Method for producing a spun-bonded nonwoven web with improved abrasion resistance

Abstract

The present invention relates to a method for improving the abrasion resistance of a spun-bonded nonwoven without substantially adversely affecting its hand or drape characteristics, by incorporating low melt binder fibers into the web during the laydown phase of the spun-bonded nonwoven production process. More specifically, improved abrasion resistance is achieved by intimately blending continuous binder fibers with the primary extruded fibers in a spun-bonded nonwoven web. Also encompassed within this invention is a spun-bonded nonwoven fabric having improved abrasion resistance and comprised of primary extruded fiber and low melt binder fiber such that the binder fiber comprises between about 1 and about 50 weight percent on weight of the spun-bonded nonwoven fabric.

I claim:  
     
         1 . A spun-bonded nonwoven fabric having improved abrasion resistance and comprised of primary extruded fiber and low melt binder fiber, wherein the low melt binder fiber comprises between about 1 and about 50 weight percent on weight of the spun-bonded nonwoven fabric, and wherein the low melt binder fiber is incorporated into the spun-bonded nonwoven fabric such that the low melt binder fiber is substantially between about 80 weight percent and about 100 weight percent below the outer surface layer of the spun-bonded nonwoven fabric on weight of the spun-bonded nonwoven fabric.  
     
     
         2 . The spun-bonded nonwoven fabric of  claim 1 , wherein the primary extruded fiber is selected from the group consisting of unitary, single component fibers, multi-component fibers, and combinations thereof.  
     
     
         3 . The spun-bonded nonwoven fabric of  claim 2 , wherein the primary extruded fiber is characterized by having a fiber size of less than 5 denier.  
     
     
         4 . The spun-bonded nonwoven fabric of  claim 3 , wherein the primary extruded fiber is a multi-component fiber, and wherein the multi-component fiber is splittable along its length by mechanical or chemical action into individual component fibers.  
     
     
         5 . The spun-bonded nonwoven fabric of  claim 4 , wherein the individual component fibers are characterized by having a fiber size of less than 1 denier.  
     
     
         6 . The spun-bonded nonwoven fabric of  claim 2 , wherein the primary extruded fiber is comprised of fibers selected from the group consisting of polyester, polyamide, polyolefin, polyaramide, polyurethane, polylactic acid, and combinations thereof.  
     
     
         7 . The spun-bonded nonwoven fabric of  claim 6 , wherein the primary extruded fiber is polyester, and wherein the polyester is selected from the group consisting of polyethylene terephthalate, polytriphenylene terephthalate, polybutylene terephthalate, and combinations thereof.  
     
     
         8 . The spun-bonded nonwoven fabric of  claim 6 , wherein the primary extruded fiber is polyamide, and wherein the polyamide is selected from the group consisting of nylon 6, nylon 6,6, and combinations thereof.  
     
     
         9 . The spun-bonded nonwoven fabric of  claim 6 , wherein the primary extruded fiber is polyolefin, and wherein the polyolefin is selected from the group consisting of polypropylene, polyethylene, and combinations thereof.  
     
     
         10 . The spun-bonded nonwoven fabric of  claim 1 , wherein the low melt binder fiber is selected from the group consisting of unitary, single component fibers, multi-component fibers, and combinations thereof.  
     
     
         11 . The spun-bonded nonwoven fabric of  claim 10 , wherein the low melt binder fiber is comprised of fibers selected from the group consisting of polyester, polyolefin, and combinations thereof.  
     
     
         12 . The spun-bonded nonwoven fabric of  claim 11 , wherein the low melt binder fiber is polyester, and wherein the polyester is selected from the group consisting of polyethylene terephthalate, polytriphenylene terephthalate, polybutylene terephthalate, and combinations thereof.  
     
     
         13 . The spun-bonded nonwoven fabric of  claim 12 , wherein the low melt binder fiber is polyester, and wherein the polyester is characterized by a melting point temperature of between about 100 and about 215 degrees C.  
     
     
         14 . The spun-bonded nonwoven fabric of  claim 12 , wherein the low melt binder fiber is polyester, and wherein the polyester is characterized by a melting point temperature of between about 110 and about 200 degrees C.  
     
     
         15 . The spun-bonded nonwoven fabric of  claim 11 , wherein the low melt binder fiber is polyolefin, and wherein the polyolefin is selected from the group consisting of polypropylene, polyethylene, and combinations thereof.  
     
     
         16 . The spun-bonded nonwoven fabric of  claim 15 , wherein the low melt binder fiber is polypropylene, and wherein the polypropylene is characterized by a melting point temperature of between about 130 and about 190 degrees C.  
     
     
         17 . The spun-bonded nonwoven fabric of  claim 15 , wherein the low melt binder fiber is polyethylene, and wherein the polyethylene is characterized by a melting point temperature of between about 100 and about 150 degrees C.  
     
     
         18 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of apparel.  
     
     
         19 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of bedding.  
     
     
         20 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of residential upholstery.  
     
     
         21 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of commercial upholstery.  
     
     
         22 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of automotive upholstery.  
     
     
         23 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of napery.  
     
     
         24 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article of drapery.  
     
     
         25 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article for residential cleaning cloths.  
     
     
         26 . The spun-bonded nonwoven fabric of  claim 1 , wherein the spun-bonded nonwoven fabric is incorporated into an article for commercial cleaning cloths.  
     
     
         27 . A spun-bonded nonwoven fabric having improved abrasion resistance and comprised of primary extruded fiber and low melt binder fiber, wherein the low melt binder fiber comprises between about 2 and about 30 weight percent on weight of the spun-bonded nonwoven fabric, and wherein the low melt binder fiber is incorporated into the spun-bonded nonwoven fabric such that the low melt binder fiber is substantially between about 80 weight percent and about 100 weight percent below the outer surface layer of the spun-bonded nonwoven fabric on weight of the spun-bonded nonwoven fabric.  
     
     
         28 . A spun-bonded nonwoven fabric having improved abrasion resistance and comprised of primary extruded fiber and low melt binder fiber, wherein the low melt binder fiber comprises between about 3 and about 15 weight percent on weight of the spun-bonded nonwoven fabric, and wherein the low melt binder fiber is incorporated into the spun-bonded nonwoven fabric such that the low melt binder fiber is substantially between about 80 weight percent and about 100 weight percent below the outer surface layer of the spun-bonded nonwoven fabric on weight of the spun-bonded nonwoven fabric.  
     
     
         29 . A spun-bonded nonwoven fabric having improved aesthetic and/or performance characteristics and comprised of primary extruded fiber and secondary fiber or yarn, wherein the secondary fiber or yarn is substantially between about 80 weight percent and about 100 weight percent below the outer surface layer of the spun-bonded nonwoven fabric on weight of the spun-bonded nonwoven fabric, and wherein the secondary fiber or yarn imparts improved aesthetic and/or performance characteristics to the spun-bonded nonwoven fabric.  
     
     
         30 . The spun-bonded nonwoven fabric of  claim 29 , wherein the primary extruded fiber is selected from the group consisting of unitary, single component fibers, multi-component fibers, and combinations thereof.  
     
     
         31 . The spun-bonded nonwoven fabric of  claim 30 , wherein the primary extruded fiber is characterized by having a fiber size of less than 5 denier.  
     
     
         32 . The spun-bonded nonwoven fabric of  claim 31 , wherein the primary extruded fiber is a multi-component fiber, and wherein the multi-component fiber is splittable along its length by mechanical or chemical action into individual component fibers.  
     
     
         33 . The spun-bonded nonwoven fabric of  claim 32 , wherein the individual component fibers are characterized by having a fiber size of less than 1 denier.  
     
     
         34 . The spun-bonded nonwoven fabric of  claim 30 , wherein the primary extruded fiber is comprised of fibers selected from the group consisting of polyester, polyamide, polyolefin, polyaramide, polyurethane, polylactic acid, and combinations thereof.  
     
     
         35 . The spun-bonded nonwoven fabric of  claim 34 , wherein the primary extruded fiber is polyester, and wherein the polyester is selected from the group consisting of polyethylene terephthalate, polytriphenylene terephthalate, polybutylene terephthalate, and combinations thereof.  
     
     
         36 . The spun-bonded nonwoven fabric of  claim 34 , wherein the primary extruded fiber is polyamide, and wherein the polyamide is selected from the group consisting of nylon 6, nylon 6,6, and combinations thereof.  
     
     
         37 . The spun-bonded nonwoven fabric of  claim 34 , wherein the primary extruded fiber is polyolefin, and wherein the polyolefin is selected from the group consisting of polypropylene, polyethylene, and combinations thereof.  
     
     
         38 . The spun-bonded nonwoven fabric of  claim 29 , wherein the secondary fiber or yarn is selected from the group consisting of unitary, single component fibers, multi-component fibers, and combinations thereof.  
     
     
         39 . The spun-bonded nonwoven fabric of  claim 38 , wherein the secondary fiber or yarn is selected from the group consisting of continuous filament fiber, spun staple yarn, spun filament yarn, and combinations thereof.  
     
     
         40 . The spun-bonded nonwoven fabric of  claim 39 , wherein the secondary fiber or yarn is comprised of natural fibers, synthetic fibers, or any combination thereof.  
     
     
         41 . The spun-bonded nonwoven fabric of  claim 40 , wherein the secondary fiber or yarn is comprised, either partially or wholly, of low melt binder fibers.  
     
     
         42 . The spun-bonded nonwoven fabric of  claim 29 , wherein improved aesthetic and/or performance characteristics may be selected from the group comprised of stretch, color, anti-microbial, odor absorbing, absorption management, flame retardance, strength, or any other desirable property, or combinations of properties, that is preferable for an end-use product incorporating the spun-bonded nonwoven fabric.