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Nonwoven web with improved adhesion and reduced dust formation

a nonwoven web and dust reduction technology, applied in the field of dry-laying and wet-laying non-woven webs, can solve the problems of limited use of tackifiers and the disclosure of fibers with tackifiers by maugans et al., and achieve the effect of improving the adhesion and improving the adhesion of these non-woven webs

Inactive Publication Date: 2005-03-24
INVISTA NORTH AMERICA R L
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0015] As stated previously, there is still a need in the art to improve the adhesion of these nonwoven webs. The present invention is an improvement over these existing nonwoven web products. In particular, the present invention improves the adhesion by employing a tackifier. Tackifiers include rosin, rosin esters, and terpene based, piperylene based, and hydrocarbon based compounds.

Problems solved by technology

Turley et al. do not teach a binder fiber wherein the tackifier is present in a low melt portion of the fiber.
Rather, the use of tackifier is limited to and only disclosed in an adhesive formulation embodiment, such as hot melts, epoxy systems, and pressure adhesives.
Further, none of the example fibers of Maugans et al. discloses a fiber with tackifier therein.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0039] Various bicomponent fibers were as shown in Table 1. The adhesion promoters were maleic anhydride grafted polyethylene obtained from Dow Chemical as ASPUN XU 60769.07 (Dow07), ethylene-acrylic copolymers obtained from DuPont as BYNEL 2022 and from ExxonMobil as ESCOR AT-325. The tackifier was a glycerin ester of tall oil rosin obtained from Eastman Chemical as PERMALYN 2085.

[0040] Nonwoven webs were made from these bicomponent fibers with a wet-lay process to give a basis weight of 51 g / m2. The web samples were dried at 100° C. for 32 seconds and then bonded in a hot air oven at 135° C. for 15 seconds. The bonding indices are shown in Table 1 and compared to the control, which did not contain a tackifier.

TABLE 1BondingBonding Index,Relative toFiberAdhesion Promoter, %Tackifier, %Temp., C.g / 25 mmControl, %ControlDow 07, 10%None135250.01Bynel 2022, 5%Permalyn, 5%135368.947.02Escor AT 325, 5%Permalyn, 5%135285.413.83Dow 07, 5%Permalyn, 5%135388.154.74Escor AT 325, 8%Permalyn,...

example 2

[0042] In this example wet laid webs were prepared in the same manner as in Example 1, and examined the effect on adhesion promoter and tackifier levels on web strength. The bicomponent compositions and bonding indices are reported in Table 2. The control was a sheath that contained no adhesion promoter or tackifier.

TABLE 2AdhesionBondingBonding Index,Relative toFiberPromoter, %Tackifier, %Temp., C.g / 25 mmControl, %ControlNoneNone135314.3 5Dow 07, 5%None135267.0−15.0 6Dow 07, 10%None135339.78.1 7NonePermalyn, 5%135415.732.3 8Dow 07, 5%Permalyn, 5%135442.240.7 9Dow 07, 10%Permalyn, 5%135412.531.210NonePermalyn, 10%135422.334.4ControlNoneNone175378.3 5Dow 07, 5%None175345.7−8.6 6Dow 07, 10%None175401.66.2 7NonePermalyn, 5%175405.77.2 8Dow 07, 5%Permalyn, 5%175493.430.4 9Dow 07, 10%Permalyn, 5%175492.930.310NonePermalyn, 10%175444.317.4

[0043] This example shows that a tackifier alone, without an adhesion promoter, improves the bonding index of the web.

example 3

[0044] This example studies the effect of tackifier level using webs prepared as in Example 1. The bicomponent compositions and bonding indices are reported in Table 3. The control was a sheath that contained 5% Dow 07 adhesion promoter.

TABLE 3AdhesionBondingBondingRelative toFiberPromoter, %Tackifier, %Temp., C.Index, g / 25 mmControl, %ControlDow 07, 5%None135210.111Dow 07, 5%Permalyn 2085, 1%135337.760.812Dow 07, 5%Permalyn 2085, 2.5%135346.364.813Dow 07, 5%Permalyn 2085, 3.75%135352.667.814Dow 07, 5%Permalyn 2085, 5%135401.691.2ControlDow 07, 5%None175268.211Dow 07, 5%Permalyn 2085, 1%175431.060.712Dow 07, 5%Permalyn 2085, 2.5%175351.431.013Dow 07, 5%Permalyn 2085, 3.75%175456.170.114Dow 07, 5%Permalyn 2085, 5%175452.768.8

[0045] This example shows that even a low level of tackifier, 1% by weight, improves the bonding index dramatically.

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Abstract

Making suitable nonwoven webs requires good adhesion between the binder and the absorbent material. The present invention relates to a nonwoven web having improved adhesion based on tackifiers present in the binder. Optionally, the binder with tackifier may also contain an adhesion promoter, usually grafted polyolefins, and an enhancement agent, usually inactive inorganic compounds in powder form. The web comprises from about 5 to about 25% by weight binder fiber and from about 75 to 95% by weight absorbent. The absorbent may be a natural absorbent or a super absorbent polymer or a combination of these. The binder fiber contains less than about 40% by weight tackifier. Tackifier is selected from the class of rosin, rosin esters, terpene based, piperylene based, and hydrocarbon based compounds.

Description

CROSS REFERENCE TO RELATED APPLICATION [0001] This application is a Continuation-in-Part Application of U.S. patent application Ser. No. 10 / 137,141 entitled NONWOVEN WEB WITH IMPROVED ADHESION AND REDUCED DUST FORMATION filed May 2, 2002, by the same inventors and assignee.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to dry laid and wet laid nonwoven webs useful in diapers, incontinent pads, sanitary napkins, and other absorbent pads for liquids. In particular, these pads usually comprise binder and wood pulp or other absorbent material. Making suitable nonwoven webs for these uses requires good adhesion between the binder and the absorbent material. More specifically, the present invention relates to a nonwoven web having improved adhesion based on tackifiers present in the binder, and specifically in a low melt portion thereof. Tackifiers include rosin, rosin esters, and terpene based, piperylene based, and hydrocarbon based com...

Claims

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Application Information

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IPC IPC(8): D01F6/46D01F8/06D01F8/10D01F8/12D01F8/14D04H1/42D04H1/54D04H1/58D04H1/60D04H3/12D04H3/14D04H5/06
CPCD01F6/46D01F8/06D01F8/10D01F8/12D01F8/14D04H1/42Y10T428/2913D04H1/58D04H1/60D04H3/12D04H3/14D04H5/06D04H1/54D04H1/4291D04H1/4334D04H1/435D04H1/43828D04H1/43835D04H1/43832
Inventor LIN, TINGDONG
Owner INVISTA NORTH AMERICA R L
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