Nonwoven fabric and method of making the same

Details Nonwoven fabric and method of making the same Nonwoven fabric and method of making the same

1996-09-17

1998-11-24

Zirker, Daniel

Fabric (woven, knitted, or nonwoven textile or cloth, etc.)

Nonwoven fabric

Including strand or fiber material which is a monofilament...

442353, 442358, 442362, 442364, 442381, 442389, 156 85, 156229, D04H 304, D04H 300

Patent

active

058406336

DESCRIPTION:

BRIEF SUMMARY
TECHNICAL FIELD

The present invention relates to a nonwoven cloth of drawn or stretched filaments of different kind polymers, which is improved in various properties such as strength, elongation, adhesion and bulkiness; and comprises stretched filament webs each of which is prepared by stretching long filaments formed of a plural kind of thermoplastic polymers of different properties in one direction, and aligning the long filaments the thus stretched in one direction, and further the invention relates to a method of manufacturing the nonwoven cloth or fabric as mentioned above.
Furthermore, the present invention relates to a stretched nonwoven fabric which is excellent particularly in the strength and the bulkiness, and a method for producing the same. More particularly, the present invention relates to a nonwoven fabric having a high strength and a high bulkiness which is prepared by joining a stretched filament web in combination with a web having different shrink properties from that of the former web, and thereafter shrinking the thus joined webs without employing any complicated and expensive apparatus; as well as relates to a method for manufacturing such nonwoven fabric.


BACKGROUND ART

Most of the conventional nonwoven fabrics were random nonwoven fabrics, so that most of them were not strong enough and poor in dimensional stability. In order to improve the disadvantages involved in these conventional nonwoven fabrics, the present inventors have proposed several methods each for manufacturing a nonwoven fabric by stretching fiber webs and crosswise laminating them together (Japanese Patent Publication No. Hei 3-36948, Japanese Patent Laid-Open Publication No. Hei 2-269859, Japanese Patent Laid-Open Publication No. Hei 2-269860). The present invention is the one which has been accomplished by improving and developing further these inventions.
Heretofore, a variety of examples have been known that mixed spun filaments or conjugate spun filaments prepared by employing polymers of different kinds are applied to the manufacturing of a nonwoven fabric.
For instance, bulky conjugate filaments are disclosed in Japanese Patent Laid-Open Publication No. Hei 4-24216 (short fiber nonwoven fabric), Japanese Patent Laid-Open Publication No. Hei 2-182963 (spunbonded nonwoven fabric), and Japanese Patent Laid-Open Publication No. Hei 4-41762 (spunbonded nonwoven fabric); adherent conjugate filaments are disclosed in Japanese Patent Laid-Open Publication No. Hei 2-61156 (spunbonded nonwoven fabric) and Japanese Patent Laid-Open Publication No. Hei 4-316608 (spunbonded nonwoven fabric); mixed filaments are disclosed in Japanese Patent Laid-Open Publication No. Hei 3-269154 (spunbonded nonwoven fabric); and the water-jet processing of nonwoven fabric composed of conjugate filaments is disclosed in Japanese Patent Laid-Open Publication No. Hei 4-316608 (spunbonded nonwoven fabric).
The above described conventional nonwoven fabrics involve the ones in which conjugate filaments and polymer filaments of different kinds are used together. However, they are short fiber nonwoven fabrics which are made by cutting conjugate filaments and polymer filaments of different kinds, so that, although the bulkiness is satisfactory, the strength and dimensional stability are not good. Furthermore, there have been long filament nonwoven fabrics such as spunbonded nonwoven fabric or melt-blown nonwoven fabric in accordance with conjugate spinning. However, since these nonwoven fabrics are not stretched, the effect of shrinkage cannot be produced, so that their bulkiness is insufficient and strength as well as dimensional stability are not satisfactory.
More specifically, in these nonwoven fabrics according to the prior art, the balance among the bulkiness, the strength as a single filament, and the strength as the whole material of nonwoven fabric is insufficient, so that they cannot not have physical properties enough as the ones which can be employed in place of the woven fabrics. In addition to the above, when a basis weight is sm

REFERENCES:
patent: 4657804 (1987-04-01), Mays et al.
patent: 5102724 (1992-04-01), Okawahara et al.
patent: 5424115 (1995-06-01), Stokes
patent: 5534339 (1996-07-01), Stokes
Jap Pat. Abst 5-230754.
Jap Pat. Abst 5-125645.
Jap Pat. Abst 2-182963.

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