Wet lap composition and related processes

Abstract

A microfiber-containing wet lap composition is provided. The wet lap composition comprises a mixture of a sulfopolyester dispersion and a plurality of water nondispersible synthetic polymer microfibers. The microfibers have an equivalent diameter of less than 5 microns and a length of less than 25 millimeters. The sulfopolyester dispersion comprises at least one sulfopolyester and water.

Description

CROSS REFERENCES TO RELATED APPLICATIONS[0001]This application is a continuation-in-part application claiming priority to application Ser. No. 12 / 199,304, filed Aug. 27, 2008, which is a continuation in part of Provisional Application Ser. No. 61 / 041,699, filed Apr. 2, 2008 and continuation-in-part application application Ser. No. 11 / 648,955 filed Jan. 3, 2007, which is a continuation-in-part of application Ser. No. 11 / 344,320 filed Jan. 31, 2006, which is a continuation-in-part of application Ser. No. 11 / 204,868, filed Aug. 16, 2005, which is a divisional of application Ser. No. 10 / 850,548, filed May 20, 2004, now issued as U.S. Pat. No. 6,989,193, which is a continuation-in-part of application Ser. No. 10 / 465,698, filed Jun. 19, 2003. The foregoing applications are hereby incorporated by reference.FIELD OF THE INVENTION[0002]The present invention pertains to water-dispersible fibers and fibrous articles comprising a sulfopolyester. The invention further pertains to multicomponent ...

AI Technical Summary

Benefits of technology

[0033]The sulfopolyester has a glass transition temperature of at least 57° C. which

Problems solved by technology

Unfortunately, the personal care products made from conventional thermoplastic polymers are difficult to dispose of and are usually placed in landfills.

The various thermoplastic polymers now used in personal care products are not inherently water-dispersible or soluble and, hence, do not produce articles that readily disintegrate and can be disposed of in a sewerage system or recycled easily.

These approaches, however, suffer from a number of disadvantages and do not provide a fibrous article, such as a fiber or nonwoven fabric, that possesses a satisfactory balance of performance properties, such as tensile strength, absorptivity, flexibility, and fabric integrity under both wet or dry conditions.

The resulting assemblies, however, generally have poor water-responsivity and are not suitable for flushable applications.

The presence of binder also may result in undesirable properties in the final product, such as reduced sheet wettability, increased stiffness, stickiness, and higher production costs.

It is also difficult to produce a binder that will exhibit adequate wet strength during use and yet disperse quickly upon disposal.

Thus, nonwoven assemblies using these binders may either disintegrate slowly under ambient conditions or have less than adequate wet strength properties in the presence of body fluids.

Ion concentrations and pH levels in public sewerage and residential septic systems, however, can vary widely among geographical locations and may not be sufficient for the binder to become soluble and disperse.

Polymers which have good water dispersibility, however, often impart tackiness to the resulting multicomponent fibers, which causes the fiber to stick together, block, or fuse during winding or storage after several days, especially under hot, humid conditions.

Such oil finishes, pigments, and fillers require additional processing steps and can impart undesirable properties to the final fiber.

Many water-dispe

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