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EP1101854B1 - Nonwoven fabric of polypropylene fiber and process for making the same - Google Patents

Nonwoven fabric of polypropylene fiber and process for making the same Download PDF

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Publication number
EP1101854B1
EP1101854B1 EP00310313A EP00310313A EP1101854B1 EP 1101854 B1 EP1101854 B1 EP 1101854B1 EP 00310313 A EP00310313 A EP 00310313A EP 00310313 A EP00310313 A EP 00310313A EP 1101854 B1 EP1101854 B1 EP 1101854B1
Authority
EP
European Patent Office
Prior art keywords
continuous fibers
nonwoven fabric
continuous
nozzle
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP00310313A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP1101854A1 (en
Inventor
Toshio c/o Technical Center Kobayashi
Satoru c/o Technical Center Tange
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unicharm Corp
Original Assignee
Unicharm Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by Unicharm Corp filed Critical Unicharm Corp
Publication of EP1101854A1 publication Critical patent/EP1101854A1/en
Application granted granted Critical
Publication of EP1101854B1 publication Critical patent/EP1101854B1/en
Anticipated expiration legal-status Critical
Revoked legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • 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
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
    • 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
    • D04H3/10—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 yarns or filaments made mechanically
    • D04H3/11—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 yarns or filaments made mechanically by fluid jet
    • 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
    • D04H3/16—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 filaments produced in association with filament formation, e.g. immediately following extrusion

Definitions

  • This invention relates to a nonwoven fabric made of continuous polypropylene fiber and to a process for making the same.
  • Japanese Patent No. 2887611 describes a process for making a nonwoven fabric of continuous microfibers having a fineness less than 1 denier. According to the process described in this Patent, continuous microfibers are stretched once on a step of melt spinning and then stretched again until its fineness is reduced to a desired value. The continuous microfibers having a fineness thereof reduced in this manner are collected and bonded together, for example, by adhesion to obtain the desired nonwoven fabric.
  • the prior art described above offers a nonwoven fabric comprising continuous microfibers of a fineness sufficiently reduced to ensure a comfortable soft touch.
  • This invention aims to add this comfortable soft touch nonwoven fabric with a high breaking extension.
  • the object set forth above is achieved, according to its first aspect, by an improvement in the nonwoven fabric made of continuous polypropylene fiber.
  • the improvement according to the first aspect of this invention is in that the continuous fibers have a fineness of 0.006 ⁇ 5.8 deniers, a birefringence of 0.019 ⁇ 0.030 and a tensile breaking extension of 100 ⁇ 300 % wherein the fibers are subjected to substantially mechanical entanglement to maintain the form of a nonwoven fabric.
  • said nonwoven fabric has a tensile strength of 1 ⁇ 3 g/d.
  • the object set forth above is achieved, according to the second aspect of this invention, by an improvement in the process for making a nonwoven fabric comprising the steps of stretching the continuous polypropylene fibers extruded from a plurality of nozzle orifices, accumulating the continuous ploypropylene fibers on a belt travelling in one direction and entangling the continuous fibers together to obtain a desired form of a nonwoven fabric.
  • the improvement according to the second aspect of this invention is in by that the process comprises the steps of heating a region of an extruder in the vicinity of said nozzle substantially at a temperature of said continuous fibers being extruded in molten state, guiding the continuous fibers through guide passage of a sucker extending through between in- and outlet thereof and being supplied with compressed air at the normal temperature discharged in a direction defined from the inlet toward the outlet, stretching the continuous fibers along a path extending between the nozzle and the sucker and thereby reducing a fineness of the continuous fibers, and orienting polypropylene molecules sufficiently to obtain a desired birefringence.
  • Fig. 1 is a diagram schematically illustrating the process for making a nonwoven fabric.
  • the melt spinning machine 1 includes a material feed hopper and a screw feed extruder (not shown), the latter being provided at its forward end with spinning nozzle 11 and hot blast blow-off orifices 12 on both sides of the nozzle 11.
  • material polypropylene having MFR, for example, of 10 ⁇ 80 g/10 min is used.
  • 600 orifices of the nozzle 11 each having an orifice diameter, for example, of 0.35 mm are arranged in line at the orifice pitch of 1 mm in a direction perpendicular to the plane of the drawing.
  • Continuous polypropylene fiber 15 is discharged through each of these orifices of the nozzle 11 at a rate of 0.13 ⁇ 0.40 g/min/nozzle.
  • the blow-off orifices 12 breathe out hot blast substantially at the same temperature as a temperature of polypropylene being discharged in molten state, i.e., at a temperature of approximately 230°C on the assumption that polypropylene is discharged through the nozzle 11 at a temperature of approximately 230°C.
  • the hot blast is breathed out at a rate of 1 ⁇ 3 Nm 3 /min and prevents polypropylene being extruded from being rapidly cooled.
  • the sucker 2 has guide passage 16 for the continuous fibers 15 and blow-off orifices 17 opening into the guide passage 16 from both sides thereof to breathe out compressed air at the normal temperature.
  • the guide passage 16 has an inlet 18 and an outlet 18 for the continuous fibers 15.
  • the sucker 2 is positioned so that a distance P between the nozzle 11 and the inlet 18 of the sucker 2 is 500 mm or less, preferably 100 ⁇ 300 mm.
  • the continuous fibers 15 travelling over the distance P preferably have a temperature falling nearly to the melting point thereof as the continuous fibers 15 reach the inlet 18. Over a distance Q between the blow-off orifices 17 and the outlet 19, the continuous fibers 15 are supplied with compressed air at the normal temperature breathed out toward the outlet 19.
  • the distance Q is preferably in a range of 20 ⁇ 500 mm and the expression "normal temperature” used herein should be understood to be the temperature in a range of 10 ⁇ 50°C.
  • the compressed air is of 0.5 ⁇ 2 kgf/cm 2 G and supplied at a flow rate of Nm 3 /min.
  • the continuous fibers 15 entering the guide passage 16 are quenched by the compressed air at the normal temperature nearly to the normal temperature and, at the same time, stretched appropriately to achieve a fineness of 0.006-5-8 deniers and a birefringence ⁇ n of 0.019 ⁇ 0.030. After stretched in this manner, the continuous fibers 15 preferably have a tensile strength of 1 ⁇ 3 g/d.
  • the endless conveyor belt 3 has its width extending in the direction orthogonal to the plane defined by the drawing.
  • a distance R between the nozzle 11 and the conveyor belt 3 is dimensioned preferably in a range of 300 ⁇ 1500 mm, more preferably in a range of 400 ⁇ 600 mm by correspondingly adjusting the distances P and Q.
  • the conveyor belt 3 travels rightward as viewed in the drawing at a speed of 2 ⁇ 8 m/min.
  • the conveyor belt 3 is made of material having a breathable nature and a suction box 21 is opposed to the sucker 2 with this conveyor belt 3 therebetween.
  • the continuous fibers 15 emerging from the outlet 19 swing transversely as well as longitudinally of the conveyor belt 3 under the effect of compressed air and suction. Consequently, the continuous fibers 15 are accumulated on the conveyor belt 3 in an irregular pattern to form web 22.
  • the high pressure water jet ejector 4 has single or dual or more nozzle array(s) 24 each comprising a plurality of orifices 23 arranged in line transversely of the conveyor belt 3 at a pitch of 0.3 ⁇ 3 mm and a suction box 26 opposed to these nozzle array(s) with the conveyor belt 3 therebetween.
  • the orifices 23 of the first array may stabilize texture of the web 22 by ejecting water jet streams of 20kgf/cm 2 and the orifices 23 of the second array serve may partially orienting the continuous fibers 15 so as to extend in a travelling direction of the web 22 or may partially intertwine the continuous fibers 15 with one another to improve a tensile strength of the web 22.
  • the web 22 may be subsequently dried on a step of drying (not illustrated) to form nonwoven fabric 26 which is, in turn, taken up by the take-up roller 6 in the form of a roll.
  • the novel process for making a nonwoven fabric enables the continuous fibers 15 to have a relatively small fineness, e.g., of 0.006 ⁇ 05.8 d and, at the same time, enables unevenness possibly occurring in the fineness to be alleviated.
  • the continuous fibers 15 obtained by such a novel process are practically free from heat-sealing with one another but only mechanically entangled with one another throughout the process to form the nonwoven fabric 26. In addition, such mechanical entanglement is not tight because the fiber is continuous, so these continuous fibers 15 moderately restrict their relative movement.
  • the nonwoven fabric 26 made of such continuous fibers 15 offer soft and comfortable touch.
  • the continuous fibers 15 appropriately stretched to obtain a birefringence of 0.019 ⁇ 0.030 have a high breaking extension since a degree at which the polypropylene molecules have been stretched is not so high that a stretchability of the continuous fibers 15 might be significantly restricted thereby.
  • a tensile test with 0 mm distance between chucks indicated that the continuous fibers 15 as a typical embodiment of this invention can be stretched to 6.38 mm.
  • the nonwoven fabric 26 formed by mechanically entangling such continuous fibers 15 with one another under the effect of high pressure water jet streams has a breaking extension as high as 100 ⁇ 300 % in MD as well as in CD because of a high breaking extension of the continuous fibers 15 and a moderate intertwining among these fibers 15.
  • the nonwoven fabric 26 as one embodiment of this invention has a breaking extension of 193 % in MD and a breaking extension of 197 % in CD.
  • the nonwoven fabric 26 obtained by the novel process is useful not only as disposable sanitary articles such as disposable diapers, sanitary napkins or disposable gowns to be used on the medical site but also as filters, wet wipes or the like.
  • the process according to this invention makes it possible to obtain a nonwoven fabric made of polypropylene having a fineness of 0.006 ⁇ 5.8 deniers, a birefringence of 0.019 ⁇ 0.030 and a tensile strength of 1 ⁇ 3 g/d.
  • a degree at which the polypropylene molecules are oriented in the course of spinning the continuous fibers is relatively low and, in addition, the continuous fibers are intertwined one with another not so tightly that they might significantly restrict their relative movement.
  • Such continuous fibers offer a comfortable soft touch and a high breaking extension.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Artificial Filaments (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
EP00310313A 1999-11-22 2000-11-21 Nonwoven fabric of polypropylene fiber and process for making the same Revoked EP1101854B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP33179399A JP3662455B2 (ja) 1999-11-22 1999-11-22 ポリプロピレン製不織布およびその製造方法
JP33179399 1999-11-22

Publications (2)

Publication Number Publication Date
EP1101854A1 EP1101854A1 (en) 2001-05-23
EP1101854B1 true EP1101854B1 (en) 2007-11-07

Family

ID=18247715

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00310313A Revoked EP1101854B1 (en) 1999-11-22 2000-11-21 Nonwoven fabric of polypropylene fiber and process for making the same

Country Status (11)

Country Link
EP (1) EP1101854B1 (id)
JP (1) JP3662455B2 (id)
KR (1) KR20010060339A (id)
CN (1) CN1237218C (id)
AU (1) AU765499B2 (id)
BR (1) BR0005847B1 (id)
CA (1) CA2326263C (id)
DE (1) DE60036994T2 (id)
ID (1) ID28425A (id)
SG (1) SG87192A1 (id)
TW (1) TW487756B (id)

Families Citing this family (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6916752B2 (en) * 2002-05-20 2005-07-12 3M Innovative Properties Company Bondable, oriented, nonwoven fibrous webs and methods for making them
EP1424425A1 (de) * 2002-11-27 2004-06-02 Polyfelt Gesellschaft m.b.H. Verfahren zur Herstellung von Geotextilien aus schmeltgesponnenen Fasern
US20050106982A1 (en) * 2003-11-17 2005-05-19 3M Innovative Properties Company Nonwoven elastic fibrous webs and methods for making them
FR2903426B1 (fr) * 2006-07-07 2008-09-12 Rieter Perfojet Soc Par Action Non-tisse utilise comme chiffon d'essuyage,son procede et son installation de production.
JP5063315B2 (ja) * 2006-12-28 2012-10-31 花王株式会社 伸縮シート
EP2379785A1 (en) 2008-12-30 2011-10-26 3M Innovative Properties Company Elastic nonwoven fibrous webs and methods of making and using
DK2603626T3 (en) 2010-08-12 2015-03-02 Boma Engineering Srl METHOD AND APPARATUS FOR SPINNING FIBERS AND SPECIFICALLY FOR MANUFACTURING A FIBER-CONTAINED NONWOVEN
JP5818636B2 (ja) * 2011-04-06 2015-11-18 旭化成せんい株式会社 熱安定性、柔軟性に優れる不織布
US8623248B2 (en) * 2011-11-16 2014-01-07 Celanese Acetate Llc Methods for producing nonwoven materials from continuous tow bands
JP6238806B2 (ja) * 2014-03-24 2017-11-29 日本バイリーン株式会社 極細繊維不織布および不織布の製造装置
US9303334B2 (en) 2014-05-07 2016-04-05 Biax-Fiberfilm Apparatus for forming a non-woven web
US11598026B2 (en) 2014-05-07 2023-03-07 Biax-Fiberfilm Corporation Spun-blown non-woven web
US9309612B2 (en) 2014-05-07 2016-04-12 Biax-Fiberfilm Process for forming a non-woven web
US10633774B2 (en) 2014-05-07 2020-04-28 Biax-Fiberfilm Corporation Hybrid non-woven web and an apparatus and method for forming said web
WO2015171707A1 (en) * 2014-05-07 2015-11-12 Biax-Fiberfilm A non-woven web
EP3655577A4 (en) * 2017-07-17 2021-04-28 Biax-Fiberfilm Corporation SPUN-BLOWN NON-WOVEN BAND
EP3960442B1 (en) * 2019-04-26 2024-05-22 Nitto Denko Corporation Stretchable laminate and method for manufacturing same
JP7581761B2 (ja) 2020-10-14 2024-11-13 王子ホールディングス株式会社 不織布の製造方法
JP7223215B1 (ja) * 2021-06-30 2023-02-15 旭化成株式会社 不織布及びその用途、並びに不織布の製造方法

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NL297313A (id) * 1962-08-30 1900-01-01
US3969462A (en) * 1971-07-06 1976-07-13 Fiber Industries, Inc. Polyester yarn production
US4013816A (en) * 1975-11-20 1977-03-22 Draper Products, Inc. Stretchable spun-bonded polyolefin web
US4347206A (en) * 1980-03-15 1982-08-31 Kling-Tecs, Inc. Method of extruding polypropylene yarn
DE3630392C1 (de) * 1986-09-06 1988-02-11 Rhodia Ag Verfahren zur Herstellung von verfestigten Vliesen
DE3941824A1 (de) * 1989-12-19 1991-06-27 Corovin Gmbh Verfahren und spinnvorrichtung zur herstellung von mikrofilamenten
JP2887611B2 (ja) * 1990-01-27 1999-04-26 三井化学株式会社 不織布の製造方法及び装置
JP2829147B2 (ja) * 1991-03-12 1998-11-25 出光石油化学株式会社 不織布の製造方法
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JP3525536B2 (ja) * 1995-02-02 2004-05-10 チッソ株式会社 改質ポリオレフィン系繊維およびそれを用いた不織布
US6013223A (en) * 1998-05-28 2000-01-11 Biax-Fiberfilm Corporation Process and apparatus for producing non-woven webs of strong filaments

Also Published As

Publication number Publication date
BR0005847A (pt) 2001-07-24
ID28425A (id) 2001-05-24
DE60036994T2 (de) 2008-08-28
JP3662455B2 (ja) 2005-06-22
CN1237218C (zh) 2006-01-18
SG87192A1 (en) 2002-03-19
CN1297075A (zh) 2001-05-30
BR0005847B1 (pt) 2011-12-27
CA2326263C (en) 2006-12-05
CA2326263A1 (en) 2001-05-22
AU765499B2 (en) 2003-09-18
AU7173900A (en) 2001-05-24
JP2001146670A (ja) 2001-05-29
EP1101854A1 (en) 2001-05-23
KR20010060339A (ko) 2001-07-06
DE60036994D1 (de) 2007-12-20
TW487756B (en) 2002-05-21

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