WO1997013909B1 - Composite nonwovens and methods for the preparation thereof - Google Patents
Composite nonwovens and methods for the preparation thereofInfo
- Publication number
- WO1997013909B1 WO1997013909B1 PCT/DK1996/000435 DK9600435W WO9713909B1 WO 1997013909 B1 WO1997013909 B1 WO 1997013909B1 DK 9600435 W DK9600435 W DK 9600435W WO 9713909 B1 WO9713909 B1 WO 9713909B1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- bulky
- fibres
- support layer
- composite nonwoven
- Prior art date
Links
- 239000002131 composite material Substances 0.000 title claims abstract 26
- 239000004745 nonwoven fabric Substances 0.000 title 1
- 239000007788 liquid Substances 0.000 claims abstract 23
- 238000000034 method Methods 0.000 claims abstract 16
- 239000000203 mixture Substances 0.000 claims abstract 5
- 230000015572 biosynthetic process Effects 0.000 claims abstract 4
- 238000005755 formation reaction Methods 0.000 claims abstract 4
- 239000000126 substance Substances 0.000 claims abstract 4
- 230000014759 maintenance of location Effects 0.000 claims abstract 3
- 238000009960 carding Methods 0.000 claims abstract 2
- 239000011159 matrix material Substances 0.000 claims 6
- -1 polyethylene Polymers 0.000 claims 6
- 239000004743 Polypropylene Substances 0.000 claims 5
- 229920000728 polyester Polymers 0.000 claims 5
- 229920001155 polypropylene Polymers 0.000 claims 5
- 239000011230 binding agent Substances 0.000 claims 4
- 239000004698 Polyethylene (PE) Substances 0.000 claims 3
- 229920000573 polyethylene Polymers 0.000 claims 3
- 229920001634 Copolyester Polymers 0.000 claims 1
- 229920002456 HOTAIR Polymers 0.000 claims 1
- 229920000297 Rayon Polymers 0.000 claims 1
- 238000004378 air conditioning Methods 0.000 claims 1
- 229920001577 copolymer Polymers 0.000 claims 1
- 230000005611 electricity Effects 0.000 claims 1
- 230000003068 static Effects 0.000 claims 1
- 238000010998 test method Methods 0.000 claims 1
Abstract
A composite nonwoven for controlled acquisition and distribution of liquid, comprising at least a first support layer and a first bulky layer, the bulky layer functioning to acquire and distribute liquid and the support layer being suitable for use either as a coverstock or as a transfer layer between the bulky layer and a liquid retention layer, the support layer and the bulky layer being bonded together, by non-chemical bonding, by a network of individual bonding points to form a liquid control system that facilitates liquid distribution within the individual layers and liquid transfer between the layers, the composite nonwoven showing a combination of a low strike-through time and a low rewet; and a high-speed in-line process for producing the composite nonwoven, the process comprising forming a first support layer, e.g. by carding or spunbonding, consolidating the first support layer, forming at least a first bulky layer containing carded fibres on top of the first support layer, and bonding the combination of the support layer and the bulky layer by non-chemical bonding means, e.g. thermobonding, during which process draft is reduced at least during formation of the first bulky layer by means of at least one laydown suction box providing suction at least at the point at which the bulky layer is formed and by means of at least one holddown suction box providing suction after formation of the bulky layer and until the point at which bonding between the layers takes place, said laydown and holddown suction boxes being located beneath an air-permeable conveyor belt.
Claims
1. A composite nonwoven for controlled acquisition and dis¬ tribution of liquid, comprising at least a first support layer
"-> and a first bulky layer, the bulky layer functioning to acquire and distribute liquid and the support layer being suitable for use either as a coverstock or as a transfer layer between the bulky layer and a liquid retention layer, the support layer and the bulky layer being bonded together by a network of individual
10 bonding points to form a liquid control system that facilitates liquid distribution within the individual layers and liquid transfer between the layers, the composite nonwoven showing a combination of a low strike-through or acquisition time and a low rewet or wetback.
15
2. A composite nonwoven according to claim 1 wherein the support layer and the bulky layer are bonded together by non-chemical bonding means.
20 3. A composite nonwoven according to claim 1 which exhibits at least one of the following properties: a) a strike-through time (3rd insult) of at the most about 2.5 sec, as determined by the modified EDANA test method described herein based on EDANA standard No. ERT 150.2-93; 2ό b) a rewet, as determined by EDANA standard No. ERT 151.0-93, of at the most about 0.20 g; c) an acquisition time (3rd insult) , as determined by the ADD method described herein, of at the most about 60 sec; and d) a wetback, as determined by the ADD method described herein, 30 of at the most about 7 g.
4. A composite nonwoven according to claim 1 which contains a second bulky layer, the second bulky layer being bonded to the first bulky layer by a network of individual bonding points to V. form a liquid control system that facilitates liquid distribution withm the individual layers and liquid transfer between the bulky layers.
5. A composite nonwoven according to claim 1 comprising at least one bulky layer comprising a mix of synthetic binder fibres and matrix fibres, said binder fibres being selected from bicomponent fibres and monocomponent fibres containing polyethylene, polypropylene, polyester or a copolymer, and said matrix fibres being selected from polypropylene, polyester and cellulosic fibres, including viscose fibres.
6. A composite nonwoven according to claim 5 wherein the binder fibres are polypropylene/polyethylene, polyester/polyethylene or polyester/copolyester bicomponent fibres and the matrix fibres are polyester fibres.
7. A composite nonwoven according to claim 1 wherein the support layer is a carded or spunbonded web.
8. A composite nonwoven according to claim 1 wherein the support layer comprises polypropylene and/or bicomponent fibres or filaments.
9. A composite nonwoven according to claim 1 wherein the support layer comprises fibres or filaments having a fineness m the range of 1-7 dtex.
10. A composite nonwoven according to claim 1 comprising at least one bulky layer comprising bicomponent fibres with a fineness in the range of 1-7 dtex and matrix fibres with a fineness in the range of 1-12 dtex.
11. A composite nonwoven according to claim 10 which comprises at least one bulky layer designed primarily for acquisition of liquid and comprising matrix fibres having a fineness in the range of 5-12 dtex, and at least one bulky layer designed primarily for distribution of liquid within the layer and comprising matrix fibres having a fineness in the range of from 1 to less than 5 dtex.
.1 12. A composite nonwoven according to claim 1 comprising bicomponent fibres and/or polypropylene fibres or filaments treated with a permanent hydrophilic spin finish.
13. A composite nonwoven according to claim 1 comprising at least 10 one bulky layer comprising fibres with a 3-dimensional crimp and/or hollow fibres.
14 A composite nonwoven according to claim 1 wherein the first support layer has a basis weight of at the most 20 g/m , the total lr> basis weight of the bulky layer(s) being m the range of 8 to 60
15. A composite nonwoven according to claim 5 wherein the percentage of binder fibres in the bulky layer(s) is in the range 20 of 10-65% by weight, based on the total weight of the bulky layer(s)
16 A high-speed m-line process for producing a composite nonwoven for controlled acquisition and distribution of liquid
25 comprising at least a first support layer and a first bulky layer, the bulky layer functioning to acquire and distribute liquid and the support layer being suitable for use either as a coverstock or as a transfer layer between the bulky layers and a liquid retention layer, the process comprising forming a first
30 support layer, consolidating the first support layer, forming a first bulky layer containing carded fibres on top of the first support layer, and bonding the combination of the support layer and the bulky layer by non-chemical bonding to form bonds within the bulky layer and a network of individual bonding points
•V) between the first bulky layer and the first support layer that facilitate liquid distribution within the individual layers and liquid transfer between the layers, the process comprising providing suction means comprising at least one laydown suction box providing suction at least at the point at which the bulky layer is formed and at least one holddown suction box providing ") suction after formation of the bulky layer and until the point at which bonding between the layers takes place, said laydown and holddown suction boxes being located beneath an air-permeable conveyor belt
0 17. A process according to claim 16 which further includes the step of forming a second bulky layer on top of the first bulky layer before bonding of the first support layer and the first bulky layer, the second bulky layer being subsequently bonded to the first bulky layer by a network of individual bonding points 5 that facilitate liquid transfer between the bulky layers.
18 A process according to claim 17 m which the second bulky layer is a carded layer formed using a second card in opposite orientation to the card forming the first bulky layer, and using 0 a perforated suction roll at the point at which the second bulky layer is laid onto the first bulky layer, wherein at least one suction box provides suction between the card exit for the second bulky layer and the perforated suction roll.
5 19. A process according to claim 16 in which consolidation of the first support layer is performed by means of thermobonding, infrared bonding or ultrasonic bonding.
20. A process according to claim 19 wherein the first support 0 layer is produced by carding and wherein, during formation of the first support layer, suction is provided from the card exit point and until the point at which consolidation takes place by means of at least one suction box
5 21. A process according to claim 20 wherein consolidation of the first support layer is performed using calender bonding means including at least upper and lower calender rolls, the first sup¬ port layer being transported to the calender bonding means on a conveyor belt, in which the calender bonding means has an arran¬ gement between the conveyor belt and the calender rolls that allows the upper calender roll to function as a rotating support for the unbonded first support layer, and in which the conveyor belt has a reduced diameter conveyor head roll that allows a reduced distance between the conveyor head roll and the upper and lower calender rolls, the distance between the conveyor head roll and the upper calender roll being essentially the same as or not substantially greater than the thickness of the first support layer to be consolidated using the calender bonding means.
22. A process according to claim 16 wherein the first support layer is produced by spunbonding.
23. A process according to claim 16 in which the bonding of the first bulky layer to the first support layer and, when present, to the second bulky layer, is performed using a through-air oven which can be adjusted to allow either the support layer or the first bulky layer or, when present, the second bulky layer to be m contact with the drum of the oven.
24. A process according to claim 16 in which air sucked from each suction box is recycled, filtered and adjusted to a desired temperature and relative humidity by an air conditioning system.
25. A process according to claim 16 in which static electricity repellency between the conveyor belts and the fibres of any of the layers is reduced by means of humidified air having a relative humidity of 45-65% being sucked through the fibrous webs and the conveyor belts .
26. A process according to claim 19 wherein consolidation of the first support layer is performed using calender bonding or a hot- air oven
27. A composite nonwoven according to claim 3 which exhibits at least one of the following properties a) a strike-through time (3rd insult) of at the most about 2.0 "> sec; b) a rewet of at the most about 0.15 g; c) an acquisition time (3rd insult) of at the most about 40 sec, and d) a wetback of at the most about 5 g. 0
28. A composite nonwoven according to claim 27 which exhibits at least one of the following properties: a) a strike-through time (3rd insult) of at the most about 1.5 sec; 5 b) a rewet of at the most about 0.10 g,- c) an acquisition time (3rd insult) of at the most about 30 sec, and d) a wetback of at the most about 4 g.
0 29. A composite nonwoven according to claim 9 wherein the support layer comprises fibres or filaments with a fineness in the range of 1.5-5 dtex.
30. A composite nonwoven according to claim 10 wherein at least 5 one bulky layer comprises bicomponent fibres with a fineness in the range of 1.5-5 dtex.
31. A composite nonwoven according to claim 14 wherein the first support layer has a basis weight of at the most 16 g/m', and the 0 total weight of the bulky layer(s) is in the range of 12-40 g/m
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP96933333A EP0859883B1 (en) | 1995-10-11 | 1996-10-11 | Composite nonwovens and methods for the preparation thereof |
| DE69603286T DE69603286T2 (en) | 1995-10-11 | 1996-10-11 | COMPOSITIONS AND METHOD FOR THE PRODUCTION THEREOF |
| DK96933333T DK0859883T3 (en) | 1995-10-11 | 1996-10-11 | Nonwoven composite materials and processes for their manufacture |
| AU72112/96A AU7211296A (en) | 1995-10-11 | 1996-10-11 | Composite nonwovens and methods for the preparation thereof |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP95402278 | 1995-10-11 | ||
| EP95402278.6 | 1995-10-11 | ||
| US1138596P | 1996-02-09 | 1996-02-09 | |
| US60/011,385 | 1996-02-09 |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| WO1997013909A2 WO1997013909A2 (en) | 1997-04-17 |
| WO1997013909A3 WO1997013909A3 (en) | 1997-05-29 |
| WO1997013909B1 true WO1997013909B1 (en) | 1997-07-31 |
Family
ID=56289713
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/DK1996/000435 WO1997013909A2 (en) | 1995-10-11 | 1996-10-11 | Composite nonwovens and methods for the preparation thereof |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US5989688A (en) |
| EP (1) | EP0859883B1 (en) |
| AT (1) | ATE182188T1 (en) |
| AU (1) | AU7211296A (en) |
| DE (1) | DE69603286T2 (en) |
| DK (1) | DK0859883T3 (en) |
| WO (1) | WO1997013909A2 (en) |
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| DE60110290T2 (en) * | 2000-02-28 | 2005-10-06 | Kao Corp. | Sheet for an absorbent article and absorbent article with such a sheet |
| WO2002004729A1 (en) * | 2000-07-11 | 2002-01-17 | Polymer Group Inc. | Multi-component nonwoven fabric for use in disposable absorbent articles |
| JP3609361B2 (en) * | 2000-10-12 | 2005-01-12 | 花王株式会社 | Three-dimensional sheet material |
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| US10667958B2 (en) | 2015-12-02 | 2020-06-02 | Kimberly-Clark Worldwide, Inc. | Acquisition distribution laminate |
| WO2018129701A1 (en) * | 2017-01-13 | 2018-07-19 | The Procter & Gamble Company | Nonwoven and absorbent articles having same |
| DE102018000854B4 (en) * | 2017-09-14 | 2022-01-27 | Sandler Ag | Liquid absorption fleece and distribution fleece for hygiene articles |
| US11136699B2 (en) | 2018-05-14 | 2021-10-05 | Fitesa Simpsonville, Inc. | Composite sheet material, system, and method of preparing same |
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-
1996
- 1996-10-11 DK DK96933333T patent/DK0859883T3/en active
- 1996-10-11 US US08/730,660 patent/US5989688A/en not_active Expired - Fee Related
- 1996-10-11 AT AT96933333T patent/ATE182188T1/en not_active IP Right Cessation
- 1996-10-11 EP EP96933333A patent/EP0859883B1/en not_active Revoked
- 1996-10-11 WO PCT/DK1996/000435 patent/WO1997013909A2/en not_active Application Discontinuation
- 1996-10-11 AU AU72112/96A patent/AU7211296A/en not_active Abandoned
- 1996-10-11 DE DE69603286T patent/DE69603286T2/en not_active Expired - Fee Related
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