CA2128732A1 - Process stable nonwoven fabric - Google Patents
Process stable nonwoven fabricInfo
- Publication number
- CA2128732A1 CA2128732A1 CA 2128732 CA2128732A CA2128732A1 CA 2128732 A1 CA2128732 A1 CA 2128732A1 CA 2128732 CA2128732 CA 2128732 CA 2128732 A CA2128732 A CA 2128732A CA 2128732 A1 CA2128732 A1 CA 2128732A1
- Authority
- CA
- Canada
- Prior art keywords
- fabric
- machine direction
- net
- cross
- elastic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G25/00—Lap-forming devices not integral with machines specified above
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/49—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation entanglement by fluid jet in combination with another consolidation means
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- D—TEXTILES; PAPER
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- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- Y10T428/24446—Wrinkled, creased, crinkled or creped
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24826—Spot bonds connect components
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/253—Cellulosic [e.g., wood, paper, cork, rayon, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T442/102—Woven scrim
- Y10T442/159—Including a nonwoven fabric which is not a scrim
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
- Y10T442/102—Woven scrim
- Y10T442/159—Including a nonwoven fabric which is not a scrim
- Y10T442/16—Two or more nonwoven layers
Abstract
PROCESS STABLE NONWOVEN FABRIC
Abstract of the Invention The invention provides elastic fabrics which are substantially non-extensible in the machine direction and have substantial elastic properties in the cross-machine direction. The process stable fabrics of the invention include a net and a fibrous layer which are secured together. The net is composed of a plurality of continuous machine direction strands and a plurality of cross-direction strands. The machine direction strands are substantially non-extensible and the cross-direction strands are substantially elastic. The fabrics of the invention can be manufactured and processed more readily than fabrics which are elastic in both the machine direction and the cross-machine direction.
Abstract of the Invention The invention provides elastic fabrics which are substantially non-extensible in the machine direction and have substantial elastic properties in the cross-machine direction. The process stable fabrics of the invention include a net and a fibrous layer which are secured together. The net is composed of a plurality of continuous machine direction strands and a plurality of cross-direction strands. The machine direction strands are substantially non-extensible and the cross-direction strands are substantially elastic. The fabrics of the invention can be manufactured and processed more readily than fabrics which are elastic in both the machine direction and the cross-machine direction.
Description
-~ 212g732 :
;
PROCESS STAE~LE NONWOVEN FABRIC
, .- .
: .: ; i .
Field of the Invention The invention relates to process stable composite elastic nonwoven fabricq and to processes for producing them. More specifically, the invention relates to process stable composite nonwoven elastic fabrics having desirable strength, conformability, and stretch and recovery properties, and which can be mors readily manufactured and processed using existing textile equipment as compared to prior nonwoven fabrics.
~ackground_of the Inv~ion Nonwoven elastic fabrics have been the subject of considerable attention and effort. Elastic fabrics are desirable for use in bandaging materials, garments, diapers, supportive clothing and personal hygiene products because of their ability to conform to irregular shapes and to allow more freedom of body mov~ment than fabrics with limited extensibility~
Elastomeric materials have been incorporated into various fabric structures to provide stretchable fabrics. In many instances, such as where the fabrics are made by knitting or weaving, there can be a relatively high cost associated with the fabric. In ;
cases where the fabrics are made using nonwoven technologies, the f~ibric can suffer from insufficient " ' :' ..'.A~'':'"
;
PROCESS STAE~LE NONWOVEN FABRIC
, .- .
: .: ; i .
Field of the Invention The invention relates to process stable composite elastic nonwoven fabricq and to processes for producing them. More specifically, the invention relates to process stable composite nonwoven elastic fabrics having desirable strength, conformability, and stretch and recovery properties, and which can be mors readily manufactured and processed using existing textile equipment as compared to prior nonwoven fabrics.
~ackground_of the Inv~ion Nonwoven elastic fabrics have been the subject of considerable attention and effort. Elastic fabrics are desirable for use in bandaging materials, garments, diapers, supportive clothing and personal hygiene products because of their ability to conform to irregular shapes and to allow more freedom of body mov~ment than fabrics with limited extensibility~
Elastomeric materials have been incorporated into various fabric structures to provide stretchable fabrics. In many instances, such as where the fabrics are made by knitting or weaving, there can be a relatively high cost associated with the fabric. In ;
cases where the fabrics are made using nonwoven technologies, the f~ibric can suffer from insufficient " ' :' ..'.A~'':'"
2~.2~732 strength and only limited stretch and recovery properties.
: , Elastomers used to fabricate elastic fabrics often have an undesirable rubbery feel. This is particularly true with thermoplastic elastomers rather than cross-linked elastomers. When these materials are used in comp~site nonwoven fabrics, the hand and texture of the fabric can be perceived by the user as stic~y or rubbery and therefore undesirable.
Nonwoven fabrics having thermopla tic elastomers incorporated into the fabric structure can be extremely difficult to process and to manufacture.
For example, tension control during fabric manufacture and/or during downstream processing can be extremely critical. A small change in tension can result in stretching or recovery of the fabric which can lead to a non-uniformly manufactured product. Tension control i~ even more aggravated when heating is required, for example, during fabric drying, adhesive application, 20 lamination, thermal bonding or other thermal treatment. ~ ~
When subjected to heat and tension, the fabric can stretch and otherwise undergo greater distortion than when the fabric is at room temperature. In addition, thermopla~tic elastomers can lose elastic properties when stressed at elevated temperatures and allowed to cool fully or partially while stressed, and/or the thermoplastic fibers and filaments are apt to break, thereby causing the elastic fabric to lose a portion or all of its elastic proper~ties. Still further, when elastic fabric~ are wound into rolls, stretching of the fabrics can occur during the winding process and the fabric can lose elastio properties during it~
subsequent storagQ due to the phenomenon of creep.
U.S. Patent 4,775,579 to Hagy, et al.
discloses desirable composite elastic nonwoven fabrics containing staple textile fibers intimately hydroentanqled with an elastic web or elastic net. One -212~732 _ 3 _ or more webs of staple textile fi~ers and/or wood pulp f i~ers can be hydroentangled with an elastic net according to the disclosure of this invention. The . ~-resulting co~posite fabric exhibits characteristics 5 comparable to those of knit textile cloth and possesses -~
superior softness and extensibility properties. The rubbery feel traditionally associated with elasto~eric materials can be minimized or eliminated in these fabrics.
U.S. Patent 4,413,623 to Pieniak disclose~ a ;
laminated structure such as a disposable diaper which can incorporate an elastic net into portions of the structure. The elastic net can be inserted in a stretch position between first and second layers of the structure and bonded to the layers while in the stretch condition. Subsequent relaxation of the elastic net can result in gathering of the structure.
U.S. Patent 4,525,407 to Ness discloses elastic fabrics which include an elastic member which may be an elastic net intermittently bonded to a substrate which prior to stretching i5 less easily extensible than the ela tic member. The non-elastic member is bonded to the elastic member and the entire composite is rendered elastic by stretching and ~ ;~
relaxation.
U.S. Patent 4,606,964 to Wideman discloses a bulk compo ite web which can be prepared by bonding a gatherable web to a differentially stretched elastic net. Subsequent relaxation of the differentially stretch net is said to result in gathering o~ the fabric.
The various problems associated with thermoplastic elastomeric materials, as discussed :~?
previously, render many of these and other composite elastic fabrics difficult to manufacture and process.
There are problems with tension control, elongation under the tension induced by converting machines, ~ 212~732 ~
irregular cut length, poor trac~ing, blocking, and similar problems. In the past, these problems have been overcome or minimized only with substantial difficulty. To minimize the problem of machine direction stretching during fabric converting and/or forming, typical approaches have been to either cool the thermoplastic elastomer to a temperature below its glass transition temperature or to make ~heat activated" materials that are rigid, but then shrink and become elastomeric when heated. These steps are often required to process the material under acceptable tension levels even at ambient temperatures.
Alternative process modifications have required extremely exact tension control mechanisms: but these do not consistently eliminate problems during normal fabric processing.
Summary of the Inv,e,~t,io~
The invention provides process stable composite elastic fabrics which can be readily processed on existing textile apparatus without requiring special tension control mechanisms and without substantial harm to the elastic properties of the fabric. The fabrics can be subjected to heat during the process of manufacturing the fabrics or thereafter without destruction o~ elastic properties.
Thus, elastic fabrics of the invention can be manufactured in a more convenient and straightforward manner and can be processed thereafter with less restrictions and/or fabric damage than prior elastic fabrics.
The process stable composite elastic fabrics of the invention are substantially non-extensible in ~ ~
the machine direction and have substantial elastic ~, properties in the cross-machine direction. Thus, the ,~
process stable fabrics of the invention can be stressed in the machine direction without substantial fabric stretching and without requiring specialized processes 212~732 . . , and/or apparatus to compensate for elastic stretching.
Moreover, because elastomeric components of the fabric are not substantially stretched when the fabric is stressed in the machine direction, thermal treatments can be more readily applied to the fabric without substantial fabric harm as a result of combined thermal and stress effects.
The process stable composite elastic fabrics of the invention have a predetermined width and an indeterminate length which is substantially greater than the width of the fabric. The width of the fabric defines the fabric's cross-machine direction and the length of the fabric defines the machine direction of the fabric. The composi~e nonwoven fabric includes at least one fibrous layer and a net combined with the fibrous layer. The net is composed of a plurality of continuous machine direction strands oriented in substantially the machine direction of the fabric and a plurality of cross-direction continuous strands oriented in substantially the cross direction of the fabric. The machine direction strands are sub~tantially non-extensible and preferably are substantially non-extensible under applied stress at temperatures of up to 70-C or higher. The cross-dlrection strands comprise a substantial amount of athermoplastic elastomer, preferably about 20 wt. %, more pre~erably at lea~t about 50 wt. %, such ~hat the net i~ elastic in the cross-direction. In one preferred embodiment, the net is combined with the fibrous web by hydroentangling. The net can alternatively be combined with the fibrous web by adhe~ive or thermal bonding. Advantageously, the fibrous web comprises staple fiber~ including polyolefins, polyesters, nylon and the like, and/or cotton, wool and wood pulp fibers. These fibers can provide de~irable aesthetic qualities to the composite 2~23732 fabric. Additlonally or alternatively the fibrous web can compris~ a spunbo~d or a meltblown we~.
Advantageously, the machine direction continuous strands employed in the net component of the composite fibrous web are formed of a crystalline polymer such as a crystallizable polyolefin material which is strong and which readily adheres to the thermoplastic elastomer material used in the cross machine direction strands of the net. In one particularly preferred embodiment of the invention, the net is formed from polyoleSin strands oriented in the machine direction and the cross machine direction strands are formed from a thermoplastic styrenic elastomer.
As compared to nonwoven fabrics which are -either non-elastic or fully elastic, the composite fabrics of the invention have various advantages and bene~its. As compared to non-elastic fabrics, the fabrics of the invention are advantageous in providing elastic properties in the cross-machine direction. As compared to conventional elastic nonwoven fabrics which are elastic in both the machine direction and the cross-machine direction, the fabrics of the invention provide significant benefits and advantages both in terms of their manuSacture and their subsequent use.
The fabrics of the invention can be manufactured and processed without the need for specialized tension control. When ther~ally treated while being processed in the machine direction, the fabrics of the invention typically do not lose elastic properties because the elastic filaments are not subjected to tensioning. The fabrics of the invention can be readily cut without deformation during the cuttinq process so that the cut length can be more accurately controlled. Similarly 35 the fabric of the invention allows for more accurate ~-~
treatment and control in other converting processes.
The fabrics of the invention can be readily wound and ': :
212~732 - 7 - .
stored in roll form under various environmental conditions without subjecting the elastic components of the f~bric to stresses which would result in creep of the fabric. In addition, the fabrics of the inv~ntion can provide significant aesthetic benefits including differential drape, curl and shear properties which are not readily provided in fully elastic and fully non-elastic composite fabrics.
Brie~ Description of the Drawin In the drawings which form a portion of the original disclosure of the invention~
Figure 1 illustrates in perspective view a net in roll form which can be used in producing fabrics of the invention;
Figure 2 is a schematic illustration of one preferred process for producing a fabric in accordance wlth the invention: ' Figure 3 is an exploded view of one preferred fabric according to the invention;
Figure 4 is a schematic illustration of a process wherein a fabric of the invention is laminated to a second fabric or film layer: and ''''~"' Figure 5 illustrates the results of thermomechanical analysis conducted on filaments 25 composed of styrenic elastomers, EVA polymer and LLDPE ' polymer. '~
~etailed,,~e~cri~ Lg~ L~vention In the following detailed description of the invention, specific preferred embodiments of the 30 invention are described to enable a full and complete ' ',' understanding of the invention. It will be recognized - ' that it is not intended to limit the invention to the particular preferred embodiments described, and although specific terms are employed in describing the 35 invention, these terms are used for the purpose of ,~' illustration and not for the purpose of limitation. It will be apparent that the invention is susceptible to 21L2~73~ ~
:``
variations and changes within the spirit of the teachings herein.
Figure 1 illustrates an elastomeric net 10 having a plurality of substantially continuous strands 5 or filaments oriented in the machine direction of the fabric as indicated by arrow 12 and a plurality of substantially continuous filaments or strands oriented in the cro~s-machine direction, that is, the width direction of the fabric as indicated by arrow 14. The strands oriented in the machine direction are substantially non-extensible strands while the strands in the cross machine direction are substantially elastic and preferably comprise a thermoplastic elastomer. As used herein and only for purposes of this application, the term "elastic" is used to mean strands and/or fabrics capable of substantially complete recovery, i.e. greater than about 75%, preferably greater than about 90% recovery, when stretched in an amount of about 10% at room temperature 20 expressed as: -% recovery = (L, - ~)/(L, - Lo) X 100 where: L, represents stretched length: Lr represents ~;~
recovered length measured one minute after recovery:
and ~ represents original length of material.
As used herein and only for the purposes of this application, the term ~substantially non-extensible" i8 used to mean fllaments and/or strands which, at 25-C exhibit an extensibility o~ 2% or less, prererably about 1% or less when subjected to an applied stress of 5 mg/denier which is a stress based on stresæes applied to a fabric by fabric conversion apparatus. In preferred embodiments of this invention, subqtantially non-extensible filaments and strands have an extQnsibility of less than about 5% at 70-C under an applied stress of 5 mg/den.
Generally, it is desirable that the number of strands per inch in each of the machine and cross~
:.
2 L2~732 _9_ machine directions of the net range from between about 2 and about 30 strands per inch preferably from 5 to about 20 strands per inch although greater numbers of filaments can be employed where desirable. Typically, the elastomeric net 10 will have a basis weight ranging from about 15 grams per square meter to about 200 grams per square meter, more preferably from about 50 to `~
about 90 grams per square meter, and can employ filaments having diameters ranging from about 50 to about 600 microns, preferably from about 150 to about 400 microns.
The elastic net 10 can be prepared by any of various well known processes including the process disclosed in U.s. Patent 4,636,419, issued January 13, 1987 to Madsen, et al., incorporated herein by reference. In general, the elastic net is made by extrudin~ a plurality of substantially non-extensible polymeric strands in the machino direction while simultaneously or thereafter extruding and ~oining to said machine direction filaments, a plurality of elastic polymeric strands oriented substantially in the cross machine direction.
The elastic material making up the strands in the cross-machine direction of the net normally 25 comprise at least one thermoplastic elastomèr. ~ -Suitable thermoplastic elastomers include the diblock, trlblock, radial and star copolymers based on polystyrene (S) and unsaturated or fully hydrogenated rubber blocks. The rubber block can consist of butadiene (B), isoprene (I), or the hydrogenated version, ethylene-butylene (E~). For example, S-B, S-I, S-EB, a8 well as S-B-S, S-I-S, S-EB-S linear block copolymers can be used. Typically when used one or more of the diblock copolymers are blended with the triblock or radial copolymer elastomers. Preferred thermoplastic elastomers of this type can include the -KRATON polymers sold by Shell Chemical Company or the 212~7~2 VEC~OR polymers sold by DEXCO. Other elastomeric thermoplastic polymers include polyurethane elastomeric materials such as ESTANE sold by BF Goodrich company;
polyester elastomers such as HYTREL sold by E. I. Du Pont De Nemours company: polyetherester elastomeric materials such as ARNITEL sold by Akzo Plastics: and polyetheramide elastomeric materials such as PEBAX sold by ATO Chemie Company; and the like.
The elastic strands in the cross-machine lo direction of the elastic net 1o can also be prepared from blends of the~noplastic elastomers with other polymers such as polyolefin polymers, e.g. blends of '~
Kraton polymers with polyolefins such as polypropylene and polyethylene, and the like. These polymers can provide lubrication and decrease the melt viscosity, allow for lower melt pressures and temperatures and/or increase throughput, and provide better bonding properties too. In a preferred embodiment of the invention, such other polymers can be included in the ;~
blend as a minor component, for example in an amount of between about 5% by weight up to 50% by weight, preferably from a~out 10 to about 30% by weight of the mixture. Suitable thermoplastic polymers, include, in addition to the polyolefin polymers, poly(ethylene-2S vinyl acetate) polymers having an ethylene content ofup to about 50% by weight, preferably between 15 and 30% by weight and copolymers of ethylene and acrylic acid or esters thereof, such as poly(ethylene-methyl acrylate) or poly(ethylene-ethyl acrylate) wherein the acrylate acid or ester component ranges from about 5 to about 50% by weight, preferably from about 15 to about 30% by weight, In addition polystyrene and poly(alpha~
methyl styrens) can be used.
The machine direction substantially non-ext~nsible strands constitute a non-elastic polymeric material including any of the various well known filament-forming polymers, such as polyolefins 212~732 including polyethylene, polypropyl ene, l inear low density polyethylene (LLDPE): polyesters such as polyethylene terephthalate; polyamides such as nylon-6 and nylon-6,6; copolymers, blends of such materials and s the like. Preferably the non-elastic polymer is a crystalline material which provides a filament with a high tenacity and a relatively ~harp melting point.
Advantageously, the substantially non-extensible strands in the machine direction are composed of a lo material which adheres readily to the elastlc strands in the cross-machine direction. In this regard it is desirable that there be substantial bonding between the strands in the machine direction and the strands in the cross-machine direction. Generally, a polyolefin material i5 preferably used for the machine direction strands when the cross-machine direction strand~ ara styrene-based elastomeric materials. Nylon continuous machine direction can be advantageously employed in combination with polyetheramide elastomeric cross-machine direction strands. Polyester-based strands advantageously can be used as machine direction strands in combination with polyetherester elastomeric cross-machine direction strands.
In one preferred embodiment of the in~ention, the machine direction substantially non-extensible strands can comprise an adherence promoting additive to improve the adherence of the machine direction strands to the cross-machine direction strands. Preferred additives to improve adherence include poly(ethylene-vinyl acetate) polymers having an ethylene content ofup to about 50% by weight, preferably between about 15 and about 30% by weight, and copolymers of ethylene and acrylic acid or esters thereof, such as poly(ethylene-methyl acrylate) or poly(ethyl acrylate) wherein the acrylic acid or ester component ranges from about 5 to about 50% by weight, preferably from about 15 to 30% by weight. These materials are preferably included in the 212~732 machine direction strands in an amount of between about 2 and about 50~ by weight, preferably between about 10 and about 30% by weight depending on the primary component of the strand. In addition other materials such as plasticizers, tackifiers, talc, and the like can be compounded into the resin at low levels to promote bending. As indicated previously, the machine direction strands are preferably stable under applied stress at high temperatures. However, if such additives are included in too great an a~ount the thermal stability of the machine direction strands can suffer.
Figure 2 illustrates one preferred process for forming a composite fabric of the invention. A
carding apparatus 20 forms a first carded layer 22 onto forming screen 24. Carded fibrous layer 22 can comprise any of various well-know synthetic or natural fibers, and in one preferred embodiment of the invention, also includes binder fibers in an amount of between about 5% and about 50~ by weight. The web 22 i~ moved by forming screen 24 in the machine direction by rolls 26.
A conventional supply system thereafter applies the elastomeric net 10 onto the moving carded -~
layer 22. As discussed previously, the elastomeric net 10 includes spaced apart machine direction and cross machine direction strands which intersect to form ~
apertures. Although it is preferred that the net have ~ ;
a substantially regular, rectangular shape, irregular geom~try nets such as diamond-shaped nets and the like can be used wherein the non-elastic strands are oriented primarily in ths machine direction and elastic strands are oriented primarily in the cross machine direction. A roll 28 applies tension to the two-layered structure 30 which is formed from thecombination of the carded layer 22 and the net layer 212~7~2 . , .
. -13-lO. ~he two layer structure is advanced in the machine direction by forming screen 24.
A second carding apparatus 32 deposits a second carded fibrous layer 34 comprising synthetic : :5 and/or natural fibers onto the two layer structure 3 0 to thereby form a three-layer composite structure 36 consisting of a carded web/elastomeric net/carded web. .
The synthetic and/or natural fibers making up carded web 34 can be the same or different as compared to the ~ :
fibers in carded web 22. The three-layer composite web 36 is conveyed in the machine direction by the combination of forming screen 24 and roll 38. It ~
be apparent to the skilled artisan that the composite structure including net 10 is subjected to tension ; ~ .
~etween the forming rolls 28 and 38. Because the machine direction strands in the net 10 are substantially non-extensible strands, the tension applied between rolls 28 and 38 does not result in substantial stretching of the net 10 and hence there i9 little or no stretching o~ the composite elastic structure 36.
The composite structure 36 is thereafter conveyed in the machine direction as shown in Figure l to a hydroentangling station 40 wherein a plurality of :
manifolds 42, each including one or more rows of fine ori~ices, direct high pressure jets of liquid through composite web 36 to intimately hydroentangle the fibers in each of the layers 22 and 34 with each other and with net 10. As a result of the hydroentangling treatment, at least a portion of the ~ibers in each o~
the carded layers 22 and 34 preferably extend through apertures in thQ net and into the carded layer on the othex side of the net.
The hydroentangling station 40 is constructed in a conventional manner as known to the skilled artisan and as described, ~or example, in U.S. Patent 3,485,706 to Evans, which is hereby incorporated by 212~32 reference. As known to the skilled artisan, fiber hydroentanglement is accomplished by jetting liquid, typically water, supplied at a pressure fro~ about 200 psig up to a~out 1,800 psig or greater, to form fine, 5 essentially columnar liquid streams. The high pressure liquid streams are directed to at least one surface of the composite layered structure. The composite is -~
supported on a fora~inous support screen 44 which can have a pattern to form a nonwoven structure with a lo pattern or with apertures, or the screen 44 can be designed and arranged to form a hydraulically entangled ~ -composite which is not patterned or apertured. The laminate can be passed through a second hydraulic entangling station schematically illustrated in Figure 15 2 by manifolds 46, to enable hydraulic entanglement on `
the other side of the composite web fabric.
During the hydraulic entanglement treatment, tha fibers in the carded layer or layer~ are forced -~
into and/or through the elastomeric net 10, thereby securing the carded fibrous layer to the elastomeric net. Preferably, the hydroentangling treatment is sufficient to force the fibers present in at least one or the layers 22 and 34 into and/or through the apertures in the elastomeric net 10. More preferably, the hydroentangling treatment is sufficient to force at least portion o~ the fibers in both carded layers 22 and 34 into and/or through the aperture~ in the elastomeric net.
The elastomeric web 10 remains in a substantially planer arrangement during the hydroentangling treatment. Thus, the machine direction and cross-machine direction filaments, respectively, oS
the ela~tomeric net undergo little if any movement in the cross-sectional direction, i.e. in the Z direction within the web. Thus, the elastomeric net remains within a discrete interior cross-sectional portion of the composite web.
2123732 ~ ~
15- :
A condensed, hydraulically entanqled composite ~eb 48 is removed from the hydroentangling :
station 40 via roll 50 which cooperates with forming wire ~4 and forming web rolls 52. The tension applied 5 to the composite web 48 by rolls 50 and 52 does not result in substantial stretching of the elastomeric -:.
composite 48 because the machine direction strands of the net lO are substantially non-extensible. ~ ;
The web 48 exiting the hydroentangling o station is thereafter preferably dried at a conventional drying station ~not shown) and thereafter ;
may be thermally treated at an optional thermal treatment station 54, shown in Figure 2 as heated calender rolls 56 and 58. The optional thermal treatment station 54 is used when binder fibers or another binder material is present in the composite web 48. The operating temperature of the heated rolls 56 and 58 is ad~usted to a surface temperature such that the binder fibers or other binder materials present in the composite web 48 are thermally activated to bind the composite web 48 into a coherent, unitary structure. In accordance with the present invention, the thermal treatment can be more readily carried out because the elastomeric strands in the net lO are not sub~ected to tension during the thermal treating process. Pre~erably, the operating temperature of the rolls 56 and 58 is maintained below a temperature which would cause thermal degradation or melting of the elastomeric materials in the net 10.
The composite web 60 is removed from the nip of rolls 56 and 58 and is wound by conventional means onto roll 62. The composite elastic web 60 can be stored on roll 62 without substantial harm to the fabric due to the phenomenon of creep: that is, de~ormation that is time dependent and is exhibited by many elastomeric materials subjected to a continuing load. In many cases, creep deformation may not be ` 212~7~2 recoverable following removal of the applied load. ;~
With the fabric 60 stored on roll 62, the elastomeric filaments of net lO are only found in the cross-machine direction of the net and therefore are not subjected to 5 stress during storage on roll form. The fabric 60 stored on roll 62 may be immediately or later passad t~
end use manufacturing processes, for example, for use in bandages, diapers, disposable undergarments, personal hygiene products, and the liXe.
lo The method illustrated in Figure 2 i8 ~ .
susceptible to numerous preferred variations. For example, although the schematic illustration of Figure 2 shows carded webs being formed directly during the in-line process, it will be apparent that the carded webs can be preformed and supplied as rolls of preformed webs. Similarly, although the elastomeric net is shown being supplied as a roll of preformed net, the net can be formed directly in-line. Similarly, although Figure 1 illustrates the use of carded fibrous webs both above and below the net 10, only a single fibrous web such as web 22 can be employed or more than two fibrous webs can be employed. Moreover, it will b apparent to the skilled artisan that fibrous we~s can be manufactured and supplied by other well known proces~es such as air-laying and the like.
The hydroentanglement station 40 is a preferred process step for securing the ela~tomeric net 10 to one or more fibrous webs 22, 34. However, in other preferred embodiments of the invention, the fibrous webs 22 and/or 24 can be secured to elastomeric net 10 by lamination including solvent-based adhesive and/or thermal adhesive lamination, needling and/or other well known texti~e processes.
The heated calender rolls 56 and 58 can, in othar embodiments of the invention, be replaced by other thermal actlvations zones, for example in the form of a through-air bonding oven or in the form of a -`.;. 212~7~2:~ -17-- . :
microwave or other RF treatment zone. An especially preferred through-air bonding or through-air dryiny treatment zone employs support screens both above and below the fabric which contact both surfaces of the -~
5 fabric during passage through the oven. The screens are advantageously metallic screens resulting in conductive heating oP both fabric surfaces by contact with the upper and lower metal screens respectively. ~ ~-Other heating stations such as ultrasonic welding stations can also be advantageously used in tha invention. Such conventional heating stations are known to those skilled in the art and are capable of -effecting substantial heating of the fabric sufficient for thermal activation of binder fibers when such fibers are incorporated into the fabric.
As indicated previously, nonwoven web~ other than carded webs are also advantageously employed in the production of fabrics according to the invention.
Nonwoven staple webs can be formed by air laying, garnetting, wet laying, and similar processes known in the art. Spunbonded webs which are extensible in the cross-machine direction because of little or no ~ilament-to-~ilament bonding can be substituted for either or both of the carded webs illustrated in Figure 2 and/or can be used in combination with one or both of the carded webs. Similarly meltblown webs which are extensible in the cross machine direction can be substituted for and/or used in conjunction with either of carded webs 22 and 34 shown in Figure 2.
Figure 3 illustrate~ an exploded view of the ;
three-layered structure 36 of Figure 2 prior to hydroentanglement. Each of webs 22 and 34 include staple and/or natural fibers such as fibers formed from polyester, polyole~ins such aR polypropylene or polyethylene, nylon, acrylic, modacrylic, rayon, cellulose acetate, biodegradable synthetics such as a biodegradable polyester, aramide, fluorocarbons, ..
"~
212~7`~,2 ~ ~
-18~
polyphenylene sulfide staple fibers and the like.
Preferred natural fibers include wool, cotton, wood pulp fibers and the like. Blends of such fibers can also be used. In addition, all or a portion of the staple fibers can be glass, carbon fibers and the like.
The webs 22 and 34 can also include binder fibers in an amount of between about 5 and about 50 wt.
%. Binder fibers are known in the art and include Sibers made from low melting polyolefin~ such as polyethylenes; polyamides and particularly co~
polyamides: polyesters and partlcularly copolyesters;
acrylics and the like. The binder fibers, when used, preferably have a lower activation temperature then the melting point of the ne~. In the case that the binder ~ibers activate above the glass transition temperaturs of the hard segment of the thermoplastic elastomer contained in the net, then heating conditions are ;
advantageously closely controlled to activate the binder fibers without degrading or deforming the net.
Particularly preferred binder fibers include bicomponent and multi-component fibers such a~
sheath/core, side-by-side, sectorized or similar bicomponent fibers wherein at least one component of the fiber is a low melting material such as polyethylenQ, a copolyester, a copolyamide or the like.
Preferred bicomponent fibers have a melting temperature for the binder portion Or the fiber in range of between about 100 and about 135'C. Such fibers include polypropylene/polyethylene and polyester/polyethylene sheath/core fibers and polyester/copolyester sheath/core fiber~. One particularly preferred binder fiber i-~ a copolyester/polyester sheath/core ~iber having a melting point of about 110-C commercially avallable from Hoechst-Celanese Corporation a~ "K-54".
As indicated previously, the fabrics o~ the invention can also incorporate spunbonded nonwovens includlng polyolefin, nylon, polyester, copolymers of ~;
'", ' '.~" '"
:' ~' ~
`:
212~73~
the same and other webs as are known to those skilled in the art. Similarly, meltblown nonwovens including both elastomeric and non-elastomeric meltblown webs prepared from polyolefins, nylons, polyesters, random 5 and block copolymers, elastomers and the like can also be included in fabrics of the invention.
Figure 4 illustrates an exemplary end-use process for a fabric 60 of the invention. The fahric 60 is substa~tially elastic in the cross-machine lo direction as indicated by arrow 70 and is substantially non-extensible in the machine direction as illustrated by arrow 72. The fabric 60 can be supplied via a roll to a lamination process as illustrated in Figure 4. A
second film or fabric 74 is supplied from roll 76 for lamination with the fabric 60. An adhesive material may be applied to the film or fabric 74 via one or more rolls 78 by conventional apparatus known to the those skilled in the art. A pair of calender rolls 80 and 82, which may be heated, are used to bond the film or fabric 74 to the elastic fabric 60 of the invention.
As is apparent to the skilled artisan, during the lamination process illustrated in Figure 4, the ~abric 60 is subjected to tension in the machine direction. During a typical lamination process, if an elastic fabric is stretched due to elasticity, the film or fabric layer 74 will be gathered following relaxation of the laminate. In addition, a~ discussed below, when elastomeric materials are stretched during heating, for example, by contact with heated calender rolls 80 and 82, a failure of elastic properties can result.
Figure 5 illustrates the results of thermal stress tests conducted on filaments of a styrenic ;
ela~tomer having a denier per filament o~ 1283 (1426 dtex); a filament composed of poly(athylena vinyl acetate) having a denier of 530 (589 dtex) and on a filament of linear low density polyethylene having a 2 1 2 ~ 7 ~
denier of 844 (937 dtex). Each of the filaments was subjected to a constant stress of 4.2 mg/den (37 ~N/dtex) and subjected to different thermal environments. As seen in Figure 5, the elastomeric ~ ~
5 filaments undergo suhstantial el~ngation even at room -: :
temperature (20'C). At 70~C, the ethylene vinyl -acetate filaments exhibit substantial elongation. At 90-C, the elastomeric filament was broken while the ethylene vinyl acetate filament was broken at 80-C.
lo The filament composed o~ linear low density polyethylene, on the other hand, exhibited substantial stability even at a temperature of lOO-C. It will be apparent that the stress employed in this series of tests (approximately 4 mg/den) is an extremely low stress. It will also be apparent that elastomeric filaments are highly unstable when subjected to the combination o~ even a low stress together with elevated with thermal treatment.
The data illustrated in Figure 5 is set forth below, in ~able 1 in tabular form.
' . ~'~ , . . .
21- 212~732 .
TABLE 1 PERCENT EI~)NGATION VS. TEMPERATURE
- _ .-=
PERCENT ELC~NGAllON ¦
TEMPERA~ (C) Sl'YRENIC .. 11 ELASI~ E~VA LLDPE
5.5 0.6 Q6 1 30 6.5 0.9 0.9~ __ 1 40 7.0 1.3 ~.1 S0 7.8 1.9 l.S l _ I
60 . 10.0 3.4 1.9 I ..
14.7 6.4 2'3 I :
. , . _ . I ;.
28.9 19.1 2.8 I .
34.6 Break 3.5 100 Break Break 4.4 . ~ . . .
.~ , ,.
110 Break Break 6.1 .... ...... ... __ ADnlTlONAL INFORMATION . ~ .
.. . . ...
Filamenl denler 1283 530 844 . `
15Size . . . . `:
dtex 1426 589 937 . . ..:
Strcss mg/den 4.21 4.23 4.23 ; . ;
~' :
_ IlN/dte~ 37.2 37.4 37.4 ~ ' ..
As is apparent from the data presented above, nonwoven fabrics with elastomeric materials in the machine direction are difficult to process. In the thermomechanical analysis test, above, the tension presented to the materials is extremely low and is lower than tensions typically achieved on forming and converting equipment. However, as is apparent from the above, even at room temperature and under this unrealistically low tension, elastomeric filaments still stretch 5-6%. In the proce~sing and/or converting environment, such stretching can interfere with steps such as cutting and the like. However, with the elastomeric fabrics of the invention, the fabrics 212~732 can be processed in the machine direction without stretching.
The following examples illustrate preparation of preferred fabrics according to the invention:
In Example 1, a process-stable nonwovPn fabric was made by using a rectangular net with 18 strands/inch in the MD and 9 strands/inch in the CD.
This net had linear low density polyethylene in the MD
lo and elastomer i~ the CD. The elastomer in the CD i~ a styrenic triblock thermoplastic rubber consisting of SIS and SBS rubber compounded with a low molecular weight polystyrene. The nonwoven composite was made by hydroentangling a polyester fiber blend consisting of 15 70% by weight Type 183, 1.5 dpf x 1.5" PET from Hoechst Celanese and 30% by weight Type K-54 2.0 dpf x l.S" :~c bicomponent fiber also from Hoechst Celanese. After entanqling, the product was through-air bonded at 320'F. Note that this bonding step could not have been per~ormed if the product was not process stable under heat and tension. The resulting product was soft, had good CD elasticity, and was resistant to ~iber pilling and fuzzing. ~ ~
EXAMPLE 2 : `
In Example 2, a process-stable nonwoven fabric was made by using a rectangular net with 12 strands/inch in the MD and 12 strands/inch in the CD.
In the MD, this net was 80% low density polyethylene (copolymer) and 20% ethylene-vinyl acetatQ copoly~er.
An SIS and SBS rubber compound blended with low molecular weight polystyrene was used as the elastomer.
The product was entangled with a ~iber blend consisting of 70% by weight Type 182, 2.2 dpf x 1.5"
Polypropylene from Hercules, and 30% by weight Type K-54 2.0 dpf x 1.5" bicomponent fiber from HoechstCelanese.
2~2~7~2 The resulting product had a very soft hand and good CD stretch.
In example 3, a process-stable non-woven fabric was made just like example 2. After forming the web, however, the product was su~sequently calender bonded. A micro-gapped, open-nip calender with two smooth rolls was used to bond the fibers with minimal ef~ect on the net.
E)CAMPLES 4, 5 AND 6 `
Examples 4, 5 and 6 were all made in a similar fashion. The difference between examples is the net used. Examples 3 used an 18 x 3 net, example 4 used an 18 x s and example 5 used an 18 x 7. All nets had a 50/50 blend of EVA with a low density polyethylene (copolymer) as the MD resin, and for the CD resin, the same SIS-S~S rubber compound used in the i previous examples.
Example 7 was made by taking a 15 x 8 net.
This net had a rectangular (rather than circular) MD
strand geometry. The net consisted of an 80/20 blend of a low density polyethylene ~copolymer) with EVA as the MD resin. Again ~or the CD reqin the same SIS-SBS
rubber compound was used as in the previous examples.
This product was entangled with a fiber blend consisting o~ 70% by weight 1.0 dpf x 1.5"
polypropylene staple, and 30% by weight Type K-54 2.0 dpf x 1.5" bicomponent fiber from Hoechst Celanese. A
micro-gapped, open-nip calender with two smooth rolls was used to bond the fibers with minimal effect on the net.
The invention has been described in ~ .
considerable detail wi~h reference to its preferred embodi~ents. It will b~ apparent however that the invention is susceptible to numerous modifications and variation without departure from the spirit and 5COp~
2 ~2~ 3æ
:: -24- -of the invention as described in the foregoing speoification and defined in th~ appended claim~
, ~
~'' ~ ''' ', ~, . ..: , :::
' ' : ~ '', . :. : ,;~, . . . :::
~'` ~
: , Elastomers used to fabricate elastic fabrics often have an undesirable rubbery feel. This is particularly true with thermoplastic elastomers rather than cross-linked elastomers. When these materials are used in comp~site nonwoven fabrics, the hand and texture of the fabric can be perceived by the user as stic~y or rubbery and therefore undesirable.
Nonwoven fabrics having thermopla tic elastomers incorporated into the fabric structure can be extremely difficult to process and to manufacture.
For example, tension control during fabric manufacture and/or during downstream processing can be extremely critical. A small change in tension can result in stretching or recovery of the fabric which can lead to a non-uniformly manufactured product. Tension control i~ even more aggravated when heating is required, for example, during fabric drying, adhesive application, 20 lamination, thermal bonding or other thermal treatment. ~ ~
When subjected to heat and tension, the fabric can stretch and otherwise undergo greater distortion than when the fabric is at room temperature. In addition, thermopla~tic elastomers can lose elastic properties when stressed at elevated temperatures and allowed to cool fully or partially while stressed, and/or the thermoplastic fibers and filaments are apt to break, thereby causing the elastic fabric to lose a portion or all of its elastic proper~ties. Still further, when elastic fabric~ are wound into rolls, stretching of the fabrics can occur during the winding process and the fabric can lose elastio properties during it~
subsequent storagQ due to the phenomenon of creep.
U.S. Patent 4,775,579 to Hagy, et al.
discloses desirable composite elastic nonwoven fabrics containing staple textile fibers intimately hydroentanqled with an elastic web or elastic net. One -212~732 _ 3 _ or more webs of staple textile fi~ers and/or wood pulp f i~ers can be hydroentangled with an elastic net according to the disclosure of this invention. The . ~-resulting co~posite fabric exhibits characteristics 5 comparable to those of knit textile cloth and possesses -~
superior softness and extensibility properties. The rubbery feel traditionally associated with elasto~eric materials can be minimized or eliminated in these fabrics.
U.S. Patent 4,413,623 to Pieniak disclose~ a ;
laminated structure such as a disposable diaper which can incorporate an elastic net into portions of the structure. The elastic net can be inserted in a stretch position between first and second layers of the structure and bonded to the layers while in the stretch condition. Subsequent relaxation of the elastic net can result in gathering of the structure.
U.S. Patent 4,525,407 to Ness discloses elastic fabrics which include an elastic member which may be an elastic net intermittently bonded to a substrate which prior to stretching i5 less easily extensible than the ela tic member. The non-elastic member is bonded to the elastic member and the entire composite is rendered elastic by stretching and ~ ;~
relaxation.
U.S. Patent 4,606,964 to Wideman discloses a bulk compo ite web which can be prepared by bonding a gatherable web to a differentially stretched elastic net. Subsequent relaxation of the differentially stretch net is said to result in gathering o~ the fabric.
The various problems associated with thermoplastic elastomeric materials, as discussed :~?
previously, render many of these and other composite elastic fabrics difficult to manufacture and process.
There are problems with tension control, elongation under the tension induced by converting machines, ~ 212~732 ~
irregular cut length, poor trac~ing, blocking, and similar problems. In the past, these problems have been overcome or minimized only with substantial difficulty. To minimize the problem of machine direction stretching during fabric converting and/or forming, typical approaches have been to either cool the thermoplastic elastomer to a temperature below its glass transition temperature or to make ~heat activated" materials that are rigid, but then shrink and become elastomeric when heated. These steps are often required to process the material under acceptable tension levels even at ambient temperatures.
Alternative process modifications have required extremely exact tension control mechanisms: but these do not consistently eliminate problems during normal fabric processing.
Summary of the Inv,e,~t,io~
The invention provides process stable composite elastic fabrics which can be readily processed on existing textile apparatus without requiring special tension control mechanisms and without substantial harm to the elastic properties of the fabric. The fabrics can be subjected to heat during the process of manufacturing the fabrics or thereafter without destruction o~ elastic properties.
Thus, elastic fabrics of the invention can be manufactured in a more convenient and straightforward manner and can be processed thereafter with less restrictions and/or fabric damage than prior elastic fabrics.
The process stable composite elastic fabrics of the invention are substantially non-extensible in ~ ~
the machine direction and have substantial elastic ~, properties in the cross-machine direction. Thus, the ,~
process stable fabrics of the invention can be stressed in the machine direction without substantial fabric stretching and without requiring specialized processes 212~732 . . , and/or apparatus to compensate for elastic stretching.
Moreover, because elastomeric components of the fabric are not substantially stretched when the fabric is stressed in the machine direction, thermal treatments can be more readily applied to the fabric without substantial fabric harm as a result of combined thermal and stress effects.
The process stable composite elastic fabrics of the invention have a predetermined width and an indeterminate length which is substantially greater than the width of the fabric. The width of the fabric defines the fabric's cross-machine direction and the length of the fabric defines the machine direction of the fabric. The composi~e nonwoven fabric includes at least one fibrous layer and a net combined with the fibrous layer. The net is composed of a plurality of continuous machine direction strands oriented in substantially the machine direction of the fabric and a plurality of cross-direction continuous strands oriented in substantially the cross direction of the fabric. The machine direction strands are sub~tantially non-extensible and preferably are substantially non-extensible under applied stress at temperatures of up to 70-C or higher. The cross-dlrection strands comprise a substantial amount of athermoplastic elastomer, preferably about 20 wt. %, more pre~erably at lea~t about 50 wt. %, such ~hat the net i~ elastic in the cross-direction. In one preferred embodiment, the net is combined with the fibrous web by hydroentangling. The net can alternatively be combined with the fibrous web by adhe~ive or thermal bonding. Advantageously, the fibrous web comprises staple fiber~ including polyolefins, polyesters, nylon and the like, and/or cotton, wool and wood pulp fibers. These fibers can provide de~irable aesthetic qualities to the composite 2~23732 fabric. Additlonally or alternatively the fibrous web can compris~ a spunbo~d or a meltblown we~.
Advantageously, the machine direction continuous strands employed in the net component of the composite fibrous web are formed of a crystalline polymer such as a crystallizable polyolefin material which is strong and which readily adheres to the thermoplastic elastomer material used in the cross machine direction strands of the net. In one particularly preferred embodiment of the invention, the net is formed from polyoleSin strands oriented in the machine direction and the cross machine direction strands are formed from a thermoplastic styrenic elastomer.
As compared to nonwoven fabrics which are -either non-elastic or fully elastic, the composite fabrics of the invention have various advantages and bene~its. As compared to non-elastic fabrics, the fabrics of the invention are advantageous in providing elastic properties in the cross-machine direction. As compared to conventional elastic nonwoven fabrics which are elastic in both the machine direction and the cross-machine direction, the fabrics of the invention provide significant benefits and advantages both in terms of their manuSacture and their subsequent use.
The fabrics of the invention can be manufactured and processed without the need for specialized tension control. When ther~ally treated while being processed in the machine direction, the fabrics of the invention typically do not lose elastic properties because the elastic filaments are not subjected to tensioning. The fabrics of the invention can be readily cut without deformation during the cuttinq process so that the cut length can be more accurately controlled. Similarly 35 the fabric of the invention allows for more accurate ~-~
treatment and control in other converting processes.
The fabrics of the invention can be readily wound and ': :
212~732 - 7 - .
stored in roll form under various environmental conditions without subjecting the elastic components of the f~bric to stresses which would result in creep of the fabric. In addition, the fabrics of the inv~ntion can provide significant aesthetic benefits including differential drape, curl and shear properties which are not readily provided in fully elastic and fully non-elastic composite fabrics.
Brie~ Description of the Drawin In the drawings which form a portion of the original disclosure of the invention~
Figure 1 illustrates in perspective view a net in roll form which can be used in producing fabrics of the invention;
Figure 2 is a schematic illustration of one preferred process for producing a fabric in accordance wlth the invention: ' Figure 3 is an exploded view of one preferred fabric according to the invention;
Figure 4 is a schematic illustration of a process wherein a fabric of the invention is laminated to a second fabric or film layer: and ''''~"' Figure 5 illustrates the results of thermomechanical analysis conducted on filaments 25 composed of styrenic elastomers, EVA polymer and LLDPE ' polymer. '~
~etailed,,~e~cri~ Lg~ L~vention In the following detailed description of the invention, specific preferred embodiments of the 30 invention are described to enable a full and complete ' ',' understanding of the invention. It will be recognized - ' that it is not intended to limit the invention to the particular preferred embodiments described, and although specific terms are employed in describing the 35 invention, these terms are used for the purpose of ,~' illustration and not for the purpose of limitation. It will be apparent that the invention is susceptible to 21L2~73~ ~
:``
variations and changes within the spirit of the teachings herein.
Figure 1 illustrates an elastomeric net 10 having a plurality of substantially continuous strands 5 or filaments oriented in the machine direction of the fabric as indicated by arrow 12 and a plurality of substantially continuous filaments or strands oriented in the cro~s-machine direction, that is, the width direction of the fabric as indicated by arrow 14. The strands oriented in the machine direction are substantially non-extensible strands while the strands in the cross machine direction are substantially elastic and preferably comprise a thermoplastic elastomer. As used herein and only for purposes of this application, the term "elastic" is used to mean strands and/or fabrics capable of substantially complete recovery, i.e. greater than about 75%, preferably greater than about 90% recovery, when stretched in an amount of about 10% at room temperature 20 expressed as: -% recovery = (L, - ~)/(L, - Lo) X 100 where: L, represents stretched length: Lr represents ~;~
recovered length measured one minute after recovery:
and ~ represents original length of material.
As used herein and only for the purposes of this application, the term ~substantially non-extensible" i8 used to mean fllaments and/or strands which, at 25-C exhibit an extensibility o~ 2% or less, prererably about 1% or less when subjected to an applied stress of 5 mg/denier which is a stress based on stresæes applied to a fabric by fabric conversion apparatus. In preferred embodiments of this invention, subqtantially non-extensible filaments and strands have an extQnsibility of less than about 5% at 70-C under an applied stress of 5 mg/den.
Generally, it is desirable that the number of strands per inch in each of the machine and cross~
:.
2 L2~732 _9_ machine directions of the net range from between about 2 and about 30 strands per inch preferably from 5 to about 20 strands per inch although greater numbers of filaments can be employed where desirable. Typically, the elastomeric net 10 will have a basis weight ranging from about 15 grams per square meter to about 200 grams per square meter, more preferably from about 50 to `~
about 90 grams per square meter, and can employ filaments having diameters ranging from about 50 to about 600 microns, preferably from about 150 to about 400 microns.
The elastic net 10 can be prepared by any of various well known processes including the process disclosed in U.s. Patent 4,636,419, issued January 13, 1987 to Madsen, et al., incorporated herein by reference. In general, the elastic net is made by extrudin~ a plurality of substantially non-extensible polymeric strands in the machino direction while simultaneously or thereafter extruding and ~oining to said machine direction filaments, a plurality of elastic polymeric strands oriented substantially in the cross machine direction.
The elastic material making up the strands in the cross-machine direction of the net normally 25 comprise at least one thermoplastic elastomèr. ~ -Suitable thermoplastic elastomers include the diblock, trlblock, radial and star copolymers based on polystyrene (S) and unsaturated or fully hydrogenated rubber blocks. The rubber block can consist of butadiene (B), isoprene (I), or the hydrogenated version, ethylene-butylene (E~). For example, S-B, S-I, S-EB, a8 well as S-B-S, S-I-S, S-EB-S linear block copolymers can be used. Typically when used one or more of the diblock copolymers are blended with the triblock or radial copolymer elastomers. Preferred thermoplastic elastomers of this type can include the -KRATON polymers sold by Shell Chemical Company or the 212~7~2 VEC~OR polymers sold by DEXCO. Other elastomeric thermoplastic polymers include polyurethane elastomeric materials such as ESTANE sold by BF Goodrich company;
polyester elastomers such as HYTREL sold by E. I. Du Pont De Nemours company: polyetherester elastomeric materials such as ARNITEL sold by Akzo Plastics: and polyetheramide elastomeric materials such as PEBAX sold by ATO Chemie Company; and the like.
The elastic strands in the cross-machine lo direction of the elastic net 1o can also be prepared from blends of the~noplastic elastomers with other polymers such as polyolefin polymers, e.g. blends of '~
Kraton polymers with polyolefins such as polypropylene and polyethylene, and the like. These polymers can provide lubrication and decrease the melt viscosity, allow for lower melt pressures and temperatures and/or increase throughput, and provide better bonding properties too. In a preferred embodiment of the invention, such other polymers can be included in the ;~
blend as a minor component, for example in an amount of between about 5% by weight up to 50% by weight, preferably from a~out 10 to about 30% by weight of the mixture. Suitable thermoplastic polymers, include, in addition to the polyolefin polymers, poly(ethylene-2S vinyl acetate) polymers having an ethylene content ofup to about 50% by weight, preferably between 15 and 30% by weight and copolymers of ethylene and acrylic acid or esters thereof, such as poly(ethylene-methyl acrylate) or poly(ethylene-ethyl acrylate) wherein the acrylate acid or ester component ranges from about 5 to about 50% by weight, preferably from about 15 to about 30% by weight, In addition polystyrene and poly(alpha~
methyl styrens) can be used.
The machine direction substantially non-ext~nsible strands constitute a non-elastic polymeric material including any of the various well known filament-forming polymers, such as polyolefins 212~732 including polyethylene, polypropyl ene, l inear low density polyethylene (LLDPE): polyesters such as polyethylene terephthalate; polyamides such as nylon-6 and nylon-6,6; copolymers, blends of such materials and s the like. Preferably the non-elastic polymer is a crystalline material which provides a filament with a high tenacity and a relatively ~harp melting point.
Advantageously, the substantially non-extensible strands in the machine direction are composed of a lo material which adheres readily to the elastlc strands in the cross-machine direction. In this regard it is desirable that there be substantial bonding between the strands in the machine direction and the strands in the cross-machine direction. Generally, a polyolefin material i5 preferably used for the machine direction strands when the cross-machine direction strand~ ara styrene-based elastomeric materials. Nylon continuous machine direction can be advantageously employed in combination with polyetheramide elastomeric cross-machine direction strands. Polyester-based strands advantageously can be used as machine direction strands in combination with polyetherester elastomeric cross-machine direction strands.
In one preferred embodiment of the in~ention, the machine direction substantially non-extensible strands can comprise an adherence promoting additive to improve the adherence of the machine direction strands to the cross-machine direction strands. Preferred additives to improve adherence include poly(ethylene-vinyl acetate) polymers having an ethylene content ofup to about 50% by weight, preferably between about 15 and about 30% by weight, and copolymers of ethylene and acrylic acid or esters thereof, such as poly(ethylene-methyl acrylate) or poly(ethyl acrylate) wherein the acrylic acid or ester component ranges from about 5 to about 50% by weight, preferably from about 15 to 30% by weight. These materials are preferably included in the 212~732 machine direction strands in an amount of between about 2 and about 50~ by weight, preferably between about 10 and about 30% by weight depending on the primary component of the strand. In addition other materials such as plasticizers, tackifiers, talc, and the like can be compounded into the resin at low levels to promote bending. As indicated previously, the machine direction strands are preferably stable under applied stress at high temperatures. However, if such additives are included in too great an a~ount the thermal stability of the machine direction strands can suffer.
Figure 2 illustrates one preferred process for forming a composite fabric of the invention. A
carding apparatus 20 forms a first carded layer 22 onto forming screen 24. Carded fibrous layer 22 can comprise any of various well-know synthetic or natural fibers, and in one preferred embodiment of the invention, also includes binder fibers in an amount of between about 5% and about 50~ by weight. The web 22 i~ moved by forming screen 24 in the machine direction by rolls 26.
A conventional supply system thereafter applies the elastomeric net 10 onto the moving carded -~
layer 22. As discussed previously, the elastomeric net 10 includes spaced apart machine direction and cross machine direction strands which intersect to form ~
apertures. Although it is preferred that the net have ~ ;
a substantially regular, rectangular shape, irregular geom~try nets such as diamond-shaped nets and the like can be used wherein the non-elastic strands are oriented primarily in ths machine direction and elastic strands are oriented primarily in the cross machine direction. A roll 28 applies tension to the two-layered structure 30 which is formed from thecombination of the carded layer 22 and the net layer 212~7~2 . , .
. -13-lO. ~he two layer structure is advanced in the machine direction by forming screen 24.
A second carding apparatus 32 deposits a second carded fibrous layer 34 comprising synthetic : :5 and/or natural fibers onto the two layer structure 3 0 to thereby form a three-layer composite structure 36 consisting of a carded web/elastomeric net/carded web. .
The synthetic and/or natural fibers making up carded web 34 can be the same or different as compared to the ~ :
fibers in carded web 22. The three-layer composite web 36 is conveyed in the machine direction by the combination of forming screen 24 and roll 38. It ~
be apparent to the skilled artisan that the composite structure including net 10 is subjected to tension ; ~ .
~etween the forming rolls 28 and 38. Because the machine direction strands in the net 10 are substantially non-extensible strands, the tension applied between rolls 28 and 38 does not result in substantial stretching of the net 10 and hence there i9 little or no stretching o~ the composite elastic structure 36.
The composite structure 36 is thereafter conveyed in the machine direction as shown in Figure l to a hydroentangling station 40 wherein a plurality of :
manifolds 42, each including one or more rows of fine ori~ices, direct high pressure jets of liquid through composite web 36 to intimately hydroentangle the fibers in each of the layers 22 and 34 with each other and with net 10. As a result of the hydroentangling treatment, at least a portion of the ~ibers in each o~
the carded layers 22 and 34 preferably extend through apertures in thQ net and into the carded layer on the othex side of the net.
The hydroentangling station 40 is constructed in a conventional manner as known to the skilled artisan and as described, ~or example, in U.S. Patent 3,485,706 to Evans, which is hereby incorporated by 212~32 reference. As known to the skilled artisan, fiber hydroentanglement is accomplished by jetting liquid, typically water, supplied at a pressure fro~ about 200 psig up to a~out 1,800 psig or greater, to form fine, 5 essentially columnar liquid streams. The high pressure liquid streams are directed to at least one surface of the composite layered structure. The composite is -~
supported on a fora~inous support screen 44 which can have a pattern to form a nonwoven structure with a lo pattern or with apertures, or the screen 44 can be designed and arranged to form a hydraulically entangled ~ -composite which is not patterned or apertured. The laminate can be passed through a second hydraulic entangling station schematically illustrated in Figure 15 2 by manifolds 46, to enable hydraulic entanglement on `
the other side of the composite web fabric.
During the hydraulic entanglement treatment, tha fibers in the carded layer or layer~ are forced -~
into and/or through the elastomeric net 10, thereby securing the carded fibrous layer to the elastomeric net. Preferably, the hydroentangling treatment is sufficient to force the fibers present in at least one or the layers 22 and 34 into and/or through the apertures in the elastomeric net 10. More preferably, the hydroentangling treatment is sufficient to force at least portion o~ the fibers in both carded layers 22 and 34 into and/or through the aperture~ in the elastomeric net.
The elastomeric web 10 remains in a substantially planer arrangement during the hydroentangling treatment. Thus, the machine direction and cross-machine direction filaments, respectively, oS
the ela~tomeric net undergo little if any movement in the cross-sectional direction, i.e. in the Z direction within the web. Thus, the elastomeric net remains within a discrete interior cross-sectional portion of the composite web.
2123732 ~ ~
15- :
A condensed, hydraulically entanqled composite ~eb 48 is removed from the hydroentangling :
station 40 via roll 50 which cooperates with forming wire ~4 and forming web rolls 52. The tension applied 5 to the composite web 48 by rolls 50 and 52 does not result in substantial stretching of the elastomeric -:.
composite 48 because the machine direction strands of the net lO are substantially non-extensible. ~ ;
The web 48 exiting the hydroentangling o station is thereafter preferably dried at a conventional drying station ~not shown) and thereafter ;
may be thermally treated at an optional thermal treatment station 54, shown in Figure 2 as heated calender rolls 56 and 58. The optional thermal treatment station 54 is used when binder fibers or another binder material is present in the composite web 48. The operating temperature of the heated rolls 56 and 58 is ad~usted to a surface temperature such that the binder fibers or other binder materials present in the composite web 48 are thermally activated to bind the composite web 48 into a coherent, unitary structure. In accordance with the present invention, the thermal treatment can be more readily carried out because the elastomeric strands in the net lO are not sub~ected to tension during the thermal treating process. Pre~erably, the operating temperature of the rolls 56 and 58 is maintained below a temperature which would cause thermal degradation or melting of the elastomeric materials in the net 10.
The composite web 60 is removed from the nip of rolls 56 and 58 and is wound by conventional means onto roll 62. The composite elastic web 60 can be stored on roll 62 without substantial harm to the fabric due to the phenomenon of creep: that is, de~ormation that is time dependent and is exhibited by many elastomeric materials subjected to a continuing load. In many cases, creep deformation may not be ` 212~7~2 recoverable following removal of the applied load. ;~
With the fabric 60 stored on roll 62, the elastomeric filaments of net lO are only found in the cross-machine direction of the net and therefore are not subjected to 5 stress during storage on roll form. The fabric 60 stored on roll 62 may be immediately or later passad t~
end use manufacturing processes, for example, for use in bandages, diapers, disposable undergarments, personal hygiene products, and the liXe.
lo The method illustrated in Figure 2 i8 ~ .
susceptible to numerous preferred variations. For example, although the schematic illustration of Figure 2 shows carded webs being formed directly during the in-line process, it will be apparent that the carded webs can be preformed and supplied as rolls of preformed webs. Similarly, although the elastomeric net is shown being supplied as a roll of preformed net, the net can be formed directly in-line. Similarly, although Figure 1 illustrates the use of carded fibrous webs both above and below the net 10, only a single fibrous web such as web 22 can be employed or more than two fibrous webs can be employed. Moreover, it will b apparent to the skilled artisan that fibrous we~s can be manufactured and supplied by other well known proces~es such as air-laying and the like.
The hydroentanglement station 40 is a preferred process step for securing the ela~tomeric net 10 to one or more fibrous webs 22, 34. However, in other preferred embodiments of the invention, the fibrous webs 22 and/or 24 can be secured to elastomeric net 10 by lamination including solvent-based adhesive and/or thermal adhesive lamination, needling and/or other well known texti~e processes.
The heated calender rolls 56 and 58 can, in othar embodiments of the invention, be replaced by other thermal actlvations zones, for example in the form of a through-air bonding oven or in the form of a -`.;. 212~7~2:~ -17-- . :
microwave or other RF treatment zone. An especially preferred through-air bonding or through-air dryiny treatment zone employs support screens both above and below the fabric which contact both surfaces of the -~
5 fabric during passage through the oven. The screens are advantageously metallic screens resulting in conductive heating oP both fabric surfaces by contact with the upper and lower metal screens respectively. ~ ~-Other heating stations such as ultrasonic welding stations can also be advantageously used in tha invention. Such conventional heating stations are known to those skilled in the art and are capable of -effecting substantial heating of the fabric sufficient for thermal activation of binder fibers when such fibers are incorporated into the fabric.
As indicated previously, nonwoven web~ other than carded webs are also advantageously employed in the production of fabrics according to the invention.
Nonwoven staple webs can be formed by air laying, garnetting, wet laying, and similar processes known in the art. Spunbonded webs which are extensible in the cross-machine direction because of little or no ~ilament-to-~ilament bonding can be substituted for either or both of the carded webs illustrated in Figure 2 and/or can be used in combination with one or both of the carded webs. Similarly meltblown webs which are extensible in the cross machine direction can be substituted for and/or used in conjunction with either of carded webs 22 and 34 shown in Figure 2.
Figure 3 illustrate~ an exploded view of the ;
three-layered structure 36 of Figure 2 prior to hydroentanglement. Each of webs 22 and 34 include staple and/or natural fibers such as fibers formed from polyester, polyole~ins such aR polypropylene or polyethylene, nylon, acrylic, modacrylic, rayon, cellulose acetate, biodegradable synthetics such as a biodegradable polyester, aramide, fluorocarbons, ..
"~
212~7`~,2 ~ ~
-18~
polyphenylene sulfide staple fibers and the like.
Preferred natural fibers include wool, cotton, wood pulp fibers and the like. Blends of such fibers can also be used. In addition, all or a portion of the staple fibers can be glass, carbon fibers and the like.
The webs 22 and 34 can also include binder fibers in an amount of between about 5 and about 50 wt.
%. Binder fibers are known in the art and include Sibers made from low melting polyolefin~ such as polyethylenes; polyamides and particularly co~
polyamides: polyesters and partlcularly copolyesters;
acrylics and the like. The binder fibers, when used, preferably have a lower activation temperature then the melting point of the ne~. In the case that the binder ~ibers activate above the glass transition temperaturs of the hard segment of the thermoplastic elastomer contained in the net, then heating conditions are ;
advantageously closely controlled to activate the binder fibers without degrading or deforming the net.
Particularly preferred binder fibers include bicomponent and multi-component fibers such a~
sheath/core, side-by-side, sectorized or similar bicomponent fibers wherein at least one component of the fiber is a low melting material such as polyethylenQ, a copolyester, a copolyamide or the like.
Preferred bicomponent fibers have a melting temperature for the binder portion Or the fiber in range of between about 100 and about 135'C. Such fibers include polypropylene/polyethylene and polyester/polyethylene sheath/core fibers and polyester/copolyester sheath/core fiber~. One particularly preferred binder fiber i-~ a copolyester/polyester sheath/core ~iber having a melting point of about 110-C commercially avallable from Hoechst-Celanese Corporation a~ "K-54".
As indicated previously, the fabrics o~ the invention can also incorporate spunbonded nonwovens includlng polyolefin, nylon, polyester, copolymers of ~;
'", ' '.~" '"
:' ~' ~
`:
212~73~
the same and other webs as are known to those skilled in the art. Similarly, meltblown nonwovens including both elastomeric and non-elastomeric meltblown webs prepared from polyolefins, nylons, polyesters, random 5 and block copolymers, elastomers and the like can also be included in fabrics of the invention.
Figure 4 illustrates an exemplary end-use process for a fabric 60 of the invention. The fahric 60 is substa~tially elastic in the cross-machine lo direction as indicated by arrow 70 and is substantially non-extensible in the machine direction as illustrated by arrow 72. The fabric 60 can be supplied via a roll to a lamination process as illustrated in Figure 4. A
second film or fabric 74 is supplied from roll 76 for lamination with the fabric 60. An adhesive material may be applied to the film or fabric 74 via one or more rolls 78 by conventional apparatus known to the those skilled in the art. A pair of calender rolls 80 and 82, which may be heated, are used to bond the film or fabric 74 to the elastic fabric 60 of the invention.
As is apparent to the skilled artisan, during the lamination process illustrated in Figure 4, the ~abric 60 is subjected to tension in the machine direction. During a typical lamination process, if an elastic fabric is stretched due to elasticity, the film or fabric layer 74 will be gathered following relaxation of the laminate. In addition, a~ discussed below, when elastomeric materials are stretched during heating, for example, by contact with heated calender rolls 80 and 82, a failure of elastic properties can result.
Figure 5 illustrates the results of thermal stress tests conducted on filaments of a styrenic ;
ela~tomer having a denier per filament o~ 1283 (1426 dtex); a filament composed of poly(athylena vinyl acetate) having a denier of 530 (589 dtex) and on a filament of linear low density polyethylene having a 2 1 2 ~ 7 ~
denier of 844 (937 dtex). Each of the filaments was subjected to a constant stress of 4.2 mg/den (37 ~N/dtex) and subjected to different thermal environments. As seen in Figure 5, the elastomeric ~ ~
5 filaments undergo suhstantial el~ngation even at room -: :
temperature (20'C). At 70~C, the ethylene vinyl -acetate filaments exhibit substantial elongation. At 90-C, the elastomeric filament was broken while the ethylene vinyl acetate filament was broken at 80-C.
lo The filament composed o~ linear low density polyethylene, on the other hand, exhibited substantial stability even at a temperature of lOO-C. It will be apparent that the stress employed in this series of tests (approximately 4 mg/den) is an extremely low stress. It will also be apparent that elastomeric filaments are highly unstable when subjected to the combination o~ even a low stress together with elevated with thermal treatment.
The data illustrated in Figure 5 is set forth below, in ~able 1 in tabular form.
' . ~'~ , . . .
21- 212~732 .
TABLE 1 PERCENT EI~)NGATION VS. TEMPERATURE
- _ .-=
PERCENT ELC~NGAllON ¦
TEMPERA~ (C) Sl'YRENIC .. 11 ELASI~ E~VA LLDPE
5.5 0.6 Q6 1 30 6.5 0.9 0.9~ __ 1 40 7.0 1.3 ~.1 S0 7.8 1.9 l.S l _ I
60 . 10.0 3.4 1.9 I ..
14.7 6.4 2'3 I :
. , . _ . I ;.
28.9 19.1 2.8 I .
34.6 Break 3.5 100 Break Break 4.4 . ~ . . .
.~ , ,.
110 Break Break 6.1 .... ...... ... __ ADnlTlONAL INFORMATION . ~ .
.. . . ...
Filamenl denler 1283 530 844 . `
15Size . . . . `:
dtex 1426 589 937 . . ..:
Strcss mg/den 4.21 4.23 4.23 ; . ;
~' :
_ IlN/dte~ 37.2 37.4 37.4 ~ ' ..
As is apparent from the data presented above, nonwoven fabrics with elastomeric materials in the machine direction are difficult to process. In the thermomechanical analysis test, above, the tension presented to the materials is extremely low and is lower than tensions typically achieved on forming and converting equipment. However, as is apparent from the above, even at room temperature and under this unrealistically low tension, elastomeric filaments still stretch 5-6%. In the proce~sing and/or converting environment, such stretching can interfere with steps such as cutting and the like. However, with the elastomeric fabrics of the invention, the fabrics 212~732 can be processed in the machine direction without stretching.
The following examples illustrate preparation of preferred fabrics according to the invention:
In Example 1, a process-stable nonwovPn fabric was made by using a rectangular net with 18 strands/inch in the MD and 9 strands/inch in the CD.
This net had linear low density polyethylene in the MD
lo and elastomer i~ the CD. The elastomer in the CD i~ a styrenic triblock thermoplastic rubber consisting of SIS and SBS rubber compounded with a low molecular weight polystyrene. The nonwoven composite was made by hydroentangling a polyester fiber blend consisting of 15 70% by weight Type 183, 1.5 dpf x 1.5" PET from Hoechst Celanese and 30% by weight Type K-54 2.0 dpf x l.S" :~c bicomponent fiber also from Hoechst Celanese. After entanqling, the product was through-air bonded at 320'F. Note that this bonding step could not have been per~ormed if the product was not process stable under heat and tension. The resulting product was soft, had good CD elasticity, and was resistant to ~iber pilling and fuzzing. ~ ~
EXAMPLE 2 : `
In Example 2, a process-stable nonwoven fabric was made by using a rectangular net with 12 strands/inch in the MD and 12 strands/inch in the CD.
In the MD, this net was 80% low density polyethylene (copolymer) and 20% ethylene-vinyl acetatQ copoly~er.
An SIS and SBS rubber compound blended with low molecular weight polystyrene was used as the elastomer.
The product was entangled with a ~iber blend consisting of 70% by weight Type 182, 2.2 dpf x 1.5"
Polypropylene from Hercules, and 30% by weight Type K-54 2.0 dpf x 1.5" bicomponent fiber from HoechstCelanese.
2~2~7~2 The resulting product had a very soft hand and good CD stretch.
In example 3, a process-stable non-woven fabric was made just like example 2. After forming the web, however, the product was su~sequently calender bonded. A micro-gapped, open-nip calender with two smooth rolls was used to bond the fibers with minimal ef~ect on the net.
E)CAMPLES 4, 5 AND 6 `
Examples 4, 5 and 6 were all made in a similar fashion. The difference between examples is the net used. Examples 3 used an 18 x 3 net, example 4 used an 18 x s and example 5 used an 18 x 7. All nets had a 50/50 blend of EVA with a low density polyethylene (copolymer) as the MD resin, and for the CD resin, the same SIS-S~S rubber compound used in the i previous examples.
Example 7 was made by taking a 15 x 8 net.
This net had a rectangular (rather than circular) MD
strand geometry. The net consisted of an 80/20 blend of a low density polyethylene ~copolymer) with EVA as the MD resin. Again ~or the CD reqin the same SIS-SBS
rubber compound was used as in the previous examples.
This product was entangled with a fiber blend consisting o~ 70% by weight 1.0 dpf x 1.5"
polypropylene staple, and 30% by weight Type K-54 2.0 dpf x 1.5" bicomponent fiber from Hoechst Celanese. A
micro-gapped, open-nip calender with two smooth rolls was used to bond the fibers with minimal effect on the net.
The invention has been described in ~ .
considerable detail wi~h reference to its preferred embodi~ents. It will b~ apparent however that the invention is susceptible to numerous modifications and variation without departure from the spirit and 5COp~
2 ~2~ 3æ
:: -24- -of the invention as described in the foregoing speoification and defined in th~ appended claim~
, ~
~'' ~ ''' ', ~, . ..: , :::
' ' : ~ '', . :. : ,;~, . . . :::
~'` ~
Claims (30)
1. A process stable composite elastic fabric of predetermined width and having a length substantially greater than said width, said width defining the cross-machine direction of said fabric and said length defining the machine direction of said fabric, said composite fabric comprising:
at least one fibrous layer, and a net combined with said fibrous layer, said net comprising a plurality of continuous machine direction strands oriented in substantially the machine direction of said fabric and a plurality of cross-machine direction strands oriented in substantially the cross-machine direction of said fabric, said machine direction strands being substantially non-extensible and said cross-machine direction strands being elastic.
at least one fibrous layer, and a net combined with said fibrous layer, said net comprising a plurality of continuous machine direction strands oriented in substantially the machine direction of said fabric and a plurality of cross-machine direction strands oriented in substantially the cross-machine direction of said fabric, said machine direction strands being substantially non-extensible and said cross-machine direction strands being elastic.
2. The process stable composite elastic fabric of Claim 1 wherein said machine direction strands have an extensibility of less than about 5%
under an applied stress of 5 mg/den at temperatures of up to about 70°C.
under an applied stress of 5 mg/den at temperatures of up to about 70°C.
3. The process stable fabric of Claim 1 wherein said cross-machine direction strands comprise at least about 20 wt. % of a thermoplastic elastomer.
4. The process stable fabric of Claim 3 Wherein said net is combined with said fibrous web by hydroentangling.
5. The process stable elastic fabric of Claim 1 wherein said fibrous web comprises staple fibers.
6. The process stable fabric of Claim 5 wherein said staple fibers are selected from the group consisting of polyolefins, polyesters, nylon, cotton, wood pulp and wool fibers.
7. The process stable fabric of Claim 6 wherein said staple fibers comprise binder fibers in an amount of at least 5 wt. %.
8. The process stable fabric of Claim 1 wherein said fibrous web is combined with said elastic net by adhesive lamination.
9. The process stable fabric of Claim 8 wherein said fibrous web includes binder fibers.
10. The process stable fabric of Claim 9 wherein at least a portion of said binder fibers are thermally activated to bond said hydroentangled fabric into a coherent, substantially unitary structure.
11. A process stable composite elastic fabric of predetermined width and having a length substantially greater than said width, said width defining the cross-machine direction of said fabric and said length defining the machine direction of said fabric, said composite fabric comprising:
at least one fibrous layer comprising staple fibers; and a net combined with said fibrous layer, said net comprising a plurality of continuous machine direction strands oriented in substantially the machine direction of said fabric and plurality of cross-machine direction strands oriented in substantially the cross-machine direction of said fabric, said machine direction strands being non-elastic and said cross-machine direction strands comprising at least about 20 wt. % of a thermoplastic elastomer;
whereby said fabric is elastic in the cross-machine direction and is substantially non-extensible in the machine direction.
at least one fibrous layer comprising staple fibers; and a net combined with said fibrous layer, said net comprising a plurality of continuous machine direction strands oriented in substantially the machine direction of said fabric and plurality of cross-machine direction strands oriented in substantially the cross-machine direction of said fabric, said machine direction strands being non-elastic and said cross-machine direction strands comprising at least about 20 wt. % of a thermoplastic elastomer;
whereby said fabric is elastic in the cross-machine direction and is substantially non-extensible in the machine direction.
12. The process stable fabric of Claim 11 wherein said fibrous layer comprises staple fibers and wherein said net is combined with said fibrous layer by hydroentanglement.
13. The process stable composite elastic fabric of Claim 12 wherein said net comprises polyolefin strands oriented in the machine direction.
14. The process stable composite elastic fabric of Claim 13 wherein said cross-direction strands of said net comprise a styrene-based thermoplastic elastomer in an amount of at least about 50 wt. %.
15. The process stable composite elastic fabric of Claim 14 wherein said fibrous layer comprises at least about 5 wt. % binder fibers having been thermally activated to bond said hydroentangled fabric into a coherent, substantially unitary structure.
16. The process stable fabric of Claim 15 wherein said staple fibers in said fibrous web are selected from the group consisting of polyolefins, polyesters, nylon, cotton, wood pulp and wool fibers.
17. The process stable fabric of Claim 11 additionally comprising at least one spunbonded web combined with said fibrous layer and to said net.
18. The process stable fabric of Claim 11 additionally comprising at least one meltblown web combined with said fibrous layer and said net.
19. The process stable fabric of Claim 11 wherein said machine direction strands of said net comprise linear low density polyethylene.
20. The process stable fabric of Claim 11 wherein said machine-direction strands of said net comprise an adhesive promoting additive.
21. The process for forming a process stable fabric comprising:
providing a fibrous nonwoven web;
providing a net comprising a plurality of continuous machine direction strands oriented in substantially the machine direction of said net and a plurality of cross-machine direction strands oriented substantially in the cross-machine direction of said net, said machine direction strands being substantially non-extensible and said cross-machine direction filaments being elastic; and combining said fibrous web with said net to thereby form a non-woven fabric which is elastic in the cross-machine direction and which is substantially non-extensible in the machine direction.
providing a fibrous nonwoven web;
providing a net comprising a plurality of continuous machine direction strands oriented in substantially the machine direction of said net and a plurality of cross-machine direction strands oriented substantially in the cross-machine direction of said net, said machine direction strands being substantially non-extensible and said cross-machine direction filaments being elastic; and combining said fibrous web with said net to thereby form a non-woven fabric which is elastic in the cross-machine direction and which is substantially non-extensible in the machine direction.
22. The process of Claim 21 wherein said fibrous web is combined with said net by hydroentangling.
23. The process of Claim 22 wherein said fibrous web comprises staple fibers.
24. The process of Claim 23 wherein said fibrous layer comprises a carded layer of staple fibers.
25. The process of Claim 21 additionally comprising the step prior to said combining step, of providing a second fibrous web, and wherein said combining step is conducted to combine both of said fibrous webs with said net.
26. The process of Claim 22 wherein said fibrous web additionally comprises binder fibers.
27. The process of Claim 26 additionally comprising the step of thermally activating said binder fibers to thereby bond said web and said net into a coherent, substantially unitary structure.
28. The process of Claim 27 wherein said thermal activation step is conducted by contacting said fibrous layer with a heated surface.
29. The process of Claim 28 wherein said binder fibers comprise bicomponent fibers.
30. The process of Claim 21 additionally comprising the step, prior to said combining step of providing a nonwoven web selected from the group consisting spunbonded webs and meltblown webs and wherein said combining step is conducted to combine said fibrous web and said net with said additionally provided web.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US825,016 | 1992-01-24 | ||
US07/825,016 US5334446A (en) | 1992-01-24 | 1992-01-24 | Composite elastic nonwoven fabric |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2128732A1 true CA2128732A1 (en) | 1993-08-05 |
Family
ID=25242909
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA 2128731 Abandoned CA2128731A1 (en) | 1992-01-24 | 1993-01-22 | Composite elastic nonwoven fabric |
CA 2128732 Abandoned CA2128732A1 (en) | 1992-01-24 | 1993-01-22 | Process stable nonwoven fabric |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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CA 2128731 Abandoned CA2128731A1 (en) | 1992-01-24 | 1993-01-22 | Composite elastic nonwoven fabric |
Country Status (9)
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US (2) | US5334446A (en) |
EP (2) | EP0621911A1 (en) |
JP (2) | JPH07503291A (en) |
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AU (3) | AU3589193A (en) |
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CA (2) | CA2128731A1 (en) |
MX (1) | MX9300386A (en) |
WO (2) | WO1993015247A1 (en) |
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US5200246A (en) * | 1991-03-20 | 1993-04-06 | Tuff Spun Fabrics, Inc. | Composite fabrics comprising continuous filaments locked in place by intermingled melt blown fibers and methods and apparatus for making |
-
1992
- 1992-01-24 US US07/825,016 patent/US5334446A/en not_active Expired - Lifetime
-
1993
- 1993-01-22 WO PCT/US1993/000566 patent/WO1993015247A1/en not_active Application Discontinuation
- 1993-01-22 AU AU35891/93A patent/AU3589193A/en not_active Abandoned
- 1993-01-22 JP JP5513333A patent/JPH07503291A/en active Pending
- 1993-01-22 EP EP93904573A patent/EP0621911A1/en not_active Withdrawn
- 1993-01-22 JP JP5513334A patent/JPH07503292A/en active Pending
- 1993-01-22 AU AU34820/93A patent/AU3482093A/en not_active Abandoned
- 1993-01-22 BR BR9305793A patent/BR9305793A/en not_active Application Discontinuation
- 1993-01-22 BR BR9305792A patent/BR9305792A/en not_active Application Discontinuation
- 1993-01-22 CA CA 2128731 patent/CA2128731A1/en not_active Abandoned
- 1993-01-22 US US08/119,104 patent/US5431991A/en not_active Expired - Lifetime
- 1993-01-22 EP EP93903631A patent/EP0621910A1/en not_active Withdrawn
- 1993-01-22 CA CA 2128732 patent/CA2128732A1/en not_active Abandoned
- 1993-01-22 WO PCT/US1993/000567 patent/WO1993015248A1/en not_active Application Discontinuation
- 1993-01-25 MX MX9300386A patent/MX9300386A/en unknown
- 1993-07-19 AU AU46828/93A patent/AU4682893A/en not_active Abandoned
-
1994
- 1994-07-23 KR KR1019940702543A patent/KR950700445A/en not_active Application Discontinuation
- 1994-07-25 KR KR1019940702561A patent/KR950700446A/en not_active Application Discontinuation
Also Published As
Publication number | Publication date |
---|---|
US5334446A (en) | 1994-08-02 |
WO1993015247A1 (en) | 1993-08-05 |
BR9305793A (en) | 1997-02-18 |
EP0621911A1 (en) | 1994-11-02 |
EP0621910A1 (en) | 1994-11-02 |
BR9305792A (en) | 1997-02-18 |
KR950700445A (en) | 1995-01-16 |
JPH07503292A (en) | 1995-04-06 |
MX9300386A (en) | 1993-08-01 |
CA2128731A1 (en) | 1993-08-05 |
AU3589193A (en) | 1993-09-01 |
JPH07503291A (en) | 1995-04-06 |
KR950700446A (en) | 1995-01-16 |
AU4682893A (en) | 1995-02-20 |
WO1993015248A1 (en) | 1993-08-05 |
AU3482093A (en) | 1993-09-01 |
US5431991A (en) | 1995-07-11 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
FZDE | Discontinued |