EP3645776B1 - Nonwoven article and method of making the same - Google Patents
Nonwoven article and method of making the same Download PDFInfo
- Publication number
- EP3645776B1 EP3645776B1 EP18749509.8A EP18749509A EP3645776B1 EP 3645776 B1 EP3645776 B1 EP 3645776B1 EP 18749509 A EP18749509 A EP 18749509A EP 3645776 B1 EP3645776 B1 EP 3645776B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- particle coating
- fiber web
- softenable
- thermally
- nonwoven
- Prior art date
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- 238000004519 manufacturing process Methods 0.000 title claims description 4
- 239000002245 particle Substances 0.000 claims description 66
- 239000000835 fiber Substances 0.000 claims description 62
- 238000000576 coating method Methods 0.000 claims description 46
- 239000011248 coating agent Substances 0.000 claims description 36
- 230000005670 electromagnetic radiation Effects 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 25
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 22
- 229910002804 graphite Inorganic materials 0.000 claims description 21
- 239000010439 graphite Substances 0.000 claims description 21
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 claims description 18
- 230000008018 melting Effects 0.000 claims description 11
- 238000002844 melting Methods 0.000 claims description 11
- 230000000717 retained effect Effects 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 8
- 239000011230 binding agent Substances 0.000 claims description 7
- 229910052582 BN Inorganic materials 0.000 claims description 6
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 6
- 238000007654 immersion Methods 0.000 claims description 5
- 239000000758 substrate Substances 0.000 description 38
- 239000000843 powder Substances 0.000 description 11
- 239000004698 Polyethylene Substances 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 8
- -1 polytetrafluoroethylene Polymers 0.000 description 8
- 229920001169 thermoplastic Polymers 0.000 description 8
- 239000002904 solvent Substances 0.000 description 6
- 239000004416 thermosoftening plastic Substances 0.000 description 6
- 229910052724 xenon Inorganic materials 0.000 description 6
- FHNFHKCVQCLJFQ-UHFFFAOYSA-N xenon atom Chemical compound [Xe] FHNFHKCVQCLJFQ-UHFFFAOYSA-N 0.000 description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 229910052743 krypton Inorganic materials 0.000 description 3
- DNNSSWSSYDEUBZ-UHFFFAOYSA-N krypton atom Chemical compound [Kr] DNNSSWSSYDEUBZ-UHFFFAOYSA-N 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 101000618467 Hypocrea jecorina (strain ATCC 56765 / BCRC 32924 / NRRL 11460 / Rut C-30) Endo-1,4-beta-xylanase 2 Proteins 0.000 description 2
- 229920001410 Microfiber Polymers 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000007429 general method Methods 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 239000003658 microfiber Substances 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 230000003595 spectral effect Effects 0.000 description 2
- 238000001228 spectrum Methods 0.000 description 2
- 241000894006 Bacteria Species 0.000 description 1
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- 208000035859 Drug effect increased Diseases 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- ABLZXFCXXLZCGV-UHFFFAOYSA-N Phosphorous acid Chemical class OP(O)=O ABLZXFCXXLZCGV-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 238000002679 ablation Methods 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- RREGISFBPQOLTM-UHFFFAOYSA-N alumane;trihydrate Chemical compound O.O.O.[AlH3] RREGISFBPQOLTM-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- FACXGONDLDSNOE-UHFFFAOYSA-N buta-1,3-diene;styrene Chemical compound C=CC=C.C=CC1=CC=CC=C1.C=CC1=CC=CC=C1 FACXGONDLDSNOE-UHFFFAOYSA-N 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000000292 calcium oxide Substances 0.000 description 1
- 235000012255 calcium oxide Nutrition 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 1
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 239000013068 control sample Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 229910052809 inorganic oxide Inorganic materials 0.000 description 1
- 239000010954 inorganic particle Substances 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 229910052753 mercury Inorganic materials 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 229910001507 metal halide Inorganic materials 0.000 description 1
- 150000005309 metal halides Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001748 polybutylene Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000306 polymethylpentene Polymers 0.000 description 1
- 239000011116 polymethylpentene Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920000346 polystyrene-polyisoprene block-polystyrene Polymers 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000010979 ruby Substances 0.000 description 1
- 229910001750 ruby Inorganic materials 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 description 1
- 235000019982 sodium hexametaphosphate Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229920000468 styrene butadiene styrene block copolymer Polymers 0.000 description 1
- 239000001577 tetrasodium phosphonato phosphate Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Images
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
- 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
- D04H1/407—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 containing absorbing substances, e.g. activated carbon
-
- 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
- D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
-
- 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
- D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M10/00—Physical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. ultrasonic, corona discharge, irradiation, electric currents, or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements
- D06M10/005—Laser beam treatment
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
- D06M11/80—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with boron or compounds thereof, e.g. borides
Definitions
- the present disclosure broadly relates to methods for improving the durability of particle coatings on nonwoven fiber webs, and articles preparable thereby.
- Coatings of powders (e.g., graphite) on nonwoven fiber webs are widely known; however, the powders are typically loosely bound to the fibers and are prone to falling off.
- Various methods have been devised to overcome this problem, including: 1) use of a curable resin applied to the fibers prior to powder coating, and that when cured securely binds the powder to the fibers; 2) in those cases where the nonwoven fiber web is durable enough, the powder may be rubbed onto it in a process known as triboadhesion; and 3) the powders can be selected to contain binder components that can fuse to the fibers on heating.
- each of these techniques has disadvantages if a particle coating consisting essentially of inorganic particles is desired.
- the presence of binder components in approaches 1) and 3) would be unacceptable in such a situation, and durability of particle coatings made by approach 2) is generally problematic as particle coatings are typically prone to damage by methods such as abrasion and/or rinsing with solvent.
- the present disclosure provides an easy method to enhance the durability of particle coatings that involves instantaneous heating by exposure to pulsed electromagnetic radiation having at least one wavelength in the range of 200 nm to 1000 nm.
- pulsed electromagnetic radiation having at least one wavelength in the range of 200 nm to 1000 nm.
- the present inventors believe that the modulated electromagnetic radiation hitting the particles in the particle coating is converted to heat that is localized adjacent to the particles thereby softening the adjacent fibers and increasing adhesion between those fibers and the particles.
- the present disclosure provides a method of making a nonwoven article, the method comprising exposing a particle coating disposed on a thermally-softenable nonwoven fiber web to pulsed electromagnetic radiation having at least one wavelength in the range of 200 to 1000 nanometers, wherein the thermally-softenable nonwoven fiber web comprises fibers having a higher melting core and a lower melting sheath, wherein the particle coating comprises loosely bound distinct particles that are not chemically bonded to each other and are not retained in a binder material other than the thermally-softenable nonwoven fiber web, wherein the particle coating comprises at least one of graphite or hexagonal boron nitride and wherein the pulsed electromagnetic radiation has sufficient fluence and pulse width to increase bonding force between at least a portion of the loosely bound distinct particles and the thermally-softenable nonwoven fiber web.
- the present disclosure provides a nonwoven article comprising a thermally-softenable nonwoven fiber web having a particle coating disposed thereon, wherein the thermally-softenable nonwoven fiber web comprises fibers having a higher melting core and a lower melting sheath, wherein the particle coating comprises distinct particles that are not chemically bonded to each other and are not retained in a binder material other than the thermally-softenable nonwoven fiber web, wherein the particle coating comprises at least one of graphite or hexagonal boron nitride, and wherein the particle coating is at least 60 percent retained after a one minute immersion in isopropanol at 22°C.
- the present disclosure provides an easy method to enhance the durability of particle coatings on nonwoven fiber webs using instantaneous heating by exposure to a modulated source of electromagnetic radiation.
- exemplary article 100 comprises a thermally-softenable nonwoven fiber web 110 having a particle coating 120 disposed thereon.
- Particle coatings on thermally-softenable nonwoven (e.g., thermoplastic) fiber webs can be carried out by various known methods including, for example, exposure to an aerosolized particle cloud, contact with a powder bed, coating with a solvent-based particle dispersion coating followed by evaporation of solvent, and/or powder-rubbed (rubbing dry particles against a substrate to form a coating of the powder particles).
- powder-rubbing methods can be found in U. S. Pat. Nos. 6,511,701 B1 (Divigalpitiya et al. ), 6,025,014 (Stango ), and 4,741,918 (Nagybaczon et al. ). The remaining methods will be familiar to those of ordinary skill in the art.
- Useful particle coatings comprise minute loosely bound particles capable of absorbing at least one wavelength of the pulsed electromagnetic radiation, preferably corresponding to a majority of the energy of the pulsed electromagnetic radiation. Suitable particles are preferably at least substantially unaffected by electromagnetic radiation, but are moderate to strong absorbers of it. This is desirable to maximize the light (electromagnetic radiation) to heat conversion yield without altering the chemical nature of the particles.
- Exemplary suitable particles include graphite, clays, hexagonal boron nitride, pigments, inorganic oxides (e.g., alumina, calcia, silica, ceria, zinc oxide, or titania), metal(s), organic polymeric particles (e.g., polytetrafluoroethylene, polyvinylidene difluoride), carbides (e.g., silicon carbide), flame retardants (e.g., aluminum trihydrate, aluminum hydroxide, magnesium hydroxide, sodium hexametaphosphate, organic phosphonates and phosphates and ester thereof), carbonates (e.g., calcium carbonate, magnesium carbonate, sodium carbonate), dry biological powders (e.g., spores, bacteria), and combinations thereof.
- organic polymeric particles e.g., polytetrafluoroethylene, polyvinylidene difluoride
- carbides e.g., silicon carbide
- flame retardants e.g., aluminum trihydrate
- the particles have an average particle size of 0.1 to 100 micrometers, more preferably 1 to 50 micrometers, and more preferably 1 to 25 micrometers, although this is not a requirement.
- the particle coating includes at least one of graphite or hexagonal boron nitride.
- the particle coating Prior to exposure to the electromagnetic radiation the particle coating comprises loosely bound distinct particles that are not chemically bonded to each other, and are not retained in a binder material other than the thermally-softenable nonwoven fiber web itself.
- the thermally-softenable nonwoven fiber web preferably comprises thermoplastic fibers, although non-thermoplastic fibers may be used alone or in combination with thermoplastic fibers, for example.
- the fibers of the thermally-softenable nonwoven fiber web are non-tacky and/or non-thermosetting, although this is not a requirement.
- thermally-softenable nonwoven fiber webs include meltspun fiber webs, blown microfiber webs, needletacked staple fiber webs, thermally bonded airlaid webs, and spunlace webs.
- the thermally-softenable nonwoven fiber web may be made by any suitable nonwoven fiber web making process. Examples include meltspun, blown microfiber (BMF), air-laid processes, wet-laid processes, and spunlace. These and other methods will be known to those of skill in the art.
- BMF meltspun, blown microfiber
- air-laid processes wet-laid processes, and spunlace.
- thermally-softenable nonwoven fiber web may be of any basis weight and may be densely compacted or lofty and open, for example.
- thermoplastic polymers materials that may be used to make nonwoven fiber web comprising thermoplastic fibers are disclosed in U. S. Pat. Nos. 5,706,804 (Baumann et al.
- At least a portion of the fibers in the thermoplastic fiber web have a higher melting core and a lower melting sheath. In such cases, the higher melting core should preferably be at least 25°C.
- the pulsed electromagnetic radiation may come from any source(s) capable of generating sufficient fluence and pulse duration to effect sufficient heating of the nonwoven fiber web to cause the particle coating to bind more tightly to it.
- At least three types of sources may be effective for this purpose: flashlamps, lasers, and shuttered lamps.
- flashlamps lasers
- shuttered lamps The selection of appropriate sources will typically be influenced by desired process conditions such as, for example, line speed, line width, spectral output, and cost.
- the pulsed electromagnetic radiation is generated using a flashlamp.
- a flashlamp xenon and krypton flashlamps are the most common. Both provide a broad continuous output over the wavelength range 200 to 1000 nanometers, however the krypton flashlamps have higher relative output intensity in the 750-900 nm wavelength range as compared to xenon flashlamps which have more relative output in the 300 to 750 nm wavelength range.
- xenon flashlamps are preferred for most applications, and especially those involving graphite particles.
- Many suitable xenon and krypton flashlamps are commercially available from vendors such as Excelitas Technologies Corp. of Waltham, Massachusetts and Heraeus of Hanau, Germany.
- the pulsed electromagnetic radiation can be generated using a pulsed laser.
- Suitable lasers may include, for example, excimer lasers (e.g., XeF (351 nm), XeCl (308 nm), and KrF (248 nm)), solid state lasers (e.g., ruby 694 nm)), and nitrogen lasers (337.1 nm).
- the pulsed electromagnetic radiation is generated using a continuous light source and a shutter (preferably a rotating aperture/shutter to reduce overheating of the shutter).
- Suitable light sources may include high-pressure mercury lamps, xenon lamps, and metal-halide lamps.
- the electromagnetic radiation spectrum is preferably most intense at wavelength(s) that are strongly absorbed by the particles, although this is not a requirement.
- the electromagnetic radiation spectrum is preferably most intense in spectral regions in which the particles are least reflective, although this is not a requirement.
- the source of pulsed electromagnetic radiation is capable of generating a high fluence (energy density) with high intensity (high power per unit area), although this is not a requirement.
- high fluence energy density
- intensity high power per unit area
- the pulse duration is preferably short; e.g., less than 10 milliseconds, less than 1 millisecond, less than 100 microseconds, less than 10 microseconds, or even less than 1 microsecond, although this is not a requirement.
- the pulsed electromagnetic radiation preferably be powerful, but the exposure area is preferably large and the pulse repetition rate is preferably fast (e.g., 100 to 500 Hz).
- the resultant exposed particle-coated nonwoven fiber web may be immersed in a solvent such as, e.g., isopropanol for a fixed interval (e.g., 1, 2, 3, 4, or even 5 minutes, or longer) at about 22°C (e.g., room temperature), and then removed, dried, and weighed. Weight loss of powder can then be determined by subtraction.
- the solvent should be selected such that it does not dissolve the nonwoven fiber web.
- the particulate coating of the nonwoven article is sufficiently bonded to the nonwoven fiber web so that after one minute of immersion in isopropanol at 22°C at least 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or even at least 90 percent of the particulate coating remains bonded to the nonwoven fiber web.
- graphite coatings were applied on PE nonwoven substrates by placing a strip of nonwoven approximately 1.5 inches (3.8 cm) by 10 inches (25.4 cm) in dimension and a small amount of MICRO850 in a sealable plastic bag. The bag was then sealed and shaken, until the PE nonwoven was visibly covered in graphite. The nonwoven was then removed, and excess graphite particles were removed by blowing with compressed nitrogen at a pressure of 40 pounds per square inch.
- the relative amount of graphite coating deposited on the PE nonwoven film was determined by measuring the weight of the sample before and after the process.
- Nonwoven samples were completely immersed (i.e., submerged) in a bath of IPA at room temperature (22°C) and stirred by hand for 1 minute. The samples were then removed and spread onto a clean surface in a chemical hood and allowed to dry completely.
- M g,i is the mass of graphite on the nonwoven just prior to immersion in isopropanol
- M g , w is the mass of graphite remaining on the nonwoven after the wash step.
- CEX-A and EX-1 to EX-12 were graphite coated PE nonwoven substrates prepared as described above.
- the substrate was not subjected to IPL and was a control sample.
- EX-1 to EX-11 were prepared by subjecting the samples to an intense pulsed light irradiation (IPL).
- IPL intense pulsed light irradiation
- the source used was a Xe flashlamp, commercially obtained from Xenon Corporation, Wilmington, Massachusetts, as a SINTERON S-2100 Xe flashlamp equipped with Type C bulb. Samples were placed beneath a quartz plate for the irradiation process.
- the substrate was treated 1 time at a pulse rate of 1 Hz and an energy density of 0.1 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 3 times at a pulse rate of 1 Hz and an energy density of 0.1 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 5 times at a pulse rate of 1 Hz and an energy density of 0.1 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 1 time at a pulse rate of 1 Hz and an energy density of 0.2 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 3 times at a pulse rate of 1 Hz and an energy density of 0.2 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 5 times at a pulse rate of 1 Hz and an energy density of 0.2 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 1 time at a pulse rate of 1 Hz and an energy density of 0.3 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 3 times at a pulse rate of 1 Hz and an energy density of 0.3 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 5 times at a pulse rate of 1 Hz and an energy density of 0.3 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 1 time at a pulse rate of 1 Hz and an energy density of 0.4 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
- the substrate was treated 3 times at a pulse rate of 1 Hz and an energy density of 0.4 J/cm 2 .
- the substrate was then removed and flipped over, and the treatment was repeated on the backside of the substrate.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Chemical Or Physical Treatment Of Fibers (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
Applications Claiming Priority (2)
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US201762526711P | 2017-06-29 | 2017-06-29 | |
PCT/IB2018/054716 WO2019003115A1 (en) | 2017-06-29 | 2018-06-26 | NONWOVEN ARTICLE AND METHOD FOR MANUFACTURING THE SAME |
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Publication Number | Publication Date |
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EP3645776A1 EP3645776A1 (en) | 2020-05-06 |
EP3645776B1 true EP3645776B1 (en) | 2021-08-25 |
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EP18749509.8A Active EP3645776B1 (en) | 2017-06-29 | 2018-06-26 | Nonwoven article and method of making the same |
Country Status (5)
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US (1) | US20200157734A1 (zh) |
EP (1) | EP3645776B1 (zh) |
KR (1) | KR102492536B1 (zh) |
CN (1) | CN110799687B (zh) |
WO (1) | WO2019003115A1 (zh) |
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EP3646069A1 (en) | 2017-06-29 | 2020-05-06 | 3M Innovative Properties Company | Article and methods of making the same |
CN113584724B (zh) * | 2021-07-28 | 2023-03-17 | 五邑大学 | 一种非织造材料的固网方法及电刺固网装置 |
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US28102A (en) | 1860-05-01 | Stove-gkrate | ||
US4419993A (en) | 1981-12-10 | 1983-12-13 | Minnesota Mining & Manufacturing Company | Anti-fogging surgical mask |
GB8401838D0 (en) | 1984-01-24 | 1984-02-29 | Tribohesion Ltd | Coating process |
BR8606973A (pt) * | 1985-11-14 | 1987-11-03 | Deutsches Textilforschzentrum | Fibra,filamento,fio e/ou artigos planos e/ou material nao tecido contendo os mesmos,bem como um processo para a producao destes |
US5318650A (en) * | 1990-06-05 | 1994-06-07 | E. I. Du Pont De Nemours And Company | Bonded fibrous articles |
US5154969A (en) * | 1990-06-05 | 1992-10-13 | E. I. Du Pont De Nemours And Company | Bonded fibrous articles |
US5134032A (en) * | 1991-02-25 | 1992-07-28 | General Electric Company | Abrasive particle and rotary seal therewith |
SG49833A1 (en) * | 1993-03-24 | 1998-06-15 | Du Pont | Wet-laid sheet material and composites thereof |
AU669420B2 (en) | 1993-03-26 | 1996-06-06 | Minnesota Mining And Manufacturing Company | Oily mist resistant electret filter media |
US5908598A (en) | 1995-08-14 | 1999-06-01 | Minnesota Mining And Manufacturing Company | Fibrous webs having enhanced electret properties |
US5706804A (en) | 1996-10-01 | 1998-01-13 | Minnesota Mining And Manufacturing Company | Liquid resistant face mask having surface energy reducing agent on an intermediate layer therein |
JP3877842B2 (ja) * | 1997-03-05 | 2007-02-07 | ユニチカ株式会社 | 面ファスナー用雌材の製造方法 |
US5827368A (en) | 1997-06-02 | 1998-10-27 | Marquette University | Device for depositing a layer of material on a surface |
US6511701B1 (en) | 2000-05-09 | 2003-01-28 | 3M Innovative Properties Company | Coatings and methods |
US20030119394A1 (en) * | 2001-12-21 | 2003-06-26 | Sridhar Ranganathan | Nonwoven web with coated superabsorbent |
JP5524862B2 (ja) * | 2007-12-31 | 2014-06-18 | スリーエム イノベイティブ プロパティズ カンパニー | 連続微粒子相を有する複合不織繊維ウェブ、並びにその作製及び使用方法 |
GB0818186D0 (en) * | 2008-10-06 | 2008-11-12 | 3M Innovative Properties Co | Scouring material comprising natural fibres |
CN102859058B (zh) * | 2010-04-22 | 2016-03-23 | 3M创新有限公司 | 含有化学活性颗粒的非织造纤维网以及制造和使用所述非织造纤维网的方法 |
EP2563413B1 (en) * | 2010-04-30 | 2017-09-13 | The Procter and Gamble Company | Nonwoven having durable hydrophilic coating |
CN103025941B (zh) * | 2010-07-07 | 2016-08-10 | 3M创新有限公司 | 图案化的气纺非织造纤维网及其制备和使用方法 |
JP2014503694A (ja) * | 2010-09-14 | 2014-02-13 | サビック・イノベーティブ・プラスチックス・アイピー・ベスローテン・フェンノートシャップ | 強化熱可塑性物品、該物品製造用組成物、製造方法および該組成物で形成された物品 |
JP2012214965A (ja) * | 2011-03-29 | 2012-11-08 | Sanyo Chem Ind Ltd | 無機繊維不織布用バインダー |
CN103781956B (zh) * | 2011-06-30 | 2016-09-28 | 3M创新有限公司 | 非织造驻极体纤维网及其制备方法 |
RU2605065C2 (ru) * | 2012-01-04 | 2016-12-20 | Дзе Проктер Энд Гэмбл Компани | Волокнистые структуры, содержащие частицы. |
CN103474610A (zh) * | 2013-09-29 | 2013-12-25 | 天津工业大学 | 一种静电纺丝/静电喷雾制备复合锂离子电池隔膜的方法 |
CN103640308A (zh) * | 2013-11-27 | 2014-03-19 | 怡星(无锡)汽车内饰件有限公司 | 汽车内饰用无纺布复合材料的加工工艺 |
MX2016010228A (es) * | 2014-02-14 | 2016-10-13 | 3M Innovative Properties Co | Articulo abrasivo y metodo para el uso de este. |
US10208408B2 (en) * | 2014-03-19 | 2019-02-19 | Jx Nippon Oil & Energy Corporation | Method for manufacturing ultrafine fiber |
WO2016053830A1 (en) * | 2014-10-01 | 2016-04-07 | 3M Innovative Properties Company | Articles including fibrous substrates and porous polymeric particles and methods of making same |
CN105463704A (zh) * | 2015-12-31 | 2016-04-06 | 福建恒安集团有限公司 | 一种吸湿用品 |
-
2018
- 2018-06-26 US US16/626,244 patent/US20200157734A1/en not_active Abandoned
- 2018-06-26 WO PCT/IB2018/054716 patent/WO2019003115A1/en unknown
- 2018-06-26 KR KR1020197038394A patent/KR102492536B1/ko active IP Right Grant
- 2018-06-26 CN CN201880042693.7A patent/CN110799687B/zh active Active
- 2018-06-26 EP EP18749509.8A patent/EP3645776B1/en active Active
Non-Patent Citations (1)
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Publication number | Publication date |
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CN110799687B (zh) | 2022-04-08 |
KR20200024163A (ko) | 2020-03-06 |
CN110799687A (zh) | 2020-02-14 |
US20200157734A1 (en) | 2020-05-21 |
KR102492536B1 (ko) | 2023-01-27 |
EP3645776A1 (en) | 2020-05-06 |
WO2019003115A1 (en) | 2019-01-03 |
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