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High loft low density nonwoven webs of crimped filaments and methods of making same

a technology of crimped filament and nonwoven webs, which is applied in the field of high loft low density nonwoven webs of crimped filament and methods of making same, and achieves the effects of high loft, greater open space and high lo

Inactive Publication Date: 2004-10-07
KIMBERLY-CLARK WORLDWIDE INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

"The present invention is about a new type of nonwoven material that is high loft and low density. This material is made from continuous fibers that have a Z-direction orientation, which results in increased uniformity and a soft feel. The nonwoven material can be used in a variety of applications such as personal care absorbent articles, surge layers, and cleaning materials. The invention uses a special processing technique to create the high loft, low density material, which involves forming precursor filaments and then crimping them to create a nonwoven material with random fiber orientation and openings between the crimped fibers. The resulting material has improved fluid control, high loft, and good web morphology. The invention also includes a method for measuring the uniformity of the nonwoven material. Overall, the invention provides a new way to produce high loft, low density nonwoven materials that have improved performance in a variety of applications."

Problems solved by technology

However, in such constructions the fibers of the web still remain in the plane of the web, it is only the plane of the web itself which has been distorted.

Method used

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  • High loft low density nonwoven webs of crimped filaments and methods of making same
  • High loft low density nonwoven webs of crimped filaments and methods of making same
  • High loft low density nonwoven webs of crimped filaments and methods of making same

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0094] Example 1, was produced according to the present invention to a basis weight of 202 gsm (5.96 osy), with a bulk of 12.6 mm (0.5 inch) and density of 0.016 g / cc. The average denier was measured to be approximately 3.3 dpf (denier per fiber). The fibers were side by side bicomponent, featuring polymer A of Dow 61800.41 polyethylene (PE) and polymer B of Exxon 3155 polypropylene (PP). A TiO.sub.2 additive from the Standridge Color Corporation, of Social Circle, Ga., tradenamed SCC-4837, was added to the polymer prior to extrusion at 2% by weight to provide white color and opacity to the web. The fibers were spun through a 96 hole per inch (hpi) spinpack, spinning in an A / B side by side (s / s) configuration, at a melt temperature of 410.degree. F.

[0095] Throughput was balanced in a 50 / 50 throughput ratio between the two polymers, with a total throughput of 0.7 grams per hole per minute (ghm). The quench air temperature was 55.degree. F. The fiber spin length was 48 inches. The fib...

example 2

[0097] Example 2, was produced according to the present invention to a basis weight of 79 gsm (2.33 osy), with a bulk of 3.8 mm (0.15 inches) and density of 0.021 g / cc. The average denier was measured to be approximately 3.3 dpf. Polymers and additives were the same as stated for Example 1.

[0098] Fiber and web formation conditions were the same as for Example 1 except the forming wire was moving at 220 ft / min, as measured on the forming wire. The HAK was set at 250.degree. F. and 5.0 inches H.sub.2O of pressure on bank 1, and 240.degree. F. and 3.5 inches H.sub.2O on bank 2, at a height of 5.0 inches above the forming wire. The below wire exhaust under the fiber draw unit was set to vacuum of approximately 1.7 inches H.sub.2O in bank 1, and 3.8 inches H.sub.2O in bank 2.

example 3

[0099] Example 3, was produced according to the present invention to a basis weight of 77 gsm (2.27 osy), with a bulk of 3.3 mm (0.13 inch) and density of 0.023 g / cc. The average denier was measured to be approximately 3.3 dpf.

[0100] Fiber and web formation conditions were the same as for Example 1 except the forming wire was moving at 229 ft / min, as measured on the forming wire. The RAK was set at 250.degree. F. and 5.0 inches H.sub.2O of pressure on bank 1, and 240.degree. F. and 3.5 inches H.sub.2O on bank 2, at a height of 5.0 inches above the forming wire. The below wire exhaust under the fiber draw unit was set to vacuum of approximately 1.6 inches H.sub.2O in bank 1, and 3.8 inches H.sub.2O in bank 2. The web was bonded at approximately 262-269.degree. F. in a through air bonder.

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Abstract

High loft, low density nonwoven webs of increased uniformity are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A / B side by side morphology in an unheated fiber draw unit. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the z-direction and produce a web of lofted material. The resultant material is particularly suitable for use as an insulator. Particulates may be added to the webs if desired.

Description

[0001] This application is a Continuation In Part application and claims priority from U.S. application Ser. No. 10 / 037,467, filed 21 Dec. 2001.[0002] This invention relates to a high loft, low density nonwoven material produced from continuous fibers in which the lofty character of the nonwoven material is the result of the fibers comprising the web having a Z-direction orientation, resulting from improved processing and the resultant crimping. These materials have increased uniformity and are particularly suitable for use in a broad range of applications including, without limitation, surge layers for personal care products, acoustic and thermal insulation, packing material, padding, absorbents, filtering, and cleaning materials.DISCUSSION OF THE RELATED ART[0003] In nonwoven webs, the fibers comprising the web are generally oriented in the X-Y plane of the web and the resulting nonwoven web material is relatively thin, that is, lacking in loft or significant thickness.[0004] Loft...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D04H3/02D04H1/50D04H3/005D04H3/16
CPCD04H1/50Y10T428/2924Y10T428/2922D04H3/16Y10T442/681Y10T442/629Y10T442/632Y10T442/638D04H3/02D04H3/005
Inventor POLANCO, BRAULIO A.FENWICK, CHRISTOPHER DALECLARK, DARRYL FRANKLINHAYNES, BRYAN DAVIDBROWN, KURTIS LEEFREESE, CHAD MICHAELKEPNER, ERIC SCOTT
Owner KIMBERLY-CLARK WORLDWIDE INC
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