US2024263374A1PendingUtilityA1

Nonwoven fabric with enhanced strength

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Assignee: PFNONWOVENS HOLDING S R OPriority: May 14, 2021Filed: May 13, 2022Published: Aug 8, 2024
Est. expiryMay 14, 2041(~14.8 yrs left)· nominal 20-yr term from priority
Inventors:Nikol PolaskovaRoman KolarikMichael Kauschke
D10B 2401/063D04H 3/147D01F 8/14D01F 1/10D04H 3/16D04H 3/08D04H 3/011C08J 2467/02C08J 2367/04C08K 5/20C08J 3/203
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Claims

Abstract

Nonwoven fabric containing endless fibers and bonding impressions or bonding points, the endless fibers containing at least 80 wt. % of aliphatic polyesters, the endless fibers containing a first component making up at least 55% of fiber surface, the first component containing at least one aliphatic polyester and at least 0.1 wt. % of an additive, the additive containing an amide group, the additive corresponding to a general formula (i) or (ii) or (iii)(i) R1-(CO)—NH2 (ii) R1-(CO)—NH-R2 (iii) R1-(CO)—NH-R3-NH—(CO)—R2 wherein R1, R2, R3 are aliphatic hydrocarbon chains.

Claims

exact text as granted — not AI-modified
1 . A nonwoven fabric comprising endless fibers and bonding impressions or bonding points,
 the endless fibers comprising at least 80 wt. % of aliphatic polyesters,   the endless fibers comprising a first component making up at least 55% of fiber surface, the first component comprising at least one aliphatic polyester and an additive in amount of at least 0.1 wt. % of the total amount of the first component,   the additive comprising an amide group,   the additive corresponding to a general formula (i) or (ii) or (iii)   
       
         
           
           
               
               
           
         
       
       wherein R1, R2, R3 are aliphatic hydrocarbon chains. 
     
     
         2 . The nonwoven fabric according to  claim 1 , wherein at least one of R1 or R2 is an aliphatic hydrocarbon chain having a length of at least 10 carbons. 
     
     
         3 . The nonwoven fabric according to  claim 1 , wherein at least one of R1 or R2 is an aliphatic hydrocarbon chain having a length of at least 12 carbons. 
     
     
         4 . The nonwoven fabric according to  claim 1 , wherein at least one of R1 or R2 is an aliphatic hydrocarbon chain having a length of at least 15 carbons. 
     
     
         5 . The nonwoven fabric according to  claim 1 , wherein at least one of R1 or R2 is an aliphatic hydrocarbon chain having a length of no more than 30 carbons. 
     
     
         6 . The nonwoven fabric according to  claim 1 , wherein at least one of R1 or R2 is an aliphatic hydrocarbon chain having a length of no more than 25 carbons. 
     
     
         7 . The nonwoven fabric according to  claim 1 , wherein at least one of R1, R2 or R3 is a straight aliphatic chain. 
     
     
         8 . The nonwoven fabric according to  claim 1 , wherein at least one of R1, R2 or R3 is a saturated aliphatic chain. 
     
     
         9 . The nonwoven fabric according to  claim 1 , wherein at least one of R1 or R2 is a straight saturated aliphatic chain comprising 10 to 30 carbons. 
     
     
         10 . The nonwoven fabric according to  claim 1 , wherein at least one of R1 and R2 is a straight saturated aliphatic chain comprising 15 to 25 carbons. 
     
     
         11 . The nonwoven fabric according to  claim 1 , wherein the first component comprises at least 0, 15 wt. % of the additive. 
     
     
         12 . The nonwoven fabric according to  claim 1 , wherein the first component comprises at least 0.20 wt. % of the additive. 
     
     
         13 . The nonwoven fabric according to  claim 1 , wherein the first component comprises at least 0.25 wt. % of the additive. 
     
     
         14 . The nonwoven fabric according to  claim 1 , wherein the first component comprises no more than 10% of the additive. 
     
     
         15 . The nonwoven fabric according to  claim 1 , wherein the first component comprises no more than 5% of the additive. 
     
     
         16 . The nonwoven fabric according to  claim 1 , wherein the first component comprises no more than 1% of the additive. 
     
     
         17 . The nonwoven fabric according to  claim 1 , wherein the first component makes up at least 70% of the fiber surface, 
     
     
         18 . The nonwoven fabric according to  claim 1 , wherein the first component makes up at least 85% of the fiber surface. 
     
     
         19 . The nonwoven fabric according to  claim 1 , wherein the first component makes up at least 90% of the fiber surface. 
     
     
         20 . The nonwoven fabric according to  claim 1 , wherein the first component makes up at least 95% of the fiber surface. 
     
     
         21 . The nonwoven fabric according to  claim 1 , wherein the first component makes up a sheath in a bicomponent fiber of a core-sheath type of fiber. 
     
     
         22 . The nonwoven fabric according to  claim 1 , wherein the first component makes up one of a side in a bicomponent fiber of a side/side type of fiber. 
     
     
         23 . The nonwoven fabric according to  claim 1 , wherein the endless fibers comprise at least 90 wt. % of polymeric constituents. 
     
     
         24 . The nonwvoven fabric according to  claim 1 , wherein the endless fibers comprise at least 95 wt. % of polymeric constituents. 
     
     
         25 . The nonwoven fabric according to  claim 1 , wherein the endless fibers comprise at least 99 wt. % of polymeric constituents. 
     
     
         26 . The nonwoven fabric according to  claim 1 , wherein the first component comprises a mixture of aliphatic poly esters with differing values of heat of cold crystallization. 
     
     
         27 . The nonwoven fabric according to  claim 1 , wherein the first component comprises PLA or combinations of at least two types of PLA with differing values of heat of cold crystallization. 
     
     
         28 . The nonwoven fabric according to  claim 27 , wherein the additive corresponds to the general formula (iii), wherein R3 is an aliphatic hydrocarbon chain having a length of 1 to 3 carbons. 
     
     
         29 . The nonwoven fabric of  claim 28 , wherein R3 is an aliphatic hydrocarbon chain having a length of 2 carbons. 
     
     
         30 . The nonwoven fabric according to  claim 28 , wherein the additive is N,N′-ethylenebis(stearamide). 
     
     
         31 . The nonwoven fabric according to  claim 27 , wherein the additive corresponds to the general formula (i), wherein R1 is a saturated aliphatic hydrocarbon chain having a length of 10 to 30 carbons. 
     
     
         32 . The nonwoven fabric according to  claim 31 , wherein the additive is behenamide. 
     
     
         33 . The nonwoven fabric according to  claim 1 , wherein the first component is made up by a mixture of PLA and another aliphatic polyester. 
     
     
         34 . The nonwoven fabric according to  claim 1 , further comprising a second component, wherein the first component has lower melting temperature than the second component. 
     
     
         35 . The nonwoven fabric according to  claim 34 , wherein the second component contains at least one aliphatic polyester. 
     
     
         36 . The nonwoven fabric according to  claim 35 , wherein the at least one aliphatic polyester contained in the second component is PLA or a mixture of different types of PLA with differing values of heat of cold crystallization. 
     
     
         37 . A method of production of a nonwoven fabric comprising the following steps:
 a) preparing a material for a production of endless fibers, the material comprising at least 80 wt. % of polymeric constituents, and constituents of a first component of the endless fibers, the first component comprising at least one aliphatic polyester and an additive in the amount of at least 0.1 wt. % of the total amount of the first component, wherein the additive comprises an amide group and corresponds to the general formula (i) or (ii) or (iii)   
       
         
           
           
               
               
           
         
       
       wherein R1, R2, R3 are aliphatic hydrocarbon chains,
 b) melting and mixing at least the constituents of the first component, 
 c) feeding at least the first component to the nozzles of the spinneret through which the endless fibers are formed, wherein at least 55% of the fiber surface is made up by the first component, and subsequently, cooling down and drawing the thus formed fibers and then depositing those on a moving belt to form a batt, and 
 d) after step c), thermally bonding the batt. 
 
     
     
         38 . The method according to  claim 37 , wherein in step d) the batt is bonded by at least one of calendaring or by hot air.

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