CA1311113C - Reversibly necked material and process to make it - Google Patents
Reversibly necked material and process to make itInfo
- Publication number
- CA1311113C CA1311113C CA000609712A CA609712A CA1311113C CA 1311113 C CA1311113 C CA 1311113C CA 000609712 A CA000609712 A CA 000609712A CA 609712 A CA609712 A CA 609712A CA 1311113 C CA1311113 C CA 1311113C
- Authority
- CA
- Canada
- Prior art keywords
- percent
- necked
- web
- reversibly
- reversibly necked
- 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.)
- Expired - Lifetime
Links
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Classifications
-
- 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
- D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
- B29C55/06—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C61/00—Shaping by liberation of internal stresses; Making preforms having internal stresses; Apparatus therefor
- B29C61/06—Making preforms having internal stresses, e.g. plastic memory
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C61/00—Shaping by liberation of internal stresses; Making preforms having internal stresses; Apparatus therefor
- B29C61/06—Making preforms having internal stresses, e.g. plastic memory
- B29C61/0608—Making preforms having internal stresses, e.g. plastic memory characterised by the configuration or structure of the preforms
- B29C61/0658—Making preforms having internal stresses, e.g. plastic memory characterised by the configuration or structure of the preforms consisting of fibrous plastics material, e.g. woven
-
- 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
- B32B5/08—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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2313/00—Use of textile products or fabrics as reinforcement
-
- 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
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/903—Microfiber, less than 100 micron diameter
-
- 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
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/91—Product with molecular orientation
-
- 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.]
-
- 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/601—Nonwoven fabric has an elastic quality
-
- 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
- Y10T442/619—Including other strand or fiber material in the same layer not specified as having microdimensions
-
- 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.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/673—Including particulate material other than fiber
Abstract
ABSTRACT
A reversibly necked material capable of stretching at least about percent and recovering at least about 50 percent when stretched about 75 percent, typically in a direction generally parallel to the direction of necking. The reversibly necked material is made by applying a tensioning force to at least one material to neck the material, heating the necked material, and cooling the necked material that the reversibly necked material possesses a greater heat of fusion and/or a lower onset of melting than the material before heating while stretched.
A reversibly necked material capable of stretching at least about percent and recovering at least about 50 percent when stretched about 75 percent, typically in a direction generally parallel to the direction of necking. The reversibly necked material is made by applying a tensioning force to at least one material to neck the material, heating the necked material, and cooling the necked material that the reversibly necked material possesses a greater heat of fusion and/or a lower onset of melting than the material before heating while stretched.
Description
~ 3 ~ 3 FIEL~ OF TH~ INVENTION
The present invention relates to elasticized materials and a method Q~ making the same.
BACXGROUND OF THE INVENTION
Plastic nonwoven webs formed by nonwoven extrusion processes such as, for example, meltblowing processes and spunbonding processes may be manufactured into products or component5 Of products so 1~ inexpensively that the products could be viewed as disposable after only one or a few uses. Repre~entatives of such products includa garment materials, diapers, tissues, wipes, garments, mattress pads and ~eminine care product5.
Nonwoven webs ~ormed from nonelastic polymers such as, for example, polypropylene are general~y consider~d nonelastic. The lack of elasticity usually restricts use of these nonwoven web materials from design applications where elasticity is necessary or desirable such as, ~or example, diapers, mattress pads, feminine care products and some of the above mentioned garment materials.
Certain fabric finishing processes such as, for example, dyeiny carried out at high dye bath temperatures utilizing roller arrangements that tension th~ material to be dyed have been observed to shrink webs of nonwoven fibers to a soft, drapeable elastic fabric which can be stretch~d and can recover to about its pre-~tretched dimen~ions. Additionally, U.S. Patent No.
3,949~128 to Ostermeier discloses a heat treated material with releasable bonds which can be stretched to about 65 percent and can recover to about its pre-stretched dimensions.
While the known elasticized fabrics provided may be useful for some purposes, fabrics having greater stretch and recovery characteristics are always desirable.
., ~, :L 3 ~
DEFINITIONS
As u~ed her~in, the term "recover" refers t~ a contraction of a stret~hed material upon termination of a biasing ~orce following stretching of the material by application o~ the biasing force.
For example, if a material having a relaxed, unbiased length of one (1) inch is elongated 50 percent by stretching to a length of one and one half (1.5) inche3 the material would be elongated 50 percent (0.5 inch) and would have a stretched length that is 150 percent o~ its relaxed length. If this exemplary st~etched material contracted, that is recovered to a length of one and one tenth (1.1) inches after release of the biasing and stretching ~orce, the material would have recovered 80 percent (0.4 inch) of its one-hal~ (0.5) inch elongation. Recovery may be expressed as [(maximum stretch length - final sample length)~(maximum stretch length - initial sample length)3 X 100.
As used herein, the term "nonwoven web" means a web that has a structure of individual fibers or threads which are interlaid, but not in an identifiable repeating manner. Nonwoven webs have been, in the past, formed by a variety of processes such as, for example, meltblowing processes, spunbonding processes and bonded carded wèb processes.
As used herein, the t~rm "microfibers" means small diameter fibers having an average diameter not greater than about 100 microns, for example~ having a diameter of from about 0.5 microns to about 50 micronsl more specifically micro~ibers may also have an averag~ diam~ter of from about 4 microns to about 40 microns.
As used herein, the term "interfiber bonding" means bonding produced by entanglement between individual meltblown fibers to form a cohe~ent web structure without the u5e o~ thermal bonding. This fiber entangling is inherent in the meltblown processes but may be generated or increased by processes such as, for example, hydraulic entangling or needlepunching.
~3~ ~ ~13 Alt~rnatively and/or additionally, a bonding agent can be utiliz~d to increa~e the desired bonding an~ to maintain structural coher~ncy of the web. For example, powdered bonding agents and chemical solvent bonding may be used.
As usd herein, the term "meltblown fibers" means ~i~ers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillarie~ as molten threads or filaments into a high velocity gas (e.g. air) stream which attenuates the filaments of molten thermoplastic material to reduce their diameters, which may ba to micro~iber diameterO
Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collectlnq surface to form a web of randomly disbursed meltblown ~ihers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,~41 to Butin.
As used herein, the term "spunbonded fibers" refers to small diameter fibers which are formed by extruding a molten thermoplastic material as filaments from a plurality o~ ~ine, usually circular, capillaries in a spinnerette with the diameter of the extruded ~ilaments then being rapidly reduced, for example, by educti~e drawing or other well-known spun bonding mechanisms~ The production o spun-bonded nonwoven webs is illustrated in patents such as, for example, in U.S. Patent No.
4,34~,563 ko App~l et al., and U.S. Patent No. 3,692,618 to Dorschner et al.
As used herein, the term "necked material" refers to any material which ~as been constricted in at least one dimension by processes such as, for example, drawing or gathering.
A~ used h~r~in, the term "neckable material" means any material which can ba n~cked.
As used herein, the term "reversibly necked material" refers to a necked material that has been treat~d whil necked to impart memory to ths material s~ that, when a force is applied to extend the material to its pre-necked dimensions, the necked and treated portions will ~enerally recover to their ne~ked dimensions upon termination of the force. One ~orm of treatment is the application of heat. Generally speaking, extension of the reversibly necked material is substantially limited to extension to its pre-necked dimensions. Therefore, unless the material i5 elastic, ~xtension too far beyond its pre-necked dimensions will resul~ in material failure. A reversibly nec~ed material may include more than one lay~r. For example, multiple layer~ o~
spunbonded web, multiple layers o~ meltblown web, multiple layer~
o~ bonded carded web or any other suitable combination or mixtures thereof.
used herein, the term "percent neckdown" re~er~ ~o the ratio determined by measuring the difference between the pre-n~cXed dimension and the necked dimension of a neckable material and then dividing that di~ference by the pre-necked dimension of the neckable material.
As us~d herein, the term "percent stretch" refers to the ratio de~ermined by measuring th2 increase in the stretched dimension and dividing that value by the oriyinal dimension, i.e., (increase in ~tretched dimension/original dimension) x 100.
The pr~s~nt invention ~vercomes the limitation to 65 percent stretch/recovery ratios that previously existed.
The pr~sent invention resides in a material ~hich is reversi~ly necked by drawing at ambient temperature and then heating and cooling while in a necked c~nfiguration so that th~ material possesses a greater heat of ~usion than before being reversibly neckedO
More speci~ically, the reversibly necked material is capable of stretching at least about 75 percent and recovering at l~ast about 50 percent when stretched ab~ut 75 percent.
~ ccDrding to one embDdiment of the present inventiDn~ the reversibly necked material may be adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent in which the reversibly necked material has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the material possesses a lower onset of melting than before being reversibly necked.
Generally speaking, the reversibly necked material may be made from any neckable material that can be treated to acquire such memory characteristics. In one embodiment, the material can have a basis weight of from about 6 to about 200 grams per square meter. In other embodiments, useful neckable materials ;nclude, for example, bonded carded webs, spunbonded webs or meltblown webs. The meltblown web may include meltblown microfibers. In yet other embodiments, the neckable material may have multiple layers such as, for example, multiple spunbond layers and/or multiple meltblown layers. In general, the neckable material may be made of polymers such as, For example, polyolefins. Exemplary polyolefins include polypropylene, polyethylene, ethylene copolymers and propylene copolymers.
The neckable material may include embodiments that are composite materials made from a mixture of two or more difFerent Fibers or a mixture of fibers and other materials. ~he other materials may include, for example, textile fibers, wood pulp and particulates such as, for example, hydrocolloid (hydrogel) particulates commonly re-ferred to as super-absorbent materials.
~3 ~ ~13 According to one embodiment of-the present invention, the reversibly necked material may be adapted tD stre-tch at least about 125 percent and recover at least about 50 percent when stretched abou-t 125 percent.
A reversibly necked material of -the present invention may be, for example, a coherent web formed o-f fibers joined solely by interFiber bonding~ in which the web is adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent and in which the reversibly necked web has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the web possesses a greater heat of fusion and/or lower onset oF
melting -than before be;ng reversibly necked and in which the fibers are joined solely by interfiber bonding to form a coherent web structure.
The present invention also encompasses a multilayer material including at least one material which is reversibly necked by drawing at ambient temperature and then heating and cooling while in a necked configuration so that the mater;al possess a greater heat of fusion and/or onset of melting than before being reversibly necked.
In one embodiment, the multilayer material may be composed o~ at least two reversibly necked materials adapted to stretch at least about 75 percent and r~covQr at least about ~ percent when stretched about 75 percent, in which the reversibly necked materials have been neck~d by drawing at ambient temperature and then heated ~nd cooled while in a neck~d con~iguration so thak the materials possess a greater heat of ~usion and/or lower onset o~ melting than be:Eore being reversibly necked.
Generally speaking, the neckable material may be necked by stretching in a direction generally perpendicular to the desired direckion of neck-down. Alternatively, the material may be compacted to effect neck-down. Memory of the ma-terial's necked configuration may be imparted to certain necked materials by:
heating -the necked material; and cooling the material while it is still in the necked configuration. Yet other memory creating procedures may be utilized as appropriate for the material.
~ 3 ~
In one embodiment of the method of the present invention, a reversibly necked material may be made by necking a neckable material by drawing at ambient temperature and then heating and cooling the ma-terial while in a necked configuration so that -the material possesses a lower onset of melting and/or greater heat of fusion than before being reversibly necked. According to one aspect of the me-thod of the present invention~ a reversibly necked material can be adapted to stretch at least about 75 percent or more (e.g., 125 percent) and recover at least about 50 percent when stretched about 75 percent or more (e.g " 125 percent).
sRI2F DESCRIPTION OF THE ~RAWINGS
Fig. 1 is a schematic representation o~ an exemplary process for forming a reversibly necked material using a series of steam cans.
FIG. 2 is a plan view of an exemplary nsckable material before tensioning and necking~
FIG. 2A is a ~lan view of an exemplary reversibly necked ~aterial.
FIG. 2B i~ a plan view of an exemplary reversibly necked material while partially strPtched.
FIG. 3 is a plot of stretch versus recovery showing exemplary stretch/recovery profiles.
FIG.4A is an exemplary ~if~erential Scanning Calorimetry scan of a neckable material before heat treatment.
FIG.4B is an exemplary Differential Scanning Calorimetry scan of a rever~ibly necked material, i . e ., a~ter treatment while necXed.
FIG. 5 is an enlarged photomicrograph of an exemplary neckable material~ prior to treatment while necked.
FIG. 6 is an enlarged photomicrograph of an exemplary reversibly necked material.
6a FIG. 7 is a sche~atic repre5entation of an exemplar~ proce5s ~r con~trict~ng a neckable material using an Srroll arrangement.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings where like reference numerals repre~ent like ~igures or process steps and, in part, to Fig. 1 there is schematically illustrated at 10 a~ exemplary process ~or ~orming a re~ersibly necked material using a ~eries of staam cans. A
neckable material 12 is unwo-md from a supply roll 14. The neckable material 12 passe~ through a nip 16 of a drive roller arrangement 18 formed by the drive rollers 20 and 22 and then past two idler rolls 24 and 26.
The neckable material 12 may be formed by Xnown nonwoven processes, such as, for example, meltblowing processe~, spunbonding processes or bonded carded wek proce~ses and passed directly through the nip 16 without first being stored on a supply roll~
The neckable material 12 may be a nonwoven material such as, for example, spunbonded web, meltblown web or bonded carded web. If the neckable material 12 is a web of meltblown fibers, it may include meltblown microfibers. The neckable material 12 is made from any material that can be treated while necked sa that, after treatment, upon application of a force to extend the necked material to its pre-n2cked dimensions, the material recovers generally to it~ nec~ed dimQnsions upon termination of the force.
A method of treatment is the application of heat. Certain polymers such as, for example, polyoleins, polyesters and polyamides may be heat treated under suitable conditions to impart such memory. Exemplary polyolefins include one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers and butene copolymers. Polypropylenes that have been found useful include, for exa~ple, polypropylene available from the ~limont Corporation under the trade designation ~. 3 ~
*PC-973, polypropylene available fro~ the Exxon Ch~mical Company under tha trada designation *Exxon 34~5, and polypropylene ava~lablQ from the Shell Chemical Company under ~he trade designation * DX 5Ao9. Chemical characteristics of these materials are available from their respective manufactur~rs.
In one embodiment of the present invention, the neckable material 12 is a multilayer material having, for example, at least one layer of spunbonded web joined to at least one layer of meltblown web, bonded carded web or other suitable material. For example, the neckable material 12 may be a multilayer material having a f irst layer o~ spunbonded polypropylene ha~ing a basis weight from about 0.2 to about 8 ounces per square yard (osy), a layer o~ meltblown polypropylene having a basis weight from about 0.2 to about 4 osy, and a second layer of spun~o~ded polypropylene having a basi~ weight of about 0.2 to about 8 osy.
Alter~atively, the neckable material 12 may be single layer of material such as, for example, a spunbonded web having a basis weight of from abvut 0.2 to about 10 osy or a meltblown web having a basis weight of from about 0.2 to about 8 osyO
The necXable mat~rial 12 may also be a composite mat~rial made of a mixture of two or mor~ different fibers or a mixture o~ ~ibers and particulates. Such miXtures may be formed by adding f ibers and~or particulates to a gas stream in which meltblown f ibers arP
caxried s~ that an intimate entangled commingling of meltblown fibers and other materials, e.g., wood pulp, stapl~ f i~ers or particulate~ such as, for example, super-absorbent materials occurs prior to collection of the fibers upon a collecting device to ~orm a coherent web of randomly dispersed meltblown f~bers and other materials such as disclosed in U.s. Patent No. 4,100,324.
* - Trade-marks ~ 3 ~ 3 If tha neckable material 12 i a nonwoven web o~ ~ibers, ~hs fiber~ ~hould b~ joined by interfiber bonding to form a coherent web struc~ure which is able to withstand neckingO Interfiber bonding may be produced by entanglement betwe~n indiYidual meltblown fibers. The fiber entangling is inherent in the meltblown process but may be generated or increased by proces~es such as, for example, hydraulic entangling or needlepunching.
Alternatively and/or additionally a bonding agent may be used to increase ~he desired bonding.
A~te~ passing through the nip 16 of the driver roller arrangement 18 and idler rollers 24 and 26, the neckable material 12 passe~
o~er a series of steam cans 28-38 in a series of reverse S loops.
The steam cans 28~38 typically have an outside diameter c~ about Z4 inches although other sized cans may be used. The con~act time or residence time o~ the neckable material on the steam cans to effect heat treatme~t will ~ary depending on faotors surh as, for example, steam can temperature, and typ~ and/or basis weight o~ material. For example, a necXed w~b o~ polypropylen~ may be passed over a series o~ steam cans heated to a measured ~emperature from about 90 to about 150~C (194-302F~ for a contact time of about 1 to about 309 seconds to effect heat treatment. More particularly, the temperature may range from about 125 to about 143C and the residence time may range ~rom about 2 to about 50 seconds.
Because th~ peripheral linear speed o~ the drive rollers 20 and 22 is controlled to b~ lower than the peripheral linear speed of the steam cans 28-38, the neckable material 12 is te~sioned between the s~eam cans 28-38 and the drive rollers 20 and 22. By adjusting the dif~erence in the speeds o~ the rollers, the neckable material 12 is tensioned so that it necks a desired amount and is maintained in such necked condition while passing over the heated steam cans 28-38. This action imparts memory of the necked condition to the neckable material 12. The neckable ~ 3 ~ l 3 materlal 12 i9 then cooled in th~ necked condition after lea~ing the la~t ~tea~ can 38. Th~ ~eripheral linear speed o~ ~he rollars o~ the idlar roller arrangement 42 are maintained at ~ha sa~e speed a~ th2 steam cans 28-38 so that the necked material 12 is cooled in the necked condition on it5 way to the wind-up roll 46. This completes formation of the reversibly n~cked material 44. The reversibly necXed material 44 can extend to at least its original, pre-necked dimensions upon applicakion of a str~tching force in a direction generally parallel to the direction of necking and then recover to within at least about 50 percent of its reversibly necked dimensions upon release of the stretching force. According to the present invention, elongation or percent stretch values of greater than 170 percent have been achieved.
Con~entional drive means and other conventional de~ices which may be utilized in conjunction with the apparatus of Fig. 1 are well known and, for purposes of clarity, have not been illustrated in the schematic view of Fig. 1.
The relation between the original width of the neckable material 12 to its width after tensioning de~ermines the stretch limits of the reversibly necked material 44. For example, with re~erence to Figs. 2, 2A, and 2B, if it is desired to prepare a reversibly necked material that can be stretched to a 150 percent elongation (i.e., 250 percent of its nec~ed width) and can recover to within about 25 percent of its necked width, a neckable material shown sche~atically and not necessarily to scale in Fig. 2 having a width ~A'~ such as, for example, 250 cm, is tensioned so that it necks down to a width "B" of about loo cm for a percent neck or percent neckdown of about 60 percent and while tensioned, is heat treated to maintain its reversibly necked con~iguration a~ shown in Fig. 2A. The resulting reversibly necked material shown schematically and not necessarily to scale in Fig. 2B has a width "~" o~ about 100 cm and is stretchable to at least the original 2~0 cm dimension "A" of the neckable material for an elongation ~ 3 ~ 1 3 or percent stretch of about 150 percent. The reversibly necked material r~kurn~ ~o within absut 25 perc~nt o~ its necked width of about loo cm, (i.e., to a width o~ about 125 cm) after release o~ the stretching force ~or a recovery oP about 83 percent.
The claims of the present invention are mea~t to encompass materials which are adapted to stretch at least 75 p~rcent and recover at least 50 percent at laast at some poi.nt during their stretch/recovery profil~. For example, the materi~ls of the present invention are adapted to str~tch at least 75 percent and recover at least 50 percent when stretched 75 percent. Fig. 3 is a plot of stretch versus recovery showing exemplary stretch/recovery pro~iles. Curve "A" is an ~xemplary stre~ch/recovery profile for a material o~ the pre~ent invention.
Curve "B" is an exemplary stretch/recovery profile ~or a material not encompassed by the present invention.
Although the present invention should not be held to a particular theory of operation, the heat treatment should raise the neckable material 12 to a temperature range ~or a speci~ied time period where it is believed that additional pol~mer crystallization occurs while the material is in the necked condition. Because certain types o~ fibers are ~ormed by methods such as, for exampl~, meltblowing and spunbonding which cool the fibers very quickly, it is believed that the polymers ~orming the fiber~ are not ~ully cryst~llized. That is, the polymers hard~n before the crystallization is complete. It is believed that additional cry~allization can be e~fected by increasing the tempera~ure of the material ~o a temperature below the material's melting poin~.
When this additional crystallization occurs while the material is in the necked condition, it is believed that memory of the necked condition is imparted to the material.
~ 3 ~ 3 Fi~. 4A i9 ~n exsmplary Di~erential Scanning Calorimetry sc:an o~
a spu~o~d~d pol~propylene material. Fig. 4~3 is an exemplary Dif ~erenti~l Scanning Calol: im~try scan of ~:he samF~ t:ype of 5 spunbonded polypropylene material which has been necked ~nd heat ~reated. Dif~eren~ial Scanning ~alorimetry can ~e used to show that neckable materials such aS, for ex~mple, spunbonded webs, which have been necked and heat treated exhibit greater heats o~
fusion than the same materials which have not been heat treated.
That is, the heat of fusion of a rever3ibly necked material is typically at least about 5 percent greater than th~ material before being reversibly necked. For exampls, from about 5 to about 15 percent greater. Additionally, the onset of melting occur~ at lower temperatures for necked and heat treated materials than for their non-heat treated counterparts. That is, the onset of melting of a reversibly necked material typically occurs at a temperature at l~ast about 5 C lower than for the material before being reversibly necked. For example, ~rom about 5'C to about 15C lower. A greater heat of fu ion i5 believed to result from additional crystallization which occurs during heat treatment. A lower t~mperature for onset of meltinq is believed to result from imperfect or strained crystals formed during heat treatment of ths material while in the necked condition.
Tensioning and heat treatment of nonelastic material 12 also adds crimps and kink~ to the material as shown in Fig. 5 particularly when compared to the untreated material shown in Fig. 6. These crimp3 and kinks are beli~ved to add to the stretch and recovery properti~ o~ the material.
~e~errin~ now to Fig. 7 o~ the drawings, there is schematically illustrated at 50 an exemplary process for necking a nec~able material util-izing an S-roll arrangement. A neckable material 52 is unwound from a supply roll 54. The nec~able material 52 then travel~ in the direction indicated by the arrow associated therew.ith as the supply roll S~ rotates in the~direction of the :~ 3 ~ 3 arr~w associated therewith. The neckable material 52 then passes through a nlp 56 ~f an S-roll arrangement 58 formed by the stack roller~ 60 and 62. Alternatively, the neckable material 52 m~y be formed by known extrusion processes, such a~, f~r example, known spunbonding or known meltblowing proces es, and passed directly through the nip 56 without first being stored on a supply roll.
The neckable material 52 passes through the nip 56 of the S roll arrangement 58 in a reverse-S wrap path as indicated by the rotation direction arrows associated with the stack rollers 60 and 62. From ths S-roll a~rangement 58, the neckable material 52 passes through the nip 64 of a drive roller arrangement 66 ~ormed by the drive rollers 58 and 70. Because the peripheral linear speed of the stack rollers 60 and 62 of the S-roll arrangement 58 is controlled to be lower than the peripheral linear ~peed of the drive rollers 68 and 70 of the drive roller arrangement 66, the neckable matPrial 52 is tensioned between the S-roll arrangement 58 and the nip 64 of the drive roller arrangement 66. By adjusting the difference in the speeds of the rollers, the neckable material 52 is tensioned so that it necks a desired amount and ls maintained ln such necked condi~ion as it is wound on a wind-up roll 72.
Alternatively, a driven wind-up roll (not shown) may be used so the neckable material 52 may be stretched or drawn between the S--roll arrange~en~ 58 and the driven wind up roll by controlling the peripheral linear speed of the rollers 60 and 62 of the S-roll arrangement 58 to be lower than the peripheral linear speed of the driven wind-up roll. In yet another embodiment, an unwind having a brake which can be set to provide a resistance may be used instead of an S-roll arrangement.
Other methods of tensioning the neckable material 52 may be used such as, ~or example, tenter frames or various cross-machine , 13 ~ 3 ~ 3 direction str~tcher arrangements that expand or stretch the neckabl~ matQrial 52 in directions such a5, ~or example, the cro~s-machine direction so that, after heat treatment, the resulting reverslbly necked material (not shown) will be elastic in a direction gen~rally perpendicular ~o t~e dir~ction o necking, e.g., in the machine direction.
The wind-up roll 72 of the necked material 52 is then heated in an oven (not shown) to promote additional crystallization of at lezst one of ~he polymers that make up the necked material. Xoll 72 of the necked material 52 is then cooled forming the reversibly necked material shown in the enlarged photomicrograph of Fig. S. Alternatively, neckable material 52 may be necked, passed khrough a heat chamber (not shown~ and then cooled while in the necked condition to form a reversibly necked material ~not shown).
Examples 1-6 Tha reYersibly necked materials of examples 1-6 were madQ in accordance with the present invention by tensioning a neckable material so that it constricted. The tensioned, necked material was heated to a temperature that increased the crystallini~y of the polymer making up the neckable material and then cooled to ambient temperature. Reverslbly necked material made in this manner was stretched to about its original, pre-necked dimensions and was found to return ~o gener211y its reversibly necked dimensions upon release o~ the stretching force. Tables 1-9 provido Grab Ten~ile Test data for control samples and reversibly necked ample~ to show the effect of necking and heat treatment 30 on th~ material. The tests were performed on a Constant Rate of Exten ion tester, *Instron Model 1122 Uni~ersal Testing Instrument using 4 inch by 6 inch samples. Th~ sample was held ~y two clamps, each having a rear jaw which was 1 inch x l l/2 inches.
The 1 inch dimension was in the direction parallel to the application of load and the 1 1/2 inch dimension was in the direction perpendicular to the application of load. The front * --Trad~mark ~31~3 jaw of each clamp was 1 inch x 1 inch. Each jaw fac~ had a smooth, rubberized, gripping surface. The following mechanical properties were determined for each sample~ Peak Load, Peak Total Energy Absorbed, and Percent Elongation.
Control samples and reversibly necked samples were also cycled on the Instron Model 1122 with*Microcon II - 50 kg load cell~ The iaw faces of the tester were 1 inch by 3 inches so the samples were cut to 3 inches by 7 inches (7 inches in the direction to be tested) and weighed individually in grams. A 4 inch gauge length was used. Chart and crosshead speeds were set for 20 inches per minute and the ~nit was ~eroed, balanced and calibrated according to the general procedure. The maximum extension limit for the cycle length was set at a distance determined by calculating 56 percent of the "elongation to breaX'` from the Grab Tensile ~e~t.
Th~ sample was cycled to the specified cycle length four time~
and then was taken to break on the f if th cycle. The test equipment was set to report Peak Load in pounds force, Peak Elongation in inches and Peak Energy Absorbed in inch pounds force per square inch. The area used in the energy measurements (i.e~, the surface area of sample tested) is the gauge length (four inches) times the sample width (3 inche~) which èquals twelve square inches. The results of the Grab Tensile Tests and cycle tests haYe been normalized for the measured basis weights of the samples.
Peak Total Energy Absorbed (~EA) as used h~rein is def ined as tha total energy under the stress v~r~us strain ( load v~xsus elonga~ion) cuæve up to the point of "peak" or maximum load. TEA
is expressed ln units o~ work/(length)2 or (pounds force *
inch)/(inches)2. These values have been normalized by dlviding by the basis weight o~ the sample in ounces per square yard (osy) which produces units of t(lbsf * inch)/inch2]/osy.
~ - Trad~rnaYk 1 3 ~ 3 Peak Load a~ u~d herein is d~ined as the maximum value o~ load or ~orcs encountered in elongating the sample to break. Peak Load is expressad in units of ~orce (lbsf) which have been normalized for the basis weight of t~e material resulting in a number expressed in units of lbs~/(osy).
Elongation as used herein is defined a~ relative increase in length of a specimen during the tensil¢ test. Elongation is lo expressed as a percentage, i.e., ~(increase in length)/(original length)] X 100.
Permanent Set a~ter a stretching cycle as used herein is defined as a ratio of the increase in length of the sampl~ after a cycle divided by the maximum stretch during cycling. Per~an~nt Set is expres~ed as a percentage, i.e., [~final sample length - initial sample length)/ (maximum stretch during cycling - initial sample length)] X 100. Permanent set is related to recovery by the expression [permanent set = 100 - recovery] when recovery i5 exprassed as a pPrcentage.
Exam~le 1 A neckable multilayer material of 0.6 osy spunbonded polypropylene, 0.6 osy meltblown polypropylene, and 0.6 osy spunbonded polypropylene having a total basis wsight o 1.8 osy was tested on an Instron Model 1122 Universal Testing Instrument.
The results are reported in Tables 1 and 2 under the heading "Control 1." The machin~ direction peak total energy absor~ed i5 given in the column o~ Table 1 entitled "MD TEA." The machine direction peak load is given in the column entitled "MD Peak Load." The machine direction elongation to break is given in the column entitled "MD Elong." The cross-machine direction peak total energy absorbed is given in the column entitled "CD TEA."
The cross-machine direction peak load is given in the column entitled "CD Peak Load." The cross-machine direction elongation to breaX is given in th~ column entitled "CD Elong."
1 3 1 ~
Pe~k TEA, Peak Load, and Pe~manent 5et ar~ given ~or ~ach st~etch cycle in Table 2. At the end of the series of cycles, the sample was elongated to break and the results reported under the heading "To Break." Th~ ~longation value in the "To Break" column and "Perm Set" row is the elongation at peak load during the last cycl~.
o The neckable multilayer spunbond~meltblo~n/spunbond polypropylene material having a width of about 15.75 inche-q wa~ fed off a "broomsticX" unwind and passed through the nip o~ drive rollers having a peripheral speed from about 3 to about 4 ~eet per minuteO The material wa~ then passed over a serie~ of four steam cans in a "Butterworth treater~ arrangement that w~re heated to about 143C (289F). The steam cans had a peripheral speed ~rom about 5 to a~out 6 feet per minute resulting in a re idence time on the can of about 180 seronds. The neckable materlal constricted or necked to a width of about 6 to about 6.5 inches.
20 About half the necking occurred before contact with the steam cans and the remaining necking occurred during contact with the steam cans. The necked material cooled as it passed over s veral idler rollers and was wound on a driven winder at a speed ranging from about 5 to about 6 feet per minute. The rev~rsibly necked 2 5 material produced in this manner was tested on the Instron Model 1î22 Uni~rer~3al Testln~ Instrument and the results are reported in Tables 1 and ~ under the heading "Example 1." Most of the tensile propertie~ given in Tables 1 and 2 are reduced by the proca~ whil~ cross-machine direction stretchability is increasad. Some of the decreas~ in tensile properties i~ due to the increase in basis weight from necking the material. .
ExamplQ 2 A roll o~ the neckable spunbond/meltblown/spunbond (SMS) polypropylene material of Example 1 havinq an initial width of about 17 inches was unwound on a "22 inch Face Coatin~ Line"
~ 3 ~ 3 rewind mad~ by the Black-Claw~on Company. Th~ wind-up speed was set at about 40 feet per minut~ and the unwind resistan~e force was set at 4n pound~ per square inch causing the necXable material to neck or constrict to a width o~ about 10 inches as it was wound up on a roll. The roll of necked materiAl was heated in an*AMSC0 Eagle Series 2021 Gravity Autocl~e at 121~C for 99 minutes which wa~ thought to b~ mor~ than the amount o time required to heat the entire roil to the autoclave temperature for more than 300 seconds. T~le heating cycle was ~ollowed by a 60 minute vacuum dry cycl~. The reversibly necked material produced in this manner was tested on the Instron Model 1122 Universal Testing Instrument and the re~ults are reported in Tables 3 and 4 under the heading "Example 2." It can be seen from Tables 3 and 4 that, when comparing the reversibly necked material to the neckable material, mo~t tengilo properties decreased, elongation to break increased in th~ cross-machine direction and decreased in the machine direction.
ExamPle_3 A nec~able web of spunbonded polypropylene having a basis weight of about O . 8 osy was tested on an Instron Model 1122 Universal Testi~g Instrument. The results are reported in Tables 5 and 7 under the heading "Control 3."
neckable web o~ tha same matQrial having a width o~
approximately 17.75 inche~ was ~ecked to a width of about 6.5 inches and hea~ treated on a series of steam cans accor~ing to the procedure of Example 1. The steam can temperatures were set fro~ about 265 to about 270 ~F but the measured temperatures o~
tha steam cans were from about 258 to about 263'F. The residence time of the necked material on the steam cans was about 270 seconds. The results o~ tes~ing are given in Tables 5 and 6 under the heading "Example 3." It can be seen ~rom Tables 5 and 6 that most tensile values were lowered by the proc~ss while cross-machine direction stretchability wa5 increased. Some of * - Trade-mark the drop in tensile strength is due to the increase in apparent ba~is w2ight of the material from necking.
E~am~le ~
A 17.75 inch wide roll of the nec~able spunbonded polypropylene material of Example 3 having a basls weight of 0.8 osy was necked to a width of about 9 inches according to the procedure o~
Exampla 2 on a "22 inch Face Coating Line" rewinder made by ~he Black~Clawson Company. The unwind speed wa~ set from a~out ~ to about 5 ~eet .per minut2 and the unwind brake ~orce was set at about 40 pounds per square inch.
The roll of necked material was heat treated for 6 hours at 120C
lS in a Fisher Econotemp~M Lab Oven Model 30 and allowed to cool.
The re~er~ibly necXed material produced in thi~ manner was tested on the Instron Model 1122 Universal Testing Instru~ent and the result~ are given in Tables 7 and 8 under the heading "Exam~le 4.l~ It can be seen fro~ th~ Tables that most tensile valua~
were low~red by the process while cross-machine direction stretchability was increased~ Some of the drop in ten~ile strength is due to the inrrease in apparent basis weight of the material fr om necking. The process produced consistent results.
2 5 Exam~le 5 The neckable spunbonded polypropylene material of Example 3 was proce~sed on a 22" Black-Clawson rewinder using the procPdure of Example 4. The~ wind-up speed was set at about 4 to a~out S feet per minut~ and ths unwind resistance force was set at 48 pounds 30 per square inch causing the 17 . 75 inch wide neckable material to neck or constrict to a width o~ about 8 . 5 inches as it was wound up on a roll. The roll o~ necked material was heated to 120 C
for 6 hours in a Fisher EconotempT~ Lab Oven Model 30 and allowed to cool. Th~ reversibly necked material was tested on the 35 Instron Model 1122 Universal Testing Instrument and the results are given in Tables 7 and 8 under the heading "Example 5."
~x~nle 6 A necka~ p~nbonded polypropy~en~ we~ having a ba~is weight o~
about 0.8 o~y, a width of about 8 inches and a length of about 10 Eeet was marked at 1 inch increments along both ~ts width and length. This material was wound up without tension onto a 2 inch feed roll of a hand-operated bench scale rewind unit. The neckable ~aterial was attached to the take-up roll of the rewind unit and wound with sufficient tension to neck the material to a lo 5 inch width.
After about lJ2 hour, about 2 feet o~ the necXed material was unwound ~rom th~ take-up roll and the distances be-tween the markin~ were measured. The sample was stretched 5 times to about its original width and then re~measur~d. The r~sults are shown on Table 9 in the row marked "Not Heat Set".
The remaining necked material on the roll was heat treated in an oven at 116~C (242F) for 1 hour and then cooled to ambient temperature forming a reversibly necked material. Two lengths o~
reversibly necked material were treated and measured according to the procedure dascri~ed above. The results are reported in Table 9 under the headings "Heat Set No. 1" and "Heat Set No. 2."
Referring to Table 9, it can be seen that a~ter 5 stretchings the "Not ~eat Set" material sample spacings returned very closely to the origi~al one ~1) inch separation while the reversibly necked "Heat Set" samples retained most o~ their reversibly necked dimensions and their cross-machine direction stretch.
Exam~le 7 Di.fferential Scanning Calorimetry analysis of a neckable spunbonded polypropylene was performed using a ~odel 1090 Thermal Analyzer available ~rom DuPont Instruments. The sample size was approximately 3.0 mg and the rate of temperature change was approximately 10C per minute. Values for heat o~ fusion were * - Tra~e-mark obtained by numerical inte~ration performed by the Model 1090 Th~rmal Analyz~r~ Values for ons~t of melting were determined from the deviation from linearity in a plot of Heat Flow versu~
Temperature. The results for the neckabl e spunbonded polypropylene material are reported in Table 10 under the heading IlNot Heat Set".
The spunbonded polypropylene wa~ heated for 2 hours at 130-C
while in the n~cked condition. The necked material was cooled and then Differential Scanning Calorimetry analysis of the treated samples wa~ performed as described above~ The results for the reversibly necked spunbonded polypropylene material are reported in Table 10 under the heading "Heat Set".
As shown in Table 10, the heats o~ fusion for the "Heat Sat"
samples are greater than the value~ for the "Not Heat Set"
samples. Additionally, the onset o~ melti~g for the l'Heat SQt'7 sample~ occurs at a lower tamperature than for the "Not Heat S~"
samples.
This application is related to U.S. Patent 4,981,747, issued January 1, 1991 in the name of Michael To Morman and is entitled "Composite Elast.ic Material Including a Reversibly Necked Material"; and copending Canadian Application Serial No.
609,711, filed August 29, 1989, also in the name of Michael T. Morman, entitled "Composite Elastic Necked-Bonded Material".
Disclosure of the presentl~ preferred embodiment of the invention is intended to ill~l~trate and not to llmit the invention. It i~
understood that those of skill in the art should be capable of making numerous modifications without departi~g from the true spirit and scope oE the invention.
GRAB TENSILES: Corrected Control 1 Example 1 MD TEA 1.07 + .28 .21 + .02 MD Peak Load 14.8 + 200 12.3 + .5 MD Elong 48 f 6 12.3 + .6 CD TEA .95 -~ .10 .57 + .11 CD Peak Load 14.9 ~ .7 4.4 + .6 CD Elong 44 + 3 150 + 13 CYCLE: 1 2 3 4 To Break Control 1 Cycled in cross~machine direction at 25% CD Elongation Peak TEA .70 + .04 .25 + .01 .20 + .01 .184 + .005 .882 + .08 Peak Load 15.9 + 1.0 13.2 + .7 12.2 + .7 11.6 + .5 18.3 + .8 Perm. Set 35 + 3 39 + 5 45 + 3 46 + 3 38 _ 2 Example 1 Cycled in cross-machine direction at 85% CD Elongation Peak TEA .095 + .007 .035 + .003 .029 r ~ 003 .026 -r ~ 003 .600 + .1 Peak Load .881 + .1 .786 + .1 .746 + .1 .722 + .1 4.23 ~ .4 Perm. Set 26 + 1 30 + 1 34 ~ .5 41. + 1 154 + 11 :~ 3 ~
GRAB TENSILES:
Control 1 Example 2 MD TEA 1.07 + .28 .27 r ~ 05 MD Peak Load 14.8 + 2.0 g.o + .
MD Elong 48 + 6 22 -~ 3 CD TEA .95 + .10 .46 + .08 CD Peak Load 14.9 _ .7 6.7 + .4 CD Elong 44 + 3 93 + 6 -CYCLE: 1 2 3 4 To Break Control 1 Cycled in cross-machine direction at 25~ CD Elongation Peak TEA . 70 + .04 .25 + .01 .20 + .01 .184 + .005 .882 + .08 Peak Load 15.9 ~ 1.0 13.2 ~ .7 12.2 -~ .7 11.6 + .5 18.3 + .8 Perm. Set 35 + 3 39 + 5 45 + 3 46 + 3 38 + 2 Example 2-Cycled in cross-machine direction at 52% CD Elongation Peak TEA .028 + .008 .013 + .004 .012 + .003 .013 + .006 .706 + .07 Peak Load .665 + .2 .57 + .17 .54 + .15 .52 -r .15 7.95 r ,4 Perm. Set 26 + 1 30 + 2 33 + 1 43 ~ 6 97 + 3 ~ 3 ~ 3 GRAB TENSILES:
Control 3 Example 3 MD TEA 1.38 + .25 .25 ~ .07 MD Peak Load17.9 + .6 15.5 + 2.3 MD Elong 56 + 6 12 + 2 CD TEA 1.5 + .1 .37 + .07 CD Peak Load 16.3 ~ .6 2.9 ~ .4 CD Elong 67 + 3 179 + 10 CYCLE: 1 2 3 4 To Break Example 3 Cycled in machine direction at 6.5% MD Elongation Peak TEA .176 + .01 .124 + oO1 .125 + .002 .11 + . 006 .504 + .1 Peak Load 20.9 ~ .8 17.8 + .8 17.9 + .4 16.6 ~ .5 33 + 3 Perm. Set 13 + 2 10 + 1.0 Example 3 Cycled in cross-machine direction at 85% CD Elongation Peak TEA .05 + .006 .022 + .002 .017 + .002 .016 + .002 .257 + .06 Peak Load .91 + .12 .81 + .11 .77 + .1 .75 + .1 2.45 ~ .17 Perm. Set 27 + 3 31 + 1 35 + .5 49 + 8 144 ~ 8 ~ 3 ~ 3 -GRAB TENSILES:
Control 3 Example 4 Exam~ e 5 MD TEA 1.38 + .25 .25 + .06 .22 + .02 MD Peak Load17.9 + .610.6 + 1.0 10.7 -~ .5 MD Elong 56 + 6 16 + 2 15 + 2 CD TEA 1.5 + .1 .28 + .05 .33 + .07 CD Peak Load16.3 + .6 3.7 + .5 4.1 + .7 CD Elong 67 + 3 143 + 6 157 + 7 CYCLE: 1 2 3 4 To Break Example 4 Cycled in cross-machine direction at 80% CD elongation Peak TEA .033 + .006 .020 + .003 .018 + .003 .017 + .002 .41 + .01 Peak Load .325 + .07 .30 + .07 .2~ + .06 .28 + ~06 4.51 + .6 Perm. Set 26 + 1 30 + 1 32 + 2 42 + 1 138 + 6 :~ 3 ~ 3 INCHES
(INCHES) (INCHES) SAMPLE MD CD CD MD
-Not Heat Set1.094 .795 .982 1.049 +.026 +.017 +.017 +.025 Heat Set No. 1 1.19 .630 .73 1.16 +.03 +.04 +.016 ~.03 Heat Set No. 2 1.23 .61 0.71 1.22 +.0~ +.06 +.05 +.04 Not Heat SetHeat Set Heat of 83.9 95.9 Fusion 86 .1 90. 5 (J/g) 8~.0 90.5 AVERAGE 84 . 6 + 1. 2 92 . 3 + 3 .1 Onset of 128 118 Mel ti ng 133 118 ( C) 132 11~
AVERAGE 131 + 2.6 117 * 2.3 CYCLE: 1 2 3 4 To Break Example 5 Cycled in machine direction at 8.3% MD Elongation Peak TEA .18 + .01 .122 + .01 ~ 004 ~11 + .007 .329 + .07 Peak Load 15~4 r .6 13.2 + .6 12.7 + .4 12.4 ~ .5 19.4 + 1~1 Perm. Set 18.8 + 1.6 1008 + 1.2 Example 5 Cycled in cross-machine direction at 88~ CD Elongation Peak TEA .019 + .002 .005 ~ .0009 .003 + .001 .002 ~ .001 .390 ~ .130 Peak Load .260 + .084 .24 + .074 .233 + .006 .225 + .069 4.12 + .608 Perm. Set 25 + 2 30 -~ 2 32 + 1 38 + 1 151 + 13
The present invention relates to elasticized materials and a method Q~ making the same.
BACXGROUND OF THE INVENTION
Plastic nonwoven webs formed by nonwoven extrusion processes such as, for example, meltblowing processes and spunbonding processes may be manufactured into products or component5 Of products so 1~ inexpensively that the products could be viewed as disposable after only one or a few uses. Repre~entatives of such products includa garment materials, diapers, tissues, wipes, garments, mattress pads and ~eminine care product5.
Nonwoven webs ~ormed from nonelastic polymers such as, for example, polypropylene are general~y consider~d nonelastic. The lack of elasticity usually restricts use of these nonwoven web materials from design applications where elasticity is necessary or desirable such as, ~or example, diapers, mattress pads, feminine care products and some of the above mentioned garment materials.
Certain fabric finishing processes such as, for example, dyeiny carried out at high dye bath temperatures utilizing roller arrangements that tension th~ material to be dyed have been observed to shrink webs of nonwoven fibers to a soft, drapeable elastic fabric which can be stretch~d and can recover to about its pre-~tretched dimen~ions. Additionally, U.S. Patent No.
3,949~128 to Ostermeier discloses a heat treated material with releasable bonds which can be stretched to about 65 percent and can recover to about its pre-stretched dimensions.
While the known elasticized fabrics provided may be useful for some purposes, fabrics having greater stretch and recovery characteristics are always desirable.
., ~, :L 3 ~
DEFINITIONS
As u~ed her~in, the term "recover" refers t~ a contraction of a stret~hed material upon termination of a biasing ~orce following stretching of the material by application o~ the biasing force.
For example, if a material having a relaxed, unbiased length of one (1) inch is elongated 50 percent by stretching to a length of one and one half (1.5) inche3 the material would be elongated 50 percent (0.5 inch) and would have a stretched length that is 150 percent o~ its relaxed length. If this exemplary st~etched material contracted, that is recovered to a length of one and one tenth (1.1) inches after release of the biasing and stretching ~orce, the material would have recovered 80 percent (0.4 inch) of its one-hal~ (0.5) inch elongation. Recovery may be expressed as [(maximum stretch length - final sample length)~(maximum stretch length - initial sample length)3 X 100.
As used herein, the term "nonwoven web" means a web that has a structure of individual fibers or threads which are interlaid, but not in an identifiable repeating manner. Nonwoven webs have been, in the past, formed by a variety of processes such as, for example, meltblowing processes, spunbonding processes and bonded carded wèb processes.
As used herein, the t~rm "microfibers" means small diameter fibers having an average diameter not greater than about 100 microns, for example~ having a diameter of from about 0.5 microns to about 50 micronsl more specifically micro~ibers may also have an averag~ diam~ter of from about 4 microns to about 40 microns.
As used herein, the term "interfiber bonding" means bonding produced by entanglement between individual meltblown fibers to form a cohe~ent web structure without the u5e o~ thermal bonding. This fiber entangling is inherent in the meltblown processes but may be generated or increased by processes such as, for example, hydraulic entangling or needlepunching.
~3~ ~ ~13 Alt~rnatively and/or additionally, a bonding agent can be utiliz~d to increa~e the desired bonding an~ to maintain structural coher~ncy of the web. For example, powdered bonding agents and chemical solvent bonding may be used.
As usd herein, the term "meltblown fibers" means ~i~ers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillarie~ as molten threads or filaments into a high velocity gas (e.g. air) stream which attenuates the filaments of molten thermoplastic material to reduce their diameters, which may ba to micro~iber diameterO
Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collectlnq surface to form a web of randomly disbursed meltblown ~ihers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,~41 to Butin.
As used herein, the term "spunbonded fibers" refers to small diameter fibers which are formed by extruding a molten thermoplastic material as filaments from a plurality o~ ~ine, usually circular, capillaries in a spinnerette with the diameter of the extruded ~ilaments then being rapidly reduced, for example, by educti~e drawing or other well-known spun bonding mechanisms~ The production o spun-bonded nonwoven webs is illustrated in patents such as, for example, in U.S. Patent No.
4,34~,563 ko App~l et al., and U.S. Patent No. 3,692,618 to Dorschner et al.
As used herein, the term "necked material" refers to any material which ~as been constricted in at least one dimension by processes such as, for example, drawing or gathering.
A~ used h~r~in, the term "neckable material" means any material which can ba n~cked.
As used herein, the term "reversibly necked material" refers to a necked material that has been treat~d whil necked to impart memory to ths material s~ that, when a force is applied to extend the material to its pre-necked dimensions, the necked and treated portions will ~enerally recover to their ne~ked dimensions upon termination of the force. One ~orm of treatment is the application of heat. Generally speaking, extension of the reversibly necked material is substantially limited to extension to its pre-necked dimensions. Therefore, unless the material i5 elastic, ~xtension too far beyond its pre-necked dimensions will resul~ in material failure. A reversibly nec~ed material may include more than one lay~r. For example, multiple layer~ o~
spunbonded web, multiple layers o~ meltblown web, multiple layer~
o~ bonded carded web or any other suitable combination or mixtures thereof.
used herein, the term "percent neckdown" re~er~ ~o the ratio determined by measuring the difference between the pre-n~cXed dimension and the necked dimension of a neckable material and then dividing that di~ference by the pre-necked dimension of the neckable material.
As us~d herein, the term "percent stretch" refers to the ratio de~ermined by measuring th2 increase in the stretched dimension and dividing that value by the oriyinal dimension, i.e., (increase in ~tretched dimension/original dimension) x 100.
The pr~s~nt invention ~vercomes the limitation to 65 percent stretch/recovery ratios that previously existed.
The pr~sent invention resides in a material ~hich is reversi~ly necked by drawing at ambient temperature and then heating and cooling while in a necked c~nfiguration so that th~ material possesses a greater heat of ~usion than before being reversibly neckedO
More speci~ically, the reversibly necked material is capable of stretching at least about 75 percent and recovering at l~ast about 50 percent when stretched ab~ut 75 percent.
~ ccDrding to one embDdiment of the present inventiDn~ the reversibly necked material may be adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent in which the reversibly necked material has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the material possesses a lower onset of melting than before being reversibly necked.
Generally speaking, the reversibly necked material may be made from any neckable material that can be treated to acquire such memory characteristics. In one embodiment, the material can have a basis weight of from about 6 to about 200 grams per square meter. In other embodiments, useful neckable materials ;nclude, for example, bonded carded webs, spunbonded webs or meltblown webs. The meltblown web may include meltblown microfibers. In yet other embodiments, the neckable material may have multiple layers such as, for example, multiple spunbond layers and/or multiple meltblown layers. In general, the neckable material may be made of polymers such as, For example, polyolefins. Exemplary polyolefins include polypropylene, polyethylene, ethylene copolymers and propylene copolymers.
The neckable material may include embodiments that are composite materials made from a mixture of two or more difFerent Fibers or a mixture of fibers and other materials. ~he other materials may include, for example, textile fibers, wood pulp and particulates such as, for example, hydrocolloid (hydrogel) particulates commonly re-ferred to as super-absorbent materials.
~3 ~ ~13 According to one embodiment of-the present invention, the reversibly necked material may be adapted tD stre-tch at least about 125 percent and recover at least about 50 percent when stretched abou-t 125 percent.
A reversibly necked material of -the present invention may be, for example, a coherent web formed o-f fibers joined solely by interFiber bonding~ in which the web is adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent and in which the reversibly necked web has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the web possesses a greater heat of fusion and/or lower onset oF
melting -than before be;ng reversibly necked and in which the fibers are joined solely by interfiber bonding to form a coherent web structure.
The present invention also encompasses a multilayer material including at least one material which is reversibly necked by drawing at ambient temperature and then heating and cooling while in a necked configuration so that the mater;al possess a greater heat of fusion and/or onset of melting than before being reversibly necked.
In one embodiment, the multilayer material may be composed o~ at least two reversibly necked materials adapted to stretch at least about 75 percent and r~covQr at least about ~ percent when stretched about 75 percent, in which the reversibly necked materials have been neck~d by drawing at ambient temperature and then heated ~nd cooled while in a neck~d con~iguration so thak the materials possess a greater heat of ~usion and/or lower onset o~ melting than be:Eore being reversibly necked.
Generally speaking, the neckable material may be necked by stretching in a direction generally perpendicular to the desired direckion of neck-down. Alternatively, the material may be compacted to effect neck-down. Memory of the ma-terial's necked configuration may be imparted to certain necked materials by:
heating -the necked material; and cooling the material while it is still in the necked configuration. Yet other memory creating procedures may be utilized as appropriate for the material.
~ 3 ~
In one embodiment of the method of the present invention, a reversibly necked material may be made by necking a neckable material by drawing at ambient temperature and then heating and cooling the ma-terial while in a necked configuration so that -the material possesses a lower onset of melting and/or greater heat of fusion than before being reversibly necked. According to one aspect of the me-thod of the present invention~ a reversibly necked material can be adapted to stretch at least about 75 percent or more (e.g., 125 percent) and recover at least about 50 percent when stretched about 75 percent or more (e.g " 125 percent).
sRI2F DESCRIPTION OF THE ~RAWINGS
Fig. 1 is a schematic representation o~ an exemplary process for forming a reversibly necked material using a series of steam cans.
FIG. 2 is a plan view of an exemplary nsckable material before tensioning and necking~
FIG. 2A is a ~lan view of an exemplary reversibly necked ~aterial.
FIG. 2B i~ a plan view of an exemplary reversibly necked material while partially strPtched.
FIG. 3 is a plot of stretch versus recovery showing exemplary stretch/recovery profiles.
FIG.4A is an exemplary ~if~erential Scanning Calorimetry scan of a neckable material before heat treatment.
FIG.4B is an exemplary Differential Scanning Calorimetry scan of a rever~ibly necked material, i . e ., a~ter treatment while necXed.
FIG. 5 is an enlarged photomicrograph of an exemplary neckable material~ prior to treatment while necked.
FIG. 6 is an enlarged photomicrograph of an exemplary reversibly necked material.
6a FIG. 7 is a sche~atic repre5entation of an exemplar~ proce5s ~r con~trict~ng a neckable material using an Srroll arrangement.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings where like reference numerals repre~ent like ~igures or process steps and, in part, to Fig. 1 there is schematically illustrated at 10 a~ exemplary process ~or ~orming a re~ersibly necked material using a ~eries of staam cans. A
neckable material 12 is unwo-md from a supply roll 14. The neckable material 12 passe~ through a nip 16 of a drive roller arrangement 18 formed by the drive rollers 20 and 22 and then past two idler rolls 24 and 26.
The neckable material 12 may be formed by Xnown nonwoven processes, such as, for example, meltblowing processe~, spunbonding processes or bonded carded wek proce~ses and passed directly through the nip 16 without first being stored on a supply roll~
The neckable material 12 may be a nonwoven material such as, for example, spunbonded web, meltblown web or bonded carded web. If the neckable material 12 is a web of meltblown fibers, it may include meltblown microfibers. The neckable material 12 is made from any material that can be treated while necked sa that, after treatment, upon application of a force to extend the necked material to its pre-n2cked dimensions, the material recovers generally to it~ nec~ed dimQnsions upon termination of the force.
A method of treatment is the application of heat. Certain polymers such as, for example, polyoleins, polyesters and polyamides may be heat treated under suitable conditions to impart such memory. Exemplary polyolefins include one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers and butene copolymers. Polypropylenes that have been found useful include, for exa~ple, polypropylene available from the ~limont Corporation under the trade designation ~. 3 ~
*PC-973, polypropylene available fro~ the Exxon Ch~mical Company under tha trada designation *Exxon 34~5, and polypropylene ava~lablQ from the Shell Chemical Company under ~he trade designation * DX 5Ao9. Chemical characteristics of these materials are available from their respective manufactur~rs.
In one embodiment of the present invention, the neckable material 12 is a multilayer material having, for example, at least one layer of spunbonded web joined to at least one layer of meltblown web, bonded carded web or other suitable material. For example, the neckable material 12 may be a multilayer material having a f irst layer o~ spunbonded polypropylene ha~ing a basis weight from about 0.2 to about 8 ounces per square yard (osy), a layer o~ meltblown polypropylene having a basis weight from about 0.2 to about 4 osy, and a second layer of spun~o~ded polypropylene having a basi~ weight of about 0.2 to about 8 osy.
Alter~atively, the neckable material 12 may be single layer of material such as, for example, a spunbonded web having a basis weight of from abvut 0.2 to about 10 osy or a meltblown web having a basis weight of from about 0.2 to about 8 osyO
The necXable mat~rial 12 may also be a composite mat~rial made of a mixture of two or mor~ different fibers or a mixture o~ ~ibers and particulates. Such miXtures may be formed by adding f ibers and~or particulates to a gas stream in which meltblown f ibers arP
caxried s~ that an intimate entangled commingling of meltblown fibers and other materials, e.g., wood pulp, stapl~ f i~ers or particulate~ such as, for example, super-absorbent materials occurs prior to collection of the fibers upon a collecting device to ~orm a coherent web of randomly dispersed meltblown f~bers and other materials such as disclosed in U.s. Patent No. 4,100,324.
* - Trade-marks ~ 3 ~ 3 If tha neckable material 12 i a nonwoven web o~ ~ibers, ~hs fiber~ ~hould b~ joined by interfiber bonding to form a coherent web struc~ure which is able to withstand neckingO Interfiber bonding may be produced by entanglement betwe~n indiYidual meltblown fibers. The fiber entangling is inherent in the meltblown process but may be generated or increased by proces~es such as, for example, hydraulic entangling or needlepunching.
Alternatively and/or additionally a bonding agent may be used to increase ~he desired bonding.
A~te~ passing through the nip 16 of the driver roller arrangement 18 and idler rollers 24 and 26, the neckable material 12 passe~
o~er a series of steam cans 28-38 in a series of reverse S loops.
The steam cans 28~38 typically have an outside diameter c~ about Z4 inches although other sized cans may be used. The con~act time or residence time o~ the neckable material on the steam cans to effect heat treatme~t will ~ary depending on faotors surh as, for example, steam can temperature, and typ~ and/or basis weight o~ material. For example, a necXed w~b o~ polypropylen~ may be passed over a series o~ steam cans heated to a measured ~emperature from about 90 to about 150~C (194-302F~ for a contact time of about 1 to about 309 seconds to effect heat treatment. More particularly, the temperature may range from about 125 to about 143C and the residence time may range ~rom about 2 to about 50 seconds.
Because th~ peripheral linear speed o~ the drive rollers 20 and 22 is controlled to b~ lower than the peripheral linear speed of the steam cans 28-38, the neckable material 12 is te~sioned between the s~eam cans 28-38 and the drive rollers 20 and 22. By adjusting the dif~erence in the speeds o~ the rollers, the neckable material 12 is tensioned so that it necks a desired amount and is maintained in such necked condition while passing over the heated steam cans 28-38. This action imparts memory of the necked condition to the neckable material 12. The neckable ~ 3 ~ l 3 materlal 12 i9 then cooled in th~ necked condition after lea~ing the la~t ~tea~ can 38. Th~ ~eripheral linear speed o~ ~he rollars o~ the idlar roller arrangement 42 are maintained at ~ha sa~e speed a~ th2 steam cans 28-38 so that the necked material 12 is cooled in the necked condition on it5 way to the wind-up roll 46. This completes formation of the reversibly n~cked material 44. The reversibly necXed material 44 can extend to at least its original, pre-necked dimensions upon applicakion of a str~tching force in a direction generally parallel to the direction of necking and then recover to within at least about 50 percent of its reversibly necked dimensions upon release of the stretching force. According to the present invention, elongation or percent stretch values of greater than 170 percent have been achieved.
Con~entional drive means and other conventional de~ices which may be utilized in conjunction with the apparatus of Fig. 1 are well known and, for purposes of clarity, have not been illustrated in the schematic view of Fig. 1.
The relation between the original width of the neckable material 12 to its width after tensioning de~ermines the stretch limits of the reversibly necked material 44. For example, with re~erence to Figs. 2, 2A, and 2B, if it is desired to prepare a reversibly necked material that can be stretched to a 150 percent elongation (i.e., 250 percent of its nec~ed width) and can recover to within about 25 percent of its necked width, a neckable material shown sche~atically and not necessarily to scale in Fig. 2 having a width ~A'~ such as, for example, 250 cm, is tensioned so that it necks down to a width "B" of about loo cm for a percent neck or percent neckdown of about 60 percent and while tensioned, is heat treated to maintain its reversibly necked con~iguration a~ shown in Fig. 2A. The resulting reversibly necked material shown schematically and not necessarily to scale in Fig. 2B has a width "~" o~ about 100 cm and is stretchable to at least the original 2~0 cm dimension "A" of the neckable material for an elongation ~ 3 ~ 1 3 or percent stretch of about 150 percent. The reversibly necked material r~kurn~ ~o within absut 25 perc~nt o~ its necked width of about loo cm, (i.e., to a width o~ about 125 cm) after release o~ the stretching force ~or a recovery oP about 83 percent.
The claims of the present invention are mea~t to encompass materials which are adapted to stretch at least 75 p~rcent and recover at least 50 percent at laast at some poi.nt during their stretch/recovery profil~. For example, the materi~ls of the present invention are adapted to str~tch at least 75 percent and recover at least 50 percent when stretched 75 percent. Fig. 3 is a plot of stretch versus recovery showing exemplary stretch/recovery pro~iles. Curve "A" is an ~xemplary stre~ch/recovery profile for a material o~ the pre~ent invention.
Curve "B" is an exemplary stretch/recovery profile ~or a material not encompassed by the present invention.
Although the present invention should not be held to a particular theory of operation, the heat treatment should raise the neckable material 12 to a temperature range ~or a speci~ied time period where it is believed that additional pol~mer crystallization occurs while the material is in the necked condition. Because certain types o~ fibers are ~ormed by methods such as, for exampl~, meltblowing and spunbonding which cool the fibers very quickly, it is believed that the polymers ~orming the fiber~ are not ~ully cryst~llized. That is, the polymers hard~n before the crystallization is complete. It is believed that additional cry~allization can be e~fected by increasing the tempera~ure of the material ~o a temperature below the material's melting poin~.
When this additional crystallization occurs while the material is in the necked condition, it is believed that memory of the necked condition is imparted to the material.
~ 3 ~ 3 Fi~. 4A i9 ~n exsmplary Di~erential Scanning Calorimetry sc:an o~
a spu~o~d~d pol~propylene material. Fig. 4~3 is an exemplary Dif ~erenti~l Scanning Calol: im~try scan of ~:he samF~ t:ype of 5 spunbonded polypropylene material which has been necked ~nd heat ~reated. Dif~eren~ial Scanning ~alorimetry can ~e used to show that neckable materials such aS, for ex~mple, spunbonded webs, which have been necked and heat treated exhibit greater heats o~
fusion than the same materials which have not been heat treated.
That is, the heat of fusion of a rever3ibly necked material is typically at least about 5 percent greater than th~ material before being reversibly necked. For exampls, from about 5 to about 15 percent greater. Additionally, the onset of melting occur~ at lower temperatures for necked and heat treated materials than for their non-heat treated counterparts. That is, the onset of melting of a reversibly necked material typically occurs at a temperature at l~ast about 5 C lower than for the material before being reversibly necked. For example, ~rom about 5'C to about 15C lower. A greater heat of fu ion i5 believed to result from additional crystallization which occurs during heat treatment. A lower t~mperature for onset of meltinq is believed to result from imperfect or strained crystals formed during heat treatment of ths material while in the necked condition.
Tensioning and heat treatment of nonelastic material 12 also adds crimps and kink~ to the material as shown in Fig. 5 particularly when compared to the untreated material shown in Fig. 6. These crimp3 and kinks are beli~ved to add to the stretch and recovery properti~ o~ the material.
~e~errin~ now to Fig. 7 o~ the drawings, there is schematically illustrated at 50 an exemplary process for necking a nec~able material util-izing an S-roll arrangement. A neckable material 52 is unwound from a supply roll 54. The nec~able material 52 then travel~ in the direction indicated by the arrow associated therew.ith as the supply roll S~ rotates in the~direction of the :~ 3 ~ 3 arr~w associated therewith. The neckable material 52 then passes through a nlp 56 ~f an S-roll arrangement 58 formed by the stack roller~ 60 and 62. Alternatively, the neckable material 52 m~y be formed by known extrusion processes, such a~, f~r example, known spunbonding or known meltblowing proces es, and passed directly through the nip 56 without first being stored on a supply roll.
The neckable material 52 passes through the nip 56 of the S roll arrangement 58 in a reverse-S wrap path as indicated by the rotation direction arrows associated with the stack rollers 60 and 62. From ths S-roll a~rangement 58, the neckable material 52 passes through the nip 64 of a drive roller arrangement 66 ~ormed by the drive rollers 58 and 70. Because the peripheral linear speed of the stack rollers 60 and 62 of the S-roll arrangement 58 is controlled to be lower than the peripheral linear ~peed of the drive rollers 68 and 70 of the drive roller arrangement 66, the neckable matPrial 52 is tensioned between the S-roll arrangement 58 and the nip 64 of the drive roller arrangement 66. By adjusting the difference in the speeds of the rollers, the neckable material 52 is tensioned so that it necks a desired amount and ls maintained ln such necked condi~ion as it is wound on a wind-up roll 72.
Alternatively, a driven wind-up roll (not shown) may be used so the neckable material 52 may be stretched or drawn between the S--roll arrange~en~ 58 and the driven wind up roll by controlling the peripheral linear speed of the rollers 60 and 62 of the S-roll arrangement 58 to be lower than the peripheral linear speed of the driven wind-up roll. In yet another embodiment, an unwind having a brake which can be set to provide a resistance may be used instead of an S-roll arrangement.
Other methods of tensioning the neckable material 52 may be used such as, ~or example, tenter frames or various cross-machine , 13 ~ 3 ~ 3 direction str~tcher arrangements that expand or stretch the neckabl~ matQrial 52 in directions such a5, ~or example, the cro~s-machine direction so that, after heat treatment, the resulting reverslbly necked material (not shown) will be elastic in a direction gen~rally perpendicular ~o t~e dir~ction o necking, e.g., in the machine direction.
The wind-up roll 72 of the necked material 52 is then heated in an oven (not shown) to promote additional crystallization of at lezst one of ~he polymers that make up the necked material. Xoll 72 of the necked material 52 is then cooled forming the reversibly necked material shown in the enlarged photomicrograph of Fig. S. Alternatively, neckable material 52 may be necked, passed khrough a heat chamber (not shown~ and then cooled while in the necked condition to form a reversibly necked material ~not shown).
Examples 1-6 Tha reYersibly necked materials of examples 1-6 were madQ in accordance with the present invention by tensioning a neckable material so that it constricted. The tensioned, necked material was heated to a temperature that increased the crystallini~y of the polymer making up the neckable material and then cooled to ambient temperature. Reverslbly necked material made in this manner was stretched to about its original, pre-necked dimensions and was found to return ~o gener211y its reversibly necked dimensions upon release o~ the stretching force. Tables 1-9 provido Grab Ten~ile Test data for control samples and reversibly necked ample~ to show the effect of necking and heat treatment 30 on th~ material. The tests were performed on a Constant Rate of Exten ion tester, *Instron Model 1122 Uni~ersal Testing Instrument using 4 inch by 6 inch samples. Th~ sample was held ~y two clamps, each having a rear jaw which was 1 inch x l l/2 inches.
The 1 inch dimension was in the direction parallel to the application of load and the 1 1/2 inch dimension was in the direction perpendicular to the application of load. The front * --Trad~mark ~31~3 jaw of each clamp was 1 inch x 1 inch. Each jaw fac~ had a smooth, rubberized, gripping surface. The following mechanical properties were determined for each sample~ Peak Load, Peak Total Energy Absorbed, and Percent Elongation.
Control samples and reversibly necked samples were also cycled on the Instron Model 1122 with*Microcon II - 50 kg load cell~ The iaw faces of the tester were 1 inch by 3 inches so the samples were cut to 3 inches by 7 inches (7 inches in the direction to be tested) and weighed individually in grams. A 4 inch gauge length was used. Chart and crosshead speeds were set for 20 inches per minute and the ~nit was ~eroed, balanced and calibrated according to the general procedure. The maximum extension limit for the cycle length was set at a distance determined by calculating 56 percent of the "elongation to breaX'` from the Grab Tensile ~e~t.
Th~ sample was cycled to the specified cycle length four time~
and then was taken to break on the f if th cycle. The test equipment was set to report Peak Load in pounds force, Peak Elongation in inches and Peak Energy Absorbed in inch pounds force per square inch. The area used in the energy measurements (i.e~, the surface area of sample tested) is the gauge length (four inches) times the sample width (3 inche~) which èquals twelve square inches. The results of the Grab Tensile Tests and cycle tests haYe been normalized for the measured basis weights of the samples.
Peak Total Energy Absorbed (~EA) as used h~rein is def ined as tha total energy under the stress v~r~us strain ( load v~xsus elonga~ion) cuæve up to the point of "peak" or maximum load. TEA
is expressed ln units o~ work/(length)2 or (pounds force *
inch)/(inches)2. These values have been normalized by dlviding by the basis weight o~ the sample in ounces per square yard (osy) which produces units of t(lbsf * inch)/inch2]/osy.
~ - Trad~rnaYk 1 3 ~ 3 Peak Load a~ u~d herein is d~ined as the maximum value o~ load or ~orcs encountered in elongating the sample to break. Peak Load is expressad in units of ~orce (lbsf) which have been normalized for the basis weight of t~e material resulting in a number expressed in units of lbs~/(osy).
Elongation as used herein is defined a~ relative increase in length of a specimen during the tensil¢ test. Elongation is lo expressed as a percentage, i.e., ~(increase in length)/(original length)] X 100.
Permanent Set a~ter a stretching cycle as used herein is defined as a ratio of the increase in length of the sampl~ after a cycle divided by the maximum stretch during cycling. Per~an~nt Set is expres~ed as a percentage, i.e., [~final sample length - initial sample length)/ (maximum stretch during cycling - initial sample length)] X 100. Permanent set is related to recovery by the expression [permanent set = 100 - recovery] when recovery i5 exprassed as a pPrcentage.
Exam~le 1 A neckable multilayer material of 0.6 osy spunbonded polypropylene, 0.6 osy meltblown polypropylene, and 0.6 osy spunbonded polypropylene having a total basis wsight o 1.8 osy was tested on an Instron Model 1122 Universal Testing Instrument.
The results are reported in Tables 1 and 2 under the heading "Control 1." The machin~ direction peak total energy absor~ed i5 given in the column o~ Table 1 entitled "MD TEA." The machine direction peak load is given in the column entitled "MD Peak Load." The machine direction elongation to break is given in the column entitled "MD Elong." The cross-machine direction peak total energy absorbed is given in the column entitled "CD TEA."
The cross-machine direction peak load is given in the column entitled "CD Peak Load." The cross-machine direction elongation to breaX is given in th~ column entitled "CD Elong."
1 3 1 ~
Pe~k TEA, Peak Load, and Pe~manent 5et ar~ given ~or ~ach st~etch cycle in Table 2. At the end of the series of cycles, the sample was elongated to break and the results reported under the heading "To Break." Th~ ~longation value in the "To Break" column and "Perm Set" row is the elongation at peak load during the last cycl~.
o The neckable multilayer spunbond~meltblo~n/spunbond polypropylene material having a width of about 15.75 inche-q wa~ fed off a "broomsticX" unwind and passed through the nip o~ drive rollers having a peripheral speed from about 3 to about 4 ~eet per minuteO The material wa~ then passed over a serie~ of four steam cans in a "Butterworth treater~ arrangement that w~re heated to about 143C (289F). The steam cans had a peripheral speed ~rom about 5 to a~out 6 feet per minute resulting in a re idence time on the can of about 180 seronds. The neckable materlal constricted or necked to a width of about 6 to about 6.5 inches.
20 About half the necking occurred before contact with the steam cans and the remaining necking occurred during contact with the steam cans. The necked material cooled as it passed over s veral idler rollers and was wound on a driven winder at a speed ranging from about 5 to about 6 feet per minute. The rev~rsibly necked 2 5 material produced in this manner was tested on the Instron Model 1î22 Uni~rer~3al Testln~ Instrument and the results are reported in Tables 1 and ~ under the heading "Example 1." Most of the tensile propertie~ given in Tables 1 and 2 are reduced by the proca~ whil~ cross-machine direction stretchability is increasad. Some of the decreas~ in tensile properties i~ due to the increase in basis weight from necking the material. .
ExamplQ 2 A roll o~ the neckable spunbond/meltblown/spunbond (SMS) polypropylene material of Example 1 havinq an initial width of about 17 inches was unwound on a "22 inch Face Coatin~ Line"
~ 3 ~ 3 rewind mad~ by the Black-Claw~on Company. Th~ wind-up speed was set at about 40 feet per minut~ and the unwind resistan~e force was set at 4n pound~ per square inch causing the necXable material to neck or constrict to a width o~ about 10 inches as it was wound up on a roll. The roll of necked materiAl was heated in an*AMSC0 Eagle Series 2021 Gravity Autocl~e at 121~C for 99 minutes which wa~ thought to b~ mor~ than the amount o time required to heat the entire roil to the autoclave temperature for more than 300 seconds. T~le heating cycle was ~ollowed by a 60 minute vacuum dry cycl~. The reversibly necked material produced in this manner was tested on the Instron Model 1122 Universal Testing Instrument and the re~ults are reported in Tables 3 and 4 under the heading "Example 2." It can be seen from Tables 3 and 4 that, when comparing the reversibly necked material to the neckable material, mo~t tengilo properties decreased, elongation to break increased in th~ cross-machine direction and decreased in the machine direction.
ExamPle_3 A nec~able web of spunbonded polypropylene having a basis weight of about O . 8 osy was tested on an Instron Model 1122 Universal Testi~g Instrument. The results are reported in Tables 5 and 7 under the heading "Control 3."
neckable web o~ tha same matQrial having a width o~
approximately 17.75 inche~ was ~ecked to a width of about 6.5 inches and hea~ treated on a series of steam cans accor~ing to the procedure of Example 1. The steam can temperatures were set fro~ about 265 to about 270 ~F but the measured temperatures o~
tha steam cans were from about 258 to about 263'F. The residence time of the necked material on the steam cans was about 270 seconds. The results o~ tes~ing are given in Tables 5 and 6 under the heading "Example 3." It can be seen ~rom Tables 5 and 6 that most tensile values were lowered by the proc~ss while cross-machine direction stretchability wa5 increased. Some of * - Trade-mark the drop in tensile strength is due to the increase in apparent ba~is w2ight of the material from necking.
E~am~le ~
A 17.75 inch wide roll of the nec~able spunbonded polypropylene material of Example 3 having a basls weight of 0.8 osy was necked to a width of about 9 inches according to the procedure o~
Exampla 2 on a "22 inch Face Coating Line" rewinder made by ~he Black~Clawson Company. The unwind speed wa~ set from a~out ~ to about 5 ~eet .per minut2 and the unwind brake ~orce was set at about 40 pounds per square inch.
The roll of necked material was heat treated for 6 hours at 120C
lS in a Fisher Econotemp~M Lab Oven Model 30 and allowed to cool.
The re~er~ibly necXed material produced in thi~ manner was tested on the Instron Model 1122 Universal Testing Instru~ent and the result~ are given in Tables 7 and 8 under the heading "Exam~le 4.l~ It can be seen fro~ th~ Tables that most tensile valua~
were low~red by the process while cross-machine direction stretchability was increased~ Some of the drop in ten~ile strength is due to the inrrease in apparent basis weight of the material fr om necking. The process produced consistent results.
2 5 Exam~le 5 The neckable spunbonded polypropylene material of Example 3 was proce~sed on a 22" Black-Clawson rewinder using the procPdure of Example 4. The~ wind-up speed was set at about 4 to a~out S feet per minut~ and ths unwind resistance force was set at 48 pounds 30 per square inch causing the 17 . 75 inch wide neckable material to neck or constrict to a width o~ about 8 . 5 inches as it was wound up on a roll. The roll o~ necked material was heated to 120 C
for 6 hours in a Fisher EconotempT~ Lab Oven Model 30 and allowed to cool. Th~ reversibly necked material was tested on the 35 Instron Model 1122 Universal Testing Instrument and the results are given in Tables 7 and 8 under the heading "Example 5."
~x~nle 6 A necka~ p~nbonded polypropy~en~ we~ having a ba~is weight o~
about 0.8 o~y, a width of about 8 inches and a length of about 10 Eeet was marked at 1 inch increments along both ~ts width and length. This material was wound up without tension onto a 2 inch feed roll of a hand-operated bench scale rewind unit. The neckable ~aterial was attached to the take-up roll of the rewind unit and wound with sufficient tension to neck the material to a lo 5 inch width.
After about lJ2 hour, about 2 feet o~ the necXed material was unwound ~rom th~ take-up roll and the distances be-tween the markin~ were measured. The sample was stretched 5 times to about its original width and then re~measur~d. The r~sults are shown on Table 9 in the row marked "Not Heat Set".
The remaining necked material on the roll was heat treated in an oven at 116~C (242F) for 1 hour and then cooled to ambient temperature forming a reversibly necked material. Two lengths o~
reversibly necked material were treated and measured according to the procedure dascri~ed above. The results are reported in Table 9 under the headings "Heat Set No. 1" and "Heat Set No. 2."
Referring to Table 9, it can be seen that a~ter 5 stretchings the "Not ~eat Set" material sample spacings returned very closely to the origi~al one ~1) inch separation while the reversibly necked "Heat Set" samples retained most o~ their reversibly necked dimensions and their cross-machine direction stretch.
Exam~le 7 Di.fferential Scanning Calorimetry analysis of a neckable spunbonded polypropylene was performed using a ~odel 1090 Thermal Analyzer available ~rom DuPont Instruments. The sample size was approximately 3.0 mg and the rate of temperature change was approximately 10C per minute. Values for heat o~ fusion were * - Tra~e-mark obtained by numerical inte~ration performed by the Model 1090 Th~rmal Analyz~r~ Values for ons~t of melting were determined from the deviation from linearity in a plot of Heat Flow versu~
Temperature. The results for the neckabl e spunbonded polypropylene material are reported in Table 10 under the heading IlNot Heat Set".
The spunbonded polypropylene wa~ heated for 2 hours at 130-C
while in the n~cked condition. The necked material was cooled and then Differential Scanning Calorimetry analysis of the treated samples wa~ performed as described above~ The results for the reversibly necked spunbonded polypropylene material are reported in Table 10 under the heading "Heat Set".
As shown in Table 10, the heats o~ fusion for the "Heat Sat"
samples are greater than the value~ for the "Not Heat Set"
samples. Additionally, the onset o~ melti~g for the l'Heat SQt'7 sample~ occurs at a lower tamperature than for the "Not Heat S~"
samples.
This application is related to U.S. Patent 4,981,747, issued January 1, 1991 in the name of Michael To Morman and is entitled "Composite Elast.ic Material Including a Reversibly Necked Material"; and copending Canadian Application Serial No.
609,711, filed August 29, 1989, also in the name of Michael T. Morman, entitled "Composite Elastic Necked-Bonded Material".
Disclosure of the presentl~ preferred embodiment of the invention is intended to ill~l~trate and not to llmit the invention. It i~
understood that those of skill in the art should be capable of making numerous modifications without departi~g from the true spirit and scope oE the invention.
GRAB TENSILES: Corrected Control 1 Example 1 MD TEA 1.07 + .28 .21 + .02 MD Peak Load 14.8 + 200 12.3 + .5 MD Elong 48 f 6 12.3 + .6 CD TEA .95 -~ .10 .57 + .11 CD Peak Load 14.9 ~ .7 4.4 + .6 CD Elong 44 + 3 150 + 13 CYCLE: 1 2 3 4 To Break Control 1 Cycled in cross~machine direction at 25% CD Elongation Peak TEA .70 + .04 .25 + .01 .20 + .01 .184 + .005 .882 + .08 Peak Load 15.9 + 1.0 13.2 + .7 12.2 + .7 11.6 + .5 18.3 + .8 Perm. Set 35 + 3 39 + 5 45 + 3 46 + 3 38 _ 2 Example 1 Cycled in cross-machine direction at 85% CD Elongation Peak TEA .095 + .007 .035 + .003 .029 r ~ 003 .026 -r ~ 003 .600 + .1 Peak Load .881 + .1 .786 + .1 .746 + .1 .722 + .1 4.23 ~ .4 Perm. Set 26 + 1 30 + 1 34 ~ .5 41. + 1 154 + 11 :~ 3 ~
GRAB TENSILES:
Control 1 Example 2 MD TEA 1.07 + .28 .27 r ~ 05 MD Peak Load 14.8 + 2.0 g.o + .
MD Elong 48 + 6 22 -~ 3 CD TEA .95 + .10 .46 + .08 CD Peak Load 14.9 _ .7 6.7 + .4 CD Elong 44 + 3 93 + 6 -CYCLE: 1 2 3 4 To Break Control 1 Cycled in cross-machine direction at 25~ CD Elongation Peak TEA . 70 + .04 .25 + .01 .20 + .01 .184 + .005 .882 + .08 Peak Load 15.9 ~ 1.0 13.2 ~ .7 12.2 -~ .7 11.6 + .5 18.3 + .8 Perm. Set 35 + 3 39 + 5 45 + 3 46 + 3 38 + 2 Example 2-Cycled in cross-machine direction at 52% CD Elongation Peak TEA .028 + .008 .013 + .004 .012 + .003 .013 + .006 .706 + .07 Peak Load .665 + .2 .57 + .17 .54 + .15 .52 -r .15 7.95 r ,4 Perm. Set 26 + 1 30 + 2 33 + 1 43 ~ 6 97 + 3 ~ 3 ~ 3 GRAB TENSILES:
Control 3 Example 3 MD TEA 1.38 + .25 .25 ~ .07 MD Peak Load17.9 + .6 15.5 + 2.3 MD Elong 56 + 6 12 + 2 CD TEA 1.5 + .1 .37 + .07 CD Peak Load 16.3 ~ .6 2.9 ~ .4 CD Elong 67 + 3 179 + 10 CYCLE: 1 2 3 4 To Break Example 3 Cycled in machine direction at 6.5% MD Elongation Peak TEA .176 + .01 .124 + oO1 .125 + .002 .11 + . 006 .504 + .1 Peak Load 20.9 ~ .8 17.8 + .8 17.9 + .4 16.6 ~ .5 33 + 3 Perm. Set 13 + 2 10 + 1.0 Example 3 Cycled in cross-machine direction at 85% CD Elongation Peak TEA .05 + .006 .022 + .002 .017 + .002 .016 + .002 .257 + .06 Peak Load .91 + .12 .81 + .11 .77 + .1 .75 + .1 2.45 ~ .17 Perm. Set 27 + 3 31 + 1 35 + .5 49 + 8 144 ~ 8 ~ 3 ~ 3 -GRAB TENSILES:
Control 3 Example 4 Exam~ e 5 MD TEA 1.38 + .25 .25 + .06 .22 + .02 MD Peak Load17.9 + .610.6 + 1.0 10.7 -~ .5 MD Elong 56 + 6 16 + 2 15 + 2 CD TEA 1.5 + .1 .28 + .05 .33 + .07 CD Peak Load16.3 + .6 3.7 + .5 4.1 + .7 CD Elong 67 + 3 143 + 6 157 + 7 CYCLE: 1 2 3 4 To Break Example 4 Cycled in cross-machine direction at 80% CD elongation Peak TEA .033 + .006 .020 + .003 .018 + .003 .017 + .002 .41 + .01 Peak Load .325 + .07 .30 + .07 .2~ + .06 .28 + ~06 4.51 + .6 Perm. Set 26 + 1 30 + 1 32 + 2 42 + 1 138 + 6 :~ 3 ~ 3 INCHES
(INCHES) (INCHES) SAMPLE MD CD CD MD
-Not Heat Set1.094 .795 .982 1.049 +.026 +.017 +.017 +.025 Heat Set No. 1 1.19 .630 .73 1.16 +.03 +.04 +.016 ~.03 Heat Set No. 2 1.23 .61 0.71 1.22 +.0~ +.06 +.05 +.04 Not Heat SetHeat Set Heat of 83.9 95.9 Fusion 86 .1 90. 5 (J/g) 8~.0 90.5 AVERAGE 84 . 6 + 1. 2 92 . 3 + 3 .1 Onset of 128 118 Mel ti ng 133 118 ( C) 132 11~
AVERAGE 131 + 2.6 117 * 2.3 CYCLE: 1 2 3 4 To Break Example 5 Cycled in machine direction at 8.3% MD Elongation Peak TEA .18 + .01 .122 + .01 ~ 004 ~11 + .007 .329 + .07 Peak Load 15~4 r .6 13.2 + .6 12.7 + .4 12.4 ~ .5 19.4 + 1~1 Perm. Set 18.8 + 1.6 1008 + 1.2 Example 5 Cycled in cross-machine direction at 88~ CD Elongation Peak TEA .019 + .002 .005 ~ .0009 .003 + .001 .002 ~ .001 .390 ~ .130 Peak Load .260 + .084 .24 + .074 .233 + .006 .225 + .069 4.12 + .608 Perm. Set 25 + 2 30 -~ 2 32 + 1 38 + 1 151 + 13
Claims (34)
1. A method of producing a reversibly necked material adapted to stretch at least about 75 percent and recover at least about so percent when stretched about 75 percent, said method comprising:
applying a tensioning force to neck a material;
heating said necked material ; and cooling said necked material; and wherein said reversibly necked material possesses a greater heat of fusion than said material before heating while necked.
applying a tensioning force to neck a material;
heating said necked material ; and cooling said necked material; and wherein said reversibly necked material possesses a greater heat of fusion than said material before heating while necked.
2. A method of producing a reversibly necked material adapted to stretch at least about 75 percent and recover at least about percent when stretched about 75 percent, said method comprising:
applying a tensioning force to neck a material;
heating said necked material ; and cooling said necked material; and wherein said reversibly necked material possesses a lower onset of melting than said material before heating while necked.
applying a tensioning force to neck a material;
heating said necked material ; and cooling said necked material; and wherein said reversibly necked material possesses a lower onset of melting than said material before heating while necked.
3. The method of claim 2 wherein said material is selected from the group consisting of a bonded carded web, a web of spunbonded fibers, a web of meltblown fibers, and a laminate of at least one web of spunbonded fibers and least one web of meltblown fibers.
4. The method of claim 3 wherein said meltblown fibers include meltblown microfibers.
5. The method of claim 3 wherein said fibers comprise a polymer selected from the group consisting of polyolefins, polyesters, and polyamides.
6. The method of claim 5 wherein said polyolefin is selected from the group consisting of one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
7. The method of claim 2 wherein said material has a basis weight of from about 6 to about 200 grams par square meter.
8. The method of claim l wherein said reversibly necked material is adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
9. The method of claim 2 wherein said reversibly necked material is adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
10. A reversibly necked material adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent wherein said reversibly necked material has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the material possesses a greater heat of fusion than before being reversibly necked.
11. A reversibly necked material adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent wherein said reversibly necked material has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the material possesses a lower onset of melting than before being reversibly necked.
12. The material of claim 11 wherein said reversibly necked material comprises a web selected from the group consisting of a bonded carded web, a web of spunbonded fibers, a web of meltblown fibers, and a multilayer material of at least one web of meltblown fibers and at least one web of spunbonded fibers.
13. The material of claim 12 wherein said meltblown fibers include meltblown microfibers.
14. The material of claim 12 wherein said fibers comprise a polymer selected from the group consisting of polyolefins, polyesters, and polyamides.
15. The material of claim 14 wherein said polyolefin is selected from the group consisting of one or more of polyethylene, polypropylene, polybutene, ethylene copolymers, propylene copolymers, and butene copolymers.
16. The material of claim 11 wherein said reversibly necked material is a composite material comprising a mixture of meltblown fibers and one or more secondary materials selected from the group consisting of textile fibers, wood pulp fibers, particulates and super-absorbent materials.
17. The material of claim 10 wherein said reversibly necked material is adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
18. The material of claim 11 wherein said reversibly necked material is adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
19. A reversibly necked polypropylene web adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent, wherein said reversibly necked polypropylene web has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the material has a greater heat of fusion than before being reversibly necked.
20. A reversibly necked polypropylene web adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent, wherein said reversibly necked polypropylene web has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the material has a lower onset of melting than before being reversibly necked.
21. The material of claim 20 wherein said reversibly necked polypropylene web comprises a web selected from the group consisting of a bonded carded web of fibers, a web of spunbonded fibers, a web of meltblown fibers, and a multilayer material of at least one web of meltblown fibers and at least one web of spunbonded fibers.
22. The material of claim 20 wherein said meltblown fibers include meltblown microfibers.
23. The material of claim 20 wherein said reversibly necked polypropylene web is a composite material comprising a mixture meltblown fibers and one or more secondary materials selected from the group consisting of textile fibers, wood pulp fibers, particulates and super-absorbent materials.
24. The material of claim 19 wherein said reversibly necked material is adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
25. The material of claim 20 wherein said reversibly necked material is adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
26. A multilayer material including at least one material which is reversibly necked by drawing at ambient temperature and then heating and cooling while in a necked configuration so that the material possess a greater heat of fusion than before being reversibly necked.
27. A multilayer material comprising at least two reversibly necked materials adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent, and wherein said reversibly necked materials have been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the materials possess a greater heat of fusion than before being reversibly necked.
28. A multilayer material comprising at least two reversibly necked materials adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent, and wherein said reversibly necked materials have been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the materials possess a lower onset of melting than before being reversibly necked.
29. The material of claim 28 wherein said reversibly necked material comprises a web selected from the group consisting of a bonded carded web, a web of spunbonded fibers, and a web of meltblown fibers.
30. The material of claim 27 wherein said reversibly necked material is adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
31. The material of claim 28 wherein said reversibly necked material is adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
32. A reversibly necked material adapted to stretch at least about 125 percent and recover at least about 50 percent when stretched about 125 percent.
33. A reversibly necked coherent web formed of fibers joined solely by interfiber bonding, said web being adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent wherein said reversibly necked web has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the web possesses a greater heat of fusion than before being reversibly necked and wherein said fibers are joined solely by interfiber bonding to form a coherent web structure.
34. A reversibly necked coherent web formed of fibers joined solely by interfiber bonding, said web being adapted to stretch at least about 75 percent and recover at least about 50 percent when stretched about 75 percent wherein said reversibly necked web has been necked by drawing at ambient temperature and then heated and cooled while in a necked configuration so that the web possesses a lower onset of melting than before being reversibly necked and wherein said fibers are joined solely by interfiber bonding to form a coherent web structure.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US07/249,050 US4965122A (en) | 1988-09-23 | 1988-09-23 | Reversibly necked material |
US249,050 | 1988-09-23 |
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CA1311113C true CA1311113C (en) | 1992-12-08 |
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ID=22941850
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Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA000609712A Expired - Lifetime CA1311113C (en) | 1988-09-23 | 1989-08-29 | Reversibly necked material and process to make it |
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EP (1) | EP0388465B1 (en) |
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EP0156234B2 (en) * | 1984-03-17 | 2001-01-03 | Asahi Kasei Kogyo Kabushiki Kaisha | Heat-resistant non-woven fabric having a high elongation at break |
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DE3689058T2 (en) * | 1985-07-30 | 1994-01-13 | Kimberly Clark Co | Non-woven elastic pleated. |
US4657802A (en) * | 1985-07-30 | 1987-04-14 | Kimberly-Clark Corporation | Composite nonwoven elastic web |
US4720415A (en) * | 1985-07-30 | 1988-01-19 | Kimberly-Clark Corporation | Composite elastomeric material and process for making the same |
US4652487A (en) * | 1985-07-30 | 1987-03-24 | Kimberly-Clark Corporation | Gathered fibrous nonwoven elastic web |
US4606964A (en) * | 1985-11-22 | 1986-08-19 | Kimberly-Clark Corporation | Bulked web composite and method of making the same |
US4652322A (en) * | 1986-02-28 | 1987-03-24 | E. I. Du Pont De Nemours And Company | Process for bonding and stretching nonwoven sheet |
DE3608902A1 (en) * | 1986-03-17 | 1987-09-24 | Brueckner Trockentechnik Gmbh | METHOD FOR THE HEAT TREATMENT OF A MATERIAL IN A TENSING MACHINE |
US4696779A (en) * | 1986-03-17 | 1987-09-29 | Kimberly-Clark Corporation | Method and apparatus for forming an isotropic self-adhering elastomeric ribbon |
US4781966A (en) * | 1986-10-15 | 1988-11-01 | Kimberly-Clark Corporation | Spunlaced polyester-meltblown polyetherester laminate |
US5467230A (en) * | 1993-08-16 | 1995-11-14 | Lowell Engineering Corp. | Dual pivoted member mount for mirror |
-
1988
- 1988-09-23 US US07/249,050 patent/US4965122A/en not_active Expired - Lifetime
-
1989
- 1989-08-29 CA CA000609712A patent/CA1311113C/en not_active Expired - Lifetime
- 1989-09-08 MX MX017480A patent/MX167638B/en unknown
- 1989-09-20 AU AU43438/89A patent/AU628871B2/en not_active Expired
- 1989-09-20 DE DE68917289T patent/DE68917289T2/en not_active Expired - Lifetime
- 1989-09-20 WO PCT/US1989/004107 patent/WO1990003258A1/en active IP Right Grant
- 1989-09-20 JP JP1510664A patent/JPH03501507A/en active Pending
- 1989-09-20 EP EP89911491A patent/EP0388465B1/en not_active Expired - Lifetime
- 1989-09-20 AT AT89911491T patent/ATE109394T1/en active
- 1989-09-20 KR KR1019900701056A patent/KR0153506B1/en not_active IP Right Cessation
- 1989-09-20 ES ES8903180A patent/ES2029147A6/en not_active Expired - Lifetime
Also Published As
Publication number | Publication date |
---|---|
EP0388465A1 (en) | 1990-09-26 |
JPH03501507A (en) | 1991-04-04 |
ATE109394T1 (en) | 1994-08-15 |
DE68917289T2 (en) | 1994-11-17 |
KR0153506B1 (en) | 1998-12-01 |
AU4343889A (en) | 1990-04-18 |
AU628871B2 (en) | 1992-09-24 |
US4965122A (en) | 1990-10-23 |
WO1990003258A1 (en) | 1990-04-05 |
ES2029147A6 (en) | 1992-07-16 |
KR900701510A (en) | 1990-12-03 |
EP0388465B1 (en) | 1994-08-03 |
DE68917289D1 (en) | 1994-09-08 |
MX167638B (en) | 1993-03-30 |
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Legal Events
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MKLA | Lapsed |