Durable hydrophilic nonwoven webs and articles formed therefrom

• US 6,696,373 B2
• Filed: 11/29/2000
• Issued: 02/24/2004
• Est. Priority Date: 01/08/1999
• Status: Expired due to Term

• Current Assignee: BBA Nonwovens Simpsonville Inc (Signature Aviation US Topco LLC)
• Original Assignee: BBA Nonwovens Simpsonville Inc (Signature Aviation US Topco LLC)
• Inventors: Henning, Gregory Neil, Kinn, Larry L., Haley, Clement J.
• Primary Examiner(s): Cole, Elizabeth M.
• Assistant Examiner(s): Pierce, Jeremy R.
• Application Number:
  US09/725,797
• Publication Number:
  US 20010008965A1
• Time in Patent Office: 1,182 Days
• Field of Search: 442/361, 442/362, 442/364, 442/414, 442/415, 428/373, 428/374
• US Class Current: 442/361
• CPC Class Codes: D04H 1/4291 Olefin series
• CPC Class Codes: D04H 1/4374 using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D04H 1/43828 sheath-core
• CPC Class Codes: D04H 1/43835 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/5412 sheath-core
• CPC Class Codes: D04H 1/5418 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 3/007 Addition polymers
• CPC Class Codes: D04H 3/147 Composite yarns or filaments
• CPC Class Codes: H01M 10/24 Alkaline accumulators
• CPC Class Codes: H01M 50/414 Synthetic resins, e.g. thermoplastics or thermosetting resins
• CPC Class Codes: H01M 50/44 Fibrous material
• CPC Class Codes: H01M 50/489 Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/2929 Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
• CPC Class Codes: Y10T 428/2931 Fibers or filaments nonconcentric [e.g., side-by-side or eccentric, etc.]
• CPC Class Codes: Y10T 442/637 Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• CPC Class Codes: Y10T 442/638 Side-by-side multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/641 Sheath-core multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/66 Additional nonwoven fabric is a spun-bonded fabric
• CPC Class Codes: Y10T 442/689 : Hydroentangled nonwoven fabric
• CPC Class Codes: Y10T 442/696 : Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
• CPC Class Codes: Y10T 442/697 : Containing at least two chemically different strand or fiber materials

Abstract

Nonwoven webs in accordance with the present invention include multicomponent fibers bonded by a multiplicity of bond sites to form a coherent web. The multicomponent fibers include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive. This second component is disposed at the surface of the fibers. The hydrophilic melt additive-modified polyolefin component can be arranged in various configurations in the cross-section of the fiber and the fibers can have various cross sections. For example, the hydrophilic component can occupy a portion of the surface of the fiber, as would occur for example with a side-by-side or segmented pie multicomponent fiber configuration. Alternatively, the modified hydrophilic polyolefin can occupy substantially the entire surface of fiber, as for example by producing the fibers in a sheath core configuration with the hydrophilic modified component forming the sheath. A particularly preferred configuration is a sheath-core bicomponent fiber where the hydrophobic polypropylene forms the core and the modified hydrophilic polyolefin forms the sheath.

Claims

1. A polyolefin nonwoven web having durable hydrophilic properties and formed of polyolefin fibers, said web comprising multicomponent fibers and a multiplicity of bond sites bonding said fibers, said multicomponent fibers including a first component formed by a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive, wherein said hydrophilic melt additive is a mixture of hydroxy phenols and polyethylene glycols, said second component being disposed at the surface of said fibers.

2. The web according to claim 1, wherein substantially the entire surface of said multicomponent fibers is formed from said second component.

3. The web according to claim 2, wherein said multicomponent fibers comprise sheath-core bicomponent fibers, and wherein said first component forms the core and said second component forms the sheath.

4. The web according to claim 3, wherein said second component is a blend of polypropylene with said hydrophilic melt additive.

5. The web according to claim 3, wherein said second component is a blend of polyethylene with said hydrophilic melt additive.

6. The web according to claim 5, wherein said web additionally includes sheath-core bicomponent fibers which have a hydrophobic polyethylene sheath component and a hydrophobic polypropylene core component.

7. The web according to claim 1, wherein said multicomponent fibers comprise an air-laid web of staple fibers, a carded web of staple fibers, a wet-laid web of staple fibers, a web of meltblown fibers or a spunbonded web of substantially continuous filaments.

8. A diaper including a nonwoven web having durable hydrophilic properties according to claim 1.

9. A feminine hygiene product including a nonwoven web having durable hydrophilic properties according to claim 1.

10. An article of apparel comprising a nonwoven web having durable hydrophilic properties according to claim 1.

11. A filter including a filtration medium comprising a nonwoven web having durable hydrophilic properties according to claim 1.

12. A filter according to claim 11, wherein said nor woven web forms a membrane support, and including an u1trafiltration membrane carried by said nonwoven web membrane support.

13. A polyolefin nonwoven web having durable hydrophilic properties and formed of polyolefin fibers, said web comprising sheath-core bicomponent fibers and a multiplicity of bond sites bonding said fibers, the core component of aid bicomponent fibers comprising a hydrophobic polypropylene and the sheath component of said bicomponent fiber comprising a blend of a hydrophilic polypropylene and a hydrophilic melt additive, wherein said hydrophilic melt additive is a mixture of hydroxy phenols and polyethylene glycols.

14. The web according to claim 13, wherein said sheath component forms at least 50 percent by weight of the fibers.

15. The web according to claim 13, wherein said bond sites comprise discrete spaced apart thermal point bonds bonding said bicomponent fibers to one another.

16. The web according to claim 13, wherein said bicomponent fibers are staple fibers and said web is a carded thermal bonded web.

17. The web according to claim 13, wherein said bicomponent fibers are continuous filaments and said web is a spunbonded web.

18. A polyolefin nonwoven web having durable hydrophilic properties and comprising a blend of non-wettable sheath-core bicomponent polyolefin fibers and wettable sheath-core bicomponent polyolefin fibers, said non-wettable fibers having a polyethylene sheath component and a polypropylene core component, and said wettable fibers having a sheath component formed of a blend of polyethylene with a hydrophilic melt additive, wherein said hydrophilic melt additive is a mixture of hydroxy phenols and polyethylene glycols, and a polypropylene core component.

20. The web according to claim 18, wherein said web comprises from 10 to 90 weight percent of said non-wettable fibers and from 90 to 10 weight percent of said wettable fibers.

19. The web according to claim wherein said non-wettable bicomponent fibers are of a lower denier than said wettable bicomponent fibers.

21. A composite fabric comprising a polyolefin nonwoven web having durable hydrophilic properties and formed of polyolefin fibers, and at least one additional layer bonded to said polyolefin nonwoven web, said nonwoven web being formed of polyolefin fibers and comprising multicomponent fibers, said multicomponent fibers including a first component formed by a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive, wherein said hydrophilic melt additive is a mixture of hydroxy phenols and polyethylene glycols, said second component being disposed at the surface of said fibers.

22. A composite fabric according to claim 21, wherein said at least one additional layer includes an additional nonwoven web.

23. A composite fabric according to claim 21, wherein said at least one additional layer includes a film.

24. A nonwoven web having durable hydrophilic properties comprising sheath-core bicomponent fibers and a multiplicity of bond sites bonding said fibers, the core component of said bicomponent fibers comprising a hydrophobic polypropylene and the sheath component of said bicomponent fiber comprising a blend of a hydrophobic polyolefin and a hydrophilic melt additive, wherein said hydrophilic melt additive is a mixture of hydroxy phenols and polyethylene glycols.

25. A nonwoven web having durable hydrophilic properties comprising multicomponent fibers, said multicomponent fibers comprising a first component formed by a hydrophobic polypropylene and a second component disposed at the surface of said fibers and formed of a blend of a hydrophobic polyethylene and a hydrophilic melt additive, said hydrophilic melt additive comprising a mixture of hydroxy phenols and polyethylene glycols.

26. A carded thermal bonded polyolefin nonwoven web having durable hydrophilic properties, said web consisting essentially of carded staple fibers and a multiplicity of bond sites bonding said fibers to form a coherent web, said web comprising multicomponent fibers including a first component formed by a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive, wherein said hydrophilic melt additive is a mixture of hydroxy phenols and polyethylene glycols, said second component being disposed at the surface if said fibers.

27. A spunbonded polyolefin nonwoven web having durable hydrophilic properties, said web consisting essentially of randomly arrange continuous filaments and a multiplicity of bond sites bonding said filaments to form a coherent web, said web comprising multicomponent filaments including a first component formed by a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive, wherein said hydrophilic melt additive is a mixture of hydroxy phenols and polyethylene glycols, said second component being disposed at the surface of said filaments.