EP2861791B1 - Tissu non tissé lissé et procédés de fabrication - Google Patents

Tissu non tissé lissé et procédés de fabrication Download PDF

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Publication number
EP2861791B1
EP2861791B1 EP13728231.5A EP13728231A EP2861791B1 EP 2861791 B1 EP2861791 B1 EP 2861791B1 EP 13728231 A EP13728231 A EP 13728231A EP 2861791 B1 EP2861791 B1 EP 2861791B1
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Prior art keywords
nonwoven fabric
recited
nonwoven
roll
smooth roll
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EP13728231.5A
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German (de)
English (en)
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EP2861791A1 (fr
Inventor
Mithun A. SHAH
Rongguo Zhao
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Ahlstrom Corp
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Ahlstrom Corp
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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
    • 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
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C15/00—Calendering, pressing, ironing, glossing or glazing textile fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C7/00—Heating or cooling textile fabrics
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/626—Microfiber is synthetic polymer

Definitions

  • This disclosure generally relates to fabrics (e.g., webs or web laminates) made of thermoplastic fibers or filaments.
  • this disclosure relates to nonwoven-fabrics such as such as those produced by melt spinning thermoplastic material.
  • nonwoven fabric means a web of individual fibers, filaments, or threads that are positioned and oriented in a random manner (i.e., without an identifiable pattern).
  • nonwoven fabrics include meltblown webs, spunbond webs, carded webs, air-laid webs, wet-laid webs and spunlaced webs and composite webs comprising two or more nonwoven layers.
  • spunbonding means a process in which filaments are formed by extruding molten thermoplastic polymer material from a plurality of fine capillaries of a spinneret, with the diameter of the extruded filaments then being rapidly reduced by drawing.
  • Spunbond nonwoven fabrics or webs are formed by laying spunbond filaments randomly on a collecting surface such as a foraminous screen or belt.
  • Spunbond webs can be bonded by methods known in the art such as hot-roll calendering, through air bonding (generally applicable to multiple component spunbond webs), or passing the web through a saturated-steam chamber at an elevated pressure.
  • bicomponent fiber refers to any fiber or filament (i.e., continuous or discontinuous) that is composed of two distinct polymers which have been spun together to form a single filament or fiber.
  • each bicomponent fiber is made from two distinct polymers arranged in distinct substantially constantly positioned zones across the cross section of the bicomponent fiber and extending substantially continuously along the length of the fiber.
  • Continuous bicomponent fibers are fibers produced by extruding two polymers from the same spinneret with both polymers contained within the same filament.
  • the structure of a bicomponent fiber can be classified as core and sheath, side by side, tipped, microdenier, mixed fibers, etc.
  • a sheath-core bicomponent fiber comprises a core made of one thermoplastic material and a sheath made of a different thermoplastic material.
  • the core can be concentric or eccentric relative to the sheath and can have the same or a different shape compared to that of the sheath.
  • the sheath-core structure is employed when it is desirable for the surface of the fiber to have the property of the sheath such as luster, dyeability or stability, while the core may contribute to strength, reduced cost and the like.
  • Nonwoven webs can be thermally bonded using methods known in the art, including point or pattern bonding.
  • Point or pattern bonding typically comprises the application of heat and pressure at discrete areas of the web, e.g., by passing the web through a nip formed by a patterned roll and a smooth roll or by two patterned rolls. One or both of the rolls can be heated to thermally bond the nonwoven web at distinct points, lines, areas, etc.
  • a nonwoven fabric or web can be thermally point bonded at a plurality of spaced thermal bond points.
  • thermal pattern bonding refers to a process that involves passing a nonwoven fabric or web through a nip formed by a heated engraved roll and a cooperating heated smooth anvil roll.
  • roll configurations e.g., the single pass, double pass, S-wrap and three-stack idler roll configurations are well known in the art.
  • Nonwoven fabrics are useful for a wide variety of applications such as surgical blankets, diapers, feminine hygiene products, towels, recreational or protective fabrics and geotextiles. In many of these applications, it is necessary for one or both surfaces of the nonwoven fabric to be abrasion resistant.
  • nonwoven fabric is passed through a nip formed by two calender rolls. Following this calendering operation, the thickness of the calendered fabric is lower than the thickness of the uncalendered fabric.
  • Another method uses a thermal point bond calendering system (the primary bonding mechanism) with a bonding area greater than about 22%. This results in a fabric with higher stiffness.
  • Yet another prior art method utilizes binders. This results in fabric with higher stiffness and affects the capillary action of the fabric.
  • thermoplastic, bicomponent spunbond nonwovens are either soft/silky/drapeable with very poor abrasion resistance or have good abrasion resistance without the characteristics of softness, silkiness or drapeability. Thickness is usually a good measure of drapeability. That is, for a given basis weight, the thinner the spunbond nonwoven fabric, the more compact it is, which translates to reduced drapeability.
  • the subject matter of this disclosure are methods for improving abrasion resistance on at least one side of a nonwoven fabric made of thermoplastic material while maintaining high degrees of drapeability and air permeability.
  • a nonwoven fabric made of thermoplastic material while maintaining high degrees of drapeability and air permeability.
  • Such fabric is useful for medical applications.
  • Nonwoven materials are often used in hospital operating rooms for various applications (e.g., patient drapes, operating staff gowns). If pills or loose fiber from a nonwoven material are formed by the movements of members of the surgical team (gloved hands moving back and forth, etc.), and these enter the patient's wound, they can form emboli in the cardiovascular system with severe consequences to the patient.
  • a glazing method can be used to manufacture spunbond webs of bicomponent fibers (e.g., sheath/core fibers having a sheath made of thermoplastic material having a melting point which is lower than the melting point of the thermoplastic material of the core).
  • the glazing method for improving abrasion resistance uses a heated smooth roll to melt the lower-melting-point portion of bicomponent fibers as the spunbond web passes over the heated smooth roll. Because there is no external pressure exerted in a nip by an opposing second roller, as in calendering, the outer surface of the web which does not contact the heated smooth roll remains essentially unchanged and the nonwoven fabric exhibits no compression as a result of the glazing process.
  • the surface temperature of the heated smooth roll and the dwell time (which is dependent on roll diameter, wrap angle and line speed) are controlled for the purpose of surface treating one side of the nonwoven fabric to improve abrasion resistance while allowing the air permeability and web thickness to remain essentially unchanged.
  • the process can repeated in order to glaze the opposite side of the fabric.
  • At least one side of a pattern bonded nonwoven web can be glazed by wrapping the web against the circumferential surface of a heated smooth roll as the web exits the nip formed by that heated smooth roll and an opposing engraved roll.
  • thermoplastic bicomponent spunmelt fabrics including but not limited to spunbond fabrics and SMS (spunbond-meltblown-spunbond) laminates. These glazing methods are best applied to spunmelt fabrics having a basis weight less than 40 gsm and a bond area of less than 22%.
  • spunbond fabrics having a basis weight less than 40 gsm and a bond area of less than 22%.
  • a spunbond fabric made of polyethylene/polyester sheath/core filaments was glazed, resulting in a surface having enhanced abrasion resistance.
  • An evaluation of the beneficial effects of the glazing processes disclosed herein included measuring the abrasion resistance of samples of untreated, glazed and calendered spunbond nonwoven fabric.
  • the abrasion resistance was measured in two ways for each fabric sample: (1) using a Taber abrasion tester, a Taber abrasion resistance roping method was used to measure the number of cycles to failure (which is a subjective visual test); and (2) after abrading each fabric sample for 40 cycles using the same Taber abrasion tester, an average Taber shaving weight loss was calculated using a process involving weighing/shaving/re-weighing of the abraded samples.
  • the abrasion-resistant nonwoven fabrics disclosed herein comprise thermoplastic filaments and have a thickness (in microns, ⁇ m) to basis weight (gsm or g/m 2 ) ratio of at least 5, wherein at least one side of the nonwoven fabric comprises thermoplastic filaments which are at least partially flattened, the one side having an average weight loss not greater than 0.62% when subjected to Taber shaving. In accordance with one embodiment, another side of the fabric has no flattened or partially flattened thermoplastic filaments.
  • spunbond webs which comprise bicomponent thermoplastic filaments and have a thickness to basis weight ratio of at least 5 ⁇ m/gsm, wherein at least one side of the spunbond web comprises bicomponent thermoplastic filaments which are at least partially flattened, the one side having an average weight loss not greater than 0.62% when subjected to Taber shaving.
  • Glazing methods in accordance with various embodiments are disclosed in detail hereinafter.
  • One method of enhancing the abrasion resistance of a surface of a nonwoven fabric disclosed herein comprises applying heat and pressure on one surface of a portion of a nonwoven fabric, while not applying any heat or pressure on the other surface of the portion of the nonwoven fabric.
  • the heat and pressure are applied by a circumferential surface of a heated smooth roll, the aforementioned portion of the nonwoven fabric being wrapped around and in contact with a portion of the circumferential surface which subtends a wrap angle.
  • the wrap angle is in a range of 25 to 85 degrees inclusive.
  • the surface temperature of the heated smooth roll is in a range of 290 to 330°F (143,3 - 165.5 °C), preferably 300 to 330°F (148,9 - 165,5 °C).
  • Another aspect is a method of enhancing the abrasion resistance of a surface of a nonwoven fabric, comprising: (a) supporting a nonwoven fabric in a position whereat a portion thereof is wrapped around and in contact with a portion of a circumferential surface of a heated smooth roll which subtends a wrap angle; and (b) advancing the nonwoven fabric in a tensioned state to maintain some portion thereof in wrapped contact with some portion of the circumferential surface of the heated smooth roll that subtends the wrap angle, wherein the length of the surface of the wrapped portion of the nonwoven fabric is a function of a diameter of the circumferential surface of the heated smooth roll and the wrap angle.
  • one portion of the nonwoven fabric is in wrapped contact with the heated smooth roll
  • another portion of the nonwoven fabric is wrapped around and in contact with a portion of a circumferential surface of at least one movable guide roll, the wrap angle of the one portion being adjustable by changing the position of the movable guide roll relative to the position of the heated smooth roll.
  • a further aspect is a method for fabricating a pattern bonded nonwoven web having a surface with enhanced abrasion resistance, comprising: (a) randomly depositing extruded filaments on a moving carrier belt or screen to form a nonwoven web; (b) forming discrete thermally bonded areas in the nonwoven web by passing the nonwoven web through a nip formed by a patterned roll and a heated smooth roll, the nip continuously forming discrete thermally bonded areas in the nonwoven web in a pattern as the nonwoven web passes therethrough; and (c) glazing a surface of the pattern bonded nonwoven web by wrapping the nonwoven web around a portion of a circumferential surface of the heated smooth roll. A terminal portion of the wrapped portion of the nonwoven web is disposed in the nip.
  • FIG. 2 through 4 Various embodiments of apparatus for enhancing the abrasion resistance of at least one surface of a nonwoven fabric produced by a well-known spunbond nonwoven process will be described later with reference to FIG. 2 through 4 . Before describing that apparatus, a known process for fabricating thermally pattern bonded nonwoven fabric will now be described.
  • FIG. 1 schematically illustrates a known apparatus for producing a thermally bonded spunbond nonwoven fabric.
  • the nonwoven fabric is formed of randomly arranged bicomponent filaments 2 that are prepared by spinneret 4 which receives two streams 6 and 8 consisting of respective different polymeric materials from a pair of extruders 10 and 12.
  • the spinneret 4 is of a type that forms sheath/core or side-by-side bicomponent filaments.
  • the two polymer components combine in the spinneret to form bicomponent filaments having the two components located in two distinct zones within the cross-section and extending continuously along the length of the filaments.
  • the filament-forming openings (not shown) in the spinneret are arranged in one or more rows to form a downwardly extending curtain of filaments 2 when the polymers are extruded through the spinneret 4.
  • a quenching gas e.g., air
  • the gas flow is sufficient to at least partially quench the filaments.
  • a fiber draw unit or aspirator 16 is positioned below the spinneret 4 for drawing and attenuating the filaments 2.
  • the filaments 2 are randomly deposited onto a moving carrier belt 18 that is driven to circulate over a set of rollers 20 by a conventional drive source (not shown), thereby forming a loose web 24 of randomly deposited filaments.
  • a suitable suction means 22 can be placed under the carrier belt 18 to assist in the deposit of filaments 2. It should be noted that while a single spinneret assembly and single-layer filament web is shown, it is possible to provide additional spinning assemblies in-line to form a heavier web or a multilayer nonwoven fabric.
  • the advancing nonwoven web 24 passes from the carrier belt 18 into and through a pressure nip formed by a pair of heated calender rolls 26 and 28.
  • One of the calender rolls has a smooth circumferential surface which contacts one side of the nonwoven web 24.
  • the other calender roll is an engraved roll having a pattern of projections or lands on its circumferential surface, which patterned surface contacts the other side of nonwoven web 24.
  • One or both calender rolls may be internally heated in a conventional manner, such as by circulation of a heat transfer fluid through the interior of the roll.
  • the time, temperature and pressure conditions at the calender nip are sufficient to heat the filaments to cause the lower-melting polymer component to melt and flow together so that the filaments are fused together in an array of discrete areas dictated by the pattern on the engraved calender roll.
  • the resulting thermally pattern bonded nonwoven fabric 30 is then advanced to a wind-up roll 32.
  • the thermally pattern bonded spunbond fabric is further treated to enhance the abrasion resistance on one or both surfaces thereof.
  • FIG. 2 shows an embodiment wherein a surface of a spunbond fabric is treated off-line.
  • FIGS. 3 and 4 show embodiments wherein a surface of a spunbond fabric is treated on-line, i.e. after thermal pattern bonding and prior to winding of the spunbond fabric on a wind-up roll.
  • FIG. 2 shows the flow for a glazing process in accordance with one embodiment (unnumbered rolls are simple guide rolls that do not affect the glazing process).
  • the spunbond fabric 30 is unwound from roll 32 and passed under tension around a heated smooth roll 36 on its way to a wind-up roll 34.
  • the wrapped portion of fabric 30 is in contact with a portion of the circumferential surface of heated smooth roll 36 which subtends a central angle referred to herein as a "wrap angle".
  • FIGS. 2-4 should be understood to represent wrap angles within the range claimed herein.
  • the wrap angle of the fabric 30 around roll 36 may be adjusted by changing the positions of guide rolls 38a and 38b relative to the position of roll 36, as indicated by arrows.
  • the wrap angle can be in a range of 25 to 85 degrees.
  • the dwell time is controlled by the wrap angle and the line speed.
  • Heat and pressure are applied by the circumferential surface of heated smooth roll 36 on the portion of the surface of fabric 30 which is in contact therewith.
  • the pressure can also be altered by adjusting the relative speeds of the machine and the glazing roll.
  • the surface temperature of the heated smooth roll can be in a range of 290 to 330°F (143,3 - 165 °C), preferably 300 to 330°F (148,9 - 165,5 °C).
  • the diameter of heated smooth roll 36 is preferably 350 to 400 mm.
  • the glazing results in improved bonding of the surface filaments/fibers. This results in improved abrasion resistance on the glazed side only. This is achieved without adversely impacting fabric thickness, capillary action or feel of the fabric. In particular, the change in thickness will be less than what would be the case if the fabric were calendered instead of glazed.
  • the spunbond fabric after the spunbond fabric has been glazed on one side, it could be glazed on the other side by repeating the process shown in FIG. 2 or by passing the glazed fabric under tension around a second heated smooth roll (not shown in FIG. 2 ) with the unglazed side of the fabric contacting the heated circumferential surface of the second roll.
  • FIG. 3 shows the flow for an on-line glazing process (again unnumbered rolls are simple guide rolls that do not affect the glazing process).
  • the advancing spunbond fabric can be passed through a pressure nip formed by a pair of heated calender rolls 26 and 28.
  • One calender roll has a smooth circumferential surface; the other calender roll is an engraved roll having a pattern of projections or lands on its circumferential surface.
  • the time, temperature and pressure conditions at the calender nip are sufficient to heat the filaments to cause the lower-melting polymer component to melt and flow together so that the filaments are fused together in an array of discrete areas dictated by the pattern on the engraved calender roll.
  • the pattern bonded spunbond fabric 30 wraps around a heated smooth roll 36.
  • the wrap angle and roll surface temperature may be in the same ranges previously described with reference to the process shown in FIG. 2 . Again the wrap angle of the fabric 30 around heated smooth roll 36 may be adjusted by changing the positions of movable guide rolls 38a and 38b relative to the position of the heated smooth roll 36.
  • the portion of fabric 30 downstream of movable guide roll 38b, which is now glazed on one side, can then be wound uniformly on a wind-up roll 34 with the aid of a secondary roll.
  • the number of rolls in the wind-up system has no bearing on the glazing system and the secondary roll can be omitted.
  • the spunbond fabric after the spunbond fabric has been glazed on one side, it could be glazed on the other side by passing the glazed fabric under tension around a second heated smooth roll (not shown in FIG. 3 ) with the unglazed side of the fabric contacting the heated circumferential surface of the second heated smooth roll.
  • a method for fabricating a pattern bonded nonwoven web having a surface with enhanced abrasion resistance comprises: (a) randomly depositing extruded filaments on a moving carrier belt or screen to form a nonwoven web; (b) forming discrete thermally bonded areas in the nonwoven web by passing the nonwoven web through a nip formed by a patterned roll and a heated smooth roll, the nip continuously forming discrete thermally bonded areas in the nonwoven web in a pattern as the nonwoven web passes therethrough; and (c) glazing a surface of the pattern bonded nonwoven web by wrapping the nonwoven web around a portion of a circumferential surface of the heated smooth roll, while a terminal portion of the wrapped portion of the nonwoven web is disposed in the nip.
  • FIG. 4 A portion of the manufacturing process described in the preceding paragraph is shown in FIG. 4 .
  • a spunbond web 30 is passed through a pressure nip formed by a pair of heated calender rolls 26 and 28.
  • roll 26 has a smooth circumferential surface while roll 28 is an engraved roll having a pattern of projections or lands on its circumferential surface.
  • the time, temperature and pressure conditions at the calender nip are sufficient to cause the filaments of the spunbond fabric to fuse together in an array of discrete areas dictated by the pattern on the engraved calender roll 28.
  • the portion of the pattern bonded spunbond fabric 30 immediately downstream of the nip formed by rolls 26 and 28 is wrapped around heated smooth roll 26 along a circumferential portion which subtends a wrap angle in the range of 25 to 85 degrees.
  • the surface temperature of the heated smooth roll 26 can be in the range of 290 to 330°F (143,3 - 165.5 °C), preferably 300 to 330°F (148,9 - 165,5 °C). Again the wrap angle can be adjusted by moving guide roll 38 relative to heated smooth roll 26.
  • the pattern bonded spunbond fabric 30, glazed on one side, is then wound on the wind-up roll 32 in a conventional manner.
  • thermoplastic nonwoven fabrics having enhanced abrasion resistance and satisfactory drapeability, capillary action and/or feel of the fabric can be produced. These methods are preferably applied to pattern bonded nonwoven fabrics having a basis weight less than 40 gsm and a bond area of less than 22% of the total area of the fabric. Testing has shown that these nonwoven fabrics have a thickness to basis weight ratio of at least 5 ⁇ m/gsm. In the event that only one side of the fabric is glazed, then that glazed surface comprises thermoplastic filaments which are at least partially flattened and has an average weight loss not greater than 0.62% when subjected to Taber shaving, while the other side of the nonwoven fabric has no thermoplastic filaments which are at least partially flattened. In addition, the glazed side does not fail a Taber abrasion resistance roping test method before 13 cycles. In the event that both sides of the fabric are glazed, then each glazed surface has the aforementioned properties.
  • FIG. 5 is an SEM image of a glazed surface of an unbonded area of a spunbond nonwoven fabric comprising PE/PET sheath/core filaments. It can be seen in this image that the surface filaments have been flattened to some extent.
  • FIG. 6 is an SEM image of a non-glazed surface of an unbonded area of a spunbond nonwoven fabric, made from the same filaments, whose opposite surface was glazed in accordance with the teaching herein. It can be seen in this image that the surface filaments have not been flattened.
  • FIG. 7 is a graph showing the average Taber shaving weight loss (%) versus thickness to basis weight ratio ( ⁇ m/gsm) for various fabric samples.
  • the data points for fabric samples of different categories of spunbond nonwoven fabric are indicated using the following symbology: ( ⁇ ) untreated; ( ⁇ ) glazed with weight loss ⁇ 0.62%; ( ⁇ ) glazed with weight loss > 0.62%; and ( ⁇ ) calendered.
  • the data graphically depicted in FIG. 7 is taken from Table 1 (below).
  • the weight loss (in %) for fabric samples belonging to the aforementioned four categories of spunbond nonwoven fabric appear in respective columns in Table 1.
  • Each weight loss is an average of the weight losses measured for 32 replicates using a Taber Shaving Weight Loss test method (described below).
  • Table 1 also lists the basis weight, thickness, thickness to basis weight ratio, and number of cycles to failure during Taber abrasion testing.
  • the second column from the right lists the standard deviation (in %) for each group of 32 weight loss measurements.
  • TABLE 1 Basis Weight (gsm) TA2 Thickness ( ⁇ m) Thickness/ Basis Weight Untreat-ed SB NW, Wt. Loss Glazed, Wt.
  • thermoplastic materials and glazing parameters used for the glazed samples are listed in Table 2, which also identifies the thermoplastic materials used for control sample No. 25716.
  • thermoplastic materials and calendering parameters used for the calendered samples are listed in Table 3, which also identifies the thermoplastic materials used for the 36-gsm control sample No. 257290.
  • the control sample 25730 (36 gsm) is another commercially available spunbond grade, which is the same grade used for all the listed calendered samples (the only difference being no post calendering).
  • the differences between the two control samples are the PE used, the PE/PET ratio and the basis weight.
  • the glazing parameters listed in Table 2 are different for different glazing samples (part of the design of the experiments). TABLE 2 PE Sheath PET Core Sheath/ Core Ratio Glazing Temp.
  • the weight loss percentages listed in Table 1 were derived using the Taber Shaving Weight Loss test method.
  • This test method is designed to quantitatively evaluate the abrasion resistance of spunbond nonwovens and composites (i.e., laminates).
  • a specimen is prepared, attached to the Taber abrasion apparatus, and abraded using two wheels comprised of abrasive particles which scuff the test sample as it rotates. Each rotation is a cycle.
  • One abrading wheel rubs the specimen outward, i.e., toward the periphery and the other rubs it inward, i.e., toward the center.
  • the wheels traverse a complete circle (cycle) on the specimen surface for a total of 40 cycles.
  • the fiber that is lifted creates an appearance of a fluffy ring on the specimen at the point of contact with the abrasive wheels.
  • the term "fluffiness” means the fuzzy appearance of the fiber after abrasion caused by fibers lifting off of the web.
  • the Taber Shaving Weight Loss is then calculated as the difference between the weight of the sample after being subjected to 40 Taber abrasion cycles (Wt 1 ) and the weight of the same abraded sample after shaving (Wt 2 ), divided by weight Wt 1 and then multiplied by 100:
  • Taber Shaving Weight Loss % Wt 1 ⁇ Wt 2 Wt 1 ⁇ 100
  • the Taber Shaving Weight Loss was measured for 32 replicates taken from each fabric sample and then an average Taber Shaving Weight Loss was calculated based on the 32 measured values to arrive at a single data point for each fabric sample.
  • the apparatus used to preform the Taber Shaving Weight Loss measurements includes the following: (1) a Taber Model 503 Abraser; (2) CS-10 (part #125320) medium abrasive wheels (with a recommended shelf life of 4 years); (3) S-11 refacing discs (for refacing the CS-10 abrasive wheels; (4) a sample cutter for producing a 51 ⁇ 4-inch test piece; (5) an Oster model 76 shaver with 000 blade attached; and (6) a weighing scale.
  • each abraded sample should be marked with a sample identifier and then the weight of the abraded sample should be measured in grams to at least four decimal places. [This pre-shaving sample weight is designated as Wt 1 in Eq. (1).] Then one side of the sample (e.g., the glazed side for glazed samples) should be shaved in the area where the sample was abraded. The person performing the shaving operation should verify that the shaver blade is clean and free of any loose fibers and dust. Then any loose or raised fibers in the abraded area should be shaved off using an Oster model 76 clipper having a 000 clipper blade attached thereto.
  • FIG. 8 shows a side view of the correct position of a clipper blade 44 (attached to a hand-held clipper 42) relative to a fabric sample when shaving loose or raised fibers from the surface 40 of the fabric sample.
  • the tester should look at the fabric sample from different angles under good light conditions (use a lamp if necessary).
  • the tester should make sure that the loose/raised fibers have been removed. If any loose or raised fibers are found, the sample should be reshaved.
  • the end result of the shaving process should be a sample with no loose/raised fibers. Although the tester may observe short severed/cut fibers that the clipper blade cannot reach, do not try to shave such fibers.
  • the Taber abrasion cycles listed in Table 1 were derived using the Taber abrasion roping method.
  • This is a subjective test method that is designed to provide a performance rating in cycles, wherein the sample is run to failure and the point of failure is noted in cycles.
  • the nature of the test first causes the sample to fluff in a circular pattern and continued cycles cause this fluff to pill into a rope-like formation and collect along the inner circumference of the abraded area.
  • the failure point is defined when roping is seen along a total of 80% of the inner circumference.
  • the sample preparation, test equipment and calibration of the equipment for the Taber abrasion roping method are the same as with the Taber Shaving Weight Loss (%) method.
  • the test procedure for the Taber abrasion roping method is as follows: Run the Taber tester for 3 continuous cycles. Stop the instrument at the completion of three cycles. Check for roping. Continue the testing, one cycle at a time until 80% roping along the inner circumference is observed. Note the number of cycles it takes to get to 80% roping as the failure point. Repeat the test for a total of four replicates. The Taber abrasion roping cycle performance is the average of these four samples.
  • the phrase “in a range” includes the endpoints of that range, and the term “average weight loss” refers to an average weight loss which is calculated based on measurements of not less than 32 replicates.

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  • Textile Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Claims (29)

  1. Procédé de fabrication d'un non-tissé dont une surface présente une résistance accrue à l'abrasion, comprenant :
    - fournir un non-tissé comprenant des filaments gaine/âme bi-composants thermoplastiques dont la gaine est en polyéthylène et dont l'âme est en téréphtalate de polyéthylène et présentant un ratio épaisseur/poids de base d'au moins 5 µm/g/m2,
    - appliquer chaleur et pression sur une surface d'une partie dudit non-tissé de façon à ce qu'au moins un côté dudit non-tissé comprenne des filaments thermoplastiques qui sont au moins partiellement aplatis, ledit côté présentant une perte en poids moyen pas supérieure à 0,62 % calculée sur la base de la perte en poids mesurée par une méthode d'essai de perte de poids sur machine d'abrasion Taber comme indiqué dans la description sans appliquer de chaleur ou de pression sur l'autre surface de ladite partie du non-tissé.
  2. Procédé selon la revendication 1, caractérisé en ce que la chaleur et la pression sont appliquées par une surface circonférentielle d'un rouleau lisse chauffé, ladite partie du non-tissé étant enroulée autour et en contact avec une partie de ladite surface circonférentielle qui sous-tend un angle d'enroulement.
  3. Procédé selon la revendication 2, caractérisé en ce que l'angle d'enroulement est compris dans une plage de 25 à 85 degrés inclus.
  4. Procédé selon la revendication 2, caractérisé en ce que la température de surface du rouleau lisse chauffé est comprise dans la plage de 290 à 330°F (143,3 - 165,5°C).
  5. Procédé selon la revendication 4, caractérisé en ce que la température de surface du rouleau lisse chauffé est comprise dans une plage de 300 à 330°F (148,9 - 165,5°C).
  6. Procédé de fabrication d'un non-tissé dont une surface présente une résistance accrue à l'abrasion, comprenant :
    (a) supporter un non-tissé comprenant des filaments thermoplastiques bi-composants gaine/âme dont la gaine est en polyéthylène et dont l'âme est en téréphtalate de polyéthylène et présentant un ratio épaisseur/poids de base d'au moins 5 µm/g/m2, dans une position dans laquelle une partie ce celui-là est enroulée autour et en contact avec une partie d'une surface circonférentielle d'un rouleau lisse chauffé qui sous-tend un angle d'enroulement ; et
    (b) avancer le non-tissé dans un état de tension pour maintenir une partie de celui-ci en contact d'enroulement avec une partie de la surface circonférentielle du rouleau lisse chauffé qui sous-tend l'angle d'enroulement, de façon à ce qu'au moins un côté dudit non-tissé comprenne des filaments thermoplastiques qui sont au moins partiellement aplatis, ledit côté ayant une perte de poids moyenne pas supérieure à 0,62 % calculée sur la base de la perte en poids mesurée par une méthode d'essai de perte de poids sur machine d'abrasion Taber comme indiqué dans la description
    caractérisé en ce que la longueur de la surface de la partie enroulée du non-tissé est fonction d'un diamètre de la surface circonférentielle du rouleau lisse chauffé et de l'angle d'enroulement.
  7. Procédé selon la revendication 6, caractérisé en ce que la température de surface du rouleau lisse chauffé est dans la plage de 290 à 330°F (143,3 - 165,5°C).
  8. Procédé selon la revendication 7, caractérisé en ce que la température de surface du rouleau lisse chauffé est comprise dans la plage de 300 à 330°F (148,9 - 165,5°C).
  9. Procédé selon la revendication 6, caractérisé en ce que l'angle d'enroulement est compris dans une plage de 25 à 85 degrés.
  10. Procédé selon la revendication 6, caractérisé en ce que le rouleau lisse chauffé forme un creux avec un rouleau à motifs, une partie terminale de la partie enroulée du tissu non tissé étant disposée dans ledit creux.
  11. Procédé selon la revendication 6, caractérisé en ce que pendant qu'une partie du non-tissé est en contact d'enroulement avec le rouleau lisse chauffé, une autre partie du tissu non tissé est enroulée autour et en contact avec une partie d'une surface circonférentielle d'un rouleau de guidage mobile, l'angle d'enroulement de la partie étant ajustable en changeant la position du rouleau de guidage mobile par rapport à la position du rouleau lisse chauffé.
  12. Procédé pour fabriquer un non-tissé lié à des motifs ayant une surface présentant une résistance accrue à l'abrasion, comprenant :
    (a) déposer de façon aléatoire des filaments extrudés sur une courroie ou tamis porteur mobile pour former une toile non tissée comprenant des filaments thermoplastiques bi-composants gaine/âme dont la gaine est en polyéthylène et dont l'âme est en téréphtalate de polyéthylène et présentant un ratio épaisseur/poids de base d'au moins 5 µm/g/m2 ;
    (b) former des zones discrètes liées thermiquement dans le non-tissé en passant la toile non tissée au travers d'un creux formé par un rouleau à motif et un rouleau lisse chauffé, ledit creux formant de façon continue des zones thermiquement liées discrètes dans le non-tissé pour donner un motif à mesure que le non-tissé passe au travers ; et
    (c) glacer une surface du non-tissé lié à motif en enroulant le non-tissé autour d'une partie d'une surface circonférentielle du rouleau lisse chauffé de façon à ce qu'au moins un côté dudit non-tissé lié à motif comprenne des filaments thermoplastiques qui sont au moins partiellement aplatis, ledit côté présentant une perte en poids moyenne non supérieure à 0,62 %, calculée sur la base de la perte en poids mesurée par une méthode d'essai de perte de poids sur machine d'abrasion Taber comme indiqué dans la description.
  13. Procédé selon la revendication 12, caractérisé en ce que la température de surface du rouleau lisse chauffé est comprise dans la plage de 290 à 330°F (143,3 - 165,6°C).
  14. Procédé selon la revendication 13, caractérisé en ce que la température de surface du rouleau lisse chauffé est comprise dans la plage de 300 à 330°F (148,9 - 165,5°C).
  15. Procédé selon la revendication 12, caractérisé en ce que l'angle d'enroulement est compris dans une plage de 25 à 85 degrés.
  16. Procédé selon la revendication 12, caractérisé en ce que une partie terminale de la partie enroulée de la toile non tissée est disposée dans ledit creux.
  17. Procédé selon la revendication 12, caractérisé en ce que pendant qu'une partie amont du non-tissé est en contact d'enroulement avec le rouleau lisse chauffé, une partie aval du non-tissé est enroulée autour et en contact avec une partie d'une surface circonférentielle d'un rouleau de guidage mobile, l'angle d'enroulement de la partie étant ajustable en changeant la position du rouleau de guidage mobile par rapport à la position du rouleau lisse chauffé.
  18. Non-tissé comprenant des filaments thermoplastiques bi-composants gaine/âme dont la gaine est en polyéthylène et dont l'âme est en téréphtalate de polyéthylène et présentant un ratio épaisseur/poids de base d'au moins 5 µm/g/m2, dans lequel au moins un côté dudit non-tissé comprend des filaments thermoplastiques qui sont au moins partiellement aplatis, ledit côté présentant une perte en poids moyenne non supérieure à 0,62 % calculée sur la base de la perte en poids mesurée par une méthode d'essai de perte de poids sur machine d'abrasion Taber telle qu'indiquée dans la description.
  19. Non-tissé selon la revendication 18, caractérisé en ce que lesdits filaments thermoplastique bi-composants gaine/âme sont fusionnés en une multiplicité de zones discrètes, la surface totale de ladite multiplicité des zones discrètes étant inférieure à 22 % de la surface totale du tissu.
  20. Non-tissé selon la revendication 18, caractérisé en ce que ledit poids de base est inférieur à 40 g/m2.
  21. Non-tissé selon la revendication 18, caractérisé en ce que ledit côté n'échoue pas à la méthode d'essai par roping de la résistance à l'abrasion sur machine d'abrasion Taber avant 13 cycles.
  22. Non-tissé selon la revendication 18, caractérisé en ce que l'autre côté dudit non-tissé n'a pas de filaments thermoplastiques bi-composants gaine/âme qui sont au moins partiellement aplatis.
  23. Non-tissé selon la revendication 18, caractérisé en ce que le tissu non tissé est une toile spunbound dans laquelle un côté de ladite toile spunbound comprend des filaments thermoplastiques bi-composants qui sont au moins partiellement aplatis et un autre côté de la toile spunbound n'a pas de filaments thermoplastiques qui sont au moins partiellement aplatis.
  24. Non-tissé selon la revendication 23, caractérisé en ce que lesdits filaments thermoplastiques sont fusionnés en une multiplicité de zones discrètes, la surface totale de ladite multiplicité de zones discrètes étant inférieure à 22 % de la surface totale du tissu.
  25. Non-tissé selon la revendication 23, caractérisé en ce que ledit un côté n'échoue pas à la méthode d'essai par roping de résistance à l'abrasion sur machine d'abrasion Taber avant 13 cycles.
  26. Non-tissé selon la revendication 19, caractérisé en ce que ledit poids de base est inférieur à 40 g/m2.
  27. Non-tissé selon la revendication 26, caractérisé en ce que ledit un côté n'échoue pas à la méthode d'essai par roping de résistance à l'abrasion sur machine d'abrasion Taber avant 13 cycles.
  28. Non-tissé selon la revendication 27, caractérisé en ce que le non-tissé est un non-tissé voie fondue.
  29. Non-tissé selon la revendication 18, caractérisé en ce que le non-tissé est un non-tissé voie fondue.
EP13728231.5A 2012-06-13 2013-05-23 Tissu non tissé lissé et procédés de fabrication Active EP2861791B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/495,572 US20130337714A1 (en) 2012-06-13 2012-06-13 Glazed Nonwoven Fabric and Methods of Manufacture
PCT/FI2013/050566 WO2013186431A1 (fr) 2012-06-13 2013-05-23 Tissu non tissé glacé et procédés de fabrication

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EP2861791A1 EP2861791A1 (fr) 2015-04-22
EP2861791B1 true EP2861791B1 (fr) 2016-09-14

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US20160009074A1 (en) * 2014-07-14 2016-01-14 Stephen J. Metcalf Inert clear cylinder with inerting rollers
KR20180125022A (ko) 2016-04-12 2018-11-21 쓰리엠 이노베이티브 프로퍼티즈 캄파니 절첩가능한 다목적 부직포 핸드 패드 및 사용 방법
KR20190002620A (ko) 2016-04-29 2019-01-08 쓰리엠 이노베이티브 프로퍼티즈 캄파니 인쇄된 지시부를 형성하는 스코어링 바디를 포함하는 세정 물품
CN109371570A (zh) * 2018-10-22 2019-02-22 山东恒鹏卫生用品有限公司 一种光辊热轧弹性非织造布及其制造方法
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CN104520487B (zh) 2016-12-28
US20130337714A1 (en) 2013-12-19
CN104520487A (zh) 2015-04-15
EP2861791A1 (fr) 2015-04-22

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