Method of making a water disintegratable non-woven fabric

• US 6,669,878 B2
• Filed: 02/16/2001
• Issued: 12/30/2003
• Est. Priority Date: 01/16/1998
• Status: Expired due to Fees

• Current Assignee: Unicharm Corporation
• Original Assignee: Unicharm Corporation
• Inventors: Yamada, Daisuke, Konishi, Takayoshi, Takeuchi, Naohito
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US09/788,157
• Publication Number:
  US 20010023160A1
• Time in Patent Office: 1,047 Days
• Field of Search: 264/103, 264/129, 264/211.12, 264/211.14, 281/04
• US Class Current: 264/103
• CPC Class Codes: A61F 13/84 Accessories, not otherwise provided for, for absorbent pads
• CPC Class Codes: D04H 1/48 in combination with at least one other method of consolidation
• CPC Class Codes: D04H 1/49 entanglement by fluid jet in combination with another consolidation means
• CPC Class Codes: D04H 1/64 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: D21H 17/26 Ethers thereof
• CPC Class Codes: D21H 17/36 Polyalkenyalcohols; Polyalkenylethers; Polyalkenylesters
• CPC Class Codes: D21H 25/005 Mechanical treatment D21H25/08, D21H25/18 take precedence
• CPC Class Codes: Y10T 428/24446 Wrinkled, creased, crinkled or creped
• CPC Class Codes: Y10T 442/20 Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/2738 Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith
• CPC Class Codes: Y10T 442/277 Coated or impregnated cellulosic fiber fabric
• CPC Class Codes: Y10T 442/2869 Coated or impregnated regenerated cellulose fiber fabric
• CPC Class Codes: Y10T 442/695 Including a wood containing layer
• CPC Class Codes: Y10T 442/698 Containing polymeric and natural strand or fiber materials

Abstract

A water disintegratable non-woven fabric having excellent water disintegratability and high wet strength can be obtained by a step of forming a fiber web from fibers having a fiber length of 10 mm or less, a step of applying a water jet treatment to the fiber web to obtain a fiber sheet having wet strength of less than 100 g/25 mm in MD and CD, the wet strength being defined by tensile strength at break of the fiber sheet, as measured by using a tensilon tester with a chuck distance of 100 mm, at a tensile speed of 100 mm/min to the fiber sheet which is cut into 25 mm width and 150 mm length and impregnated with water in an amount 2.5 times the weight of the fiber sheet, and a step of adding at least one binder selected from the group consisting of carboxymethyl cellulose, alkylcellulose, polyvinyl alcohol and modified polyvinyl alcohol to the fiber sheet. The water disintegratable non-woven fabric is sufficiently bulky and has an excellent wiping effect.

Claims

1. A method of manufacturing a water disintegratable non-woven fabric, comprising:

a step of forming a fiber web from fibers having a fiber length of 10 mm or less,

a step of applying a water jet treatment to the fiber web to obtain a fiber sheet having a wet strength of less than 100 g/25 mm in MD and CD;

a step of adding a binder of alkylcellulose to the fiber sheet, to obtain a water disintegratable non-woven fabric; and

a step of impregnating the non-woven fabric with an aqueous solution in which an electrolyte selected from the group consisting of monovalent organic salt and monovalent inorganic salt is dissolved.

2. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 1, wherein a basis weight of the fiber web is from 20 to 100 g/m².

3. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 2, wherein the fibers comprise pulp of conifer and rayon having a fiber length of 7 mm or less.

4. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 3, wherein a blending ratio of the pulp of conifer is 30% by weight or more, the blending ratio of the rayon is 70% by weight or less.

5. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 2, wherein a work load of the water jet treatment per one processing is from 0.05 to 0.5 kW/m² and the fiber web is processed with the water jet treatment from 2 to 4 times.

6. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 5, wherein the water jet treatment is conducted by using nozzles having a diameter of from 90 to 100 μ

m and aligned each at an interval of from 0.3 to 0.7 mm in CD.

7. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 5, wherein water disintegratability of the fiber sheet is 100 sec or less.

8. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 7, wherein a content of the binder is from 0.5 to 30 g based on 100 g of the fibers.

9. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 2, wherein a content of the binder is from 0.5 to 30 g based on 100 g of the fibers.

10. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 1, wherein the fiber sheet further comprises:

copolymers of polymerizable acid anhydride compounds; and

amino acid derivatives.

11. A method of manufacturing a water disintegratable non-woven fabric as defined in claim 10, wherein the alkylcellulose is methylcellulose, the electrolyte is sodium sulfate, the copolymer is partial sodium salt of (meth)acrylic acid (ester)-maleic acid copolymer, and the amino acid derivative is trimethyl glycine.