EP1678361B1 - Method of producing a nonwoven material - Google Patents
Method of producing a nonwoven material Download PDFInfo
- Publication number
- EP1678361B1 EP1678361B1 EP04793820A EP04793820A EP1678361B1 EP 1678361 B1 EP1678361 B1 EP 1678361B1 EP 04793820 A EP04793820 A EP 04793820A EP 04793820 A EP04793820 A EP 04793820A EP 1678361 B1 EP1678361 B1 EP 1678361B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- fibers
- web
- filaments
- continuous filaments
- weight
- Prior art date
- Legal status (The legal status 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 status listed.)
- Not-in-force
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Classifications
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- 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
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
- D04H5/03—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
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- 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
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
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- 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
- D04H13/00—Other non-woven fabrics
-
- 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
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
Definitions
- the present invention refers to a method of producing a nonwoven material, comprising forming a web of continuous filaments on a forming member and applying a wet- or foam formed fiber dispersion containing natural fibers and/or synthetic staple fibers on top of said continuous filaments, thus forming a fibrous web containing said continuous filaments and said natural fibers and/or synthetic staple fibers and subsequently hydroentangling the fibrous web to form a nonwoven material.
- Hydroentangling or spunlacing is a technique introduced during the 1970'ies, see e g CA patent no. 841 938 .
- the method involves forming a fiber web which is either drylaid or wetlaid, after which the fibers are entangled by means of very fine water jets under high pressure. Several rows of water jets are directed against the fiber web which is supported by a movable wire. The entangled fiber web is then dried.
- the fibers that are used in the material can be synthetic or regenerated staple fibers, e g polyester, polyamide, polypropylene, rayon or the like, pulp fibers or mixtures of pulp fibers and staple fibers.
- Spunlace materials can be produced in high quality to a reasonable cost and have a high absorption capacity. They can e g be used as wiping material for household or industrial use, as disposable materials in medical care and for hygiene purposes etc.
- the base material i e the fibrous material which is exerted to hydroentangling, either consists of at least two preformed fibrous layer where one layer is composed of meltblown fibers or of a "coform material" where an essentially homogeneous mixture of meltblown fibers and other fibers is airlaid on a wire and after that is exerted to hydroentangling.
- EP-A-0 308 320 it is known to bring together a web of continuous filaments with a wetlaid fibrous material containing pulp fibers and staple fibers and hydroentangle together the separately formed fibrous webs to a laminate.
- the fibers of the different fibrous webs will not be integrated with each other since the fibers already before the hydroentangling are bonded to each other and only have a very limited mobility.
- EP-A-0 938 601 discloses a method of producing a nonwoven material by hydroentangling a fiber mixture containing continuous filaments, e g meltblown and/or spunbond fibers, and other fiber.
- the method is characterized by foamforming a fibrous dispersion of natural fibers and/or synthetic staple fibers and hydroentangling together the foamed fiber dispersion with the continuous filaments for forming a composite material, in which the continuous filaments are well integrated with the rest of the fibers.
- the object of the present invention is to provide a method for producing a hydroentangled nonwoven material of a fibrous mixture of continuous filaments, e g in the form of meltblown and/or spunbond fibers and a wet- or foam formed fiber dispersion of natural fibers and/or synthetic staple fibers, in which the above problem occurring in the interface between the different process components is avoided or at least minimized.
- the web of continuous filaments is flattened out and a firm contact between the web and the forming wire, due to the surface tension of the liquid used for moistening the web, is established before it enters the zone, usually a headbox, in which the wet- or foam formed fiber dispersion is laid on top of the web of continuous filaments.
- the surface tension of the liquid used for moistening the web will cause an adhesive effect between the filament web and the forming wire.
- the fibrous web is wet-formed or foam-formed.
- a surfactant is added to the water used for moistening the web of continuous filaments.
- the fibrous web comprises between 20 and 85% by weight, preferably between 40 and 75% by weight natural fibers.
- the natural fibers as in one embodiment pulp fibers.
- the fibrous web may further contain between 5 and 50% by weight, preferably between 5 and 20% by weight synthetic or regenerated staple fibers.
- at least a major part, which means at least 50, preferably at least 70, more preferably at least 90 and most preferably at least 100% by weight of said synthetic or regenerated staple fibers have a fiber length between 3 and 7 mm.
- the content of continuous filaments in the web is suitably between 0.5 and 50% by weight, preferably between 15 and 30% by weight.
- the continuous filaments are usually in the form of spunlaid or meltblown filaments.
- Fig. 1 shows schematically an embodiment of a process for producing a hydroentangled nonwoven material according to the invention.
- the hydroentangled composite material according to the invention comprises a mixture of continuous filaments and natural fibers and/or synthetic staple fibers. These different types of fibers are defined as follows.
- the continuous filaments are fibers that in proportion to their diameter are very long, in principle endless. They can be produced by extruding a molten thermoplastic polymer through fine nozzles, whereafter the polymer will be cooled and drawn, preferably by the action of an air flow blown at and along the polymer streams, and solidified into strands that can be treated by drawing, stretching or crimping. Chemicals for additional functions can be added to the surface.
- Filaments can also be regenerated fibers produced by chemical reaction of a solution of fiber-forming reactants entering a reagent medium, for example by spinning of regenerated cellulose fibers from a cellulose xanthate solution into sulphuric acid.
- regenerated cellulose fibers are rayon, viscose or lyocell fibers.
- Continuous filaments may be in the form of spunlaid filaments or meltblown filaments.
- Spunlaid filaments are produced by extruding a molten polymer, cool and stretch to an appropriate diameter.
- the fiber diameter is usually above 10 ⁇ m, e g between 10 and 100 ⁇ m.
- Production of spunlaid filaments is e g described in US patents 4,813,864 and 5,545,371 .
- meltblown filaments are formed by means of a meltblown equipment 10, for example of the kind shown in the US patents 3,849,241 or 4,048,364 .
- the method shortly involves that a molten polymer is extruded through a nozzle in very fine streams and converging air streams are directed towards the polymer streams so that they are drawn out into continuous filaments with a very small diameter.
- the filaments can be microfibers or macrofibers depending on their dimension. Microfibers have a diameter of up to 20 ⁇ m, but usually are in the interval between 2 and 12 ⁇ m in diameter. Macrofibers have a diameter of over 20 ⁇ m, e g between 20 and 100 ⁇ m.
- thermoplastic polymers can in principle be used for producing spunlaid and meltblown filaments.
- useful polymers are polyolefins, such as polyethylene and polypropylene, polyamides, polyesters and polylactides. Copolymers of these polymers may of course also be used.
- Tow is another type of filaments, which normally are the starting material in the production of staple fibers, but which also is sold and used as a product of Its own.
- tow is produced from fine polymer streams that are drawn out and stretched, but instead of being laid down on a moving surface to form a web, they are kept in a bundle to finalize drawing and stretching.
- this bundle of filaments is then treated with spin finish chemicals, are often crimped and then fed into a cutting stage where a wheel with knives will cut the filaments into distinct fiber lengths that are packed into bales to be shipped amd used as staple fibers.
- the filament bundles are packed, with or without spin finish chemicals, into bales or boxes.
- continuous filaments will in the following be described as spunlaid fibers, but it is understood that also other types of continuous filaments, e g meltblown fibers, can be used.
- the natural fibers are usually cellulose fibers, such as pulp fibers or fibers from grass or straw. Pulp fibers are the most commonly used natural fibers and are used in the material for their tendency to absorb water and for their tendency to create a coherent sheet. Both softwood fibers and hardwood fibers are suitable, and also recycled fibers can be used, as well as blends of these types of fibers. The fiber lengths will vary from around 2-3 mm for softwood fibers and around 1-1.5 mm for hardwood fibers, and even shorter for recycled fibers.
- the staple fibers used can be produced from the same substances and by the same processes as the filaments discussed above. They may either be synthetic fibers or regenerated cellulose fibers, such as rayon, viscose or lyocell.
- the cutting of the fiber bundles is normally done to result in a single cut length, which can be altered by varying the distances between the knives of the cutting wheel.
- the fiber lengths of conventional wetlald hydroentangled nonwovens are usually in the interval 12-18 mm. However according to the present Invention also shorter fiber lengths, from about 2-3 mm, can be used.
- continuous filaments 11 in the form of spunlaid fibers are produced by extruding a molten polymer, cool and stretch to an appropriate diameter.
- the fiber diameter is usually above 10 ⁇ m, e g between 10 and 100 ⁇ m.
- meltblown fibers are formed by means of a meltblown equipment.
- the meltblown technique shortly involves that a molten polymer is extruded through a nozzle in very fine streams and converging air streams are directed towards the polymer streams so that they are drawn out into continuous filaments with a very small diameter.
- the fibers can be microfibers or macrofibers depending on their dimension.
- Microfibers have a diameter of up to 20 ⁇ m, but usually are in the interval between 2 and 12 ⁇ m in diameter.
- Macrofibers have a diameter of over 20 ⁇ m, e g between 20 and 100 ⁇ m.
- thermoplastic polymers can in principle be used for producing spunlaid and meltblown fibers.
- useful polymers are polyolefins, such as polyethylene and polypropylene, polyamides, polyesters and polylactides. Copolymers of these polymers may of course also be used.
- continuous filaments will in the following be described as spunlaid fibers, but it is understood that also other types of continuous filaments, e g meltblown fibers, can be used.
- the spunlaid fibers 11 are laid down directly on a forming wire 12 where they are allowed to form a relatively loose, open web structure in which the fibers are relatively free from each other. This is achieved either by making the distance between the spunlaying nozzle and the wire relatively large, so that the filaments are allowed to cool down before they land on the wire 12, at which their stickiness is reduced.
- the basis weight of the formed spunlaid layer should be between 2 and 50 g/m 2 and the bulk between 5 and 15 cm 3 /g.
- aqueous or a foamed fibrous dispersion 13 from a headbox 14 is laid on top of the spunlaid filaments.
- the fibers are dispersed in water, with optional additives, and the fiber dispersion is dewatered on a forming fabric to form a wet laid fibrous web.
- the foam forming technique a fibrous web is formed from a dispersion of fibers in a foamed liquid containing water and a tenside.
- the foam forming technique is described in for example GB 1,329,409 , US 4,443,297 , WO 96/02701 and EP-A-0 938 601 .
- a foam-formed fibrous web has a very uniform fiber formation.
- the spunlaid filaments and the fiber dispersion of natural fibers and/or synthetic staple fibers may be formed on the same or on different wires.
- the web of spunlaid filaments laid on the wire 12 has a rather low basis weight and Is substantially unbonded, which means that the web is very weak and has to be handled and transferred to the next forming station, the headbox 14, very gently.
- no substantial bonding means that there will be no substantial bonding effect in addition to what is caused by the surface tension of the liquid used.
- a tenside may be added in the spraybar 23 to wet the fibers.
- a further advantage of having the spunlaid filaments wetted before applying the wet- or foam formed fiber dispersion thereon is that an improved penetration of the fibers contained in the fiber dispersion is obtained, resulting in a better integration between the spunlaid filaments and the fibers from the fiber dispersion.
- a small amount of a tenside, between 0.001 and 0.1% by weight, may be added to the water used for moistening the spunlaid filaments in order to increase the wettability of the filaments.
- a relatively coarse forming wire 12 is used. This will aid in “binding” or “holding” the web of spunlaid filaments to the wire by bending up and down and conform to the topography of the wire and thus prevent it from moving when the wet- or foam formed fiber dispersion flushes down from the headbox 12 on top of the spunlaid web.
- Fibers of many different kinds and in different mixing proportions can be used for making the wet laid or foam formed fibrous web.
- pulp fibers or mixtures of pulp fibers and synthetic staple fibers e g polyester, polypropylene, rayon, lyocell etc.
- Varying fiber lengths can be used.
- relatively short staple fibers below 10 mm, preferably In the interval 2 to 8 mm and more preferably 3 to 7 mm. This is for some applications an advantage because the short fibers will more easily mix and integrate with the spunlaid filaments than longer fibers. There will also be more fiber ends sticking out form the material, which increases softness and textile feeling of the material.
- wet laying and foam forming techniques may be used.
- Long fibers can be used than what is possible with wetlaying technique.
- Long fibers, ca. 18-30 mm, may in another aspect of the invention be an advantage, since they increase the strength of the hydroentangled material in dry as well as in wet condition.
- pulp fibers As a substitute for pulp fibers other natural fibers with a short fiber length may be used, e g esparto grass, phalaris arundinacea and straw from crop seed.
- the fibrous web comprises as least between 20 and 85% by weight, preferably between 40 and 75% by weight natural fibers, for example pulp fibers.
- the fibrous web contains between 10 and 50% by weight, preferably between 15 and 30% by weight, continuous filaments, for example in the form of spunlaid or meltblown filaments.
- the fiber dispersion laid on top of the spunlaid filaments is dewatered by suction boxes (not shown) arranged under the wire 12.
- suction boxes not shown
- the wet- and foam formation benefits from an increased openness in the forming wire 12.
- the short pulp fibers and synthetic staple fibers are formed on top of the spunlaid web, which provides the necessary closeness and acts like an extra sieve for the formation of the short fibers. Also from this point of view the choice of forming wire 12 may be done from the coarse end of the available spectrum.
- the thus formed fibrous web comprising spunlaid filaments and other fibers is quite stable by the presence of the pulp fibers and/or staple fibers that will interlock the spunlaid fibers, which in their turn, reinforce the structure.
- the web is then hydroentangled In an entangling station 16 including several rows of nozzles, from which very fine water jets under high pressure are directed against the fibrous web.
- the fibrous web can before hydroentangling be transferred to a special entangling wire, which optionally may be patterned in order to form a patterned nonwoven fabric.
- the web can also prior to the transfer be hydroentangled by a first entangling station with one or more rows of nozzles in order to consolidate the web.
- a pre-entangling will nest the material to the wire, which will require a successively increasing draw in the transfer to the entangling wire.
- the fibrous web is formed and hydroentangled on the same wire 12.
- the hydroentangling may in a known manner from both sides of the fibrous material (not shown) at which a more homogeneous equilateral material is obtained.
- the forming wire 12 and/or the entangling wire 16 may of course be substituted for another appropriate forming and entangling member respectively, such as an apertured belt, an apertured drum etc.
- the spunlaid web is secured to the forming wire which is done by moistening or pre-wetting the spunlaid web.
- the formation of the whole composite material is then completed on the same wire, which can be relatively coarse.
- the material 17 After the hydroentangling the material 17 is dried and wound up. The material is then converted in a known manner to a suitable format and is packed.
- the water that has been dewatered at the forming, moistening and hydroentangling steps is preferably recirculated.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Nonwoven Fabrics (AREA)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE0302875A SE0302875D0 (sv) | 2003-10-31 | 2003-10-31 | Method of producing a nonwoven material |
PCT/SE2004/001518 WO2005042825A1 (en) | 2003-10-31 | 2004-10-21 | Method of producing a nonwoven material |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1678361A1 EP1678361A1 (en) | 2006-07-12 |
EP1678361B1 true EP1678361B1 (en) | 2012-12-19 |
Family
ID=29580176
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP04793820A Not-in-force EP1678361B1 (en) | 2003-10-31 | 2004-10-21 | Method of producing a nonwoven material |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP1678361B1 (sv) |
BR (1) | BRPI0416053A (sv) |
SE (1) | SE0302875D0 (sv) |
WO (1) | WO2005042825A1 (sv) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
RU2549869C1 (ru) * | 2014-02-25 | 2015-04-27 | Открытое акционерное общество "Композит" (ОАО "Композит") | Установка для получения нетканых материалов |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FI115512B (sv) * | 2001-11-09 | 2005-05-31 | Ahlstrom Glassfibre Oy | Förfarande och anordning för att utföra formning med skum |
US8763219B2 (en) * | 2011-05-04 | 2014-07-01 | Sca Hygiene Products Ab | Method of producing a hydroentangled nonwoven material |
RU2596105C2 (ru) | 2012-05-03 | 2016-08-27 | Ска Хайджин Продактс Аб | Способ получения гидроспутанного нетканого материала |
AU2012397883B2 (en) * | 2012-12-27 | 2016-01-14 | Sca Hygiene Products Ab | Hydroformed composite nonwoven |
US20150330004A1 (en) * | 2012-12-27 | 2015-11-19 | Sca Hygiene Products Ab | An embossed composite nonwoven web material |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4808467A (en) * | 1987-09-15 | 1989-02-28 | James River Corporation Of Virginia | High strength hydroentangled nonwoven fabric |
US4775579A (en) * | 1987-11-05 | 1988-10-04 | James River Corporation Of Virginia | Hydroentangled elastic and nonelastic filaments |
SE9703886L (sv) * | 1997-10-24 | 1999-04-25 | Sca Hygiene Paper Ab | Metod för framställning av ett nonwovenmaterial och framställt enligt metoden |
SE518035C2 (sv) * | 2000-12-18 | 2002-08-20 | Sca Hygiene Prod Ab | Metod för framställning av ett nonwovenmaterial |
JP2003064570A (ja) * | 2001-08-28 | 2003-03-05 | Nippon Petrochemicals Co Ltd | 複合不織布 |
-
2003
- 2003-10-31 SE SE0302875A patent/SE0302875D0/sv unknown
-
2004
- 2004-10-21 WO PCT/SE2004/001518 patent/WO2005042825A1/en active Application Filing
- 2004-10-21 BR BRPI0416053-3A patent/BRPI0416053A/pt active Search and Examination
- 2004-10-21 EP EP04793820A patent/EP1678361B1/en not_active Not-in-force
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
RU2549869C1 (ru) * | 2014-02-25 | 2015-04-27 | Открытое акционерное общество "Композит" (ОАО "Композит") | Установка для получения нетканых материалов |
Also Published As
Publication number | Publication date |
---|---|
BRPI0416053A (pt) | 2007-01-02 |
EP1678361A1 (en) | 2006-07-12 |
WO2005042825A1 (en) | 2005-05-12 |
SE0302875D0 (sv) | 2003-10-31 |
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