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US20030124941A1 - Poly (trimethylene terephthalate) based spunbonded nonwovens - Google Patents

Poly (trimethylene terephthalate) based spunbonded nonwovens Download PDF

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Publication number
US20030124941A1
US20030124941A1 US10/285,832 US28583202A US2003124941A1 US 20030124941 A1 US20030124941 A1 US 20030124941A1 US 28583202 A US28583202 A US 28583202A US 2003124941 A1 US2003124941 A1 US 2003124941A1
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ptt
seconds
polymers
bicomponent
liquid strike
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US10/285,832
Inventor
Charles Hwo
Dong Zhang
Christine Sun
Ian Carson
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Shell USA Inc
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Individual
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Priority to US10/285,832 priority Critical patent/US20030124941A1/en
Assigned to SHELL OIL COMPANY reassignment SHELL OIL COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CARSON, IAN GUILLAND, HWO, CHARLES CHIU-HSIUNG, SUN, CHRISTINE QIN, ZHANG, DONG
Publication of US20030124941A1 publication Critical patent/US20030124941A1/en
Abandoned legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43828—Composite fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43832—Composite fibres side-by-side
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43838—Ultrafine fibres, e.g. microfibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/638—Side-by-side multicomponent strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
    • Y10T442/641—Sheath-core multicomponent strand or fiber material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/681—Spun-bonded nonwoven fabric

Definitions

  • This invention relates to spunbonded microfiber nonwoven materials made from polytrimethylene terephthalate.
  • thermoplastic resins have been extruded to form fibers and webs for a number of years.
  • the most common thermoplastics for this application are polyolefins and polyesters.
  • Other materials such as polyetheresters, polyamides and polyurethanes are also used for this purpose.
  • Each material has its characteristic advantages and disadvantages vis-a-vis the properties desired in the final product to be made from such fibers.
  • a spunbond line consists of the following elements: an extruder for forming filaments; a metering pump; a die assembly; a filament spinning, drawing, and deposition system; a belt for collecting the filaments; a bonding zone; and a winding unit.
  • thermal, adhesive/chemical, and needling In the former two, point and area bonding are used using heat and pressure to bond in point bonding and usually only heat in area bonding.
  • bicomponent usually refers to fibers which have been formed at least two polymers extruded from separate extruders but spun together to form one fiber.
  • the configuration of such a bicomponent fiber may be a sheath/core arrangement wherein one polymer is surrounded by another or may be a side by side arrangement. It was often desirable that the fabics have the combination of the advantages of different polymers in one spun fiber.
  • This invention is a spunbonded nonwoven material which is formed of polytrimethylene terephthalate (PTT).
  • PTT polytrimethylene terephthalate
  • This material may be a microfiber material which is 1 dpf (denier per filament) or less in fiber diameter.
  • This nonwoven material is unique in that it has a hydrostatic head of no more than 10 cm, preferably no more than 5 cm.
  • the liquid strike-through is no more than 25 seconds, more preferably no more than 15 seconds, even more preferably no more than 10 seconds, and most preferably no more than 7 seconds, and thus it is better than that of PET.
  • the PTT nonwoven web is useful as a stocking for a diaper since it is important that materials for this use have low liquid strike-through time.
  • the web also has good permeability to air.
  • the air permeability is at least 200 m 3 /m 2 /min.
  • This invention also includes bicomponent spunbonded microfiber nonwoven materials made from PTT wherein at least two different polymers have been extruded and spun together in either a side by side or core/sheath configuration and wherein at least one of the polymers is polytrimethylene terephthalate (PTT).
  • PTT polytrimethylene terephthalate
  • the ratio of PTT to the other polymer(s) ranges from 1:99 to 99:1, based on the weight of the polymers.
  • the preferred weight ratio range of PTT to other polymer(s) is 25:75 to 75:25 and the most preferred ratio is 25:75 to 50:50.
  • the other polymer(s) in PTT based spunbonded nonwoven may be one of the following thermoplastics: polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide (PA), and polylactide (PLA).
  • PP polypropylene
  • PE polyethylene
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • PA polyamide
  • PLA polylactide
  • the present invention also provides a process for making such a bicomponent fiber.
  • the present invention also provides a process for making such a spunbonded microfiber nonwoven material.
  • Spunbonding is a process to make microfiber nonwovens from thermoplastic polymers wherein the melt filaments are first formed by extrusion and drawing and then are laid on a continuous belt. Bonding is then accomplished by several methods such as hot roll calendaring or by passing the web through a saturated steam chamber at an elevated pressure. It has become an important industrial technique in nonwovens because of its ability to produce fabrics of microfiber structure suitable for filtration media, thermal insulators, battery separators, oil absorbents and many laminate applications. Polypropylene (PP) is the most widely used polymer for this process.
  • PE polyethylene
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • PA polyamide
  • Polytrimethylene terephthalate is primarily a linear aromatic polyester which can be prepared from the condensation polymerization of 1,3-propane diol and terephthalic acid.
  • PTT polytrimethylene terephthalate
  • PTT itself is described more specifically and processes for making it also in U.S. Pat. No. 6,277,947, which is herein incorporated by reference.
  • PTT a member of the polyester family, is based upon a three-carbon diol. Its structure is shown below along with those of PET and PBT which are based on two-carbon and four-carbon diols, respectively.
  • PTT combines the physical properties of PET (strength, toughness, stiffness, heat resistance) with the processing advantages of PBT (low melt and processing temperatures, rapid crystallization, faster production cycles). PTT is less rigid than PET, exhibiting greater elasticity. Other desirable properties of PTT are resilience, softness, elastic recovery, moisture resistance, chemical resistance, dimensional stability, stain resistance, weather/UV resistance and ease of dying or painting into many different colors. PTT does very well in the carpet industry, textiles, films and other thermoplastic applications.
  • polypropylene is preferred.
  • the polypropylene which can be used in the present invention is commercially available crystalline isotactic polypropylene. These products are well known and have been the subject of many patents, including U.S. Pat. Nos. 3,112,300 and 3,112,301, which are herein incorporated by reference.
  • Isotactic polypropylene is a straight chain of propylene units wherein the methyl groups are all aligned on one side of the polymer chain.
  • the bicomponent spunbonded microfiber nonwoven material which is comprised of at least two different polymers may be made by extruding and spinning them together in a core/sheath configuration.
  • the bicomponent fiber material may be made by a process which comprises extruding at least two different polymers and spinning them together in a side by side configuration.
  • the PTT samples of nonwovens used herein were produced in a Reifenhauser spunbond line.
  • the polyethylene terethphalate (PET) and polypropylene (PP) samples were commercially available materials.
  • PTT absorbs moisture which causes thermal degradation of PTT at melt processing temperatures. Drying of the polymer is required before spunbonding and the MFR measurement. The drying condition was: 120° C. for 3 hours, which reduced moisture content from 0.22% before drying to 0.003% (30 ppm) after drying. The MFR value of PTT was 385 (tested at 270° C.) and 844 (tested at 300° C.) indicating that a melt temperature of 270-300° C. is suitable for the spunbonded process.
  • Testing of these webs included basis weight (g/cm 2 ), fiber diameter (um), air permeability (ASTM D 737—m 3 /m 2 /min), liquid strike-through (seconds), and hydrostatic head (IST 80.4-92—cm).
  • the fiber diameter was measured by optical microscope with the software of Image Pro. Liquid strike-through is measured by using a Lenzing Lister strike-through tester.
  • the PTT spunbonded nonwovens sample had a basis weight of 20.26 and a fiber diameter of 14.99.
  • the PET spunbonded nonwovens sample had a basis weight of 22.68 and a fiber diameter of 10.81.
  • the PP spunbonded nonwovens sample had a basis weight of 20.63 and a fiber diameter of 12.24. The basis weight and fiber diameters of these samples are relatively close for comparative purposes.
  • the air permeability of the PTT, PET, and PP nonwovens webs was 240, 135, and 129 m 3 /m 2 /min, respectively.
  • the liquid strike-through for the three samples was 7.24, 27.12, and >1000 seconds, respectively, and the hydrostatic head was 5.7, 5.7, and 16.5 cm, respectively. It can be seen that the PTT web exhibits the best combination of hydrostatic pressure and liquid strike-through (both low) of the three webs and is thus the most suitable for use in filtration applications.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

This invention is a spunbonded nonwoven material which is formed of polytrimethylene terephthalate (PTT). This material may be a microfiber material which is 1 dpf or less in fiber diameter. This nonwoven material is unique in that it has a hydrostatic head of no more than 10 cm, preferably no more than 5 cm.

Description

    FIELD OF THE INVENTION
  • This invention relates to spunbonded microfiber nonwoven materials made from polytrimethylene terephthalate. [0001]
    • BACKGROUND OF THE INVENTION
  • Thermoplastic resins have been extruded to form fibers and webs for a number of years. The most common thermoplastics for this application are polyolefins and polyesters. Other materials such as polyetheresters, polyamides and polyurethanes are also used for this purpose. Each material has its characteristic advantages and disadvantages vis-a-vis the properties desired in the final product to be made from such fibers. [0002]
  • In nonwovens industries, fibers have been developed for use in meltblown and spunbond processes to make nonwovens webs. Dupont developed the first commercial spunbond process in the late 1950's. A primary factor in the production of spunbond fabrics is control of four simultaneous integrated operations: filament extrusion, drawing, laydown, and bonding. In its simplest form, a spunbond line consists of the following elements: an extruder for forming filaments; a metering pump; a die assembly; a filament spinning, drawing, and deposition system; a belt for collecting the filaments; a bonding zone; and a winding unit. There are three basic bonding techniques employed in a spunbond process: thermal, adhesive/chemical, and needling. In the former two, point and area bonding are used using heat and pressure to bond in point bonding and usually only heat in area bonding. These are well known and commonly used techniques in the industry. [0003]
  • The term “bicomponent” usually refers to fibers which have been formed at least two polymers extruded from separate extruders but spun together to form one fiber. The configuration of such a bicomponent fiber may be a sheath/core arrangement wherein one polymer is surrounded by another or may be a side by side arrangement. It was often desirable that the fabics have the combination of the advantages of different polymers in one spun fiber. [0004]
    • SUMMARY OF THE INVENTION
  • This invention is a spunbonded nonwoven material which is formed of polytrimethylene terephthalate (PTT). This material may be a microfiber material which is 1 dpf (denier per filament) or less in fiber diameter. This nonwoven material is unique in that it has a hydrostatic head of no more than 10 cm, preferably no more than 5 cm. Preferably, the liquid strike-through is no more than 25 seconds, more preferably no more than 15 seconds, even more preferably no more than 10 seconds, and most preferably no more than 7 seconds, and thus it is better than that of PET. Thus, the PTT nonwoven web is useful as a stocking for a diaper since it is important that materials for this use have low liquid strike-through time. It is preferable that the web also has good permeability to air. Preferably, the air permeability is at least 200 m[0005] 3/m2/min.
  • This invention also includes bicomponent spunbonded microfiber nonwoven materials made from PTT wherein at least two different polymers have been extruded and spun together in either a side by side or core/sheath configuration and wherein at least one of the polymers is polytrimethylene terephthalate (PTT). The ratio of PTT to the other polymer(s) ranges from 1:99 to 99:1, based on the weight of the polymers. The preferred weight ratio range of PTT to other polymer(s) is 25:75 to 75:25 and the most preferred ratio is 25:75 to 50:50. The other polymer(s) in PTT based spunbonded nonwoven may be one of the following thermoplastics: polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide (PA), and polylactide (PLA). [0006]
  • The present invention also provides a process for making such a bicomponent fiber. The present invention also provides a process for making such a spunbonded microfiber nonwoven material. [0007]
    • DETAILED DESCRIPTION OF THE INVENTION
  • Spunbonding is a process to make microfiber nonwovens from thermoplastic polymers wherein the melt filaments are first formed by extrusion and drawing and then are laid on a continuous belt. Bonding is then accomplished by several methods such as hot roll calendaring or by passing the web through a saturated steam chamber at an elevated pressure. It has become an important industrial technique in nonwovens because of its ability to produce fabrics of microfiber structure suitable for filtration media, thermal insulators, battery separators, oil absorbents and many laminate applications. Polypropylene (PP) is the most widely used polymer for this process. Others such as polyethylene (PE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide (PA) can be also used to produce the spunbonded webs. A lot of efforts have been made in the last 30 years on the process study, new resin and product development, and process improvement. [0008]
  • Polytrimethylene terephthalate (PTT) is primarily a linear aromatic polyester which can be prepared from the condensation polymerization of 1,3-propane diol and terephthalic acid. For commercial applications, it is desirable to produce PTT having an intrinsic viscosity greater than 0.7 dl/g and preferably greater than 0.8 dl/g. PTT itself is described more specifically and processes for making it also in U.S. Pat. No. 6,277,947, which is herein incorporated by reference. [0009]
  • PTT, a member of the polyester family, is based upon a three-carbon diol. Its structure is shown below along with those of PET and PBT which are based on two-carbon and four-carbon diols, respectively. [0010]
    Figure US20030124941A1-20030703-C00001
  • PTT combines the physical properties of PET (strength, toughness, stiffness, heat resistance) with the processing advantages of PBT (low melt and processing temperatures, rapid crystallization, faster production cycles). PTT is less rigid than PET, exhibiting greater elasticity. Other desirable properties of PTT are resilience, softness, elastic recovery, moisture resistance, chemical resistance, dimensional stability, stain resistance, weather/UV resistance and ease of dying or painting into many different colors. PTT does very well in the carpet industry, textiles, films and other thermoplastic applications. [0011]
  • Many polymers can be used in this invention as the other polymer fiber in a bicomponent structure but polypropylene is preferred. The polypropylene which can be used in the present invention is commercially available crystalline isotactic polypropylene. These products are well known and have been the subject of many patents, including U.S. Pat. Nos. 3,112,300 and 3,112,301, which are herein incorporated by reference. Isotactic polypropylene is a straight chain of propylene units wherein the methyl groups are all aligned on one side of the polymer chain. [0012]
  • The bicomponent spunbonded microfiber nonwoven material which is comprised of at least two different polymers may be made by extruding and spinning them together in a core/sheath configuration. The bicomponent fiber material may be made by a process which comprises extruding at least two different polymers and spinning them together in a side by side configuration.[0013]
    • EXAMPLES
  • The PTT samples of nonwovens used herein were produced in a Reifenhauser spunbond line. The polyethylene terethphalate (PET) and polypropylene (PP) samples were commercially available materials. [0014]
  • Like PET and PBT, PTT absorbs moisture which causes thermal degradation of PTT at melt processing temperatures. Drying of the polymer is required before spunbonding and the MFR measurement. The drying condition was: 120° C. for 3 hours, which reduced moisture content from 0.22% before drying to 0.003% (30 ppm) after drying. The MFR value of PTT was 385 (tested at 270° C.) and 844 (tested at 300° C.) indicating that a melt temperature of 270-300° C. is suitable for the spunbonded process. [0015]
  • Test and Characterization [0016]
  • Testing of these webs included basis weight (g/cm[0017] 2), fiber diameter (um), air permeability (ASTM D 737—m3/m2/min), liquid strike-through (seconds), and hydrostatic head (IST 80.4-92—cm). The fiber diameter was measured by optical microscope with the software of Image Pro. Liquid strike-through is measured by using a Lenzing Lister strike-through tester.
  • Results [0018]
  • The PTT spunbonded nonwovens sample had a basis weight of 20.26 and a fiber diameter of 14.99. The PET spunbonded nonwovens sample had a basis weight of 22.68 and a fiber diameter of 10.81. The PP spunbonded nonwovens sample had a basis weight of 20.63 and a fiber diameter of 12.24. The basis weight and fiber diameters of these samples are relatively close for comparative purposes. [0019]
  • The air permeability of the PTT, PET, and PP nonwovens webs was 240, 135, and 129 m[0020] 3/m2/min, respectively. The liquid strike-through for the three samples was 7.24, 27.12, and >1000 seconds, respectively, and the hydrostatic head was 5.7, 5.7, and 16.5 cm, respectively. It can be seen that the PTT web exhibits the best combination of hydrostatic pressure and liquid strike-through (both low) of the three webs and is thus the most suitable for use in filtration applications.

Claims (9)

We claim:
1. A spunbonded nonwoven material with a hydrostatic head of no more than 10 cm which is comprised of polytrimethylene terephthalate.
2. The material of claim 1 wherein the hydrostatic head is no more than 5 cm.
3. The material of claim 1 wherein the liquid strike-through is no more than 25 seconds.
4. The material of claim 3 wherein wherein the liquid strike-through is no more than 15 seconds.
5. The material of claim 4 wherein the liquid strike-through is no more than is 10 seconds.
6. The material of claim 5 wherein the liquid strike-through is no more than 7 seconds.
7. The material of claim 1 wherein the web is a bicomponent web which is comprised of at least two different polymers and the other polymer(s) is (are) selected from the group consisting of polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide (PA), and polylactide (PLA).
8. The bicomponent spunbonded nonwoven material of claim 7 wherein the polymers have been extruded and spun together in a core/sheath configuration.
9. The bicomponent spunbonded nonwoven material of claim 7 wherein the polymers have been extruded and spun together in a side by side configuration.
US10/285,832 2001-11-06 2002-11-01 Poly (trimethylene terephthalate) based spunbonded nonwovens Abandoned US20030124941A1 (en)

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US20090047856A1 (en) * 2007-08-17 2009-02-19 Fiberweb, Inc. Area bonded nonwoven fabric from single polymer system
US20090233510A1 (en) * 2006-09-21 2009-09-17 Fiberweb Corovin Gmbh Lightweight spun-bonded nonwoven fabric having special barrier properties
US20100146921A1 (en) * 2005-10-04 2010-06-17 Toray Industries, Inc. Nonwoven fabric for filters
US20100203395A1 (en) * 2005-05-02 2010-08-12 Amer-Sil S.A. Non-woven gauntlets for batteries
WO2012082694A3 (en) * 2010-12-17 2012-11-08 E. I. Du Pont De Nemours And Company Bicomponent spunbond nonwoven web
WO2013032912A1 (en) * 2011-08-26 2013-03-07 E. I. Du Pont De Nemours And Company Insulating material comprising nonwoven webs
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US20100203395A1 (en) * 2005-05-02 2010-08-12 Amer-Sil S.A. Non-woven gauntlets for batteries
DE102005054726A1 (en) * 2005-08-02 2007-02-15 Carl Freudenberg Kg Nonwovens and process for their preparation
US20070184741A1 (en) * 2005-08-02 2007-08-09 Carl Freudenberg Kg Non-woven fabrics and method for producing them
US8308833B2 (en) * 2005-10-04 2012-11-13 Toray Industries, Inc. Nonwoven fabric for filters
US20100146921A1 (en) * 2005-10-04 2010-06-17 Toray Industries, Inc. Nonwoven fabric for filters
US20090233510A1 (en) * 2006-09-21 2009-09-17 Fiberweb Corovin Gmbh Lightweight spun-bonded nonwoven fabric having special barrier properties
US7919420B2 (en) * 2006-09-21 2011-04-05 Fiberweb Corovin Gmbh Lightweight spun-bonded nonwoven fabric having special barrier properties
US20110230110A1 (en) * 2007-08-17 2011-09-22 Fiberweb, Inc. Area Bonded Nonwoven Fabric From Single Polymer System
US7994081B2 (en) * 2007-08-17 2011-08-09 Fiberweb, Inc. Area bonded nonwoven fabric from single polymer system
US20090047856A1 (en) * 2007-08-17 2009-02-19 Fiberweb, Inc. Area bonded nonwoven fabric from single polymer system
US8465611B2 (en) 2007-08-17 2013-06-18 Fiberweb, Inc. Area bonded nonwoven fabric from single polymer system
US8951633B2 (en) 2007-08-17 2015-02-10 Fiberweb, Inc. Area bonded nonwoven fabric from single polymer system
WO2012082694A3 (en) * 2010-12-17 2012-11-08 E. I. Du Pont De Nemours And Company Bicomponent spunbond nonwoven web
WO2013032912A1 (en) * 2011-08-26 2013-03-07 E. I. Du Pont De Nemours And Company Insulating material comprising nonwoven webs
CN103890256A (en) * 2011-08-26 2014-06-25 纳幕尔杜邦公司 Insulating material comprising nonwoven webs
US9028727B2 (en) 2011-09-23 2015-05-12 E I Du Pont De Nemours And Company Dielectric fluids comprising polyol esters
US20140349539A1 (en) * 2013-05-21 2014-11-27 Toray Advanced Materials Korea Inc. Nonwoven fabric having improved air permeability and manufacturing method thereof

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