Material comprising a nonwoven layer of fibers

Abstract

A process for providing a material comprising a nonwoven layer of fibers is provided comprising: providing a material composition comprising: 90 to 98.7 wt. % of a recycled polyester polymer, 1 to 5 wt. % of a polyolefin polymer, and 0.3 to 5 wt. % of a compatibilizer based on the total weight of the recycled polyester polymer, the polyolefin polymer and the compatibilizer; melting the material composition; extruding the molten material composition through spinning holes in a spinneret to form extruded fibers; supplying the extruded fibers to form a nonwoven web of fibers; and consolidating the nonwoven web to obtain a material comprising a nonwoven layer of fibers.

1 . A process for providing a material comprising a nonwoven layer of fibers, the process comprising:
 providing a material composition comprising:   90 to 98.7 wt. % of a recycled polyester polymer,   1 to 5 wt. % of a polyolefin polymer, and   0.3 to 5 wt. % of a compatibilizer based on the total weight of the recycled polyester polymer, the polyolefin polymer and the compatibilizer;   melting the material composition;   extruding the molten material composition through spinning holes in a spinneret to form extruded fibers;   supplying the extruded fibers to form a nonwoven web of fibers; and   consolidating the nonwoven web to obtain a material comprising a nonwoven layer of fibers.   
     
     
         2 . The process according to  claim 1  wherein the fibers have an average tenacity of at least 2.4 cN/dtex determined according to ISO 5079:2020. 
     
     
         3 . The process according to  claim 1  wherein the recycled polyester polymer is a recycled polyethylene terephthalate. 
     
     
         4 . The process according to  claim 1  wherein the polyolefin polymer is a polyethylene. 
     
     
         5 . The process according to  claim 4 , wherein the polyethylene is a recycled polyethylene. 
     
     
         6 . The process according to  claim 1  wherein the compatibilizer is a polyolefin polymer grafted with maleic anhydride, a polyolefin co-polymer grafted with maleic anhydride or a mixture thereof. 
     
     
         7 . The process according to  claim 1  wherein the compatibilizer is an ethylene-methyl-acrylate copolymer, an ethylene-methyl-acrylate copolymer grafted with maleic anhydride or a mixture thereof. 
     
     
         8 . The process according to  claim 1  wherein the compatibilizer is a polymer comprising a glycidyl-methacrylate monomer. 
     
     
         9 . A material comprising:
 a nonwoven layer of fibers, the fibers comprising:   90 to 98.7 wt. % of a recycled polyester polymer,   1 to 5 wt. % of a polyolefin polymer, and   0.3 to 5 wt. % of a compatibilizer based on the total weight of the recycled polyester polymer, the polyolefin polymer and the compatibilizer.   
     
     
         10 . The material according to  claim 8  wherein the fibers have an average tenacity of at least 2.4 cN/dtex determined according to ISO 5079:2020. 
     
     
         11 . The material according to  claim 9  wherein the polyester is a polyethylene terephthalate. 
     
     
         12 . The material according to  claim 9  wherein the polyolefin is a polyethylene. 
     
     
         13 . The material according to  claim 12 , wherein the polyethylene is a recycled polyethylene. 
     
     
         14 . The material according to  claim 9  wherein the compatibilizer is a polyolefin polymer grafted with maleic anhydride, a polyolefin co-polymer grafted with maleic anhydride or a mixture thereof. 
     
     
         15 . The material according to  claim 9  wherein the compatibilizer is an ethylene-methyl-acrylate copolymer, an ethylene-methyl-acrylate copolymer grafted with maleic anhydride or a mixture thereof. 
     
     
         16 . A fiber for a nonwoven layer of fibers, the fiber comprising:
 90 to 98.7 wt. % of a recycled polyester;   1 to 5 wt. % of a polyolefin; and   0.3 to 5 wt. % of a compatibilizer based on the total weight of the recycled polyester, the polyolefin and the compatibilizer.   
     
     
         17 . The fiber according to  claim 16  wherein the fiber has an average tenacity of at least 2.4 cN/dtex determined according to ISO 5079:2020.