Textiles: manufacturing – Textile product fabrication or treatment – Fiber entangling and interlocking
Patent
1992-06-08
1994-12-27
Crowder, Clifford D.
Textiles: manufacturing
Textile product fabrication or treatment
Fiber entangling and interlocking
264121, 264122, 19296, 156202, D04H 144
Patent
active
053753062
DESCRIPTION:
BRIEF SUMMARY
The invention concerns an absorbing web, i.e., a non-woven product constituted on the whole by short absorbing fibers, such as from wood pulp, and by longer synthetic fibers. The web is produced by hydraulic bonding.
As regards a current technique for making paper-fiber based products, an aqueous fiber suspension is prepared from which a sheet is then made. Depending on the kind of fibers and the processing of the sheet, various grades of papers are obtained, among which is cellulose wadding. It is widely used in households for sanitary uses, as towels, etc. However, cellulose wadding is mechanically weak, especially when moist, and therefore it is unsuitable for industrial or household mopping.
In another and so-called dry technique, illustratively described in British Patent No. 2,015,604 (Kroyer), the fibers are suspended in a gas flow and then deposited in layer form on a permeable cloth. The low moisture precludes inter-fiber bonding. A binder must be added, as a rule a latex, to make the layer cohesive. In such manner, a product with improved tear resistance over conventional paper is produced which also is quite absorbing. The applications of this product essentially are the same as for the former one. However, incorporating a binder, such as a latex, also entails drawbacks. Illustratively, it increases product stiffness and it may react chemically with the fluids it may come in contact with. This is the case in particular when it is desired to make linen impregnated with a liquid such as skin-lotion or the like.
Instead of using a chemical binder, thermoplastic synthetic fibers have already been suggested to be incorporated into the layer of absorbing fibers to serve as thermally activated binders. Illustratively, European Patent Application No. 070164 (Chicopee) describes an absorbing web that is thermally bound and of which the low density, namely less than 0.15 g/cm.sup.3 (0.06 g/cm.sup.3 in the described embodiments), is composed of paper-type absorbing fibers mixed with two conjugate component synthetic fibers, namely polyethylene and polyester. The manufacturing procedure is to prepare a layer from a homogeneous mixture of absorbing and of conjugate fibers; and then heat-processing it in bulk at low pressure and at sufficient temperature to melt the polyethylene that is present at the surface of the synthetic fibers, but not the polyester. Thereby, following cooling, a low-density web is obtained of which the synthetic component has retained its fiber nature. The preservation of the integrity of the synthetic fibers is an important factor in this patent in order to make a high volume-to-mass product with high absorption. Consequently, the applications considered therein are notably in personal hygiene and menstrual napkins for instance. However, post-strengthening (calendering, crinkling) appears required when this web must be used for wiping or mopping, for example where the mechanical stresses are larger.
European Patent Application No. 0326771 (James River) describes a resistant and absorbing fabric composed of paper-pulp and of textile fibers, and which is free of any binder. This fabric is made from one or more webs previously formed in the papermaking wet way and consisting of a homogeneous mixture of fibers containing 50 to 75% by weight wood pulp, and 25 to 50% by weight textile-length synthetic fibers. The webs, moreover, were subjected to water-jet bonding treatment known per se and with sufficient energy to form a relatively dense uniform non-woven with good inter-fiber cohesion.
Further, U.S. Pat. No. 4,442,161 (Kirayoglu) discloses a manufacturing method of a web bonded by water jets and consisting of wood-pulp and synthetic fibers. The bonding is carried out in particular from synthetic fibers in the form of a non-woven web of continuous fibers and of wood-pulp fibers in the form of a paper sheet. The treatment takes place under conditions allowing enhancing of the liquid-barrier properties of the web, in particular for use as sheeting for medical or surgical purposes.
The objec
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Calvert John J.
Crowder Clifford D.
Kaysersberg
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