A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape

Definitions

  • Fibers forming nonwoven webs are generally oriented in the x-y plane of the web, resulting in a nonwoven web material that is relatively thin, and lacking in loft or thickness.
  • Loft or thickness in a nonwoven web suitable for use in personal care absorbent articles promotes comfort (softness) to the user, surge management and fluid distribution to adjacent layers.
  • lofty nonwoven webs are produced using staple fibers that can be entangled or rely on pre-forming processes such as fiber crimp formed on a flat wire or drum, and postforming processes such as creping or pleating of the formed web.
  • the filaments or fibers are often crimped.
  • Multicomponent filaments may be either mechanically crimped or, if the appropriate polymers are used, naturally crimped. Difficulties have been experienced in the past, however, in producing filaments that will crimp naturally to the extent required for the particular application. Also, it has been found to be very difficult to produce naturally crimped fine filaments, such as filaments having a linear density of less than two denier. Specifically, the draw force used to produce fine filaments usually prevents or removes any meaningful latent crimp attributes that may be contained in the filaments.
  • lofty nonwoven materials with desirable combinations of physical properties have been produced, but limitations have been encountered.
  • polymeric materials such as polypropylene may have a desirable level of strength but not a desirable level of softness.
  • materials such as polyethylene may, in some cases, have a desirable level of softness but not a desirable level of strength.
  • spunbond nonwoven polymeric fabrics made from multicomponent or bicomponent filaments and fibers have been developed.
  • one component exhibits different properties than the other so that the filaments exhibit properties of the two components.
  • one component may be polypropylene which is relatively strong and the other component may be polyethylene which is relatively soft.
  • the end result is a strong yet soft nonwoven fabric.
  • use of different polymers in the multicomponent filaments can make recycling the multicomponent filaments and webs made therefrom impractical or impossible if one of the polymers is not recyclable, as it would be difficult to separate the polymers to extract the recyclable one.
  • bicomponent fibers require the use of through-air bonding, or the like, in order to maintain the fibers into a nonwoven structure. Namely, due to the use of more than one component, more strong and resistant methods, such as point bonding, cannot be utilized, as it would result in melting of the fibers utilized to improve the softness of the bicomponent fiber.
  • nonwoven web formed from a fiber having enhanced inherent crimp properties without the need for the use of separate crimping treatments (e.g . , mechanical crimping). It would also be a benefit to provide a nonwoven web formed from an inherently crimped fiber that can be easily recycled. It would yet another benefit to provide a nonwoven web formed from a crimped fibers that have undergone point bonding. In addition, it would be a benefit to provide a nonwoven web that can be recycled without sacrificing one or more of loft, softness, strength, and absorbency.
  • the present disclosure is generally directed to a nonwoven web that contains a multicomponent fiber.
  • the multicomponent fiber includes a first polymer containing component and a second polymer containing component, where the second polymer containing component includes a rapid crystallization additive, and has a solidification and/or crystallization rate that is at least about 10% or more than a solidification and/or crystallization rate of the first polymer containing component, and where the first polymer component and/or the second polymer component comprises one or more polymers having a melting temperature of at least about 130°C or greater, such as 135°C or greater, such as 140°C or greater, such as 145°C or greater, such as 150°C or greater.
  • the nonwoven web exhibits a TS7 softness value of about 6 or less, measured as an output of an EMTEC Tissue Softness Analyzer (“TSA”).
  • TSA EMTEC Tissue Softness Analyzer
  • the nonwoven web has a thickness of about 0.5 mm or greater. Additionally or alternatively, in an aspect, the nonwoven web has a thickness normalized for basis weight of about 0.015 mm per gsm (gram per square meter) or greater. In yet another aspect, the nonwoven web has a density of about 76 kg/m 3 or less, and/or has a TSA stiffness of about 3.25 mm/N or less. In one aspect, the nonwoven web exhibits a tensile peak load of about 4.5 Ibf or greater.
  • At least one of the first polymer containing component and the second polymer containing component includes greater than about 90% polypropylene by weight, based upon the weight of the respective component.
  • the multicomponent fiber includes greater than about 70% polypropylene by weight, based upon the weight of the fiber.
  • the multicomponent fibers includes greater than about 90 wt.% polypropylene, based upon a total weight of polymers present in the fiber.
  • the rapid crystallization additive is present in the second polymer containing component in an amount of about 5 wt.% to about 50 wt.%, preferably about 20 wt.% to about 30 wt.% based on the weight of the second polymer containing component.
  • the multicomponent fiber includes an average of at least about 8 crimps per cm and has a denier of about 5 or less.
  • the rapid crystallization additive has a melt flow rate (mfr) between about 81 g/10 min and about 50 g/10 min as measured at a temperature of 230 °C and a load of 2.16 kg as determined in accordance with ASTM D1238.
  • the rapid crystallization additive is a polypropylene polymer, preferably, in one aspect, wherein a polypropylene homopolymer.
  • At least one of the first polymer containing component and second polymer containing component includes 50 wt.% or more, preferably, in one aspect, from about 90 wt.% to about 100 wt.%, based upon a total weight of polymer in the respective polymer containing component, of a polymer having a melting temperature of about 130°C or more, preferably, in one aspect, wherein at least one of the first polymer containing component and second polymer containing component is generally free of polyethylene polymers or copolymers.
  • the polymer can have a melting point of about 135°C or greater, such as about 140°C or greater, such as about 145°C or greater, such as about 150°C or greater.
  • the present disclosure is also generally directed to an absorbent article including the nonwoven web according to any one or more of the above aspects.
  • the present disclosure is also generally directed to a method for forming a nonwoven web that includes: spinning a fiber having at least a first polymer containing component and a second polymer containing component, wherein the second polymer containing component contains a rapid crystallization additive, and has a solidification and/or crystallization rate that is at least about 10% or more than a solidification and/or crystallization rate of the first polymer containing component; drawing the fibers; depositing the fibers onto a forming surface; and subjecting the fibers to a high temperature bonding treatment of about 130°C or more.
  • the fibers include greater than about 70% polypropylene by weight, based upon the weight of the fiber. In yet a further aspect, the fibers include greater than about 90 wt.% polypropylene, based upon a total weight of polymers present in the fiber.
  • the multicomponent filaments are continuous or discontinuous. In yet a further aspect, the fibers include an average of at least about two crimps per cm without heat treatment. Moreover, in one aspect, the high temperature bonding treatment is thermal point bonding, and/or wherein the nonwoven web has a total bond area of less about 30% or less.
  • FIG. 1 is a schematic drawing of a process line for making an embodiment of the present invention
  • FIG. 2A is a schematic drawing illustrating the cross section of a filament made according to an embodiment of the present invention with the polymer components A and B in a side-by-side arrangement;
  • FIG. 2B is a schematic drawing illustrating the cross section of a filament made according to an embodiment of the present invention with the polymer components A and B in an eccentric sheath/core arrangement;
  • FIG. 3A is a top-down SEM photograph of Sample 1 of the examples of the present disclosure.
  • FIG. 3B is a top-down SEM photograph of Control 1 of the examples of the present disclosure.
  • FIG. 3C is a top-down SEM photograph of Control 2 of the examples of the present disclosure.
  • FIG. 3D is a top-down SEM photograph of Control 3 of the examples of the present disclosure.
  • FIG. 4A is a cross-sectional SEM photograph of Sample 1 ;
  • FIG. 4B is a cross-sectional SEM photograph of Control 1 .
  • the terms “about,” “approximately,” or “generally,” when used to modify a value, indicates that the value can be raised or lowered by 10%, such as, such as 7.5%, 5%, such as 4%, such as 3%, such as 2%, such as 1%, and remain within the disclosed aspect.
  • the term “substantially free of’ when used to describe the amount of substance in a material is not to be limited to entirely or completely free of and may correspond to a lack of any appreciable or detectable amount of the recited substance in the material.
  • a material is "substantially free of' a substance when the amount of the substance in the material is less than the precision of an industry-accepted instrument or test for measuring the amount of the substance in the material.
  • a material may be “substantially free of’ a substance when the amount of the substance in the material is less than 10%, less than 9%, less than 8%, less than 7%, less than 6%, less than 5%, less than 4%, less than 3%, less than 2%, less than 1%, less than 0.5%, or less than 0.1 % by weight of the material.
  • the term “elastomeric” and “elastic” refers to a material that, upon application of a stretching force, is stretchable in at least one direction (such as the CD or MD direction), and which upon release of the stretching force, contracts/returns to approximately its original dimension.
  • a stretched material may have a stretched length that is at least 50% greater than its relaxed unstretched length, and which will recover to within at least 50% of its stretched length upon release of the stretching force.
  • a hypothetical example would be a one (1) inch sample of a material that is stretchable to at least 1 .50 inches and which, upon release of the stretching force, will recover to a length of not more than 1 .25 inches.
  • the material contracts or recovers at least 50%, and even more desirably, at least 80% of the stretched length.
  • fibers generally refer to elongated extrudates that may be formed by passing a polymer through a forming orifice, such as a die.
  • the term “fibers” includes discontinuous fibers having a definite length (e.g., stable fibers) and substantially continuous filaments.
  • Substantially filaments may, for instance, have a length much greater than their diameter, such as a length to diameter ratio (“aspect ratio”) greater than about 15,000 to 1 , and in some cases, greater than about 50,000 to 1 .
  • the term “extensible” generally refers to a material that stretches or extends in the direction of an applied force (e.g., CD or MD direction) by about 50% or more, in some aspects about 75% or more, in some aspects about 100% or more, and in some aspects, about 200% or more of its relaxed length or width.
  • nonwoven web generally refers to a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric.
  • suitable nonwoven fabrics or webs include, but are not limited to, meltblown webs, spunbond webs, bonded carded webs, airlaid webs, coform webs, hydraulically entangled webs, and so forth.
  • meltblown web generally refers to a nonwoven web that is formed by a process in which a molten thermoplastic material is extruded through a plurality of fine, usually circular, die capillaries as molten fibers into converging high velocity gas (e.g ., air) streams that attenuate the fibers of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers.
  • high velocity gas e.g ., air
  • meltblown fibers may be microfibers that are substantially continuous or discontinuous, generally smaller than 10 microns in diameter, and generally tacky when deposited onto a collecting surface.
  • spunbond web generally refers to a web containing small diameter substantially continuous fibers.
  • the fibers are formed by extruding a molten thermoplastic material from a plurality of fine, usually circular, capillaries of a spinnerette with the diameter of the extruded fibers then being rapidly reduced as by, for example, eductive drawing and/or other well- known spunbonding mechanisms.
  • the production of spunbond webs is described and illustrated, for example, in U.S. Patent Nos.
  • Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers may sometimes have diameters less than about 40 microns, and are often between about 5 to about 20 microns.
  • coform generally refers to composite materials comprising a mixture or stabilized matrix of thermoplastic fibers and a second non-thermoplastic material.
  • coform materials may be made by a process in which at least one meltblown die head is arranged near a chute through which other materials are added to the web while it is forming.
  • Such other materials may include, but are not limited to, fibrous organic materials such as woody or non- woody pulp such as cotton, rayon, recycled paper, pulp fluff and also superabsorbent particles, inorganic and/or organic absorbent materials, treated polymeric staple fibers and so forth.
  • thermal point bonding generally refers to a process performed, for example, by passing a material between a patterned roll (e.g., calender roll) and another roll (e.g., anvil roll), which may or may not be patterned. One or both of the rolls are typically heated.
  • a patterned roll e.g., calender roll
  • anvil roll e.g., anvil roll
  • ultrasonic bonding generally refers to a process performed, for example, by passing a material between a sonic horn and a patterned roll (e.g., anvil roll). For instance, ultrasonic bonding through the use of a stationary horn and a rotating patterned anvil roll is described in U.S. Patent Nos.
  • a “mechanically crimped filament” is a filament that is crimped by activating a latent crimp contained in the filaments.
  • filaments can be mechanically crimped by subjecting the filaments to a gas, such as a heated gas, during or after being drawn or through air drying or the use of an air knife.
  • the multicomponent filaments of the present disclosure may generally refer to “inherently crimped fibers or filaments” that exhibit a high degree of crimp without the use of any additional or subsequent crimping treatments.
  • the present invention allows for simplified and less energy intensive processes for the production of highly crimped multicomponent filaments and nonwoven webs formed therefrom.
  • the present disclosure is directed to a nonwoven web that has a unique and beneficial array of properties.
  • the present disclosure has surprisingly found that by utilizing a rapid crystallization additive, fibers may be formed that are generally free of low melting point polymers that are often necessary for imparting softness.
  • the fibers can be formed from one or more polymers having a melting temperature of at least about 130°C or greater, examples of which will be discussed in greater below.
  • the melting temperature for instance, can be about 135°C or greater, such as about 140°C or greater, such as about 145°C or greater, such as about 150°C or greater.
  • the rapid crystallization additive imparts a crystallization gradient within the fiber, yielding a different crystallization and/or solidification rate between two or more components within the fiber such that the fiber can undergo inherent crimping. More particularly, the rapid crystallization additive can impart one of the fiber components with a faster solidifying and/or crystallizing rate than at least one of the polymeric components, yielding crimping properties similar to those achieved via mechanical crimping to the fiber, and also without the need for low melting temperature components.
  • nonwoven webs according to the present disclosure exhibit a unique blend of properties, such as softness and loft, without sacrificing abrasion resistance, and/or other properties.
  • nonwoven webs according to the present disclosure have excellent loft, even at low basis weights.
  • a nonwoven web according to the present disclosure has a thickness of about 0.5 millimeters (mm) or greater, such as about 0.55 mm or greater, such as about 0.6 mm or greater, such as about 0.65 mm or greater, such as about 0.7 mm or greater, up to about 1 mm or less, such as about 0 9 mm or less, such as about 0.8 mm or less, or any ranges or values therebetween.
  • a nonwoven web according to the present disclosure has a basis weight of about 50 gsm or less, such as about 47.5 gsm or less, such as about 45 gsm or less, such as about 42.5 gsm or less, such as about 40 gsm or less, such as 37.5 gsm or less, such as greater than about 25 gsm, such as greater than about 30 gsm, or any ranges or values therebetween.
  • a nonwoven web according to the present disclosure has a thickness (loft) normalized for basis weight of about 0.015 mm/gsm (grams per square meter) or greater, such as about 0.016 mm/gsm or greater, such as about 0.017 mm/gsm or greater, such as about 0.018 mm/gsm or greater, such as about 0.019 mm/gsm or greater, such as about 0.02 mm/gsm or greater, up to about 0.03 mm/gsm or less, such as about 0.028 mm/gsm or less, such as about 0.025 mm/gsm or less, or any ranges or values therebetween.
  • a nonwoven formed according to the present disclosure may also exhibit improved loft without sacrificing strength and/or softness.
  • the helical crimp of the filaments creates an open web structure with substantial void portions between filaments and the filaments are bonded at points of contact.
  • the nonwoven web of the present invention has a density of about 76 kg/m 3 or less, such as about 75 kg/m 3 or less, such as about 70 kg/m 3 or less, such as about 60 kg/m 3 or less, such as about 50 kg/m 3 or less, such as about 40 kg/m 3 or less, such as about 30 kg/m 3 or less, such as about 25 kg/m 3 or less, such as about 20 kg/m 3 or less, such as about 10 kg/m 3 or less, or any ranges or values therebetween.
  • the nonwoven according to the present disclosure also exhibits excellent softness without the use of a low melting point polymer in the fiber as discussed above.
  • a nonwoven web according to the present disclosure exhibits a TS7 value of about 6 or less, such as about 5.5 or less, such as about 5 or less, such as about 4.5 or less, such as about 4 or less, such as about 3.5 or less, such as about 3 or less, such as about 2.5 or less, or any ranges or values therebetween.
  • TS7 and “TS7 value” refer to an output of an EMTEC Tissue Softness Analyzer (“TSA”) (Emtec Electronic GmbH, Leipzig, Germany) as described in the Test Methods section.
  • TSA EMTEC Tissue Softness Analyzer
  • the units of the TS7 value are dB V 2 rms, however, TS7 values are often referred to herein without reference to units.
  • the nonwoven web according to the present disclosure also exhibits excellent stiffness.
  • a nonwoven according to the present disclosure can exhibit a stiffness of about 3.25 mm/N or less, such as about 3 mm/N or less, such as about 2.75 mm/N or less, such as about 2.5 mm/N or less, or any ranges or values therebetween.
  • the nonwoven according to the present disclosure can exhibit a cup crush total energy of about 7.5 N-mm or less, such as about 7 N-mm or less, such as about 6 N- mm or less, such as about 5 N-mm or less, such as about 4 N-mm or less, such as about 3 N-mm or less, or any ranges or values therebetween.
  • the nonwoven according to the present disclosure can exhibit a cup crush peak load of about 45 gf or less, such as about 40 gf or less, such as about 35 gf or less, such as about 30 gf or less, such as about 25 gf or less, or any ranges or values therebetween.
  • the nonwoven web according to the present disclosure may also exhibit excellent drape, such as about 4.25 cm or less, such as about 4 cm or less, such as about 3.75 cm or less, such as about 3.5 cm or less, such as about 3.25 cm or less, such as about 3 cm or less, or any ranges or values therebetween.
  • a nonwoven web according to the present disclosure also exhibits excellent abrasion resistance.
  • a nonwoven web according to the present disclosure exhibits a Martindale Abrasion rating of about 2 or more, such as about 2.5 or more, such as about 3 or more, such as about 3.5 or more such as about 4 or more, up to about 5 or less, or any ranges or values therebetween, after 25 cycles, as discussed in the test methods below.
  • the nonwoven web according to the present disclosure can exhibit a tensile peak load of about 12.5 Ibf (pounds force) or less, such as about 11 Ibf or less, such as about 10 Ibf or less, such as about 9.5 Ibf or less, such as about 9 Ibf or less, or such as about 4.5 Ibf or greater, such as about 5 Ibf or greater, such as about 6 Ibf or greater, such as about 7 Ibf or greater, such as about 8 Ibf or greater, or any ranges or values therebetween.
  • Ibf pounds force
  • the nonwoven web according to the present disclosure can exhibit a Young’s modulus of about 4000 psi or less, such as about 3500 psi or less, such as about 3000 psi or less, such as about 2500 psi or less, such as about 2000 psi or less, such as about 1500 psi or less, such as about 1000 psi or less, such as about 500 psi or less, or such as about 250 psi or more, or any ranges or values therebetween.
  • a nonwoven web according to the present disclosure may exhibit excellent intake speeds (saline uptake), such as about 7.5 seconds or less, such as about 7.25 seconds or less, such as about 7.0 seconds or less, such as about 6.75 seconds or less, or any ranges or values therebetween, as measured according the examples below.
  • the nonwoven web exhibit excellent rewet, or amount of flow back to the surface of the nonwoven web, such as about 1 .5 g or less, such as about 1 .25 g or less, such as about 1 g or less, or any ranges or values therebetween, as measured according to the examples below.
  • the nonwoven web exhibits a Lister strike-through of about 15 seconds or less, such as about 13 seconds or less, such as about 12 seconds or less.
  • the nonwoven web according to the present disclosure can exhibit an air permeability of about 475 (ft3/ft2/min) or more, such as about 485 (ft3/ft2/min) or more, such as about 495 (ft3/ft2/min) or more, such as about 500 (ft3/ft2/min) or more, such as about 510 (ft3/ft2/min) or more, such as about 520 (ft3/ft2/min) or more, such as about 530 (ft3/ft2/min) or more, such as about 1000 (ft3/ft2/min) or less, such as about 900 (ft3/ft2/min) or less, such as about 800 (ft3/ft2/min) or less, such as about 750 (ft3/ft2/min) or less, or any ranges or values therebetween.
  • the solidification and/or crystallization rate of a polymer refers to the rate at which a softened or melted polymer hardens and forms a fixed structure.
  • the solidification and/or crystallization rate of a polymer is influenced by different parameters including the melting temperature and the rate of crystallization of the polymer.
  • the inherent crimping of the fibers is due at least in part to the differences in the shrinkage properties, i.e., differences in the rates of solidification and/or crystallization, between two or more components of a multicomponent fiber.
  • the fibers according to the present disclosure may have a side-by- side, eccentric, or sheath-core arrangement, and therefore be generally referred to as “multicomponent” e.g. having at least two distinct components formed from polymer containing compositions, where the composition forming at least one component of the fiber includes a rapid crystallization additive as discussed herein.
  • multicomponent e.g. having at least two distinct components formed from polymer containing compositions, where the composition forming at least one component of the fiber includes a rapid crystallization additive as discussed herein.
  • the fibers according to the present disclosure can have an average of at least about 2 crimps per cm, such as an average of about 4 crimps per cm or more, such as an average of about 8 crimps per cm or more, such as an average of about 12 crimps per cm or more, such as an average of about 16 crimps per cm or more, such as an average of about 20 crimps per cm or more, or any ranges or values therebetween. Further, as noted above, such crimping is exhibited without mechanical intervention or further treatments.
  • the nonwoven web may have randomness or fiber orientation of about 0.35 or greater, such as about 0.4 or greater, such as about 0.5 or greater, such as about 0.6 or greater, such as about 0.7 or greater, or any ranges or values therebetween.
  • the nonwoven web may also, in one aspect, have an average height of surface of greater than about 75 micrometers, such as about 77.5 micrometers or more, such as about 80 micrometers or more.
  • the nonwoven web can also have a surface area of greater than about 7 micrometers, such as about 7.1 micrometers or more, such as about 7.2 micrometers or more, such as about 7.3 micrometers or more, such as about 7.4 micrometers or more, or any ranges or values therebetween.
  • the nonwoven web can also have a profile height of about 325 micrometers or more, such as about 350 micrometers or more, such as about 375 micrometers or more, such as about 380 micrometers or more, such as about 390 micrometers or more, or any ranges or values therebetween.
  • the fibers according to the present disclosure have denier of about 5 or less, such as bout 4.5 or less, such as about 4 or less, such as about 3.5 or less, such as about 3 or less, such as about 2.5 or less, such as about 2 or less, or, about 0.5 or greater, such as about 1 or greater, or any ranges or values therebetween.
  • the rapid crystallization additive is a polyolefin having a latent heat of fusion (AHr), which is an indicator of the degree of crystallinity, of from about 25 to about 210 Joules per gram (“J/g”), in some aspects from about 35 to about 150 J/g, in some aspects from about 50 to about 100 J/g, and in some aspects, from 60 to about 90 J/g, or any ranges or values therebetween.
  • AHr latent heat of fusion
  • the rapid crystallization additive can have one or more of the above latent heat of fusion values
  • the rapid crystallization additive has a latent heat of fusion that is about 1 .05 times the latent heat of fusion of at least one of the polymer components of the fiber, such as about 1.1 times or greater, such as about 1.15 times or greater, such as about 1 .2 times or greater, such as about 1 .25 times or greater than a latent heat of fusion of at least one of the polymer components of the multicomponent fiber.
  • the above ratios are relative to two (or more, if present) of the polymeric fiber components, and in one aspect, the ratio is relative to all of the polymeric components of the fiber.
  • the rapid crystallization additive is a polyolefin having an mfr (melt flow rate) of about 1 gram per 10 minutes to about 50 grams per 10 minutes, such as from about 2.5 grams per 10 minutes to about 40 grams per 10 minutes, such as about 5 grams per ten minutes to about 30 grams per ten minutes, such as about 7.5 grams per ten minutes to about 20 grams per ten minutes, such as about 10 grams per ten minutes to about 17.5 grams per ten minutes, or any ranges or values therebetween, at a load of 2.16 kg as determined in accordance with ASTM D1238 and a density of 0.9 g/cm 3 .
  • the latent heat ef fusion (AHt) and melting temperature may be determined using differential scanning calorimetry (“DSC”) in accordance with ASTM D-3417 as is well known to those skilled in the art.
  • the rapid crystallization additive is a polypropylene polymer, which, can, in one aspect, be a polypropylene homopolymer.
  • An example of such a polymer may be Achieve Advanced PP3684 from ExxonMobil.
  • the rapid crystallization additive is generally free of phthalates
  • the rapid crystallization additive is present in at least one of the one or more polymer containing components in an amount of about 50 wt.% or less, such as about 45 wt.% or less, such as about 40 wt.% or less, such as about 35. wt.% or less, such as about 30 wt.% or less, based upon the weight of the respective component, or any ranges or values therebetween.
  • the rapid crystallization additive is present in the entire fiber forming composition in an amount of about 25 wt.% or less, such as about 20 wt.% or less, such as about 15 wt.% or less, such as about 12.5 wt.% or less, such as about 10 wt.% or less, or any ranges or values therebetween, based upon the weight of the fiber forming composition.
  • fibers of the present disclosure are formed from continuous or discontinuous multicomponent polymeric filaments that include at least first and second polymer containing components.
  • the fibers include a bicomponent fiber, that can be continuous, that includes a first polymer containing component A and a second polymer containing component B.
  • the first and second components A and B are arranged in substantially distinct zones across the cross-section of the fiber and extend continuously along the length of the fiber in a side-by-side, eccentric, or sheath-core arrangement.
  • a fiber having two polymer containing components can be arranged such that first and second polymer containing components A and B, for example, are arranged in either a side-by-side arrangement as shown in FIG. 2A or an eccentric sheath/core arrangement as shown in FIG. 2B so that the resulting filaments exhibit an inherent helical crimp.
  • polymer containing component A is the core of the filament
  • polymer containing component B is the sheath in the sheath/core arrangement
  • a sheath/core arrangement could be achieved with B in the core and A as a sheath.
  • one of the polymer containing components exhibits one or more properties resulting in a faster solidification and/or crystallization rate than the other polymer containing component(s).
  • one of the two or more polymer containing components has a higher melting temperature than the other polymer containing component(s).
  • the rate of solidification and/or crystallization of one of the polymer containing components is about 5% faster or more than the rate of solidification and/or crystallization of the other polymer containing component(s), such as about 10% faster or more, such as at least about 15% faster or more, such as about 20% faster or more, such as about 25% faster or more, such as about 30% faster or more, such as about 40% faster or more, such as about 50% faster or more, such as about 60% faster or more, such as about 70% faster or more, such as about 80% faster or more, such as about 90% faster or more, such as about 100% faster than the rate of solidification and/or crystallization of one or more of the further polymer containing component(s).
  • one or more of the polymer containing components can include any one or more of the following polymers:
  • Exemplary semi-crystalline polyolefins include polyethylene, polypropylene, as well as their blends and copolymers thereof.
  • a polyethylene is employed that is a copolymer of ethylene and an a-olefin, such as a C3-C20 a-olefin or C3-C12 a-olefin.
  • Suitable a-olefins may be linear or branched (e.g. , one or more C1-C3 alkyl branches, or an aryl group).
  • Specific examples include 1 -butene; 3-methyl-1 -butene; 3, 3-dimethyl-1 -butene; 1 -pentene; 1 -pentene with one or more methyl, ethyl, or propyl substituents; 1-hexene with one or more methyl, ethyl, or propyl substituents; 1- heptene with one or more methyl, ethyl or propyl substituents; 1-octene with one or more methyl, ethyl or propyl substituents; 1-nonene with one or more methyl, ethyl or propyl substituents; ethyl, methyl or dimethyl-substituted 1 -decene; 1 -dodecene; and styrene.
  • a-olefin comonomers are 1- butene, 1-hexene, and 1-octene.
  • the ethylene content of such copolymers may be from about 60 mole% to about 99 mole%, in some aspects from about 80 mole% to about 98.5 mole%, and in some aspects, from about 87 mole% to about 97.5 mole%.
  • the a-olefin content may likewise range from about 1 mole% to about 40 mole%, in some aspects from about 1 .5 mole% to about 15 mole%, and in some aspects, from about 2.5 mole% to about 13 mole%.
  • the density of the polyethylene may vary depending on the type of polymer employed, but generally ranges from about 0.85 g/cm 3 to about 0.96 g/cm 3 .
  • Polyethylene "plastomers”, for instance, may have a density in the range of from 0.85 g/cm 3 to 0.91 g/cm 3 .
  • LLDPE linear low density polyethylene
  • LDPE low density polyethylene
  • HDPE high density polyethylene
  • suitable polyethylene copolymers are those that are “linear” or “substantially linear.”
  • the term “substantially linear” means that, in addition to the short chain branches attributable to comonomer incorporation, the ethylene polymer also contains long chain branches in the polymer backbone. “Long chain branching” refers to a chain length of at least 6 carbons. Each long chain branch may have the same comonomer distribution as the polymer backbone and be as long as the polymer backbone to which it is attached.
  • Preferred substantially linear polymers are substituted with from 0.01 long chain branch per 1000 carbons to 1 long chain branch per 1000 carbons, and in some aspects, from 0.05 long chain branch per 1000 carbons to 1 long chain branch per 1000 carbons.
  • the term “linear” means that the polymer lacks measurable or demonstrable long chain branches. That is, the polymer is substituted with an average of less than 0.01 long chain branch per 1000 carbons.
  • Suitable plastomers for use in the present disclosure are ethylene-based copolymer plastomers available under the designation EXACTTM from ExxonMobil Chemical Company of Houston, Texas, ENGAGETM and AFFINITYTM from Dow Chemical Company of Midland, Michigan, and olefin block copolymers available from Dow Chemical Company of Midland, Michigan under the trade designation INFUSETM, such as INFUSETM 9807.
  • a polyethylene that can be used in a fiber of the present disclosure is DOWTM 61800.41 .
  • Still other suitable ethylene polymers are available from The Dow Chemical Company under the designations DOWLEXTM (LLDPE), ASPUNTM (LLDPE), and ATTANETM (ULDPE).
  • the polymer components is/are formed from one or more ethylene or propylene polymers, such as one or more generally non- elastomeric ethylene or propylene polymers.
  • the non-elastomeric polyolefin may include generally inelastic polymers, such as conventional polyolefins, (e.g., polyethylene), low density polyethylene (LDPE), Ziegler-Natta catalyzed linear low density polyethylene (LLDPE), etc.), ultra low density polyethylene (ULDPE), polypropylene, polybutylene, etc.; polytetrafluoroethylene; polyesters, e.g ., polyethylene terephthalate (PET), etc.; polyvinyl acetate; polyvinyl chloride acetate; polyvinyl butyral; acrylic resins, e.g., polyacrylate, polymethylacrylate, polymethylmethacrylate, etc.; polyamides,
  • one or more of the polymer compoments can include an LLDPE available from Dow Chemical Co. of Midland, Mich., such as DOWLEXTM 2517 or DOWLEXTM 2047, or a combination thereof, or Westlake Chemical Corp, of Houston, Tex.
  • one or more of the polymer components may be other suitable ethylene polymers, such as those available from The Dow Chemical Company under the designations ASPUNTM (LLDPE) and ATTANETM (ULDPE). available from The Dow Chemical Company under the designations DOWLEXTM (LLDPE), ASPUNTM (LLDPE), and ATTANETM (ULDPE).
  • ASPUNTM LLDPE
  • ATTANETM UTDPE
  • Propylene polymers are also suitable for use as a semi-crystalline polyolefin.
  • Suitable plastomeric propylene polymers may include, for instance, copolymers or terpolymers of propylene include copolymers of propylene with an a-olefin (e.g., C3-C20), such as ethylene, 1 -butene, 2-butene, the various pentene isomers, 1 -hexene, 1 -octene, 1 -nonene, 1 -decene, 1 -unidecene, 1 -dodecene, 4- methyl-1 -pentene, 4-methyl-1-hexene, 5-methyl-1 -hexene, vinylcyclohexene, styrene, etc.
  • a-olefin e.g., C3-C20
  • the comonomer content of the propylene polymer may be about 35 wt.% or less, in some aspects from about 1 wt.% to about 20 wt.%, and in some aspects, from about 2 wt.% to about 10 wt.%.
  • the density of the polypropylene e.g., propylene/a-olefin copolymer
  • the density of the polypropylene may be 0.91 grams per cubic centimeter (g/cm 3 ) or less, in some aspects, from 0.85 to 0.88 g/cm 3 , and in some aspects, from 0.85 g/cm 3 to 0.87 g/cm 3 .
  • Suitable propylene-based copolymer plastomers are commercially available under the designations VISTAMAXXTM (e.g., 2330, 6202, and 6102), a propylene-ethylene copolymer-based plastomer from ExxonMobil Chemical Co. of Houston, Texas; FINATM (e.g., 8573) from Atofina Chemicals of Feluy, Belgium; TAFMERTM available from Mitsui Petrochemical Industries; and VERSIFYTM available from Dow Chemical Co. of Midland, Michigan.
  • VISTAMAXXTM e.g., 2330, 6202, and 6102
  • FINATM e.g. 8573
  • TAFMERTM available from Mitsui Petrochemical Industries
  • VERSIFYTM available from Dow Chemical Co. of Midland, Michigan.
  • Other examples of suitable propylene polymers are described in U.S. Patent No.
  • one or more of the polymers in one or more of the polymer containing components is formed from a propylene polymer and/or copolymer, such as, in one aspect, a polypropylene homopolymer.
  • the polyolefin is a propylene homopolymer or copolymer (e.g., random or block) containing about 10 wt. % or less of co-monomers (e.g., a-olefins), and in some embodiments, about 2 wt. % or less.
  • the propylene polymer may be syndiotactic or isotactic.
  • the term “syndiotactic” generally refers to a tacticity in which a substantial portion, if not all, of the methyl groups alternate on opposite sides along the polymer chain.
  • the term “isotactic” generally refers to a tacticity in which a substantial portion, if not all, of the methyl groups are on the same side along the polymer chain.
  • Such polymers are typically formed using a Ziegler-Natta catalyst, either alone or in combination with a small amount of an o-olefin co-monomer.
  • Isotactic polymers typically have a density in the range of from 0.90 to 0.94 g/cm 3 , such as determined in accordance with ASTM 1505-10.
  • propylene homopolymers may include, for instance, MetoceneTM MF650Y and MF650X (Basell Polyolefins); PP2252E1 , PP 3155 or PP 2252 (ExxonMobil); and M3661 PP (Total Refining and Chemicals).
  • MetoceneTM MF650Y and MF650X Basell Polyolefins
  • PP2252E1 PP 3155 or PP 2252
  • M3661 PP Total Refining and Chemicals
  • suitable propylene polymers may be described in U.S. Pat. No. 6,500,563 to Datta, et al.; U.S. Pat. No. 5,539,056 to Yang, et al.; and U.S. Pat. No. 5,596,052 to Resconi, et al.
  • one or more of the polymer components is formed from a propylene-based copolymer plastomers, such as a propylene-based copolymer commercially available under the designations VISTAMAXXTM (e.g., 2330, 6202, 6102, and 7050), a propylene-ethylene copolymer-based plastomer from ExxonMobil Chemical Co. of Houston, Texas; Fl NATM (e.g., 8573) from Atofina Chemicals of Feluy, Belgium; TAFMERTM available from Mitsui Petrochemical Industries; VERSIFYTM available from Dow Chemical Co. of Midland, Michigan.
  • a propylene-based copolymer plastomers such as a propylene-based copolymer commercially available under the designations VISTAMAXXTM (e.g., 2330, 6202, 6102, and 7050), a propylene-ethylene copolymer-based plastomer from ExxonMobil Chemical Co. of Houston, Texas
  • one or more of the polymers in one or more of the polymer containing components includes a spunbond grade polypropylene with no a-olefin comonomer, such as a polypropylene homopolymer, also referred to as a spunbond grade polypropylene.
  • a polypropylene homopolymer is present in one or more of the polymer containing components in an amount of about 15 wt.% or more, such as about 20 wt.% or more, such as about 25 wt.% or more, such as about 30 wt.% or more, such as about 35 wt.% or more, such as about 40 wt.% or more, such as about 45 wt.% or more, such as about 50 wt.% or more, such as about 55 wt.% or more, based upon the weight of any one or more of the polymer containing components.
  • a polypropylene homopolymer is present in an amount of about 50 wt.% or more, such as about 55 wt.% or more, such as about 60 wt.% or more, such as about 65 wt.% or more, such as about 70 wt.% or more, based upon the total weight of the fiber forming composition.
  • a polypropylene utilized in one or more of the polymer components can have a melt flow rate of about 5 to about 200 grams per 10 minutes, such as from about 15 to about 150 grams per 10 minutes, such as from about 17.5 to about 100 grams per 10 minutes, such as from about 20 grams to about 55 grams per ten minutes at 230 °C and a load of 2.16 kg as determined in accordance with ASTM D1238.
  • polypropylene co-polymers having small co-monomer amounts of ethylene may be present in one or more of the polymer containing components of the fiber forming composition.
  • the ethylene co-monomer is present in an amount of about 10 wt.% or less, such as about 7.5 wt.% or less, such as about 5 wt.% or less, such as about 2.5 wt.% or less, such as about 1 wt.% or less, such as about 0.5 wt.% or less, such as about 0.1 wt.% or less, or, in one aspect, the propylene co-polymer may be generally free of non-polypropylene monomers, such as polyethylene co-monomers, based upon the total weight of polymers in the fiber forming composition.
  • the percentage of non-polypropylene polymers can refer to polymers having a melting temperature of less than 130°C, including polypropylene homopolymers or copolymers having a melting temperature of less than 130°C.
  • a rapid crystallization additive improves the softness and crystallization of the multicomponent fiber without the use of low melting point polymers.
  • such a fiber forming composition allows the use of more temperature intensive bonding processes, such as point bonding, which will be discussed in greater detail below, allowing the nonwoven web formed from the fibers of the present disclosure to exhibit both softness and strength properties, in addition to the improved loft.
  • each of the one or more of the polymer containing components may contain a two or more, such as three or more, such as four or more, such as five or more distinct polymers.
  • each of the polymers is from the same general polyolefin class, such as, in one aspect, each of the polymers is a polypropylene polymer containing less than 10% comonomers as discussed above.
  • the polymer(s) may be generally free of comonomers, and may therefore all be homopolymers, which, as noted above, can further improve the recyclability of the nonwovens of the present disclosure.
  • olefin polymers may be formed using a free radical or a coordination catalyst (e.g., Ziegler-Natta).
  • a coordination catalyst e.g., Ziegler-Natta
  • the olefin polymer is formed from a single-site coordination catalyst, such as a metallocene catalyst.
  • a metallocene catalyst Such a catalyst system produces ethylene copolymers in which the comonomer is randomly distributed within a molecular chain and uniformly distributed across the different molecular weight fractions.
  • Metallocene-catalyzed polyolefins are described, for instance, in U.S. Patent. Nos.
  • metallocene catalysts include bis(n- butylcyclopentadienyl)titanium dichloride, bis(n-butylcyclopentadienyl)zirconium dichloride, bis(cyclopentadienyl)scandium chloride, bis(indenyl)zirconium dichloride, bis(methylcyclopentadienyl)titanium dichloride, bis(methylcyclopentadienyl)zirconium dichloride, cobaltocene, cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride, isopropyl(cyclopentadienyl,-1 -flourenyl)zirconium dichloride, molybdocene dichloride, nickelocene, niobocene dichloride, ruthenocene, titanocene dichloride, zirconocene chloride
  • metallocene catalysts typically have a narrow molecular weight range.
  • metallocene-catalyzed polymers may have polydispersity numbers (Mw/M n ) of below 4, controlled short chain branching distribution, and controlled isotacticity.
  • polymer containing component A includes a polypropylene polymer and polymer containing component B includes a polypropylene polymer
  • the ratio of the first polymer containing component (component A) to the second polymer containing component (component B) is from about 50:50 to about 90:10 by weight, such as from about 50:50 to about 65:35, or from about 50:50 to about 75:25 by weight.
  • one or more of the polymer containing components also include additional ingredients in one aspect.
  • additional ingredients are present in an amount of about 30 wt.% or less, such as about 25 wt.% or less, such as about 22.5 wt.% or less, such as about 20 wt.% or less, such as about 17.5 wt.% or less, such as about 15 wt.% or less, such as about 12.5 wt.% or less, such as about 10 wt.% or less, such as about 7.5 wt.% or less, such as about 5 wt.% or less, based upon the weight of any respective individual polymer containing component or based upon the entire weight of the fiber forming composition.
  • Suitable additional ingredients for use in the multicomponent filaments of the present invention include softness/loft enhancers, pigments, fillers, and slip aids, for example only.
  • softness/loft enhancers include softness/loft enhancers, pigments, fillers, and slip aids, for example only.
  • Other inert additives as known in the art may be included as would be understood by one having skill in the art.
  • one or more of the polymer containing components can include one or more inorganic fillers.
  • the one or more of the polymer containing components include one or more of calcium carbonate (CaCOa), various kinds of clay, silica (SO2), alumina, barium sulfate, sodium carbonate, talc, magnesium sulfate, titanium dioxide, zeolites, aluminum sulfate, cellulose-type powders, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder, cellulose derivative, polymer particles, chitin and chitin derivatives.
  • the inorganic particles may include calcium carbonate, diatomaceous earth, or combinations thereof.
  • one or more of the polymer containing components can include one or more pigment particles.
  • one or more pigment particles are included in one or more of the polymer containing components in an amount of about 0.1 % to about 5% by weight pigment particles based upon the total weight of the component, such as about 0.5% to about 4.5%, such as about 1 % to about 4%, such as about 1 .5% to about 3.5%, or any ranges or values therebetween.
  • Suitable pigments can include white pigments such as titanium dioxide and/or zinc dioxide.
  • the pigment is a white pigment such as SCC-4837, titanium dioxide, available from the Standridge Color Corporation, Social Circle, Ga.
  • Suitable softness/loft enhancers include polypropylene/polyethylene copolymers, such as Vistamaxx 7050, a polypropylene/polyethylene copolymer containing 13% by weight of ethylene and having a mass flow rate of 45 g/10 min at 230 °C and a load of 2.16 kg as determined in accordance with ASTM D1238, available from ExxonMobil and Americhem 48137, a secondary fatty acid amide, available from Americhem of Cuyahoga Falls, OH.
  • polypropylene/polyethylene copolymers such as Vistamaxx 7050, a polypropylene/polyethylene copolymer containing 13% by weight of ethylene and having a mass flow rate of 45 g/10 min at 230 °C and a load of 2.16 kg as determined in accordance with ASTM D1238, available from ExxonMobil and Americhem 48137, a secondary fatty acid amide, available from Americhem of Cuyahoga Falls, OH.
  • Suitable slip aids include primary and secondary amides.
  • the slip aid is a fatty acid amide, such as a suitable amide compound derived from the reaction between a fatty acid and ammonia or an amine-containing compound (e.g . , a compound containing a primary amine group or a secondary amine group) to yield a secondary amide.
  • the fatty acid may be any suitable fatty acid, such as a saturated or unsaturated C8-C28 fatty acid or a saturated or unsaturated C12-C28 fatty acid.
  • the fatty acid may be erucic acid (i.e., cis-13-docosenoic acid), oleic acid (i.e., cis-9- octadecenoic acid), stearic acid (octadecanoic acid), behenic acid (i.e., docosanoic acid), arachic acid (i.e., arachidinic acid or eicosanoic acid), palmitic acid (i.e., hexadecanoic acid), and mixtures or combinations thereof.
  • erucic acid i.e., cis-13-docosenoic acid
  • oleic acid i.e., cis-9- octadecenoic acid
  • stearic acid octadecanoic acid
  • behenic acid i.e., docosanoic acid
  • arachic acid i.e., arachidinic acid or e
  • the amine-containing compound can be any suitable amine-containing compound, such as fatty amines (e.g., stearylamine or oleylamine), ethylenediamine, 2,2'- iminodiethanol, and 1 ,T-iminodipropan-2-ol.
  • fatty amines e.g., stearylamine or oleylamine
  • ethylenediamine 2,2'- iminodiethanol
  • 1 ,T-iminodipropan-2-ol 1 ,T-iminodipropan-2-ol.
  • the secondary amide may be a fatty acid amide having the structure of one of Formula (l)-(lll): wherein,
  • R14, R15, R , and R are independently selected from C7-C27 alkyl groups and C7-C27 alkenyl groups, and in some aspects, C11-C27 alkyl groups and C11-C27 alkenyl groups;
  • R17 is selected from C8-C28 alkyl groups and C8-C28 alkenyl groups, and in some aspects, C12- C28 alkyl groups and C12-C28 alkenyl groups.
  • the secondary amide may also contain a mixture of two or more such fatty acid amides.
  • the secondary amide additive is erucamide, oleamide, oleyl palmitamide, ethylene bis-oleamide, stearyl erucamide, or combinations thereof.
  • the secondary amide may be a non-fatty acid amide.
  • the slip aid is present in at least one of the one or more polymer containing components in an amount between about 0.1 % and about 1 % by weight or between about 0.2% and about 0.5% based on the weight of the respective polymer containing component.
  • nonwoven webs formed according to the present disclosure are particularly useful for making various products including liquid and gas filters, personal care articles and garment materials, such as, surge layers for personal care products, acoustic and thermal insulation, packing material, padding, absorbents, filtering, and cleaning materials.
  • Personal care articles include infant care products such as disposable baby diapers, child care products such as training pants, and adult care products such as incontinence products and feminine care products.
  • Suitable garments include safety apparel, work wear, and the like.
  • the present disclosure is also generally directed to a method for forming a nonwoven web as discussed above.
  • One process for producing nonwoven webs according to the present disclosure will now be discussed in detail with reference to FIG. 1 .
  • the following process is similar to the process described in U.S. Pat. No. 5,382,400 to Pike et al., which is incorporated herein by reference in its entirety.
  • FIG 1 a process line 10 for preparing an aspect of the present disclosure is disclosed.
  • the filaments described herein can be made through either a “closed” or “open” spunbond system, as described below.
  • the process line 10 is arranged to produce bicomponent continuous fibers, but it should be understood that the present disclosure comprehends nonwoven fabrics made with multicomponent fibers having more than two components.
  • the nonwoven of the present disclosure can be made with fibers having three or four or more components as discussed above.
  • the process line 10 includes a pair of extruders 12a and 12b for separately extruding a polymer containing component A and a polymer containing component B.
  • Polymer containing component A is fed into the respective extruder 12a from a first hopper 14a and polymer containing component B is fed into the respective extruder 12b from a second hopper 14b.
  • Polymer containing component A are fed from the extruders 12a and 12b through respective polymer conduits 16a and 16b to a spinneret 18.
  • any polymers contained the respective polymer containing component can be dry mixed in the hopper or prior to incorporation into the hopper with any other additives.
  • the polymer containing component is the faster crystallizing component
  • the polymer may be dry mixed with the rapid crystallization agent, as well as any desired additives, such as slip aids, pigments, and the like, prior to extrusion.
  • a spinneret 18 includes a housing containing a spin pack which includes a plurality of plates stacked one on top of the other with a pattern of openings arranged to create flow paths for directing polymer containing components A and B separately through the spinneret.
  • the spinneret 18 has openings arranged in one or more rows. The spinneret openings form a downwardly extending curtain of filaments when the polymers are extruded through the spinneret.
  • spinneret 18 may be arranged to form side-by-side, eccentric, or sheath/core multicomponent fibers illustrated in FIGS. 2A and 2B.
  • the process line 10 also includes a quench blower 20 positioned adjacent the curtain of fibers extending from the spinneret 18. Air from the quench air blower 20 quenches the filaments extending from the spinneret 18. The quench air can be directed from one side of the filament curtain as shown FIG. 1 , or both sides of the filament curtain.
  • a fiber draw unit or aspirator 22 is positioned below the spinneret 18 and receives the quenched fibers.
  • Fiber draw units or aspirators for use in melt spinning or spunbond polymers are well- known as discussed above.
  • Suitable fiber draw units for use in the process of the present disclosure include a linear fiber aspirator of the type shown in U S Pat. No. 3,802,817 and educative guns of the type shown in U.S. Patent Nos. 3,692,618 and 3,423,266, the disclosures of which are incorporated herein by reference.
  • Deposition of the fibers is aided by an under-wire vacuum supplied by a suction box 30 that pulls down the fibers onto the forming wire 26.
  • the forming wire 26 is porous so that vertical air flow created by the suction box 30 can cause the fibers to lie down.
  • the flow rate of this air flow can be kept relatively low to enhance the tendency of the fibers to remain oriented in the MD direction.
  • the suction box can contain sections that extend in the machine direction to disrupt the vertical air flow with at the point where the fibers are laid onto the moving web, thereby allowing the fibers to have a higher degree of orientation in the machine direction.
  • the flow rate of this air flow can be kept relatively low to enhance the tendency of the fibers to remain oriented in the MD direction, however, it should be understood that, in one aspect, the fibers are not oriented in primarily the MD direction.
  • the present disclosure has found that the fibers formed according to the present disclosure can have further loft and texture by utilizing a textured forming wire. Namely, the inherent crimp and high temperature properties of the fibers allow the fibers to maintain a textured surface imparted by the textured forming wire 26.
  • the resulting fibers may then be bonded to form a consolidated, coherent nonwoven web structure.
  • Any suitable bonding technique may generally be employed in the present disclosure, such as adhesive or autogenous bonding (e.g. , fusion and/or self-adhesion of the fibers without an applied external adhesive).
  • Autogenous bonding for instance, may be achieved through contact of the fibers while they are semi-molten or tacky, or simply by blending a tackifying resin and/or solvent with polymer composition used to form the fibers.
  • Suitable autogenous bonding techniques may include ultrasonic bonding, thermal bonding, through-air bonding, and so forth.
  • Thermal point bonding typically employs a nip formed between two rolls, at least one of which is patterned.
  • Ultrasonic bonding typically employs a nip formed between a sonic horn and a patterned roll.
  • the fibers according to the present disclosure are particularly suited for high temperature bonding methods, such as thermal point bonding.
  • the present disclosure has surprisingly found that the combination of rapid crystallization additive and high melt temperature polymer(s) allows a nonwoven according to the present disclosure to be thermal point bonded without melt damage to the web.
  • the nonwoven web according to the present disclosure may be subjected to a high temperature bonding process, such as thermal point bonding, such that the nonwoven web exhibits improved abrasion resistance and strength as compared to low temperature bonding applications, such as through air bonding, in addition to the beneficial properties already discussed.
  • bonding pattern can vary as desired.
  • One suitable bond pattern for instance, is known as an "S-weave” pattern and is described in U.S. Patent No.
  • a bond pattern may also be employed that contains bond regions that are generally oriented in the machine direction and have an aspect ratio of from about 2 to about 100, in some aspects from about 4 to about 50, and in some aspects, from about 5 to about 20.
  • the pattern of the bond regions is also generally selected so that the nonwoven web has a total bond area of less than about 50% (as determined by conventional optical microscopic methods), and in some aspects, about 30% or less, such about 25% or less, such as about 20% or less, such as about 17.5% or less, such about 15% or less, such as about 12.5% or less, such as about 10% or less, or any ranges or values therebetween, in one aspect.
  • the process line 10 further includes a bonding apparatus such as thermal point bonding rollers 34 (shown in phantom) or a through-air bonder 36.
  • a bonding apparatus such as thermal point bonding rollers 34 (shown in phantom) or a through-air bonder 36.
  • Thermal point bonders and through-air bonders are well-known to those skilled in the art and are not disclosed here in detail.
  • the through-air bonder 36 includes a perforated roller 38, which receives the web, and a hood 40 surrounding the perforated roller.
  • the process line 10 includes a winding roll 42 for taking up the finished fabric.
  • the fabric of the present invention may be treated with conventional surface treatments or contain conventional polymer additives to enhance the wettability of the fabric.
  • the fabric of the present invention may be treated with polyalkylene-oxide modified siloxanes and silanes such as polyalkylene-oxide modified polydimethyl-siloxane as disclosed in U.S. Pat. No. 5,057,361. Such a surface treatment enhances the wettability of the fabric.
  • the spunbond web may also be subjected to one or more additional post-treatment steps as is known in the art.
  • the spunbond web may be stretched in the cross-machine direction using known techniques, such as tenter frame stretching, groove roll stretching, etc.
  • the spunbond web may also be subjected to other known processing steps, such as aperturing, heat treatments, etc.
  • the spunbond web formed according to the present disclosure may form all or a part of a nonwoven facing of a composite.
  • the nonwoven facing may contain additional layers (e.g., nonwoven webs, films, strands, etc.) if so desired.
  • the facing may contain two (2) or more layers, and in some aspects, from three (3) to ten (10) layers (e.g., 3 or 5 layers).
  • the nonwoven facing may contain an inner nonwoven layer (e.g., meltblown or spunbond) positioned between two outer nonwoven layers (e.g., spunbond).
  • the inner nonwoven layer may be formed from the spunbond web of the present disclosure and one or both of the outer nonwoven layers may be formed from the spunbond web of the present disclosure or a conventional nonwoven web.
  • the inner nonwoven layer may be formed from the spunbond web of the present disclosure or a conventional nonwoven web and one or both of the outer nonwoven layers may be formed from the spunbond web of the present disclosure.
  • the facing may have other configurations and possess any desired number of layers, such as a spunbond-meltblown-meltblown- spunbond (“SMMS”) laminate, spunbond-meltblown (“SM”) laminate, etc.
  • SMMS spunbond-meltblown-meltblown- spunbond
  • SM spunbond-meltblown
  • the nonwoven facing may be used in a laminate by laminating the nonwoven facing to an elastic film or other backing, or any other layer as discussed above. Lamination may be accomplished using a variety of techniques, such as by adhesive bonding, thermal point bonding, ultrasonic bonding, etc.
  • the particular bond pattern is not critical to the present disclosure, and any bond pattern, aperture forming, and stretching discussed above in regards to the spunbond web may also be employed for lamination.
  • a stretch ratio of about 1.5 or more, or 2 to 6 or 2.5 to 7.0, or 3.0 to 5.5, is used to achieve the desired degree of tension in the film during lamination
  • the stretch ratio may be determined by dividing the final length of the film by its original length.
  • the stretch ratio may also be approximately the same as the draw ratio, which may be determined by dividing the linear speed of the film during lamination (e.g., speed of the nip rolls) by the linear speed at which the film is formed (e.g., speed of casting rolls or blown nip rolls).
  • the spunbond web may be used in a wide variety of applications.
  • the spunbond web may be used in an absorbent article.
  • An “absorbent article” generally refers to any article capable of absorbing water or other fluids.
  • absorbent articles examples include, but are not limited to, personal care absorbent articles, such as diapers, training pants, absorbent underpants, incontinence articles, feminine hygiene products (e.g., sanitary napkins, pantiliners, etc.), swim wear, baby wipes, and so forth; medical absorbent articles, such as garments, fenestration materials, underpads, bedpads, bandages, absorbent drapes, and medical wipes; food service wipers; clothing articles; and so forth, and may be uniquely situated for wearable articles due to its improved garment-like feel.
  • personal care absorbent articles such as diapers, training pants, absorbent underpants, incontinence articles, feminine hygiene products (e.g., sanitary napkins, pantiliners, etc.), swim wear, baby wipes, and so forth
  • medical absorbent articles such as garments, fenestration materials, underpads, bedpads, bandages, absorbent drapes, and medical wipes
  • food service wipers clothing articles; and so forth, and may be
  • absorbent articles include a substantially liquid- impermeable layer (e.g., outer cover), a liquid-permeable layer (e.g., bodyside liner, surge layer, etc.), and an absorbent core.
  • a substantially liquid- impermeable layer e.g., outer cover
  • a liquid-permeable layer e.g., bodyside liner, surge layer, etc.
  • an absorbent core e.g., a substantially liquid- impermeable layer (e.g., outer cover), a liquid-permeable layer (e.g., bodyside liner, surge layer, etc.), and an absorbent core.
  • the nonwoven according to the present disclosure may be suitable for any one or more liquid-permeably layers.
  • TS7 and TS750 values were measured using an EMTEC Tissue Softness Analyzer (“TSA”) (Emtec Electronic GmbH, Leipzig, Germany)
  • TSA comprises a rotor with vertical blades which rotate on the test piece applying a defined contact pressure. Contact between the vertical blades and the test piece creates vibrations, which are sensed by a vibration sensor. The sensor then transmits a signal to a PC for processing and display. The signal is displayed as a frequency spectrum.
  • TSA Emtec Electronic GmbH, Leipzig, Germany
  • the first frequency analysis is performed in the range of approximately 200 Hz to 1000 Hz, with the amplitude of the peak occurring at 750 Hz being recorded as the TS750 value.
  • the TS750 value represents the surface smoothness of the sample. A high amplitude peak correlates to a rougher surface.
  • a second frequency analysis is performed in the range from 1 to 10 kHZ, with the amplitude of the peak occurring at 7 kHz being recorded as the TS7 value.
  • the TS7 value represents the softness of sample. A lower amplitude correlates to a softer sample.
  • Both TS750 and TS7 values have the units dB V 2 rms.
  • the samples were measured in an environment having 50% relative humidity and at 22 °C.
  • the rotor is initially loaded against the sample to a load of 100 mN. Then, the rotor is gradually loaded further until the load reaches 600 mN. As the sample is loaded the instrument records sample displacement (pm) versus load (mN) and outputs a curve over the range of 100 to 600 mN.
  • the modulus value “E” is reported as the slope of the displacement versus loading curve for this first loading cycle, with units of mm displacement/N of loading force.
  • the instrument After the first loading cycle from 100 to 600 mN is completed, the instrument reduces the load back to 100 mN and then increases the load again to 600 mN for a second loading cycle.
  • the slope of the displacement versus loading curve from the second loading cycle is called the “D" modulus value.
  • the softness of a sample may also be measured according to the “cup crush” test according to WSP Standard Test No. 402.0 (09), which evaluates softness by measuring the peak load (“cup crush load”) that is required for a straight shaped foot (15mm diameter, model 12) to crush a sample (153mm x 153 mm) into an inverted cup shape while the cup-shaped sample remains surrounded by a forming cup/cylinder (approximately 58 mm tall with a 35 mm diameter) to maintain uniform deformation. An average of 5 readings is used. The foot and cup are aligned to avoid contact between the cup walls and the foot which could affect the readings.
  • the peak load is measured while the foot is descending at a rate of about 380 mm per minute and is measured in grams.
  • the cup crush test also yields a value for the total energy required to crush a sample (the cup crush energy), which is the energy from the start of the test to the peak load point, i.e. the area under the curve formed by the load in grams on the one axis and the distance the foot travels in millimeters on the other. Cup crush energy is therefore reported in g*mm. Lower cup crush values indicate a softer material.
  • One suitable device for measuring cup crush is a model FTD-G-500 load cell (500 gram range) available from the Schaevitz Company of Pennsauken, N.J.
  • the sample (3” CD x 6” MD) was held between grips having a front and back face measuring 25.4 millimeters x 76 millimeters.
  • the grip faces were rubberized, and the longer dimension of the grip was perpendicular to the direction of pull.
  • the grip pressure was pneumatically maintained at a pressure of 60 pounds per square inch.
  • the tensile test was run at a 305-mi Hi meter per minute rate with a gauge length of 76 millimeters and a break sensitivity of 65%.
  • Air Permeability was measured in cubic feet of air per minute passing through a 38 square cm area (circle with 7 cm diameter) using a Textest FX3300 air permeability tester manufactured by Textest Ltd., Zurich, Switzerland. All tests were conducted in a laboratory with a temperature of 23 ⁇ 2° C. and 50 ⁇ 5% relative humidity. Specifically, a nonwoven sheet is allowed to dry out and condition for at least 12 hours in the 23 ⁇ 2° C. and 50 ⁇ 5% relative humidity laboratory before testing. The nonwoven sheet is clamped in the 7 cm diameter sheet test opening and the tester is set to a pressure drop of 125 Pa. Placing folds or crimps above the fabric test opening is to be avoided if at all possible. The unit is turned on by applying clamping pressure to the sample. The air flow under the 125 Pa pressure drop is recorded after 15 seconds of airflow to achieve a steady state value.
  • the Lister test is used to determine the liquid strike-th rough time of a test sample of nonwoven fabric.
  • the strike-through time is the time taken by a specified amount of liquid to be absorbed in the nonwoven fabric.
  • One suitable test procedure is the EDANA test No. 150.9-1 (liquid strike-through time test).
  • a 4 inch by 4 inch (10.2 cmx10.2 cm) sample of the selected nonwoven fabric material is weighed and placed on a 4 inch by 4 inch (10.2 cmx10.2 cm) assembly of 5-ply filter paper, type ERT FF3 (available from: Hollingsworth and Vose Co., East Walpole, Mass.).
  • the sample assembly is then placed under a Lister tester.
  • a suitable Lister tester is available from W.
  • a strike-through plate is employed for the testing, and is positioned over the test sample and under the Lister test equipment.
  • a 5 mL amount of 0.9% saline is delivered onto the sample assembly.
  • the time to absorb the liquid is measured automatically by the Lister testing equipment and displayed.
  • a new 5-ply blotter assembly is quickly placed underneath the nonwoven sample within 20 seconds, and the 5 mL delivery of saline is repeated.
  • the 5 mL delivery of liquid is performed 5 times on the selected nonwoven sample, and each strike-through time is recorded.
  • the sample is weighed again after the sequence of 5 tests. For a given nonwoven fabric sample, the 5-sequence test is repeated five times, and the results are averaged to provide the strike-through time of the material.
  • the Cusick drape test can be performed using any suitable drape tester to obtain a drape coefficient.
  • Commercially available drape testers include TF118 tester marked by Testex of Dongguam, China or Model 665 drape tester marketed by James H Heal & Co of Suite, England.
  • the drape test can be tested in accordance with ISO Test 9073-9 (2008).
  • This test can measure the relative resistance of a sample to abrasion according to Worldwide Strategic Partners (“WSP”) Standard Test No. 20.5 (08).
  • WSP Worldwide Strategic Partners
  • a circular specimen of 165 mm ⁇ 6.4 mm in diameter with an area of 18,258 sq mm is subjected to a requested number of cycles (10 or 60) with an abradant under a pressure of 9 kilopascals (kPa).
  • the abradant is a 36 inch by 4 inch by 0.05 thick silicone rubber wheel reinforced with fiberglass having a rubber surface hardness 81A Durometer, Shore A of 81 ⁇ 9.
  • the specimen is examined for the presence of surface fuzzing (fiber lofting), pilling (small dumps of fibers), roping, delamination or holes and assigned a numerical rating of 1 , 2, 3, 4, or 5 based on comparison to a set of standard photographs similarly numbered, with “1” showing the greatest wear and “5” the least.
  • the test is carried out with a Martindale Wear and Abrasion Tester such as Model No. 103 or 403 from James H. Heal & Company, Ltd of West Yorkshire, England.
  • Topographical maps were obtained of the surface of each spunbond web sample (10 mm by 10 mm portions of each sample) utilizing a confocal microscope (Keyence VK-X160K 3D Laser Confocal Microscope using the VKViewer software supplied with the microscope by Keyence). A background plane was subtracted from each map in order to flatten each map and correct for any tilt in samples. The data analysis was performed using the Multi FileAnalyze software provided by Keyence. The corrected maps were utilized in accordance with ISO Procedure 25178 and surface roughness measurements to calculate:
  • Sa -Average mean height of the surface in micrometers
  • Sq -Root mean square (RMS) surface height in micrometers
  • Str -Surface texture ratio (expressed as a unitless value) -indicates the uniformity of the surface texture (Str. Ranges from 1 for an isotropic surface to 0 for an oriented surface (i.e. a brushed surface))
  • Profile height analysis Two lines were drawn across each map and the height profile of the surface along that line was extracted. The height between the lower portion of the profile and the higher portion of the profile was measured.
  • the Keyence software was used to isolate the bottom 10% of each topographic map and the average height of this area calculated.
  • the Keyence software was used to isolate the top 10% of each topographic map and the average height of this area calculated.
  • the Cradle Test replicates real-life positioning of a garment on a wearer, and can be used to determine intake rates, flowback, and fluid distribution of a garment.
  • This method uses a slotted cradle, as shown in Figs. 4b and of US Patent No. 6,727,404, both made up of a water-resistant material such as acrylic plastic and simulating body curvature of a wearer.
  • the cradle (for diapers, etc.) has an overall length of 305 mm, a side-to-side width of 350 mm in the slot direction and a height of 255 mm (including 57 mm height below the slot). Material used in the construction varies in thickness from 6 mm to 12 mm.
  • the cradle has a 6 mm wide slot at the lowest point which runs the length of the cradle.
  • the curvature of the cradle is formed by a 60-degree angle.
  • test fluid 0.9 w/v% saline solution
  • Test fluid amount will be 50 ml for adult care products or 85 ml for baby diaper products.
  • the hose end or nozzle should have an exit diameter of 0.125 inches.
  • C. Position the specimen, liner/inside side up, with the "pre-marked" center of the product lined up with and touching the lowest point in the cradle. The entire length of the outer cover/outside of the product should make contact with the cradle. Clip or otherwise attach the product to the cradle at the front and back waist edges to keep it in place. Gently pull on the fron t/back waist of the specimen to smooth out any wrinkles or creases in the product. For the cradle testing, all product codes will be insulted at a point 95 mm forward from the center of the product. D. Hold the nozzle above the target area and perpendicular to the specimen. The bottom of the nozzle should be within 5 to 10 mm from the specimen.
  • Flowback is the amount of unabsorbed fluid after the third insult. More specifically, it is defined as the amount of fluid that can be absorbed from an insulted specimen onto a blotter as it is subjected to a predetermined vacuum pressure for a specified amount of time.
  • Nonwoven webs were made according to the present disclosure as shown in Table 1 :
  • A Polypropylene homopolymer, an example of which is available as 3155 from Exxon Mobile
  • Titanium dioxide particles in a polypropylene carrier resin 50 wt.% Titanium dioxide particles in a polypropylene carrier resin, an example of which is available from
  • the nonwoven webs were also formed into liners and incorporated as a liner over a surge layer, and subjected to various testing, as illustrated in Tables 3 to 5.
  • SEM photographs showing the crimp and irregularity of each code is illustrated in Figs. 3A to 3D.
  • Absorbent articles were constructed from the liner and surge layer.
  • Tables 3 and 4 below the absorbent article was tested for absorbency characteristics.
  • the absorbent article contained an 80 gsm nonwoven absorbent structure containing superabsorbent particles and included a 74 mm x 178 mm surge layer.
  • Table 3 displays the results of the Cradle Test as described above.
  • the samples were also subjected to micro-CT and image analysis to determine percent porosity and projection height.
  • a Bruker SKYSCAN 1272 Micro-CT was used to x-ray scan the samples under the following conditions:
  • Image pixel size 10.0 urn
  • NRECON software was used to reconstruct the x-ray images into cross-sections.
  • DATAVIEWER software was then used to extract a minimum of five transaxial view images per code. These images were then analyzed via the image analysis algorithm ‘Z-Projection Height (Micro-CT Slices)-1 ’ to arrive at the results presented below. A minimum of 12 measurements were made per code.
  • CTAn software was used to acquire the 3D micro-CT results. The following results were obtained: Table 6

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

La divulgation concerne des bandes non tissées formées à partir de fibres comprenant au moins deux composants contenant un polymère, ainsi que des procédés de formation de telles bandes non tissées. Les fibres contiennent un additif de cristallisation rapide qui peut augmenter le taux de cristallisation et/ou de solidification du composant contenant un polymère respectif. L'utilisation de l'additif de cristallisation rapide dans l'un des composants polymères des filaments multicomposants permet de réduire ou d'éliminer les polymères à basse température, généralement nécessaires pour conférer de la souplesse, tout en maintenant la souplesse et la résistance du non-tissé.
PCT/US2023/037000 2022-11-11 2023-11-08 Bandes non tissées fabriquées à partir de filaments multicomposants et procédé de formation de bandes non tissées WO2024102390A1 (fr)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020098764A1 (en) * 1997-09-30 2002-07-25 Mleziva Mark M. Crimped multicomponent filaments and spunbond webs made therefrom
US20030059612A1 (en) * 2001-05-10 2003-03-27 Eun-Lai Cho Polyester multifilament yarn
WO2017091669A1 (fr) * 2015-11-25 2017-06-01 Dow Global Technologies Llc Filaments bicomposants
US20190145032A1 (en) * 2017-11-13 2019-05-16 Berry Global, Inc. Multi-component fibers with improved inter-component adhesion
US20200102672A1 (en) * 2018-09-28 2020-04-02 Berry Global, Inc. Self-crimped multi-component fibers and methods of making the same

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020098764A1 (en) * 1997-09-30 2002-07-25 Mleziva Mark M. Crimped multicomponent filaments and spunbond webs made therefrom
US20030059612A1 (en) * 2001-05-10 2003-03-27 Eun-Lai Cho Polyester multifilament yarn
WO2017091669A1 (fr) * 2015-11-25 2017-06-01 Dow Global Technologies Llc Filaments bicomposants
US20190145032A1 (en) * 2017-11-13 2019-05-16 Berry Global, Inc. Multi-component fibers with improved inter-component adhesion
US20200102672A1 (en) * 2018-09-28 2020-04-02 Berry Global, Inc. Self-crimped multi-component fibers and methods of making the same

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