Mixing of particulate material and coaxial meltblown fibers

Abstract

FIELD OF THE INVENTION The present invention relates to an apparatus for producing a web material containing fibers and particulate material, a process for operating such an apparatus, and certain materials produced thereby.

Description

[Technical Field]

[0001] The present invention relates to an apparatus for manufacturing web materials comprising fibers and particulate materials, a process for operating such an apparatus, and specific materials that may be produced thereby. [Background technology]

[0002] As used herein, “coforming” and / or “coforming process” means a well-known method of mixing two or more distinct materials so that a filament, typically such as a polymer filament, is bonded with one or more other materials, such as short fibers, such as pulp fibers, or particulate materials such as particles. The mixture of filaments and particulate materials can be assembled to form a fibrous structure.

[0003] Such structures can be used in a wide range of applications, including absorbent media for aqueous and organic fluids, filtration media for wet and dry applications, adsorption media for removing gaseous fluids or components, insulating materials, protective buffering materials, containment and delivery systems, as well as wiping media for both wet and dry applications, and wiping media, in particular, for infant care. Liquid absorbency can be significantly enhanced by the use of particulate absorbents or superabsorbent polymer (SAP) materials, which may be provided as particulate materials in the form of particles or fibers.

[0004] In many applications, the use of filaments significantly improves the usability of structures that would be hindered by the lack of integrity in the case of particulate materials alone: ​​for example, pure wood pulp fiber structures have little mechanical integrity and undergo a high degree of collapse when wet. Similarly, when using at least a large amount of SAP (up to pure SAP), there is little integrity and immobilization. By combining these with thermoplastic fiber materials, the properties of such structures, including both wet and dry tensile strength, can be greatly improved, especially when the thermoplastic fiber material is formed in situ into filaments, i.e., when it is formed substantially simultaneously with the combination with particulate materials.

[0005] Furthermore, it has been found to be advantageous to use melt-blown fibers as the outer layer of the fiber structure, and, referring to, for example, US8017534 / EP2265756(KC), the objective is to provide a homogeneously formed fiber structure comprising melt-blown fiber material and at least one secondary fiber material, such as pulp, so that it can be used as a wet wipe. This structure can be formed by providing first and second flows of melt-blown fiber material from a melt-blown die, mixing these with a flow of natural fibers, such as pulp fibers, in a forming zone, and then collecting it on a forming wire.

[0006] Each melt-blown die is configured such that two flows of damping gas for each die converge to form a single flow of gas that draws in and dampens the molten filament as it exits the small hole or orifice within the melt-blown die. In the well-known melt-blown method, the damping gas, typically air, is supplied at an angle of about 60° to the filament flow direction, also known as an "air knife".

[0007] WO2017004117 / WO2017004116 (P&G, Burt et al.) discloses a co-formed fibrous web structure having a co-formed core layer sandwiched between two scrim layers. The core layer may be formed from a blend of cellulose pulp fibers and melt-spun filaments, and the scrim layer may be formed from melt-spun filaments, thereby the melt spinning may be melt-spun filaments. The scrim layer has a density of 0.1 g / m 2 From 3.0g / m 2 The total basis weight may be less than [amount missing]. Furthermore, it is stated that multiple fibers, such as pulp fibers, may be mixed with multiple filaments, such as polypropylene filaments.

[0008] As a variation of the melt-blown system using the "air knife" system described above, WO2009002612(3M) Micro and Meso-Melted-Blown Fibers describes a single row of orifices of two diameters, thereby producing a porous nonwoven web containing melt-blown fibers that present a bimodal mixture of microfibers and mesofibers that can be combined with short fibers.

[0009] US5665278 (J&M) describes meltblown thermoplastic fibers that are cooled or quenched by micro-sized water droplets generated by an airless nozzle, having droplets with an average diameter of less than 20 microns.

[0010] Furthermore, for multi-row spunbonds with separate melting channels and insulating channels operating at different temperatures, it is known to use two types of polyester polymers exhibiting a melting temperature difference between 5°C and 50°C, as described in US6164950 (Freudenberg), using different types of polymers in a single die head.

[0011] In contrast to the "air knife" meltblowing system described above in this specification, WO2009010940 (P&G) describes forming a fibrous co-form structure by using a multi-row meltblowing system with substantially parallel airflows, i.e., angled at less than about 10°, which may also be referred to as "coaxial meltblowing" or hereinafter "CA meltblowing".

[0012] Such a filament forming system is also known from US5476616 or US9303334 (Biax) (hereinafter referred to as US’616 and US’334 respectively), where a "hybrid system" between spin bonding and melt foaming is called "Spunblown®".

[0013] This apparatus includes a die block, a spinneret fixed thereto, and a plurality of nozzles grouped in an array of a plurality of rows and a plurality of columns and fixed to the spinneret.

[0014] Furthermore, at least the nozzles are surrounded by substantially concentrically arranged openings configured such that pressurized gas passes through the nozzles to cover the filaments, and substantially continuous filaments coagulate and attenuate into fibers and are collected on a laminating belt by a large amount of suction from a vacuum box below.

[0015] For example, as described in US’334, all around the filaments / fibers extruded from the array of nozzles may be covered by another pressurized gas curtain to isolate them from the surrounding air. Furthermore, it is mentioned that the nozzle openings can exhibit different sizes.

[0016] Further improvements to the coforming process are described in US20160355950 (P&G). Thus, two or more separate materials, for example, a filament and a solid additive such as short fibers and / or fine particles, are mixed in a forming box. Such a forming box may include a housing having one or more filament inlets and one or more solid additive inlets. The filament can be supplied from a polymer filament source such as a filament forming die, and the flows of the filament and solid additive can be mixed in the box at an angle of less than 90° to each other. Such a setup is intended to provide superior mixing of materials with significantly reduced vacuum suction compared to, for example, the system described in US'334 above.

[0017] WO2020 / 099193 (filed as PCT / EP2019 / 080293, TKWM) describes a particular CA melt blowout die block, wherein the spinneret block includes a nozzle integrated with the spinneret body. The nozzle is arranged in an array of nozzles which may be arranged in subarrays. Furthermore, the nozzles may be chamfered to allow a smooth flow of polymer through the capillaries of the nozzles.

[0018] WO2020 / 104190 (filed as PCT / EP2019 / 080291; TKWM) describes a further specific CA molten blow die block, in which the nozzle is removable from the spinneret block. Furthermore, the nozzle may be chamfered to allow a smooth flow of polymer through the capillaries of the nozzle. The die spinneret block may further include grooves, which, when filled with sealant, allow each row of the spinneret block to be deselected. [Overview of the project]

[0019] The present invention relates to a web forming apparatus adapted for forming a mixed web, wherein the mixed web is - Particulate material selected individually or in combination from the group consisting of short fibers, preferably pulp fibers, and particles, preferably superabsorbent particles, -CA meltblown type synthetic fiber, It includes.

[0020] Therefore, the device includes the following: - A particulate material supply system, A particulate material feeding system directed to supply a flow of particulate material moving substantially / primarily / generally vertically downwards; - With at least one polymer supply system adapted to provide polymer material below; -A first and second multi-row CA meltblown system, each of which is adapted to form CA meltblown fibers, A first and second multi-row CA meltblown system comprising arrays of polymer release orifices including at least two substantially intersecting rows of polymer release orifices, -Forming box, The forming box is adapted to form a mixed material containing the above-mentioned particulate material and CA meltblown fibers. The forming box is · An inlet for particulate material connected to the particulate material supply system; Each of the two CA melt-blown fiber inlets is connected to one of the CA melt-blown systems; • Outlet for mixed material; A forming box and; -Collector, preferably a forming belt, To collect the mixed short fibers and CA meltblown fibers from the outlet of the forming box, The device is adapted to move along the mechanical direction, Optionally, the web may be shown with protrusions for creating a patterned or textured structure. Collector, preferably forming belt and; It is equipped with, As a result, each of the CA melt-blown inlets of the forming box is positioned in the machine direction, in front of (upstream) and behind (downstream) the inlet of the particulate material.

[0021] The array of polymer-releasing orifices comprises at least first and second subarrays, each subarray comprising at least one, preferably at least two, more preferably at least four, and most preferably six or more orifice rows.

[0022] As a result, at least one orifice of the subarray is adapted to emit fibers with different properties than the orifices of different subarrays in one or more functions selected from the group consisting of the following: The orifices of the aforementioned subarray exhibit different orifice diameters; The orifice of the subarray is a polymer supply system, For different polymer types; For different polymer throughputs; For different polymer supply pressures It is connected to the polymer supply system; The orifice of the subarray is connected to an independent temperature control system.

[0023] The apparatus may further include a quenching system which includes the following: A first quenching device machine positioned directionally upstream of the first CA melt-blown system; A second quenching device machine positioned directionally between the first CA melt-blown system and the inlet of the particulate material; A third quenching device machine positioned directionally between the inlet of the particulate material and the second CA melt-blown system; A fourth quenching device machine positioned directionally downstream of the second CA melt-blown system; It is equipped with, Accordingly, each of the quenching devices is adapted to discharge first, second, third, and fourth quenching fluid flows into the forming box, respectively.

[0024] The quenching device includes a quenching fluid flow control system configured to control at least one characteristic of the quenching fluid flow independently of at least one other characteristic of the quenching fluid flow by control means of the control system selected individually or in combination from the following list. - The quenching device is connected to a different type of quenching fluid, preferably a fluid selected from the group consisting of air, water, and steam; - Quenching fluid temperature control means; - Quenching fluid supply pressure adjustment means; - Quenching fluid supply flow rate; - The outlet angle of the quenching fluid relative to the CA melt blow head or the particulate material supply axis.

[0025] The apparatus may further comprise one or more features selected from the group consisting of the following: - Removable nozzle, more preferably a chamfered grooved die head; - A single die head including a spinneret block and nozzle; - Variable die head angle relative to the die head axis; - Vico nozzles connected to individual polymer supply systems.

[0026] The subarrays in both CA meltblown systems may include orifices having a larger diameter than the orifices of the other subarray and be positioned in the machine direction toward the inlet of the particulate material.

[0027] The apparatus may further include at least one web-forming element positioned upstream and / or downstream of the forming box, adapted to extrude a filament, and to form a scrim layer on the outer surface of the mixed web.

[0028] The present invention also includes a process for forming a mixed web, comprising the following steps. - Particulate materials selected individually or in combination from the group consisting of short fibers, preferably pulp fibers, and particles, preferably superabsorbent particles; With one or more types of polymer materials; The above-mentioned device and; The process of providing; - A step of supplying the particulate material to the forming box; -In the CA melt-blown system, a step of forming at least two types of CA melt-blown filaments from the polymer material, A process for forming a fiber that differs in at least one property selected from the group consisting of the following: Offering different polymer types; Offers different polymer throughput; Provides different polymer supply pressures; - A step of supplying these to the forming box; - The process of collecting a mixed web in a collection device; - A step of removing the collected mixed web from the apparatus.

[0029] This process may further include the following steps: - A step of arranging a plurality of quenching devices for delivering the quenching fluid to the forming box, wherein for each of the CA melt-blown systems, one quenching device is positioned upstream and another quenching device is positioned downstream; -A step of supplying a flow of quenching fluid to the forming box by arranging a plurality of quenching devices for delivering the quenching fluid, such that for each of the CA melt-blown systems, one quenching device is positioned upstream and another quenching device is positioned downstream; -A step of adjusting the flow properties of the quenching fluid to the properties of each of the CA meltblown fibers by adjusting one or more properties selected from the group consisting of the following; The type of quenching fluid, preferably air, water, or steam; temperature; flow rate; speed; direction; - Preferably, the process involves extruding a polymer filament to form a first scrim layer, and depositing the first scrim layer in the collector upstream of the forming box; - Preferably, a step of extruding a polymer filament to form a second scrim layer, and depositing the second scrim layer in the collector downstream of the forming box.

[0030] This invention is also a comingled web, A particulate material selected individually or in combination from the group consisting of short fibers, preferably pulp fibers, and particles, preferably superabsorbent particles, CA meltblown type synthetic fiber, It includes.

[0031] The x, y, and z (thickness) directions are shown. First and second surface regions extending in the xy direction, Contains CA meltblown type synthetic fibers, Substantially free of the aforementioned particulate material, It comprises a first and a second surface region, A central region arranged in the z-direction between the aforementioned surface regions, - Mixed particulate material, -CA meltblown type synthetic fiber, It comprises a central region including, The CA meltblown type synthetic fiber included in the central region is characterized in that it substantially differs from the fiber in the surface region in at least one property selected from the group consisting of the following. Fiber diameter; Type of polymer; Type of fiber; Average fiber length; Fiber strength.

[0032] The CA melt-blown type synthetic fibers in the central region of the mixed web may further comprise at least first and second pluralities of CA melt-blown type fibers having different one or more fiber characteristics selected from the group consisting of the following. Fiber diameter; Type of polymer; Type of fiber; Average fiber length; Fiber strength.

[0033] The first and second types of synthetic fibers in the first and second surface regions of the mixed web may optionally be substantially the same.

[0034] The mixed web may further comprise at least one scrim layer forming the outer surface of the mixed web, and the scrim layer has a basis weight of less than 10 g / m 2 Preferably less than about 5 g / m 2 More preferably less than about 3 g / m 2 Preferably less than about 0.1 g / m 2 And may exhibit a basis weight greater than.

[0035] The mixed web has a basis weight greater than about 20 g / m 2 Preferably greater than about 35 g / m 2 More preferably greater than about 45 g / m 2 Greater than, and about 500 g / m 2 Preferably less than about 100 g / m 2 More preferably less than about 70 g / m 2 And may exhibit a basis weight less than.

[0036] The particulate matter of the mixed web may be present in an amount greater than about 50%, preferably greater than about 70%, more preferably greater than 85%, or even more preferably greater than about 90% or greater than 95%, based on the total weight of the mixed web, including the scrim layer if present.

[0037] The present invention also relates to the use of mixed webs for the manufacture of wipes. [Brief explanation of the drawing]

[0038] Figure 1 shows the configuration of the apparatus according to the present invention. Figures 2A and 2B illustrate specific embodiments of the present invention. Figures 3A and 3B illustrate a specific embodiment of the present invention. Figure 4 shows the flow path or trajectory during operation of the process according to the present invention. Figure 5 shows a cross-section of the mixed web according to the present invention. Figure 6 shows a further specific embodiment of the equipment according to the present invention. Figure 7 shows a cross-section of another mixed web according to the present invention.

[0039] The same number indicates the same or equivalent features, and one or more apostrophes indicate multiple equivalent features, such as "first and second" or "left and right." The diagram is a schematic and not necessarily to scale. [Modes for carrying out the invention]

[0040] In one embodiment, the present invention relates to an apparatus for continuously manufacturing webs and a process for operating such an apparatus.

[0041] The term "machine direction" (MD) or x-direction generally corresponds to the manufacturing direction of the web, while the "cross direction" or y-direction is perpendicular to it.

[0042] Generally, MDs and CDs are aligned horizontally and perpendicular to the vertical direction, either along or against gravity.

[0043] However, those skilled in the art will readily recognize that if the continuous manufacturing process involves any upward or downward movement, the MD may deviate from the horizontal.

[0044] Regarding the relative arrangement of equipment elements, the terms "upstream," "downstream," and related terms are generally used to describe the relative arrangement along the manufacturing path on the equipment.

[0045] Furthermore, the terms “up,” “down,” and related terms are commonly used to describe the arrangement relative to gravity. However, those skilled in the art will readily recognize cases where a particular embodiment is tilted or even inverted without losing its functionality, as described herein.

[0046] When considering materials, especially web materials, the thickness or extension in the z-direction is typically much smaller than the MD or CD, the latter referring to the orientation of the web material during manufacturing. Typically, though not always, the MD and CD of a web can be identified by those skilled in the art.

[0047] Polymeric filaments are typically considered to be continuous or substantially continuous. Non-limiting examples of filaments include meltblown, spunbond, or CA meltblown filaments, which may be substantially continuous or fractured into fractured filaments, as described below. Non-limiting examples of materials that can be formed into filaments include, but are not limited to, natural polymers, e.g., starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, and synthetic polymers, e.g., polyvinyl alcohol filaments and / or polyvinyl alcohol derivative filaments, and thermoplastic polymer filaments, e.g., polyester, nylon, polyolefins, e.g., polypropylene filaments, polyethylene filaments, and biodegradable or compostable thermoplastic filaments, e.g., polylactic acid filaments, polyhydroxyalkanoate filaments, and polycaprolactone filaments. Filaments may be single-component filaments or multi-component filaments such as two-component filaments. In one example, the polymer filament of the present invention comprises a thermoplastic polymer selected from the group consisting of polyolefins such as polypropylene and / or polyethylene, polyester, polyvinyl alcohol, nylon, polylactic acid, polyhydroxyalkanoate, polycaprolactone, and mixtures thereof. In one example, the thermoplastic polymer comprises a polyolefin, such as polypropylene and / or polyethylene. In another example, the thermoplastic polymer comprises polypropylene.

[0048] Other suitable polymer filaments can be made from a curable liquid binder system containing a high concentration of one or more binder compounds in a solvent or carrier, preferably water, as described in further detail in application GB2005832.7 (unpublished, TKWM), which refers to binder systems and their processing.

[0049] The term "fibers" includes natural fibers such as wood pulp fibers, modified natural material fibers such as cellulose-based molded fibers such as viscose® or rayon®, or synthetic polymer-based fibers. In this context, a distinction is made between short fibers such as cellulose pulp fibers or staple fibers that are manufactured and supplied as fibrous materials (which may need to be broken down as is well known in the case of cellulose pulp, but can be delivered in rolls or bales, and which are opened to form fibers, typically individualized fibers) and filament fibers that are formed in situ from molten polymers during the process of the present invention, for example.

[0050] In the first embodiment, the term “different polymer types” refers to polymers of different chemical species, such as polyester or polyethylene terephthalate vs. polypropylene vs. polyethylene. In the second embodiment, it also refers to polymers of the same species when their properties differ due to different polymer chain lengths, melt flow index, or additives. Two fiber types may also differ, for example, when two two-component or multi-component fibers exhibit different amounts of components or different geometric arrangements, such as core-sheath vs. side-by-side.

[0051] In this context, the term “particulate matter” may refer to pre-formed, discontinuous, typically short individual fibers such as cellulose pulp fibers or short synthetic fibers such as staple fibers, and particles such as functional particles that are adsorbent for use in odor adsorption structures, for example, or liquid absorbent, such as polyacrylate-type superabsorbent polymers (SAP). Such short fibers typically exhibit a length-to-diameter ratio of at least about 10 and typically have a length of less than about 5 cm.

[0052] In one embodiment of the present invention, “short fibers” means wood such as eucalyptus or acacia or northern or southern coniferous pulp fibers, or chemical pulps such as kraft, sulfite and sulfate pulps, and mechanical pulps, including, for example, crushed wood, thermomechanical pulp and chemically modified thermomechanical pulp. Also applicable to the present invention are fibers derived from recycled paper, which may include any or all of the above categories, as well as other non-fibrous materials such as fillers and adhesives used to facilitate the original papermaking process. In addition to various wood pulp fibers, other cellulose fibers such as cotton linters, rayon, lyocell and bagasse can be used in the present invention.

[0053] As used herein, “coforming” and / or “coforming process” means a process in which two or more distinct materials are mixed together. In one example, coforming includes a process in which one or more first materials, such as polymer filaments, are coming together with one or more second materials, such as particulate materials, such as pulp fibers, or particles. In a coforming process, two or more distinct materials are mixed together to form a mixture of the two or more materials, which does not necessarily have to be a homogeneous mixture. For example, in a coforming process, filaments may be mixed with fibers to form a mixture of filaments and fibers that can be collected to form a fibrous structure according to the present invention.

[0054] As used herein, “fibrous structure” means a structure comprising one or more filamentary materials and / or one or more particulate materials. In one example, a fibrous structure according to the present invention means that filaments or fibers and particles are regularly arranged within the structure in order to perform a function. The fibrous structure of the present invention may be uniform, but preferably comprises different regions in the z direction, which may exhibit sharp boundaries, i.e., be layered, or may transition gradually from one region to an adjacent region. If regionized or layered, the fibrous structure may comprise at least two and / or at least three and / or at least four and / or at least five regions or layers.

[0055] As used herein, "stream of material" generally refers to material moving along a common trajectory, such as particulate materials like short fibers or particles, molten materials, especially polymer materials, solidified materials, or solidified materials, and fibers, such as filaments like fractured or continuous solidified filaments. Depending on its trajectory, the stream may be substantially parallel, divergent, or convergent.

[0056] In this context, the term "die block" refers to an element of a multi-row CA melt-blown system in which molten polymer is supplied and polymer filaments are formed by pressing the polymer through the capillaries of multiple nozzles. A die block is typically, - A spinneret block, - The top plate and, Here, the term "upper part" usually means the "molten polymer supply side," -Lower plate and, A spinneret block equipped with, - Multiple nozzles, It may be integrated with the spinneret block or be detachable. Multiple nozzles forming an arrangement of rows and columns of nozzles, -Air distribution plate and; - External air plate and; - Cover strip and fixing means, It is equipped with.

[0057] The multi-row CA melt-blown system may include further elements such as means for supplying polymer and means for supplying curtain air to cover the array of nozzles, or means for temperature control of the polymer and air.

[0058] As used herein, “a” and “an,” for example, “a fiber,” are understood to mean one or more of the claimed or described materials.

[0059] Unless otherwise specified, all percentages and ratios are calculated in weight.

[0060] Referring to the schematic cross-sectional view in Figure 1 for illustrative purposes, the present invention is, in a first embodiment, an apparatus 1000 for forming a mixed web 1900 including a forming box 1100. Particulate material 1400 is supplied by a particulate material supply system 1410, and a first polymer material 1200 and a second polymer material 1300 are supplied from first (1210) and second (1310) polymer supply systems to first (1220) and second (1320) polymer filament forming systems. The materials are supplied to specific material inlets 1114 of the forming box 1100, and to first and second polymer material inlets 1112 and 1113, respectively. With the help of a vacuum in a suction box 1700, the mixed material exits the forming box at an outlet 1119 of the forming box as a mixed web 1900 placed on a collector 1600 such as a movable screen.

[0061] The apparatus has a general three-dimensional extension, showing the height direction 1005 of the apparatus, which corresponds to the thickness of the web formed thereon or the z-direction. It further shows the machine direction or x-direction 1002 and the cross direction or y-direction (represented by "x" representing the fretting of the direction arrow 1008). Thus, Figure 1 shows a cross-sectional view in the zx direction, where the left portion shows the upstream portion 1001 as seen by the observer, while the right portion, which has the mixed web 1900 on the collector 1600, shows the downstream portion 1009, where the collector is configured to move from the upstream portion to the downstream portion, thereby collecting the mixed web with increasing web height until the final web height or caliper is reached. In the cross direction, the apparatus is horizontally aligned and has an extension that may be less than 1m, but is often greater than 1m, greater than 3m or even greater than 5m in the case of large production apparatus, but typically does not exceed 10m. The apparatus may consist of several subunits in the lateral direction or may be a single unit across the entire width. The former allows for easier handling, such as setting up, cleaning, repairing, or changing specific parts to adjust a different number of nozzles, while the latter avoids discontinuities in the intersecting direction of the web.

[0062] The web forming apparatus may be a separate, independent modular device that can be inserted into a larger manufacturing machine, such as an absorbent article or wipe manufacturing machine, and / or may be a fully integrated component of such a larger machine.

[0063] A forming box 1100 suitable for the present invention includes a housing and a closed or partially closed forming chamber 1110 formed by one or more walls through which one or more materials pass inlet or outlet. The forming box can be made from a wide variety of materials, such as metal, often steel, but can also be made from a sufficiently rigid polymer material such as polycarbonate, or glass.

[0064] The material inlets of the forming box are connected to their respective material supply systems, and the inlet 1112 for the first polymer filament is positioned upstream of the inlet 1114 for particulate material, which is located upstream of the inlet 1113 for the second polymer filament.

[0065] In certain preferred embodiments, the inlet for the particulate material may be positioned so that the particulate material flows through the forming chamber 1110 toward the collector largely in line with gravity, although a slight inclination with respect to the vertical is permitted.

[0066] A specific material inlet 1114 may exhibit an extension in the MD direction of more than approximately 0.07 cm, or more than approximately 0.1 cm, or more than approximately 0.1 cm, or more than approximately 0.3 cm, and / or less than approximately 25 cm, or less than approximately 12.5 cm, or less than approximately 7.5 cm.

[0067] The inlets 1112 and 1113 for the first and second polymer filaments are preferably positioned at a vertical inclination between 30° and 90°, preferably 60°, and are adapted to entangle downward-flowing particulate material before the emitted filaments come into contact with the surface of the collector means, although they may not necessarily be symmetrical if necessary.

[0068] The polymer filament entry points 1112 and 1113 may exhibit MD-direction extensions of more than approximately 0.25 cm, more than 1.25 cm, or more than approximately 2.5 cm, and / or less than approximately 40 cm, less than approximately 25 cm, or less than approximately 15 cm, respectively.

[0069] The mixed material is positioned toward a collector such as a moving belt 1600 and exits the forming chamber via a forming chamber outlet 1119, which is further aided by vacuum suction by a suction box 1700.

[0070] The exit of the forming chamber may exhibit MD extensions of more than approximately 0.25 cm, or more than approximately 1.25 cm, or more than approximately 2.5 cm, and / or less than approximately 75 cm, or less than approximately 50 cm, or less than approximately 130 cm.

[0071] Particularly preferred embodiments of the forming box are described in more detail in US2016335950 above, which provides clear references to the design of the forming box, particularly its dimensions and operation.

[0072] For the sake of simplicity, the inlet for particulate material and the inlet for filament are described singly, but performing either of these multiple times is quite conceivable and may be done using conventional techniques.

[0073] The particulate material 1400 is delivered to the particulate material inlet 1114 of the forming box 1100. For this purpose, the particulate material is supplied as bulk material or, in the case of short fibrous material, in the form of rolls or bales, which can then be broken down into individualized fibers by conventional means such as a hammer mill and / or solid additive spreader and / or forming head, or an air-laid device such as a forming head from Dan-Web Machinery A / S. In certain embodiments where high homogeneity of the resulting web is to be aimed at, the apparatus includes or can be connected to a cross-directional spatially controllable eductor that can be operated in operation to control the pressure, velocity, mass, and / or flow CD profile of the particulate material, such as short fibers, when suspended in a fluid medium. Specific implementations of such eductors are disclosed in US2016 / 354736, which makes an explicit reference to specific disclosures for such eductors and their operation.

[0074] Particulate material can be supplied to the inlet 1114 of the forming box by gravity, pneumatic transport, other mechanical feeders, or a combination thereof. Furthermore, the apparatus includes at least two multi-row CA melt-blown systems 1220 and 1320 which can be connected in common or (as shown in Figure 1) to separate polymer supply systems 1210 and 1310 which supply appropriate polymers 1200 and 1300 to CA melt-blown dies or die blocks, respectively connected to the respective filament inlets 1112 and 1113 of the forming box 1100.

[0075] In this context, the term "connected" means positioning the filament released by the CA melt-blown system so that it flows directly into the forming chamber 1110 of the forming box 1100.

[0076] As will be described in more detail below, the multi-row CA melt-blown system follows the general teachings of US'616 or US'334 (Biax), namely, multiple nozzles arranged in rows and columns to discharge filaments into the forming chamber 1110.

[0077] The orientation of the system is as described above for the polymer inlet, and thereby the nozzle defines the orientation of the die in the system, having a die block centerline parallel to the nozzle.

[0078] For operation, the nozzles are adapted to discharge filaments primarily along the nozzle centerline through the nozzle orifice, inclined with respect to the particulate material inlet, shown here as vertical, as shown in Figure 1, so that the die block centerline intersects with the trajectory of the particulate material vapor (see below). Towards the mechanical directional limits of the nozzle array, the direction of the filaments may be shifted outward. Further design and operational details are explicitly referenced in US'616, while US'334 details the optional use of a shielding air curtain around the nozzle array.

[0079] A particular element of the present invention is that the polymer supply system includes a subarray of nozzles, each of which has a die block adapted to form a plurality of filaments exhibiting different properties.

[0080] The nozzle array may include at least two sub-arrays that differ in the geometric shape of the nozzles, i.e., in terms of inner or outer diameter or nozzle length. Optionally, the capillaries of the nozzles in the sub-arrays may exhibit different cross-sectional shapes, such as non-circular shapes, like star-shaped or bi- or multiglobal shapes.

[0081] The first option of this approach is described in more detail in WO2020 / 099193 (PCT / EP2019 / 080293, TKWM), which refers to the design and operation of a die block including a single spinneret block with two subarrays of nozzles.

[0082] As shown in Figure 2A, the spinneret block 152, which may be part of a die block (not shown) or either a polymer filament forming system 1220 or 1320, includes a spinneret body 153 integrated with nozzles, one row of which shows five nozzles 158, each representing a row extending in one direction, together forming arrays of nozzles 1225 and 1325. As illustrated, the nozzles are oriented vertically along gravity (1005). However, the orientation of the system connected to the forming box may be such that the nozzle orientation is inclined with respect to gravity (see Figure 1), and those skilled in the art will readily adapt terms to determine relative positions such as “up” or “down” accordingly. Figure 2A further shows a polymer supply cavity 130 for supplying molten polymer to the nozzles, an air supply passage 132 for supplying air to shroud each of the filaments, and holes for connecting components of the die block 199.

[0083] The array of nozzles 1225 includes sub-arrays 1222, 1322, and 1228, 1328, respectively. Such sub-arrays do not need to extend across the entire width of the die block, but preferably may include at least one row of nozzles. In certain embodiments, as shown in Figure 2A, the nozzles 158' of sub-arrays 1222, 1322 differ substantially from the nozzles 158'' of sub-arrays 1228, 1328 in at least one dimension selected from the group consisting of the inner diameter of the nozzle, the outer diameter of the nozzle, and the length of the nozzle, here indicated by different inner nozzle or capillary diameters 157' and 157''. In this context, the term “substantially different” refers to a difference of at least 5%, often more than 10%, of each dimension.

[0084] In a second option of this approach, the die block includes a spinneret block with a removable nozzle, as described in more detail in WO2020 / 104190 (PCT / EP2019 / 080291, TKWM), which refers to the design of a removable nozzle.

[0085] Referring to Figure 2B, a first embodiment of a spinneret block 152 for polymer filament forming systems 1220 and 1320 is shown, comprising a spinneret body having an upper plate (151) and a lower plate (155), and nozzles 158 detachably disposed through holes in the lower plate, one of which row shows eight nozzles 158, each representing a row extending in one intersecting direction, together forming an array of nozzles 1225 and 1325. As illustrated, the nozzles are oriented vertically along gravity (1005). However, the orientation of the system connected to the forming box may be such that the orientation of the nozzles is inclined with respect to gravity (see Figure 1), and those skilled in the art will readily adapt terms to determine the relative positions, such as “up” or “down,” accordingly. As shown in Figure 1, the inclination of the two polymer filament forming systems 1220 and 1320 may be symmetric with respect to the vertical or particle injection direction, but this is not necessarily the case. Figure 2B further shows a polymer supply cavity 130 for supplying molten polymer to the nozzle, an air supply passage 132 for supplying air to shroud each of the filaments, and holes for connecting the components of the die block 199.

[0086] The arrays of nozzles 1225, 1325 each include sub-arrays 1222, 1322, and 1228, 1328, respectively. Such sub-arrays do not need to extend across the entire width of the die block, but preferably may include at least one row of nozzles. In certain embodiments, as shown in Figure 2A, the nozzles 158' of sub-arrays 1222, 1322 differ substantially from the nozzles 158'' of sub-arrays 1228, 1328 in at least one dimension selected from the group consisting of the inner diameter of the nozzle, the outer diameter of the nozzle, and the length of the nozzle, here indicated by different inner nozzle or capillary diameters 157' and 157''. In this context, the term “substantially different” refers to a difference of at least 5%, often more than 10%, of each dimension.

[0087] Another approach to providing filaments with different properties involves connecting the nozzles of the subarray to separate polymer supply systems.

[0088] In the first option for this approach, as long as different polymers are used, also refer to WO2020 / 099193 cited above, in Figure 3A, in a configuration similar to that in Figure 2A, the cavity 130 for polymer supply is separated into sub-chambers 130' and 130'' by a separation means 131, which supplies different types of polymers to nozzles of sub-arrays 1222, 1322 and 1228, 1328, thereby the polymers differ in at least one of qualitative characteristics such as polymer type, or quantitative parameters such as polymer flow rate, polymer pressure, etc., thereby differing by at least 5%, often 10% or more based on the respective smallest values, or in polymer temperature, thereby differing by at least 5°C. Optionally, the nozzles may be run with sub-capillaries arranged coaxially to produce two-component or multi-component fibers, each of which is supplied with a different type of immiscible polymer.

[0089] In any of these modifications, the nozzle is preferably constructed such that the smooth flow of the molten polymer is enhanced by chamfering the nozzle inlet portion. When implemented using a removable nozzle, the groove can be constructed using a chamfer positioned within the groove, as further described in the referenced application, and the spinneret block can be filled with sealing means for selectively excluding a particular row of the die head, as far as nozzle design is concerned, refer to the above application.

[0090] In the second option of this approach, the aforementioned WO2020 / 104190 is also referenced, insofar as different polymers are used.

[0091] As shown in Figure 3B, a similar configuration of the spinneret 152 as in Figure 2B may be shown, where the nozzle 158' of one subarray 1222, 1322 is connected to the first separated polymer supply system via the first molten polymer supply cavity 130', which is separated from the second polymer supply cavity 130'' by the separation means 131, and a first type of molten polymer different from the molten polymer supplied to the first subarray 1222, 1328 via the second molten polymer supply cavity 130'' and then supplied to the nozzle 158'' is supplied to the first subarray 1222, 1328. The nozzle may be adapted to supply to 22, thereby the polymer may differ by at least 5%, often 10% or more, in at least one of qualitative characteristics such as polymer type, or quantitative parameters such as polymer flow rate, polymer pressure, or by at least 5°C in polymer temperature. Optionally, the nozzle may be run with coaxially arranged subcapillaries to produce two-component or multi-component fibers, each of which is supplied with a different type of immiscible polymer.

[0092] Another option for inducing different filament properties from different nozzles is simply to apply different settings to different quenching devices, as described in the process section below.

[0093] Referring again to Figure 1, the apparatus 1000 further includes a quenching system, which comprises quenching devices 1510, 1520, 1530, and 1540 positioned adjacent to the polymer filament inlets 1112, 1113 to supply at least quenching fluid to the filaments of the outer nozzles of the nozzle array emerging from the filament forming systems 1220, 1320. Quenching is intended to control the solidification and crystallization of the polymer filaments immediately after they exit the filament forming nozzles, i.e., web properties such as shot formation, hand, elasticity, and tear strength. Quenching also affects web properties, for example, through interfiber fusion and fiber entanglement.

[0094] The quenching fluid can be a gas such as air or vapor, a liquid such as water spray, or a combination thereof. The effect of quenching depends, for example, in the case of a quenching fluid containing a liquid such as water, on the properties of the quenching fluid such as temperature, the flow direction and velocity of the quenching fluid, and the amount of quenching fluid relative to the amount of filament in contact. Typically, the quenching fluid is supplied at a temperature lower than the temperature of the filament when it leaves the nozzle.

[0095] In contrast to conventional quenching systems without a forming box, where ambient air is entrained from the environment by the movement of the filament flow, a preferred embodiment provides a fluid medium with controlled properties, such as conditioned air or water spray.

[0096] In a particularly preferred embodiment of the present invention, the quenching system is adapted to selectively control a separate quenching device. This is particularly relevant to embodiments using nozzle subarrays on which the filaments may exhibit different filament characteristics on the respective upstream and downstream portions of the die. The separate control means for the quenching device may be influenced and tuned by adapting them to control, for example, the following: - The type of quenching fluid, e.g., air, steam, water spray; - Fluid temperature and energy content; - The amount of quenching fluid flow, which can be expressed as follows: -As mass flow rate expressed as mass per unit time, -Or, for example, as momentum expressed in [kg*m / sec], -or, [kg / (m 2 As a mass flux represented by *seconds); - Typically expressed in meters per second, the velocity of the quenching fluid flow as it exits the quenching device; - The direction of the quenching fluid flow relative to the flow direction of adjacent filaments.

[0097] Although this apparatus is described by reference to an apparatus comprising a single particulate material supply system and two polymer filament forming systems, those skilled in the art will readily understand that there are more such apparatuses, and in some cases, they may include more quenching devices. Furthermore, the housing may have additional openings for accommodating other additives, additional quenching devices, etc.

[0098] The web forming apparatus may optionally include additional web forming elements to apply a filament layer or scrim to one or both surfaces of the web. Preferably, the polymer filament forming system is adapted to form filaments in situ by melt extrusion, e.g., spunbond, melt blow, or CA melt blow, as is well known in the art. More preferably, the polymer filament forming system is a CA melt blow type as described above in US'616, US'334, or WO2020 / 099193 or WO2020 / 080291, all of which are expressly referenced as far as filament extrusion apparatuses are concerned. It is also within the scope of the invention that such web forming elements include a multi-row CA melt blow system having subarrays of nozzles for dispensing filaments having different properties, as described above with respect to filament formation in a forming box. While not limiting the embodiments shown in Figure 6, with reference to exemplary examples, the first polymer scrim filament forming system 1650' is configured to deposit the first scrim 2140 onto a collector belt 1600, which is located upstream of the forming chamber 1100 and preferably supported by a suction box 1710', as described above and shown in Figure 1. The mixed web 1900 is formed on this scrim as described above. A second polymer scrim filament forming system 1650'' may be located downstream of the forming box 1100 to deposit the second scrim 2130 onto the mixed web 1900, which is preferably supported by a suction box 1710''.

[0099] Optionally, one or both of the scrim layers may be made, preferably at about 10 g / m². 2 Less than or approximately 5 g / m 2 It can be applied as a preformed web, such as a spunbonded web, with a low basis weight of less than 100%.

[0100] The collector 1600 on which the mixed web and / or scrim layer is deposited may be any air-permeable device such as a wire belt. Optionally, it may exhibit a specific xy-directional pattern having portions raised or deepened in the z-direction, configured to impart a pattern or texturing to the structure laid thereon. Such collectors are described, for example, in US2017 / 0165720A1 or US20170022660A1, which make references to such collectors, their operation, and the resulting properties of the web deposited thereon.

[0101] A mixed web that optionally includes one or two scrim layers may be further treated by certain embossing processes, also known as printed embossing, as described in US9714484B2 or US20150086760A1, to which explicit reference is made with respect to bonding patterns, particularly the ratio of bonding areas.

[0102] Furthermore, a liquid processing unit may be placed after the web forming step, for example, to form a wet wipe. The final web may optionally contain a liquid and be processed in one or more finishing units, such as units for rolling, winding, partial or complete separation, folding, or packaging. The present invention enables previously unknown operations for achieving mixed web properties by allowing adjustment of a number of process parameters, in particular by enabling independent control of process conditions for subarrays and quenching devices (if any).

[0103] Referring to Figure 4, the apparatus described above and in Figure 1 is schematically shown, and the trajectories of material flow are schematically shown. Generally, the trajectories of all materials are influenced not only by gravity, material properties (density, dimensions), and the flow characteristics of each material (velocity, direction), but also by the flow characteristics of other materials. This influence is particularly strong when flows merge and materials are mixed. In this context, the term "trajectory" refers to the flow path of a material, which typically shows a different path for each element of the material, i.e., each particle, fiber, filament, droplet, or fluid element. However, in the following description, "trajectory" is considered to represent an exemplary specific path of an element from the material entering the forming box at each inlet to the forming box outlet 1119 and collector 1600.

[0104] The particulate material entering the forming box at the particulate material inlet 1114 moves toward the collector 1600 along the particulate material flow trajectory 1450 (shown by a thin dashed line). The velocity of the particulate material flow can vary from a low velocity, for example, for particles falling freely into the forming box, where they are substantially accelerated by gravity, to a velocity of the carrier fluid, for example, when fiber particles are air-transported from their respective sources.

[0105] Polymer filaments can be formed in combination with specific embodiments of the apparatus described above, in accordance with the teachings of US'616 or US'334, or by incorporating the teachings of GB 2005832.7 (unpublished, TKWM) cited above.

[0106] The filament trajectories 1252, 1352 (thick solid line), 1258, and 1358 (thin solid line) depend on which part of the sub-array 1222, 1228, 1322, and 1328 a particular filament is ejected from, and depend on the characteristics of the filament, such as its size and composition, as well as the rate at which the filament is ejected from the nozzle, as described above, but also on the positioning of the ejection nozzle within the sub-array.

[0107] It should be noted that while the filament is substantially continuous as it exits the nozzle, and preferably remains continuous, breakage into polymer fibers of a certain length or even into droplets may occur along its path to the collector. However, in the representation in Figure 2, the trajectories of the continuous filament and the resulting polymer fibers or droplets are considered to be the same.

[0108] The trajectories of the quenching fluids 1515, 1525, 1235, and 1545 depend primarily on the positioning of the respective quenching fluid inlets 1512, 1522, 1532, and 1542, the type of quenching fluid, and the direction and velocity of the quenching fluid flow. Thus, the entire trajectory of all material flows influences the trajectories of all other materials, thereby providing mixing of the materials. Most of the mixing occurs before deposition on the collector 1600, but some additional mixing may occur there.

[0109] The parameters described above, which influence each trajectory of the material flow, allow for very precise control over a wide range of mixing and the resulting web properties. Referring again to Figure 2, specific settings are shown for illustrative purposes, but are not intended to limit the scope.

[0110] Firstly, the trajectories 1252 of the filaments and fibers emitted from the first subarray 1222 of the first die block 1220 do not intersect with the trajectories of particulate material, and therefore provide a particulate material-free layer on the collector.

[0111] As illustrated in Figure 2, the trajectories of the particulate material 1450 intersect with the trajectories of filaments or fibers released from the second subarrays 1228 and 1328 of the first and second die blocks 1220 and 1230, respectively.

[0112] Finally, the orbitals 1352 of the filaments and fibers emitted from the first subarray 1322 of the second die block 1320 do not intersect with the orbitals of the particulate material, and thus provide a layer above the central layer that does not contain particulate material.

[0113] This allows for the formation of a structure that exhibits a particle-free surface and a central layer in which fibers and particulate material are mixed, resulting in the surface fibers having a different size from the fibers in the central layer, for example, a finer diameter.

[0114] Furthermore, the adjustment of the quenching fluid, as well as the balancing of the material flow and the suction of the suction box 1700 and 1750, allows for more options for engineering the resulting material.

[0115] In certain examples, the adjustment of the first and third quenching devices may be such that the rows of filament discharge nozzles impart a functionally different impact to the filaments and fibers discharged from the second subarrays of the first and second die blocks, respectively, than would occur if they were closer to the quenching device or further inside. This can, in practice, provide stepped changes in conditions such as temperature or flow rate and direction for each of the filaments 1258 and 1538, resulting in a mixed web having a characteristic gradient over its thickness or z-direction.

[0116] Optionally, by using an air-permeable collector, a mixed web and / or scrim layer can be deposited to impart a pattern or texture to the web, exhibiting a specific xy-directional pattern with portions raised or deepened in the z-direction. Such collectors are described, for example, in US2017 / 0165720A1 or US20170022660A1, which make references to such collectors, their operation, and the resulting properties of the web deposited thereon.

[0117] Optionally, the scrim layer can be formed by a polymer scrim filament forming system as described above, and can also operate as a conventionally known system such as a spun bonding system for providing substantially endless relatively thick fibers, a melt-blown system for providing broken thin fibers, or a CA melt-blown system for providing fine but strong substantially continuous filaments, optionally including the teachings of the present invention relating to polymer filament forming systems of forming boxes.

[0118] A mixed web that optionally includes one or two scrim layers may be further processed by applying certain embossing processes, also known as printed embossing, as described in US9714484B2 or US20150086760A1, where explicit references are made as far as the operation of the embossing unit is concerned.

[0119] After the web is formed, it may be subjected to further processing steps to form a precursor for use or a final article, for example, but not limited to, the addition of materials such as binders, folds, or packaging, or surface treatment operations such as tufting, heat bonding, ultrasonic bonding, drilling, and the application of lotions, silicones and / or other materials and mixtures thereof.

[0120] A fiber-mixed web fabricated on the apparatus using the described method exhibits multiple fiber regions in the z direction.

[0121] In one option, the fibrous structure of the present invention exhibits a pore volume distribution such that more than 8% and / or at least 10% and / or at least 14% and / or at least 18% and / or at least 20% and / or at least 22% and / or at least 25% and / or at least 29% and / or at least 34% and / or at least 40% and / or at least 50% of the total pore volume present in the fibrous structure is located in pores with a radius of 2.5 μm to 50 μm, which is measured by a pore volume distribution test method such as that described in US2016 / 355950 mentioned herein with respect to the present test method, and this measurement method is explicitly referenced in the above-mentioned document.

[0122] While the present invention can be used in the manufacture of well-known materials, a special feature is that the apparatus and its operation enable the manufacture of new types of materials with novel properties.

[0123] Referring to Figure 5, a z-direction cross-sectional view of an exemplary embodiment of a mixed web obtained by operating the apparatus according to the method of the present invention is shown, comprising two CA melt-blown fiber surface regions 2110, 2120, two inner regions having CA melt-blown fibers 2210, 2220, and a central region 2300 containing particulate material.

[0124] Here, at least in sub-regions of the internal region, the CA meltblown fibers are substantially different from the CA meltblown fibers in the surface region. In this context, the term “substantially different” means that a first group of fibers within a given region exhibits properties that differ from those of adjacent second groups of regions by at least 5% of the lowest value in one or more of the following properties: - Fiber diameter; - Fiber length; - Fiber strength; - Fiber composition: -Types of polymers; - Melt flow index or rate; - Fiber structure -crimp; -Cross-sectional configuration.

[0125] The total weight of the mixed web is approximately 10 g / m². 2 exceeding, or approximately 15g / m 2 exceeding, or approximately 30g / m 2 exceeding, or approximately 40g / m 2 exceeding, or approximately 60g / m 2 exceeding, or approximately 100g / m² 2 exceeding, or approximately 150g / m² 2 exceeding and / or approximately 500g / m² 2 Less than 300g / m² 2 Less than 150g / m² 2 Less than or approximately 100g / m² 2 It is possible to show a total basis weight of mixed webs exceeding this amount.

[0126] Each of the surface areas that is substantially free of particulate material contains approximately 0.5 g / m² 2 exceeding, or approximately 1 g / m 2 exceeding, or approximately 2g / m 2 exceeding and / or approximately 20 g / m 2 Less than 10 g / m² 2 Less than or approximately 5 g / m 2 It can exhibit a surface area basis weight of less than a certain amount. The particulate material is approximately 10 g / m². 2 exceeding, or approximately 20g / m 2 exceeding, or approximately 40g / m 2 exceeding, or approximately 60g / m 2 exceeding, or approximately 100g / m² 2 exceeding, or approximately 150g / m² 2 exceeding, or approximately 300g / m² 2 exceeding and / or approximately 300 g / m² 2 Less than 150g / m² 2 Less than or approximately 100g / m² 2 Less than 50g / m² 2 Less than 30g / m² 2 The basis weight of the particulate material may be less than the following.

[0127] Certain materials may represent a weight percentage of particulate material exceeding approximately 50%, 70%, 85%, 90%, or even 95% of the total weight of the mixed web, including the scrim layer if present.

[0128] In contrast to webs formed by conventional technologies, the present invention can generate smoother transitions from one region to an adjacent region, or even allow inner regions 2210 and 2220 to overlap in the central region 2300.

[0129] In contrast to many prior art multilayer embodiments that show relatively clear separation of each sublayer, the processes and apparatus described above enable the provision of a mixed web having a gradual transition from one sub-region to the next. The gradually changing properties may be fiber properties such as fiber type, diameter, and crimp, in addition to other parameters, which affect web properties such as local void volume distribution or local composition, and the term “local” may mean a volume at least three times the average void volume of the entire structure.

[0130] In addition to the layered structure of the mixed structure, the web may further include a scrim layer of polymer filaments so that it can contain polymers suitable for forming filaments of the mixed layer. In a preferred embodiment, one or both of the scrim layers may be about 10 g / m² 2 Less than or approximately 5 g / m 2 Less than, or approximately 3 g / m² 2 Although less than 0.1 g / m³, it is typically about 0.1 g / m³. 2 It exhibits a basis weight exceeding that amount.

[0131] In certain options, a mixed web or a mixed web having scrim may exhibit a liquid absorption capacity greater than 12 g / g when measured according to a liquid absorption capacity test method such as that described in US20150086659A1, for which the above document is explicitly referenced.

[0132] In particular, as a often preferred option, a mixed web having scrim can be combined with a liquid to form a wet wipe, where such liquid may be aqueous, oily, or an emulsion or lotion. The liquid may contain one or more optional components such as emulsifiers, film-forming agents, skin treatment surfactants, preservatives, pH buffers, antioxidants, chelating agents, fine particles, polymer opacifiers, opacifying minerals, perfumes, and various other auxiliary components as described in US7,666,827;7,005,557;8,221,774; and US2011 / 0268777.

[0133] In certain options, mixed webs with mixed webs or scrims may exhibit a soil leak-through value of less than 8.5 when measured according to the Soil Leak Through Test Method described in US963132B2, for which the above document is explicitly referenced.

[0134] In certain options where the liquid composition includes a lotion composition, wet wipes using such lotion may exhibit a lotion release greater than 0.25 as measured according to the Lotion Release Test Method, as described in US9631321B2, for which the above literature is explicitly referenced.

[0135] In certain options, the mixed web or the mixed web having scrim may contain a liquid composition and may have a Tactile Sensory Coefficient of Friction (TACTI) less than 0.60 as measured according to the Tactile Sensory Coefficient of Friction Test Method described in US20150086659A1.

[0136] Webs produced on or in the apparatus of the present invention, or according to the process of the present invention, can be used not only as or in articles for personal, surface, or food cleaning, but also as liquid absorbent or adsorbent articles or as filter media. Specific applications include paper towels, bath tissues, facial tissues, napkins, children's wipes, adult wipes, wet wipes, cleaning wipes, abrasive wipes, cosmetic wipes, car care wipes, wipes containing activators to perform specific functions, cleaning substrates for use with instruments and mixtures thereof.

[0137] When used herein, the web is particularly suitable for use in "sanitary tissue products," being soft and typically low in density (i.e., about 0.15 g / cm³), useful for post-urination and post-defecation cleansing (toilet tissues), orthopedic excretion (facial tissues), and especially for use as a multi-functional absorbent and wiping tool for cleansing purposes (absorbent towels). 3 It refers to the web (less than).

[0138] As used herein, the term “wipe” refers to an article comprising a sheet of fibrous material. Wipes are also called “cleaning sheets.” Wipes, whether dry or wet, are intended to be used to remove material from living or non-living surfaces or objects, or to apply material to living or non-living surfaces or objects. For example, wipes can be used to clean hard surfaces such as floors. Wipes can also be used for cleansing or wiping humans or animals, such as for cleansing the anus, perineum, genitals, face or hands. Wipes can also be used for the application of substances to the body, including but not limited to cosmetics, skin conditioners, ointments, and drugs. They can also be used for grooming pets. Furthermore, they can be used for general cleaning of surfaces and objects such as kitchen and bathroom surfaces in homes, eyeglasses, sports and athletic equipment, and automobile surfaces. In this disclosure, wipes can be cleaning sheets for human cleansing. Wipes may also be wipes containing lotion. The wipes can be wet wipes.

[0139] Those skilled in the art will understand that this disclosure focuses on several embodiments that may be used individually or in combination with one another. In particular, various options may be combined unless expressly described as “alternative” or “first and second” options.

[0140] For example, explaining the principle by changing the thickness of the filament (see Figure 2) does not mean that this principle cannot be applied to filaments exhibiting different polymer types or properties, or both.

Claims

1. A web forming apparatus adapted for forming a mixed web, The aforementioned mixed web is - Particulate material selected individually or in combination from the group consisting of short fibers and particles, - Coaxial multi-row meltblown synthetic fiber, Includes, The aforementioned device is - A particulate material supply system, A particulate material supply system directed to supply a flow of particulate material moving vertically downwards; - With at least one polymer supply system adapted to provide polymer material below; - A first and second coaxial multi-row melt-blown system, Each of the systems is adapted to form coaxial meltblown fibers and comprises a first and second coaxial multi-row meltblown system comprising an array of polymer release orifices including at least two rows of polymer release orifices extending in intersecting directions; - A forming box, The forming box is adapted to form a mixed material containing the particulate material and coaxial melt-blown fibers, The forming box is - An inlet for particulate material connected to the particulate material supply system; - Two coaxial melt-blown fiber inlets, each connected to one of the aforementioned coaxial multi-row melt-blown systems; • Outlet for the mixed material; A forming box and; - It is a collector, The device is adapted to move along the mechanical direction, Collector and; It is equipped with, As a result, each of the coaxial melt-blown fiber inlets of the forming box is positioned in the machine direction, in front of (upstream) and behind (downstream) the inlet of the particulate material. - The array of polymer-releasing orifices comprises at least first and second subarrays, each subarray comprising at least one orifice row. The apparatus is characterized in that, thereby, at least one orifice of the subarray is adapted to emit fibers having different properties from the orifices of different subarrays in one or more functions selected from the group consisting of the following. The orifices of the aforementioned subarray exhibit different orifice diameters; The orifice of the subarray is connected to a polymer supply system for different polymer types; The orifice of the subarray is connected to a polymer supply system for different polymer throughputs; The orifice of the subarray is connected to a polymer supply system for different polymer supply pressures; The orifice of the subarray is connected to an independent temperature control system.

2. The system further comprises a quenching system, and the quenching system is A first quenching device directionally positioned upstream of the first coaxial multi-row meltblowing system; A second quenching device is directionally positioned between the first coaxial multi-row meltblowing system and the inlet of the particulate material; A third quenching device is directionally positioned between the inlet of the particulate material and the second coaxial multi-row meltblowing system; A fourth quenching device directionally positioned downstream of the second coaxial multi-row meltblowing system; It is equipped with, Each of the quenching devices is adapted to discharge first, second, third, and fourth quenching fluid flows into the forming box; The apparatus according to claim 1, comprising a quenching fluid flow control system configured to control at least one characteristic of the quenching fluid flow independently of at least one other characteristic of the quenching fluid flow by control means of the quenching fluid flow control system selected individually or in combination from the following list. - Connect each of the quenching devices to a different type of quenching fluid; - Quenching fluid temperature control means; - Quenching fluid supply pressure adjustment means; - Quenching fluid supply flow rate; - The outlet angle of the quenching fluid relative to the coaxial melt-blown head or the supply axis of the particulate material.

3. The apparatus according to claim 1 or 2, further comprising one or more features selected from the group consisting of the following: - Removable nozzle; - A single die head including a spinneret block and nozzle; - Variable die head angle relative to the die head axis; - Nozzles connected to individual polymer supply systems.

4. The apparatus according to any one of claims 1 to 3, wherein the subarrays of both coaxial melt-blown systems, each having an orifice having a larger diameter than the orifice of the other subarray, are arranged in the mechanical direction toward the inlet of the particulate material.

5. The apparatus according to any one of claims 1 to 4, further comprising at least one web-forming element positioned upstream and / or downstream of the forming box, adapted to extrude a filament, and forming a scrim layer on the outer surface of the mixed web.

6. A process for forming a mixed web, - Particulate materials selected individually or in combination from the group consisting of short fibers and particles; With one or more types of polymer materials; The apparatus according to any one of claims 1 to 5; The process of providing; - A step of supplying the particulate material to the forming box; - In the coaxial multi-row meltblown system, a step of forming at least two types of coaxial multi-row meltblown filaments from the polymer material, A step for forming a fiber that differs in at least one property selected from the group consisting of the following: Offering different polymer types; Offers different polymer throughput; Provides different polymer supply pressures; - A step of supplying these to the forming box; - The process of collecting a mixed web in a collection device; - A step of removing the collected mixed web from the apparatus; A process that includes this.

7. The process according to claim 6, - A step of arranging a plurality of quenching devices for delivering a quenching fluid to the forming box, wherein, for each of the coaxial multi-row meltblowing systems, one quenching device is positioned upstream and another quenching device is positioned downstream; - A step of supplying a flow of quenching fluid to the forming box by arranging a plurality of quenching devices for delivering the quenching fluid, such that for each of the coaxial multi-row meltblowing systems, one quenching device is positioned upstream and another quenching device is positioned downstream; - A step of adjusting the flow properties of the quenching fluid to the properties of each of the coaxial meltblown fibers by adjusting one or more properties selected from the group consisting of the following: Type of quenching fluid; temperature; Flow rate; speed; direction; - A step of forming a first scrim layer and depositing the first scrim layer in the collector upstream of the forming box; - A step of forming a second scrim layer and depositing the second scrim layer in the collector downstream of the forming box; A process that further includes the following.

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