CaCO3 IN POLYESTER FOR NONWOVEN AND FIBERS

Abstract

The present invention concerns a nonwoven fabric comprising at least one polymer comprising a polyester and at least one filler comprising calcium carbonate. The present invention further relates to a process of producing such a nonwoven fabric as well as to the use of calcium carbonate as filler in a nonwoven fabric comprising at least one polymer comprising a polyester.

1 . A nonwoven fabric comprising
 at least one polymer comprising a polyester, and   at least one filler comprising calcium carbonate.   
     
     
         2 . The nonwoven fabric of  claim 1 , wherein the polyester is selected from the group consisting of a polyglycolic acid, a polycaprolactone, a polyethylene adipate, a polyhydroxyalkanoate, a polyhydroxybutyrate, a polyethylene terephthalate, a polytrimethylene terephthalate, a polybutylene terephthalate, a polyethylene naphthalate, a polylactic acid, or a mixture thereof, or copolymers thereof, preferably the polyester is a polyethylene terephthalate. 
     
     
         3 . The nonwoven fabric of  claim 1 , wherein the polyester has a number average molecular weight from 5000 to 100000 g/mol, preferably from 10000 to 50000 g/mol, and more preferably from 15000 to 20000 g/mol. 
     
     
         4 . The nonwoven fabric of  claim 1 , wherein the calcium carbonate is ground calcium carbonate, precipitated calcium carbonate, modified calcium carbonate, surface-treated calcium carbonate, or a mixture thereof, preferably surface-treated calcium carbonate. 
     
     
         5 . The nonwoven fabric of  claim 1 , wherein the calcium carbonate has an average particle size d 50  from 0.1 to 3 μm, preferably from 0.4 to 2.5 μm, more preferably from 1.0 to 2.3 μm, and most preferably from 1.2 to 1.8 μm. 
     
     
         6 . The nonwoven fabric of  claim 1 , wherein the calcium carbonate has an top cut particle size d 98  from 1 to 10 μm, preferably from 5 to 8 μm, more preferably from 4 to 7 μm, and most preferably from 6 to 7 μm. 
     
     
         7 . The nonwoven fabric of  claim 1 , wherein the calcium carbonate is present in the nonwoven fabric in an amount from 0.1 to 50 wt.-%, preferably from 0.2 to 40 wt.-%, and more preferably from 1 to 35 wt.-%, based on the total weight of the nonwoven fabric. 
     
     
         8 . A process for producing a nonwoven fabric comprising the steps of
 a) providing a mixture of at least one polymer comprising a polyester and at least one filler comprising calcium carbonate,   b) forming the mixture into fibers, filaments and/or film-like filamentary structures, and   c) forming a nonwoven fabric from the fibers, filaments and/or film-like filamentary structures.   
     
     
         9 . The process of  claim 8 , wherein in step b) the mixture is formed into fibers, preferably by an extrusion process, and more preferably by a melt blown process, a spunbond process, or a combination thereof. 
     
     
         10 . The process of  claim 9 , wherein the nonwoven fabric is formed by collecting the fibers on a surface or carrier. 
     
     
         11 . The process of  claim 8 , wherein steps b) and c) are repeated two or more times to produce a multilayer nonwoven fabric, preferably a spundbonded-meltblown-spunbonded (SMS), a meltblown-spunbonded-meltblown (MSM), a spundbonded-meltblown-spunbonded-meltblown (SMSM), a meltblown-spunbonded-meltblown-spunbonded (MSMS), a spundbonded-meltblown-meltblown-spunbonded (SMMS), or a meltblown-spunbonded-spunbonded-meltblown (MSSM) nonwoven fabric. 
     
     
         12 - 13 . (canceled) 
     
     
         14 . Construction products, waterproofing, thermal insulation, soundproofing, roofing, consumer apparel, upholstery and clothing industries, industrial apparel, medical products, home furnishings, protective products, packaging materials, cosmetic products, hygiene products, or filtration materials comprising the nonwoven fabric according to  claim 1 . 
     
     
         15 . Construction products, consumer apparel, industrial apparel, medical products, home furnishings, protective products, packaging materials, cosmetic products, hygiene products, or filtration materials comprising the nonwoven fabric according to  claim 1 .