 METHOD FOR THE PRODUCTION OF A CONTINUOUS NON-WOVEN SHEET, AND, A CONTINUOUS NON-WOVEN SHEET
专利摘要:
method for producing a non-woven web, non-woven web, and cleaning tissue. a method for preparing nonwoven webs which have good md and cd strength, and are disposable in water is provided. the method includes hydroentangling an air-spun web of not less than 50% by weight of natural cellulose fibers having a fiber length of not more than 3.5 mm and not more than 50% by weight of staple fibers having a fiber length of not less than 8.0 mm. the air conveyed spun web is not spun into a precursor web and no adhesive, binder or thermal bonding is used. air conveying spinning and hydroentangling are conducted in continuous operation. products can be obtained according to the method of this invention which goes according to the municipal disintegration capacity guidelines. 公开号:BR112015013767B1 申请号:R112015013767-9 申请日:2013-08-06 公开日:2021-07-13 发明作者:Richard KNOWLSON；Eric Mariani；Katherine Dyrmose Petersen 申请人:Jacob Holm & Sons Ag； IPC主号:
专利说明:
CROSS REFERENCE TO RELATED ORDERS [001] This request claims priority for the Provisional Request U.S. No. 61/736837, filed December 13, 2012, the description of which is incorporated herein by reference in its entirety. FIELD OF THE INVENTION [002] This invention relates to a continuous method for preparing continuous disposable non-woven sheets that employ a minimum number of operations and provide an economical product that is useful as a disintegratable or disposable article such as a handkerchief or disposable cloths. BACKGROUND OF THE INVENTION [003] Disposable non-woven substrates are employed for the production of a wide variety of consumer products that are generally used once and discarded. Such products include disposable wipes, disposable diapers, disposable adult incontinence products, disposable absorbents typically employed in hospitals for absorbing bodily fluids, and cosmetic applicators or cosmetic absorbents for removing makeup and other keratinous substrate materials. [004] Such commercial products constitute an industry having a potential for growth and expansion of utility in constant increase. However, as virtually all products potentially enter the environment through landfill or sewage systems, there is a need for disposable non-woven material that is simple to produce, that contains minimal or no amounts of chemical components that have low biodegradability. such as binders, adhesives or thermoplastic polymers and yet have good wet tensile strength as required for performance. Additionally, a product is ordered which is constructed to have minimal cotton fiber content and meets codes to categorize as an acceptable disintegrated article for municipal and private sewer systems, while being economical to disintegrate. to produce. [005] Conventionally, non-woven disposable tissue products can be produced via one of the two basic technologies known in the industry as air-transport interlacing and "hydrospun" processes. Different producers may drive these technologies with variation based on the intended end use and available production equipment, but the basic principles of operation are retained. [006] Air transport interlacing methods combine the depositing operations of an air spun web of discontinuous length fibers and wood pulp fibers into a non-woven carrier layer or a precursor base non-woven web and hydroentangling the air-transport spun layer with the non-woven carrier. This technology is described in U.S. 8,250,719 to Ouellette and references described therein. In addition to employing a carrier web, Ouellette describes joining the spun fibers by air transport with hot air or a spray adhesive. [007] According to the method of "hydrospination" as described in the U.S. 4,755,421 to Manning et al a water-carrying web of pulp and synthetic fibers is hydroentangled and dried. However, U.S. 5,292,581 to Viazmensky et al. indicates that such products suffer from poor moisture resistance and describes that the addition of binders substantially increases strength. More recently, U.S. 7,732,357 to Annis et al. describes the use of bonding fibers for the non-woven sheet which on heating becomes active by at least partial casting and forms fiber for fiber bonds. Bonding fibers contain polyethylene, polypropylene, polyethylene terephthalate and mixtures thereof. [008] Therefore, there remains a need for a method for preparing a non-woven web that does not contain any adhesive, binder or bonding fibers, is convenient and economical to conduct, and provides a disposable non-woven web having good strength performance, and still being accepted as a product capable of being disintegrated into municipal sewers and private septic systems. SUMMARY OF THE INVENTION [009] Accordingly, an object of the present invention is to provide a method for producing a non-woven web that includes minimal processing operations, that does not use adhesives, binders or bonding fibers and provides a non-woven web having wet tensile strength enough for use as a scarf. Another object of this invention is to provide a non-woven web having moisture resistance to be employed as a handkerchief that is acceptable for disposal in sewage and septic systems. [0010] This and other objectives have been achieved according to the present invention, the first embodiment of which includes a method for producing a non-woven web, comprising: preparing a mixture of natural cellulose fibers and staple fibers; air-form the mixture to obtain at least one continuous sheet spun by homogeneous air transport; hydroentangling the air spun web to consolidate the web on at least one side; and drying the hydroentangled web to obtain a non-woven web; wherein air forming and hydroentangling are conducted in a continuous operation, a content of natural cellulose fibers in the fiber blend is not less than 50% by weight and a content of staple fibers is not greater than 50% by weight, no binder, adhesive or thermal bonding fibers are used, a fiber length of natural cellulose fibers is not more than 3.5 mm, a fiber length of staple fibers is not less than 8.0 mm, a basis weight of the non-woven web is 20 g/m2 to 100 g/m2, and a thickness of non-woven web is 0.25mm to 2mm. [0011] In a preferred embodiment of the first embodiment, the air spun web is formed directly on an air former carrier without preforming a precursor web or incorporating a web of continuous filament. [0012] In a further preferred embodiment, no adhesive, binder or binder fiber is applied to the non-woven web and a ratio of the tensile strength in a machine direction to the tensile strength in a direction perpendicular to the machine direction ( MD/CD) is less than 3. [0013] Additionally, in one embodiment, the present invention provides a non-woven web obtained by the method of any of the above method embodiments; wherein the non-woven web comprises: 75% by weight wood pulp; and 25% lyocell by weight. The basis weight of the non-woven web according to this modality is 40 g/m2 to 6 g/m2, an MD/CD ratio is less than 3, a CD wet tensile strength is at least 5 N/5 cm , and the nonwoven web is a product capable of being disintegrated according to the July 2009 issue of ED ANA's Guidance Document for Assessing the Flushability of Nonwoven Consumer Products. [0014] In another embodiment, the present invention provides a non-woven web obtained by the method of any of the above method embodiments; wherein the non-woven web comprises: about 50% m by weight of wood pulp; and about 50% viscose by weight; where the basis weight of the non-woven web is 40 g/m2 to 6-g/m2, an MD/CD ratio is less than 3, and a CD wet tensile strength is at least 12N/5cm. BRIEF DESCRIPTION OF THE DRAWINGS [0015] Fig. 1 shows a schematic drawing of an arrangement of water jets in a hydroentanglement unit according to an embodiment of the invention. [0016] Fig. 2 shows comparative data for disposable and non-disposable nonwoven webs according to the invention compared to commercially available wipes. DETAILED DESCRIPTION OF THE INVENTION [0017] According to the following description, all numerical ranges described including sub-ranges and all values in between, unless otherwise specified. The following description provides a general description of the present invention and specific preferred embodiments. However, a person of ordinary skill will recognize that many variations of the invention may be possible without departing from the essence of the invention. This description and the following claims are intended to include all such variations. [0018] In a first embodiment, the present invention provides a method for producing a non-woven web, comprising: preparing a mixture of natural cellulose fibers; air-form the mixture to obtain at least one continuous sheet spun by homogeneous air transport; hydroentangling the air spun web to consolidate the web on at least one side; and drying the hydroentangled web to obtain the non-woven web; wherein air forming and hydroentangling are conducted in continuous operation, a content of the natural cellulose fibers in the fiber mixture is not less than 50% by weight, preferably not less than 60% by weight and more preferably at least 75% by weight. Weight. A content of staple fibers is not more than 50% by weight, preferably not more than 40% by weight and more preferably not more than 25%. No binder, adhesive or thermally bonded fibers are used in the air forming and hydroentangling operations in accordance with the present invention. [0019] The length of the natural cellulose fibers is not greater than 3.5mm, preferably 1.5mm to 3.5mm, more preferably 2.5 to 3.5mm. Any natural cellulose fiber can be used as the short fiber in the blend. In one embodiment, a wood pulp of the length described can be the short fiber in a preferred embodiment, a Southern Pine Kraft can be the natural cellulose fiber. Wood pulp obtained from a sulphite pulping process can additionally be the source of the natural cellulose fibers. Blends of natural cellulose fibers can be used. Natural cellulose fibers can be defibrated in hammer mills to form a blend of individual loose fibers. [0020] The staple fibers may be non-thermoplastic synthetic fiber that is not less than 8.0 mm in length, preferably 8.0 to 10.0 mm, more preferably 8 mm to 25 mm. Preferably, the staple fiber is viscose or lyocell. Non-thermoplastic fiber blends can be used. [0021] The method of forming a spun web by air transport is generally described in U.S. 4,640,810 to Laursen et al. Discontinuous and defibrated natural cellulose fibers are combined into a homogeneous mixture and at the same time they are supported in a stream of air transported to a distributor unit. [0022] The dispenser unit contains a rotating cylinder or drum that is drilled with holes, slits or other appropriately shaped holes designed to allow the fibers to pass through a foraminous carrier. The construction of the drum and the configuration and size of the holes can vary according to the characteristics of the fiber mixture to be employed and to obtain a single web construction. Under the influence of any combination of any of air flow, mechanical agitation within the drum and suction from under the carrier, the fibers are directed through the openings of the perforated drum and form a homogeneous continuous sheet on the surface of the carrier. The height and degree of matting of the dry web can vary via control of process variables including fiber content and size, drum hole size and shape, air flow rate, degree of suction applied from the bottom of the carrier, and speed of the carrier. carrier. [0023] The width of the continuous sheet depends on the type of air forming equipment used and can vary from 1m to 6m. Conventional commercial units such as those supplied by Dan-Web, Oerlikon and Anpap Or ranging from 2 to 5m in width. [0024] In accordance with the present invention, the formed air spun web is transported directly and continuously to a hydroentanglement unit or a spin entanglement unit, where the air spun spun tangle is reached by a series of high pressure water jets to tangle or mechanically consolidate the fibers to form the non-woven web. The jets can be oriented perpendicular to the carrier surface or angled to provide unique properties for the web. Jets can be placed to consolidate the web on one side, preferably the top side or both the top and bottom sides. The pressure of the jets may be 0.04 bars/kg/h/m at 15 bars/kg/h/m, preferably 0.1 bars(10 kPa)/kg/h/m at 10 bars (100 kPa)/kg/hm, and more preferably 0.3 bars (30 kPa)/kg/h/m at 4 bars (400 kPa)/kg/h/m. [0025] An embodiment showing an arrangement of jets for consolidating a web on both sides is shown schematically in Fig. 1. As indicated in Fig. 1, the air spun web taken directly from the former with air is passed along a series of conveyor belts and exposed to high pressure jets indicated in numerical order. Jets 11, 12 and 13 collide with the top of the web while jets 21 and 22 hit the opposite or bottom side. The schematic jets represent jet banks across the web width and the jet banks can be positioned and arranged to transmit by varying the entirety of the entanglement across the web. Thus, the entanglement can be patterned or random, depending on the intended end use of the non-woven web. [0026] The drape, softness and comfortable hand of the non-woven web can be controlled by the energy released by the high pressure jets and the speed of travel of the web through the equipment. In accordance with the present invention, by controlling both water pressure and web travel speed through the spin weave equipment as well as the absence of adhesives, binders or bonding fibers, a non-woven web having varying degrees of strength, absorption, softness and thickness can be obtained. [0027] Spinning interlocking or hydroentangling units are available from Fleissner GmbH (Germany) and Andritz Perfojet (France). [0028] In a variation of the above basic embodiment, spun webs can be prepared and stacked prior to spin weaving so that thicker non-woven webs can be produced. The respective stacked layers may be of the same fiber composition or may have different compositions selected for the intended end use of the non-woven web. In every possible modality, entanglement can be achieved by varying the water jet pressure and web travel speed through the spinning interlocking unit. No binders, adhesives or bonding fibers are used. [0029] Following the spin weave, the wet non-woven web can be dried and rolled up for transport and storage. In a further embodiment, prior to drying, the tangled web can be embossed either by a hydro-embossing process or by thermal embossing. [0030] The basis weight of the non-woven web can be from 20 g/m2 to 100 g/m2, preferably 40 g/m2 to 80 g/m2 for a non-woven web of 0.25 mm to 2 mm in thickness. However, when multiple air spun webs are stacked, the basis weight and thickness may not be in these ranges. Basis weights can be varied by controlling the process variables described for both the air conveying and spin interlacing spinning operations and by other process variables conventionally known to one skilled in the present technology. [0031] The non-woven webs according to the present invention have strength profiles that are more unidirectional than some conventionally available non-woven webs. The ratio of wet tensile strength in the machine direction (MD) to the cross machine direction (CD) is less than 3. As shown in the table in Fig. 2, JHI products according to the invention without adhesive, binder or bonding fibers, have significantly lower basis weights than comparative commercially available wipes, yet have MD and CD tensile strengths of similar value. Such a property is especially surprising because a CD wet tensile strength is known to be difficult to obtain in products that meet standard guidelines for disintegration capability. [0032] In a preferred special embodiment, a product capable of being disintegrated is made in accordance with the present invention with a composition of about 75% by weight of defibrated wood pulp fibers having a length of 3.5 mm or less and 25% by weight of lyocell having fibers of 8mm or greater. The air spun web is hydroentangled at a jet pressure of 0.35 bars (35 kPa)/kg/h/m to 2.1 bars (210 kPa)/kg/h/m. The CD wet tensile strength of the non-woven web is at least 5.0 N/5 cm and the MD/CD ratio is less than 3. This non-woven web meets the test standards for disintegration capacity as defined in the edition July 2009 of EDANA's Guidance Document for Assessing the Flushability of Non woven Consumer Products. Importantly, this product passes the municipal sewage pump test, where less than 10% of all data points measured over 5 total rounds of 60 wipes each having a power increase of more than 10% and preferably less that 10% causes an increase in potency of 10%. [0033] In another special embodiment having greater strength, a non-woven web is prepared in accordance with the method of the present invention with a 50% by weight bristle mixture of defibrated wood pulp fibers having a length of 3.5 mm or less and about 50% by weight viscose having fibers of 8 mm or greater. The air spun web is hydroentangled at a jet pressure of about 0.3 bars (30 kPa)/kg/h/m at 15 bars (1500 kPa)/kg/h/m, preferably 0.4 bars/kg/h /ma 6 bars (600 kPa)/kg/h/m. The CD wet tensile strength of the non-woven web is at least 12N/5 cm and the MD/CD ratio is less than 3. Significantly, the cotton fiber property of this product is significantly lower than that of currently used commercial products such as baby wipes or hard surface cleaning wipes.
权利要求:
Claims (17) [0001] 1. Method for producing a non-woven web, comprising: preparing a homogeneous dry mixture of natural cellulose fibers, which are defibered wood pulp, and staple fibers of at least one of viscose and lyocell; passing the homogeneous dry mixture through a perforated cylinder to a foraminous carrier to air-form the mixture to obtain at least one air-transport spun homogeneous web; hydroentangle the air-carried spun web on the foraminous carrier to consolidate the web into at least one side; Drying the hydroentangled web to obtain the non-woven web; characterized by the fact that: air forming and hydroentangling are conducted in a continuous operation, a content of natural cellulose fibers in the fiber mixture is not less than 50% by weight and a content of staple fibers is not more than 50% by weight, no binder, adhesive or thermal bonding fibers are used, a fiber length of natural cellulose fibers is not more than 3.5mm, a fiber length staple is not less than 8.0mm, a basis weight of nonwoven web is 20g/m2 to 100g/m2, and a thickness of nonwoven web is 0.25mm to 2mm. [0002] 2. Method according to claim 1, characterized in that the content of the natural cellulose fibers in the mixture is at least 75% by weight and the content of the staple fibers is 25% by weight or less. [0003] 3. Method according to claim 1, characterized in that the basis weight is from 40 g/m2 to 60 g/m2. [0004] 4. Method according to claim 1, characterized in that the wood pulp is a sulphite pulp obtained by the formation of sulphite pulp. [0005] 5. Method according to claim 1, characterized in that the air spun web is hydroentangled to consolidate the web on both sides. [0006] 6. Method according to claim 1, characterized in that an applied pressure of the hydroentanglement is 0.04 bars (4 kPa)/kg/h/m to 15 bars (1500 kPa)/kg/h/m. [0007] 7. Method according to claim 6, characterized in that the applied pressure of the hydroentanglement is 0.3 bars (30 kPa)/kg/h/m to 4 bars (400 kPa)/kg/h/m. [0008] 8. Method according to claim 1, characterized in that it further comprises: embossing the hydroentangled web; wherein the embossing operation is continuous with air forming and hydroentangling. [0009] 9. Method according to claim 1, characterized in that the air forming of the air spun web is conducted in a single air former. [0010] 10. Method according to claim 1, characterized in that the air forming of the air spun web is conducted in more than one air former and the fiber content of each web is the same. [0011] 11. Method according to claim 1, characterized in that air forming of the air spun web is conducted in more than one air former and a fiber content of at least one web is different from fiber content of another web. [0012] 12. The method of claim 1, characterized in that the air-spun web is directly formed on a former carrier carrier with air without running a precursor web or incorporating a continuous filament web. [0013] 13. Method according to claim 1, characterized in that a pressure of the hydroentanglement of the continuous web spun by air transport is 0.35 bars (35 kPa)/kg/h/m at 15 bars (1500 kPa)/ kg/h/m. [0014] 14. The method of claim 13, characterized in that no adhesive, binder or fiber binder is applied to the non-woven web and a ratio of tensile strength in a machine direction to tensile strength in a direction perpendicular to the machine direction (MD/CD) is less than 3. [0015] 15. Non-woven web obtained by the method as defined in claim 1, the non-woven web consisting of shredded wood pulp and staple fibers of at least one of viscose and lyocell; characterized by the fact that: a content of wood pulp shredded is not less than 50% by weight; and a staple fiber content is not more than 50% by weight, the non-woven web does not comprise any binder, adhesive or thermal bonding fibers are used, a fiber length of the defibrated wood pulp is 2.5 mm to 3 .5 mm, a fiber length of staple fibers is not less than 8.0 mm, a basis weight of non-woven web is 20g/m2 to 100g/m2, and a thickness of non-woven web when a web spun. by air transport it is hydroentangled and dried is from 0.25 mm to 2 mm. [0016] 16. Non-woven web according to claim 15, characterized in that the non-woven web consists of: 75% by weight of wood pulp; e25% by weight of lyocell; wherein the basis weight of the non-woven web is 40 g/m2 to 60 g/m2, an MD/CD ratio is less than 3, a wet tensile strength of CD is at least 5 N/5 cm, and the nonwoven web is a sandblastable product as defined in the July 2009 edition of EDANA's Guidance Document for Assessing the Flushability of Nonwoven Consumer Products. [0017] 17. Non-woven web according to claim 15, characterized in that the non-woven web consists of: 50% by weight of wood pulp; e50% by weight of viscose; where the basis weight of the non-woven web is 40 g/m2 to 60 g/m2, an MD/CD ratio is less than 3, a wet tensile strength of CD is at least 12 N /5cm.
类似技术:
公开号 | 公开日 | 专利标题 BR112015013767B1|2021-07-13|METHOD FOR THE PRODUCTION OF A CONTINUOUS NON-WOVEN SHEET, AND, A CONTINUOUS NON-WOVEN SHEET US10415166B2|2019-09-17|Hydroentangled airlaid process and industrial wipe products US10745836B2|2020-08-18|Multistrata nonwoven material AU2001290859C1|2006-10-26|Disposable nonwoven wiping fabric and method of production RU2564613C2|2015-10-10|Absorbing composite with resilient layer manufactured by combined moulding JP2008542570A|2008-11-27|Fabric of molded fiber PT777782E|2000-04-28|NON-FABRIC MATERIAL UNDERTAKING A CERTAIN PROPORTION OF RECYCLED FIBERS FROM NON-WOVEN AND / OR TEXTILE WASTE WO2014145804A1|2014-09-18|Multistrata nonwoven material MX2009000078A|2009-01-23|A web comprising a tuft. BR112012014276B1|2020-12-29|resilient coform nonwoven fabric, absorbent personal care article, and resilient coform nonwoven fabric formation method US20180251925A1|2018-09-06|Hydroentangled web with ultrafine fibers JP2015048569A|2015-03-16|Nonwoven fabric and method for producing nonwoven fabric JP2008546917A5|2009-07-09| MX2008016292A|2009-01-15|Nonwoven fibrous structure comprising a multifilament fiber. JP4722222B2|2011-07-13|Cosmetic sheet and method for producing the same JP2006241644A|2006-09-14|Flexible spunlace nonwoven fabric KR20140116598A|2014-10-06|Spunlaced nonwoven fabrics, wet tissue comprising the same, and method for preparing the same US20210230808A1|2021-07-29|Nonwoven web composition, method to prepare the composition and articles thereof JP4368775B2|2009-11-18|Kitchen paper products Cuervo Garcia2018|Influence of Pressure and Specific Energy on the Structure of the Hydroentangled Fabrics. Garcia2018|Influence of Pressure and Specific Energy on the Structure of the Hydroentangled Fabrics
同族专利:
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法律状态:
2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]| 2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]| 2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. | 2019-12-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]| 2021-03-02| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]| 2021-06-01| B09A| Decision: intention to grant [chapter 9.1 patent gazette]| 2021-07-13| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 06/08/2013, OBSERVADAS AS CONDICOES LEGAIS. |
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申请号 | 申请日 | 专利标题 US201261736837P| true| 2012-12-13|2012-12-13| US61/736,837|2012-12-13| PCT/US2013/053756|WO2014092806A1|2012-12-13|2013-08-06|Method for production of a hydroentangled airlaid web and products obtained therefrom| 相关专利
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