MANUFACTURING METHOD AND NONWOVEN MATERIAL

Abstract: This invention relates to a method of making nonwovens with good absorbency, softness and strength, where the fibrous web (2) is formed by air laying from natural fibres such as wood fibres or from a blend of natural fibres and bonding fibres after which the web is both prebonded and spunlaced, and to a nonwoven (14) produced according to this method. The invention relates particularly but not exclusively to such nonwovens that can be used in wet wipes or in the surface layers of absorbent disposables such as children's diapers, feminine pads, incontinence products, etc.

Description: MANUFACTURING METHOD AND NONWOVEN MATERIAL Field of the invention This invention relates to a manufacturing method of nonwovens where the web is formed using an air laying method after which the web is both prebonded and hydro entangled- and to a nonwoven manufactured according to the said method. More particularly, this invention relates to nonwovens made from natural fibres such as wood fibre or from natural fibres and plastic fibres, which nonwovens have good absorbency, softness and strength properties. Particularly, but not exclusively, this invention relates to a nonwoven which can be used for wet wipes or for the surface layers of absorbent disposables such as children's diapers, feminine pads and incontinence products etc. Background of the invention In the manufacture of air laid nonwovens, natural fibres are used to form a web onto which a bonding agent or bonding fibres are applied which under the influence of heat bind the formed web into a porous material layer. Such layers are formed on top of each other as many as the desired thickness of the product requires. Material layers produced as described are used in the manufacture of various table top, hygiene, hospital and wipe products. The problem with this type of products, however, is their often inadequate strength resulting in breaking of products or deleterious dusting of fibres. In the manufacture of spunlaced nonwovens, the fibrous structure is created by using fine water jets to entangle the fibres of a fibrous web with each other. These jets are directed at the fibrous layer supported by a liquid permeable wire moving in a specific speed When the fibres pass under the jets, the liquid jets penetrating the layer impinge the fibres. The joint influence of this and of the jets reaching the wire cause the fibres to entangle with each other. This method can be used to produce nonwoven fabrics from fibres of different origin selected on the basis of their intended usage, as long as the fibre minimum length is adequate. However, the problem with this type of a process is often that short fibres are flushed out or that they pass through the wire which causes fibre loss, cleaning problems and extra costs. Summary of the invention This invention relates to a method which can be used to create from low-cost raw materials a nonwoven with good absorbency, softness and strength which, if necessary, can be manufactured so that it decomposes quickly, for example, in a natural environment. A method according to the present invention is characterized in that the manufacture of the nonwoven comprises the following stages: A fibrous web is air laid from natural fibres such as wood fibres or a blend of natural fibres and bonding fibres; The fibrous web is prebonded either by using bonding fibres and heat, or by applying a liquid bonding agent to the fibrous web and bonding it with thermal bonding, or by moisturising the fibrous web and bonding it with heated calenders; - The fibrous web is spunlaced. Thus a low-cost nonwoven according to the present invention is produced stage by stage in a production line which comprises the aforesaid stages. Good absorbency, softness and low raw material costs are based on the large proportion of wood fibres. Extremely good biodegradability can be achieved by using merely wood fibre, such as mechanical or chemical pulp, and in addition, if necessary, a small amount of rayon fibre. To the surprise of the applicant, prebonding prevents fibres from flushing during spunlacing. Spunlacing produces the good strength of the web while maintaining good absorbency and softness. Thus the surprising result is that the nonwoven produced is absorbent, soft and strong. Raw material costs of the nonwoven are low and the nonwoven can be manufactured, if necessary, so that it has very good biodegradability. Other preferred embodiments of the method according to the present invention are characterized by what is stated in the claims. A nonwoven according to the present invention and its preferred embodiments are also characterized by what is stated in the claims. Brief description of the attached drawing The invention is described with the help of the following example with reference to the attached drawing, Figure 1, presenting a production line of a nonwoven according to the present invention. Detailed description of the preferred embodiments Figure 1 presents a nonwoven production line where a fibrous web (2) is formed on a wire (1) with the help of a former (3). A blend of fibres and air is blown to the former which extends crosswise over the whole width of the wire, after which the blend is mixed and screened to form a uniform fibrous web on the moving wire (1) underneath according to the known technique. The number of formers used can be selected on the basis of the desired layer thickness and as production requires; a layer after a layer is formed on the same production line until the desired thickness is achieved. In addition, the proportion of different fibres in different layers can be varied within the frames of the invention. Wood fibre is preferably relatively long-fibred mechanical or chemical pulp whereas rayon fibres should be staple fibres made of regenerated cellulose. The plastic bonding and/or reenforcing fibres may be of any staple fibre quality suitable for nonwovens, e.g., polyethylene, polypropylene or for instance bicomponent fibres with a core of polypropylene and a sheath of polyethylene. The particle content limits in the fibrous web can be, for example, as follows: Natural fibre such as wood fibre 0...100 %, plastic fibre 0...50 %, and rayon fibre 0...100 %. The basis weight of the fibrous web can be, for example, 30...300 g/m 2 . The fibrous web is prebonded with the help of plastic fibres by blending the fibre- air blend with 3...50 % of plastic fibres of thermobonding quality, preferably 5 bi component fibres with a core of polypropylene and a sheath of polyethylene. After the forming stage, the upper surface of the fibrous web is calendered with a heated roll (5), and the under side of the web with a heated roll (7), after which the fibrous web is thermobonded in a dryer (8). After prebonding the fibrous web is spunlaced according to the known method on a bonding station (9) after which o the web is dried in a dryer (10). The fibrous web is prebonded with the help of a liquid bonding agent by applying the aqueous latex binder on the upper surface of the web with a spray manifold (11). The penetration of the latex binder into the web is controlled, for instance, 5 by selecting the composition and pressure of the sprayed binder appropriately to ensure penetration of the binder deep enough. One further way of controlling the penetration of the binder is to use a suction box (not shown) placed opposite the spray manifold on the other side of the web whereby penetration can be controlled by adjusting the vacuum applied by the suction box on the web. After spraying the o binder, the water is evaporated and the binder matured and perhaps cured in a dryer (8). Having been bonded on the upper surface, the web can be transferred to another prebonding stage (not shown) where the prebonding process is repeated, this time from the under side of the web. After prebonding, the web is spunlaced according to the known method on a bonding station (9) after which the 5 web is dried in a dryer (10). The fibrous web is prebonded with the help of moisturising and thermocalendering by adding moisture on the upper surface of the web with a manifold (12) after which the surface is calendered with a heated roll (5). The 0 under side of the web is correspondingly moisturised with a manifold (13) after which the thermocalendering is performed with a heated roll (7). As a result of moisturising and thermocalendering, fibre bonds are created which noticeably increase web strength thus enabling the transfer of the web onto a bonding station (9) where spunlacing is carried out according to the known method. The nonwoven (14) is essentially only one seamless layer even though the thickness and composition of the layers can be adjusted and controlled during the forming stage. What is essential is that the layers are formed and the fibrous web prebonded and spunlaced on the same line.

Claims: Claims: 1. A method of making a nonwoven (14) with good absorbency, softness and strength by air laying a fibrous web (2) from natural fibres such as wood fibres 5 and/or rayon fibres, or from a blend of wood fibres and/or rayon fibres and bonding fibres, and by spunlacing the web, characterized in that the fibrous web is prebonded prior to spunlacing. 2. A method according to claim 1, characterized in that prebonding is carried out o with the help of plastic fibres which are blended into a fibre-air flow prior to the forming stage of the fibrous web (2) which is prebonded with heat in a dryer (8). 3. A method according to claim 2, characterized in that the plastic fibres are bicomponent fibres with a core of polypropylene and a sheath of polyethylene. 5 4. A method according to claim 2, characterized in that the proportion of plastic fibres is 2...50 % of the surface weight of the fibrous web. 5. A method according to claim 1, characterized in that prebonding is carried out o with the help of a liquid binder which is applied to the upper surface of the fibrous web (2) with a spray manifold (11) and the said fibrous web is prebonded with heat in a dryer (8). 6. A method according to claim 1 , characterized in that prebonding is carried out 5 with the help of a liquid binder which is applied to the upper surface of the fibrous web (2) with a spray manifold (11) and the said fibrous web is prebonded with heat in a dryer (8) and the binder is applied to the under side of the fibrous web (2) with a spray manifold underneath (not shown) and the said fibrous web is prebonded with heat in a dryer (not shown). 0 7. A method according to claim 5, characterized in that the proportion of natural fibres such as wood fibres is 0...100 % of the surface weight, the proportion of rayon fibres is 0...100 % of the surface weight and the proportion of plastic fibres is 0...50 % of the surface weight. 8. A method according to claim 1, characterized in that prebonding is carried out by adding moisture on the upper surface of the fibrous web with a manifold (12) after which the surface is calendered with a heated roll (5). 9. A method according to claim 1 , characterized in that prebonding is carried out by adding moisture on the upper surface of the fibrous web with a manifold (12) after which the surface is calendered with a heated roll (5), and by adding moisture on the under side of the fibrous web with a manifold (13) after which the surface is calendered with a heated roll (7). 10. A method according to claims 7 - 8, characterized in that the proportion of natural fibres such as wood fibres is 0...100 % of the surface weight, the proportion of rayon fibres is 0...100 % of the surface weight and the proportion of plastic fibres is 0...50 % of the surface weight. 11. A nonwoven (14) with good absorbency, softness and strength which is manufactured by air laying from natural fibres such as wood fibres, and/or rayon fibres, or from a blend of wood fibres and/or rayon fibres and bonding fibres, and which has been spunlaced, characterized in that the fibrous web is formed essentially as one layer and prebonded prior to spunlacing on the same continuous production line. 12. A nonwoven (14) according to claim 10, characterized in that the proportion of natural fibres such as wood fibres is 0...100 %, the proportion of rayon fibres 0...100 %, and the proportion of plastic fibres 0...50 %.

Inventors: NIEMI TAPIO, PIRINEN PENTTI, NIEMI, TAPIO, PIRINEN, PENTTI
Applicants: NIEMI TAPIO, PIRINEN PENTTI, UPM KYMMENE OY, NIEMI, TAPIO, PIRINEN, PENTTI, UPM-KYMMENE OY
Application year: 1996
Main classification: D04H1
IPC codes: A61F5, A61F13, D04H1