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Elastic nonwoven materials comprising propylene-based and ethylene-based polymers

A polymer and non-woven technology, which is applied in the field of elastic non-woven materials and non-woven materials, can solve the problems of increasing cost, extra volume or weight, low crystallinity of elastomers, and difficulty in processing elastomers.

Inactive Publication Date: 2014-03-12
EXXONMOBIL CHEM PAT INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Heavier basis weight fabrics may be undesirable because of the added cost and unwanted extra bulk or weight of the resulting finished consumer article
[0003] Furthermore, because elastomers generally have low crystallinity and may not solidify quickly enough to form useful fibers or fabrics at commercially desirable output rates without clogging, processing on conventional fiber spinning and nonwoven equipment is net based on Propylene elastomers are difficult

Method used

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  • Elastic nonwoven materials comprising propylene-based and ethylene-based polymers
  • Elastic nonwoven materials comprising propylene-based and ethylene-based polymers
  • Elastic nonwoven materials comprising propylene-based and ethylene-based polymers

Examples

Experimental program
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preparation example Construction

[0050] Preparation of Propylene-Based Polymers

[0051] Polymerization of the propylene-based polymer can be carried out by reacting the monomers in the presence of the catalyst system described herein at a temperature of 0°C to 200°C for a period of 1 second to 10 hours. Preference is given to using homogeneous conditions, such as continuous solution processes or bulk polymerization processes with excess monomers used as diluents. Continuous processes may use some form of agitation to reduce concentration differences in the reactor and maintain steady state polymerization conditions. The heat of polymerization is preferably removed by cooling the polymerization feed and allowing the polymerization to heat up to polymerization, although an internal cooling system may be used.

[0052] Further descriptions of exemplary processes suitable for preparing the propylene-based polymers described herein can be found in US Patent No. 6,881,800, incorporated herein by reference in acco...

Embodiment 1

[0125] Using standard commercial fiber spinning equipment with a throughput of 0.4 grams per hole per minute (ghm), the present invention consists of 85 wt% PBP1 (visbroken to an MFR of about 40 g / 10min) and 15 wt% EPB1 The blend formed a partially oriented yarn (72 filaments). The fibers were drawn at 1500 m / min. Comparative fibers were also prepared from PBP2 using the same equipment and method. The results of the first and second cycle hysteresis for the blends of the invention are as follows Figure 1a shown and compared materials such as Figure 1b shown.

[0126] like Figure 1a and 1b As shown in , the addition of ethylene-based polymers provides a favorable balance of better elasticity and processability compared to the use of polypropylene as a blending partner (as in Figure 1b among the comparative polymers shown in). This is done with Figure 1b When comparing, Figure 1a Evidenced by the significantly reduced area within the hysteresis curves of the blends. ...

Embodiment 2

[0128] Partially oriented yarns were spun from a comparative polymer blend and two inventive polymer blends using the same equipment and method as in Example 1 . A comparative polymer blend comprised 85% by weight of PBP1 and 15% by weight of a propylene homopolymer having an MFR of about 35 g / 10min. The first and second cycle hysteresis loops of the comparative blends are as Figure 2a shown in . The first inventive polymer blend comprised 85% by weight of PBP1 and 15% by weight of EBP2. The first and second cyclic hysteresis loops of the first inventive blend are as follows Figure 2b shown. The second inventive polymer blend comprised 87.4% by weight of PBP1, 5.5% by weight of EBP1 and 7.1% by weight of EBP3. The first and second cycle hysteresis loops for the second inventive blend are shown in Figure 2c. In all cases, PBP1 was first visbroken to an MFR of about 40 g / 10 min before blending with the specified blending partners.

[0129] Figure 3a , 3b and 3c are re...

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Abstract

The present invention relates to elastic nonwoven materials comprising an elastic layer formed from a polymer blend comprising a propylene-based polymer and a minor amount of an ethylene-based polymer. The propylene-based polymer may comprise from about 75 to about 95 wt% propylene and from about 5 to about 25 wt% ethylene and / or a C4-Ci2 a-olefin, and may have a triad tacticity greater than about 90% and a heat of fusion less than about 75 J / g. The ethylene-based polymer may comprise from about 65 to about 100 wt% ethylene and from 0 to about 35 wt% of one or more C3-C12 a-olefins.

Description

Background of the invention [0001] Propylene-based polymers and copolymers are well known in the art for their use in the manufacture of nonwoven fibers and fabrics. Such fibers and fabrics have a variety of uses, particularly in applications such as medical and hygiene products, clothing, filter media and sorbent products, among others. In hygiene and other markets, there is a widespread need for elastic fabrics with superior aesthetics and low cost. Such fabrics have previously been prepared using propylene-based elastomers alone or in combination with homopolypropylene. [0002] Multilayer fabrics and laminates are also known and may typically comprise a propylene based elastomer with one or more facing layers comprising polypropylene, polyethylene terephthalate, blends thereof, etc. core layer. Despite the good elastic properties and aesthetics of such multilayer fabrics, increased strength without increasing the basis weight of the cover and / or core is still desired in...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): D04H1/4291D04H3/007D04H5/08C08F2/06D01F6/46
CPCD01F6/30C08F210/16D01F6/46C08F210/06D04H3/00D04H1/00Y10T442/601C08F2500/11C08F2500/12C08F2500/15C08F2500/18C08F2500/20C08F2500/23
Inventor A·K·迈塔C·R·哈里斯G·E·基斯赵斌G·C·里奇森
Owner EXXONMOBIL CHEM PAT INC