US2002144384A1PendingUtilityA1

Thermally bonded fabrics and method of making same

47
Assignee: DOW CHEMICAL COPriority: Dec 11, 2000Filed: Dec 11, 2001Published: Oct 10, 2002
Est. expiryDec 11, 2020(expired)· nominal 20-yr term from priority
Inventors:Rexford A. Maugans
D04H 1/544D04H 3/14D04H 1/4291D04H 1/54
47
PatentIndex Score
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Claims

Abstract

A method for producing a nonwoven fabric comprises passing a fiber web through a pair of rollers to obtain a thermally bonded fabric with a high percentage of bond areas. The high percentage of bond areas is formed by an engraved pattern on at least one of the rollers. The engraved pattern has a high percentage of bond point areas and wide bond point angles. The nonwoven fabric has increased tensile strength, elongation, abrasion resistance, flexural rigidity, and/or softness.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A method of making a non-woven fabric, comprising: 
 passing a fiber web through a pair of rolls to obtain a thermally bonded fabric with a high percentage of bond areas, 
 wherein the high percentage of bond areas is formed by an engraved pattern on one of the rolls, and the engraved pattern has a high percentage of bond point areas.  
   
     
     
         2 . The method of  claim 1 , wherein the engraved pattern has a high percentage of bond point area and a wide bond point angle.  
     
     
         3 . The method of  claim 1 , wherein the percentage of bond areas is at least about 16 percent.  
     
     
         4 . The method of  claim 1 , wherein the percentage of bond areas is at least about 20 percent.  
     
     
         5 . The method of  claim 1 , wherein the percentage of bond areas is at least about 24 percent.  
     
     
         6 . The method of  claim 2 , wherein the bond point angle is about 20° or higher.  
     
     
         7 . The method of  claim 2 , wherein the bond point angle is about 35° or higher.  
     
     
         8 . The method of  claim 2 , wherein the bond point angle is about 37° or higher.  
     
     
         9 . The method of  claim 2 , wherein the bond point angle is about 42° or higher.  
     
     
         10 . The method of  claim 2 , wherein the bond point angle is about 46° or higher.  
     
     
         11 . The method of  claim 1 , wherein the engraved pattern has at least about 1.55×10 5  bond points per square meter.  
     
     
         12 . The method of  claim 1 , wherein the engraved pattern has at least about 2.31×10 5  bond points per square.  
     
     
         13 . The method of  claim 1 , wherein the engraved pattern has at least about 3.1×10 5  bond points per square meter.  
     
     
         14 . The method of  claim 1 , wherein the engraved pattern has at least about 3.44×10 5  bond points per square meter.  
     
     
         15 . The method of  claim 1 , wherein the engraved pattern has at least about 4.6×10 5  bond points per square meter.  
     
     
         16 . The method of  claim 1 , wherein the engraved pattern has at least about 4.65×10 5  bond points per square meter.  
     
     
         17 . The method of  claim 1 ,  4 ,  7 , or  14 , wherein the fiber web comprises polyethylene.  
     
     
         18 . The method of  claim 17 , wherein the polyethylene is a homopolymer of ethylene.  
     
     
         19 . The method of  claim 17 , wherein the polyethylene is a copolymer of ethylene and a comonomer.  
     
     
         20 . The method of  claim 17 , wherein the polyethylene is obtained in the presence of a metallocene catalyst.  
     
     
         21 . The method of  claim 17 , wherein the polyethylene is obtained in the presence of a constrained geometry catalyst.  
     
     
         22 . The method of  claim 17 , wherein the polyethylene is obtained in the presence of a single site catalyst.  
     
     
         23 . A non-woven fabric comprising a polymer, wherein the fabric is characterized by a high percentage of bond areas and a high abrasion resistance.  
     
     
         24 . The non-woven thermal bonding fabric of  claim 23 , wherein the polymer is polyethylene.  
     
     
         25 . The method of  claim 23 , wherein the percentage of bond areas is at least about 16 percent.  
     
     
         26 . The method of  claim 23 , wherein the percentage of bond areas is at least about 20 percent.  
     
     
         27 . The method of  claim 23 , wherein the percentage of bond areas is at least about 24 percent.  
     
     
         28 . A fabric made by the method, comprising: 
 passing a fiber web through a pair of rolls to obtain a thermally bonded fabric with a high percentage of bond areas, 
 wherein the high percentage of bond areas is formed by an engraved pattern on one of the rolls, and the engraved pattern has a high percentage of bond point areas.  
   
     
     
         29 . The fabric of  claim 28 , wherein the engraved pattern has a wide bond point angle.  
     
     
         30 . The fabric of  claim 28 , wherein the percentage of bond areas is at least about 16 percent.  
     
     
         31 . The fabric of  claim 28 , wherein the percentage of bond areas is at least about 20 percent.  
     
     
         32 . The fabric of  claim 28 , wherein the percentage of bond areas is at least about 24 percent.  
     
     
         33 . The fabric of  claim 29 , wherein the bond point angle is about 20 degrees or higher.  
     
     
         34 . The fabric of  claim 29 , wherein the bond point angle is about 35 degrees or higher.  
     
     
         35 . The fabric of  claim 29 , wherein the bond point angle is about 37 degrees or higher.  
     
     
         36 . The fabric of  claim 29 , wherein the bond point angle is about 42 degrees or higher.  
     
     
         37 . The fabric of  claim 29 , wherein the bond point angle is about 46 degrees or higher.  
     
     
         38 . The fabric of  claim 28 , wherein the engraved pattern has at least about 1.55×10 5  bond points per square meter.  
     
     
         39 . The fabric of  claim 28 , wherein the engraved pattern has at least about 2.31×10 5  bond points per square meter.  
     
     
         40 . The fabric of  claim 28 , wherein the engraved pattern has at least 3.1×10 5  bond points per square meter.  
     
     
         41 . The fabric of  claim 28 , wherein the engraved pattern has at least about 3.44×10 5  bond points per square meter.  
     
     
         42 . The fabric of  claim 28 , wherein the engraved pattern has at least about 4.6×10 5  bond points per square meter.  
     
     
         43 . The fabric of  claim 28 , wherein the engraved pattern has at least about 4.65×10 5  bond points per square meter.  
     
     
         44 . The fabric of  claim 28 ,  31 ,  34 , or  41 , wherein the fiber web comprises polyethylene.  
     
     
         45 . The fabric of  claim 43 , wherein the polyethylene is a homopolymer of ethylene.  
     
     
         46 . The fabric of  claim 43 , wherein the polyethylene is a copolymer of ethylene and a comonomer.  
     
     
         47 . The fabric of  claim 43 , wherein the polyethylene is obtained in the presence of a metallocene catalyst.  
     
     
         48 . The fabric of  claim 43 , wherein the polyethylene is obtained in the presence of a constrained geometry catalyst.  
     
     
         49 . The fabric of  claim 43 , wherein the polyethylene is obtained in the presence of a single site catalyst.  
     
     
         50 . A method of making a non-woven polyethylene fabric, comprising: 
 passing a polyethylene fiber web through a pair of rolls to obtain a thermally bonded fabric with at least 20 percent of bond areas,    wherein the bond areas is formed by an engraved pattern on one of the rolls, and the engraved pattern has at least about 3.1×10 5  bond points per square meter.    
     
     
         51 . The method of  claim 50 , wherein the engraved pattern has a bond point angle of about 20° or higher.  
     
     
         52 . The method of  claim 51 , wherein the bond point angle is about 35° or higher.  
     
     
         53 . The method of  claim 51 , wherein the bond point angle is about 37° or higher.  
     
     
         54 . The method of  claim 51 , wherein the bond point angle is about 42° or higher.  
     
     
         55 . The method of  claim 51 , wherein the bond point angle is about 46° or higher.  
     
     
         56 . The method of  claim 50 , wherein the engraved pattern has at least about 3.44×10 5  bond points per square meter.  
     
     
         57 . The method of  claim 50 , wherein the percentage of bond areas is at least about 24 percent.

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