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
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4326—Condensation or reaction polymers
  • D04H1/435—Polyesters
• • 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
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
• • 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
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
  • D04H1/645—Impregnation followed by a solidification process

Definitions

• Carboxylated styrene-butadiene latices were originally proposed as binders for paper coating compositions. Such latices have been sold from the mid 1950's to the present time.
• a latex of a polymer of a monocarboxylic acid monomer, styrene and butadiene with a specific composition has enhanced properties as a binder for webs of synthetic fibers.
• Such latices impart satisfactory wet tensile strength in both the machine direction and across the machine direction.
• the present invention provides product web and a method of manufacturing a non-woven web of synthetic fiber(s), characterised by consolidating (optionally impregnating) the web (optionally a dry web) with a binder (optionally a sole binder) substantially comprising a polymer or a latex, provided by polymerizing:
• the polymer is polymerized from a monomeric mixture comprising from about 57 to about 59 parts by weight of a monoaromatic vinyl or vinylidene monomer; from about 38 to about 40 parts by weight of a C 4-6 conjugated diolefin; and from about 2 to about 4 parts by weight of a C 3-6 ethylenically unsaturated monocarboxylic acid monomer.
• the preferred monomeric mixture comprises about 58 parts by weight of the monoaromatic vinyl or vinylidene monomer; about 39 parts by weight of a C 4-6 conjugated diolefin; and about 3 parts by weight of a C 3-6 ethylenically unsaturated monocarboxylic acid.
• the solids content of the latex binder be as high as possible to minimize the water which must be removed from the non-woven web.
• the latex may be compounded with conventional antioxidants, optical brighteners and fillers. The use of such compounding agents is well known to those skilled in the art.
• the compound may then be diluted or concentrated to achieve a solids content sufficient to consolidate the web. Examples of solids contents for the latex, or a compound of the latex, range from about 2.5 to about 55 weight per cent.
• Examples of monoaromatic vinyl or vinylidene monomers are styrene and styrene derivatives substituted in the aromatic ring or in the vinyl radical by a C 1-4 alkyl radical.
• Some derivatives are d-methyl styrene, p-methyl styrene, and p-tertiary butyl styrene.
• C 4-8 conjugated diolefins are well known to those skilled in the art, e.g. butadiene and isoprene.
• the ethylenically unsaturated monocarboxylic acid monomer contains from three to six carbon atoms. Some monomers are acrylic acid, methacrylic acid, crotonic acid, 2 pentenoic acid, 3 pentenoic acid, and hexenoic acid. The most commonly available acids are acrylic and methacrylic acid.
• the polymer may be prepared by conventional emulsion polymerization techniques which are well known to those skilled in the art.
• Aqueous monomeric emulsion(s) are prepared using surfactants which may be anionic or a mixture of anionic and nonionic surfactants.
• the emulsion is polymerized at temperatures up to about 85 0 C using redox or peroxide initiator systems.
• the polymerization may be conducted to a high conversion. Chain transfer agents and electrolytes may be present during polymerization.
• the resulting base latex is then stripped of residual monomer and compounded with conventional additives such as bactericide, fungicide, electrolytes, antioxidants and surfactants.
• the various ingredients used in polymerizing the base latex and compounding the final latex should be selected on the bases of minimizing irritation to the skin.
• the resulting finished latex may be used per se as a sole binder or in combination with other known cobinders in e.g. saturating a web of non-woven synthetic fibers.
• the synthetic non-woven web is then impregnated (e.g. saturated)with the latex or compound.
• Some methods are saturation, spraying, printing, foam bonding, etc.
• excess latex or compound may be removed from the web by passing the impregnated web through squeeze rolls. The web is then dryed in a drying tunnel.
• the amount of latex or compound used to impregnate the web is expressed as the percentage of the weight of latex or compound solids taken into the weight of the web.
• web impregnation levels range from about 15 per cent to about 75 per cent.
• a preferred level of web impregnation is about 30 to about 50 per cent.
• polyesters There are many types of synthetic fibers which may be used to make the web. Some synthetic fibers are polyesters, polyamides and regenerated cellulose fibers. Polyesters are preferred.
• a series of latices was prepared with a fixed ratio of styrene to butadiene,and 3 parts per hundred parts of monomer of an acid or a mixture of an acid and an acid anhydride.
• the resulting latices were used to impregnate a polyester web weighing 1.0 oz/sq.yd (0.034 kg/sq.metre) at about 30 per cent latex solids. Measurements were made of the wet tensile strength of the web in the machine direction (MD) and across the machine direction (CMD). The results are set forth in the following table.
• the latices were compared with commercially available carboxylated styrene-butadiene latices and acrylic latices used as impregnants for non-woven polyester webs (1 oz/sq.yd.) (0.034 kg/sq. metre).
• the amount of latex used is expressed as the percentage of latex solids in the web relative to the weight of the unimpregnated web. Measurements were made of the tensile strength and elongation of the web in the machine direction and across the machine direction. The results are set forth in Table II.
• a polyester web (1.4 oz./sq.yd.) (0.047 kg/sq.metre) was saturated with compounds of latices having the following polymeric composition: and a commercially available acrylic latex.
• a series of latexes was prepared from styrene, butadiene and methacrylic acid.
• the latices were used to impregnate a polyester web weighing 0.7 oz/sq.yd. (0.024 kg/sq.metre).
• the properties of the latex and the impregnated web are set forth in Table IV.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Dispersion Chemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Reinforced Plastic Materials (AREA)
• Nonwoven Fabrics (AREA)

Applications Claiming Priority (2)

Publications (2)

Family

ID=4125329

Family Applications (1)

Country Status (2)

Cited By (129)

Citations (7)

• 1984
  • 1984-05-23 EP EP84303485A patent/EP0149880A3/de not_active Withdrawn
  • 1984-05-24 ES ES532753A patent/ES8603600A1/es not_active Expired

Patent Citations (7)

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