CA2048333C - Hydraulically needled nonwoven pulp fiber web - Google Patents

Hydraulically needled nonwoven pulp fiber web Download PDF

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Publication number
CA2048333C
CA2048333C CA002048333A CA2048333A CA2048333C CA 2048333 C CA2048333 C CA 2048333C CA 002048333 A CA002048333 A CA 002048333A CA 2048333 A CA2048333 A CA 2048333A CA 2048333 C CA2048333 C CA 2048333C
Authority
CA
Canada
Prior art keywords
web
nonwoven
pulp
fibrous web
nonwoven fibrous
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 - Fee Related
Application number
CA002048333A
Other languages
French (fr)
Other versions
CA2048333A1 (en
Inventor
Harold K. Barnes
Ronald F. Cook
Cherie H. Everhart
Ann L. Mccormack
Fred R. Radwanski
Paulette M. Rosch
Adrian J. Trevisan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Original Assignee
Kimberly Clark Worldwide Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Worldwide Inc filed Critical Kimberly Clark Worldwide Inc
Publication of CA2048333A1 publication Critical patent/CA2048333A1/en
Application granted granted Critical
Publication of CA2048333C publication Critical patent/CA2048333C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
    • D21H25/005—Mechanical treatment
    • 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
    • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
    • D04H1/26—Wood pulp
    • 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
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24174—Structurally defined web or sheet [e.g., overall dimension, etc.] including sheet or component perpendicular to plane of web or sheet
    • Y10T428/24182—Inward from edge of web or sheet
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y10T428/249964—Fibers of defined composition
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
    • Y10T428/249964—Fibers of defined composition
    • Y10T428/249965—Cellulosic

Abstract

A hydraulically needled nonwoven pulp fiber web is disclosed. This nonwoven pulp fiber web has a mean flow pore size ranging from about 18 to about 100 microns, and a Frazier porosity of at least about 100 cfm/ft2. The web may also be characterized by a specific volume ranging from about 8 to about 15 cm3/g. The nonwoven pulp fiber web may contain a significant proportion of low-average fiber length pulp and still have a total absorptive capacity greater than about 500 percent and a wicking rate greater than about 2 centimeters per 15 seconds.
The hydraulically needled nonwoven pulp fiber web may be used as a hand towel, wipe, or as a fluid distribution material in an absorbent personal care product. Also disclosed is a method of making the hydraulically needled nonwoven pulp fiber web.

Claims (33)

1. A hydraulically needled nonwoven wet laid fibrous web wherein the fibrous material of the web consists essentially of pulp, said nonwoven web having a mean flow pore size ranging from about 18 to about 100 microns and a Frazier porosity of at least about 100 cfm/ft2.
2. The nonwoven fibrous web of claim 1 wherein the web has a specific volume ranging from about 8 to about 15 cm3 g.
3. The nonwoven fibrous web of claim 1 wherein the web has a total absorptive capacity greater than about 500 percent and a wicking rate greater than about 2 cm per 15 seconds.
4. The nonwoven fibrous web of claim 1 wherein the pulp is a high-average fiber length pulp.
5. The nonwoven fibrous web of claim 4 wherein the pulp has an average fiber length from about 2 to about 5 mm.
6. The nonwoven fibrous web of claim 1 wherein the pulp comprises more than about 50% by weight, low-average fiber length pulp and less than about 50% by weight, high-average fiber length pulp.
7. The nonwoven fibrous web of claim 6 wherein the low-average fiber length pulp has an average length from about 0.8 mm to about 1.1 mm.
8. The nonwoven fibrous web of claim 4 wherein the high-average fiber length pulp is a wood pulp selected from bleached virgin softwood fiber pulp and unbleached virgin softwood fiber pulp.
9. The nonwoven fibrous web of claim 1 wherein the mean flow pore size is from about 20 to about 40 microns.
10. The nonwoven fibrous web of claim 3 wherein the nonwoven web has a total absorptive capacity between about 500 and about 750 percent.
11. The nonwoven fibrous web of claim 3 wherein the nonwoven web has a wicking rate from about 2 to about 3 cm per 15 seconds.
12. The nonwoven fibrous web of claim 1 wherein the nonwoven web has a Frazier porosity from about 150 to about 200 cfm/ft2.
13. The nonwoven fibrous web of claim 1 wherein the nonwoven web further comprises particulates selected from the group consisting of activated charcoal, clay, starch, and hydrocolloid materials commonly referred to as superabsorbent materials.
14. An absorbent paper towel comprising the nonwoven fibrous web of claim 1 having a basis weight ranging from about 18 to about 120 grams per square meter.
15. An absorbent paper towel according to claim 14 wherein the nonwoven fibrous web has a basis weight ranging from about 30 to about 75 grams per square meter.
16. A fluid distribution component of an absorbent personal care product, said component comprising the nonwoven fibrous web of claim 1 having a basis weight ranging from about 7 to about 70 grams per square meter.
17. The fluid distribution component of an absorbent personal care product according to claim 16, wherein said component has a basis weight ranging from about 25 to about 50 grams per square meter.
18. A hydraulically needled nonwoven wet laid fibrous web wherein the fibrous material of the web consists essentially of pulp, said web having a mean flow pore size ranging from about 18 to about 100 microns and a Frazier porosity of at least about 100 cfm/ft2, said pulp comprising:
at least about 50%, by weight, pulp having an average fiber length from about 0.7 to 1.2 mm; and less than about 50%, by weight, pulp having an average fiber length from about 1.5 to about 6 mm.
19. The nonwoven fibrous web of claim 18 wherein the web has a specific volume ranging from about 8 to about 15cm3 /g.
20. The nonwoven fibrous web of claim 18 wherein the web has a total absorptive capacity greater than about 500 percent and a wicking rate greater than about 2 cm per 15 seconds.
21. The nonwoven fibrous web of claim 18 wherein the mean flow pore size ranges from about 20 to about 40 microns.
22. The nonwoven fibrous web of claim 20 wherein the nonwoven web has a total absorptive capacity between about 500 and about 750 percent.
23. The nonwoven fibrous web of claim 20 wherein the nonwoven web has a wicking rate between about 2 to about 3 cm per 15 seconds.
24. The nonwoven fibrous web of claim 18 wherein the nonwoven web has a Frazier porosity between about 150 and 250 cfm/ft2.
25. The nonwoven fibrous web of claim 18 wherein the nonwoven web further comprises particulates selected from the group consisting of activated charcoal, clays, starches, and hydrocolloid materials commonly referred to as superabsorbent materials.
26. An absorbent paper towel comprising the nonwoven fibrous web of claim 18 having a basis weight ranging from about 18 to about 120 grams per square meter.
27. A fluid distribution component of an absorbent personal care product, said component comprising the nonwoven fibrous web of claim 18 having a basis weight ranging from about 7 to about 70 grams per square meter.
28. A method of making a hydraulically needled nonwoven fibrous web wherein the fibrous material of the web consists essentially of pulp, said web having a mean flow pore size ranging from about 18 to about 100 microns and a Frazier porosity of at least about 100 cfm/ft2, said method comprising the steps of:
forming a wet-laid nonwoven web from an aqueous dispersion of pulp fibers;
hydraulically needling the wet-laid nonwoven web on a foraminous surface at an energy level of about 0.03 to about 0.002 horsepower-hours/pound of dry web; and drying the wet-laid, hydraulically needled nonwoven web.
29. The method of claim 28 wherein the foraminous surface is a single plane mesh having a mesh size of from about 40X40 to about 100x100.
30. The method of claim 28 wherein the foraminous surface is selected from mufti-ply meshes having an effective mesh size of from about 50x50 to about 200X200.
31. The method of claim 28 wherein the drying step utilized a process selected from the group consisting of through-air-drying, infra red radiation, yankee dryers, steam cans, microwaves, and ultrasonic energy.
32. The method of claim 28 wherein the wet-laid nonwoven web is hydraulically needled while at a consistency of about 25 to about 35 percent, by weight, solids.
33. The method of claim 28 wherein the aqueous dispersion of pulp fibers comprises more than about 50%, by weight, low-average fiber length pulp and less than about 50%, by weight, high-average fiber length pulp.
CA002048333A 1990-11-01 1991-08-01 Hydraulically needled nonwoven pulp fiber web Expired - Fee Related CA2048333C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US07/608,095 US5137600A (en) 1990-11-01 1990-11-01 Hydraulically needled nonwoven pulp fiber web
US608,095 1990-11-01

Publications (2)

Publication Number Publication Date
CA2048333A1 CA2048333A1 (en) 1992-05-02
CA2048333C true CA2048333C (en) 2001-01-23

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA002048333A Expired - Fee Related CA2048333C (en) 1990-11-01 1991-08-01 Hydraulically needled nonwoven pulp fiber web

Country Status (12)

Country Link
US (1) US5137600A (en)
EP (1) EP0483816B1 (en)
JP (1) JP3083602B2 (en)
KR (1) KR100188053B1 (en)
AU (1) AU646100B2 (en)
BR (1) BR9104746A (en)
CA (1) CA2048333C (en)
DE (1) DE69124064T2 (en)
ES (1) ES2095897T3 (en)
MX (1) MX9101883A (en)
TW (1) TW215465B (en)
ZA (1) ZA918180B (en)

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