Spunbond laminate

Patent metadata

Field	Value
Publication number	US-11318712-B2
Application number	US-202016940926-A
Country	US
Kind code	B2
Filing date	Jul 28, 2020
Priority date	Jul 30, 2019
Publication date	May 3, 2022
Grant date	May 3, 2022

Abstract

A spunbond nonwoven laminate has a first spunbond nonwoven layer having crimped filaments formed by a first component on an outer surface of the filaments of the first layer consisting or substantially consisting of a polyolefin and a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the first layer. A second outermost spunbond nonwoven layer on the first layer having filaments as a cover layer and formed by a first component on an outer surface of the filaments of the second layer consisting or substantially consisting of a polyolefin, and a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the second layer.

First claim

The invention claimed is:

1. A spunbond nonwoven laminate comprising:
a first spunbond nonwoven layer having crimped multicomponent or bicomponent filaments formed by
a first component on an outer surface of the filaments of the first layer consisting or substantially consisting of a polyolefin, and
a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the first layer; and

a second outermost spunbond nonwoven layer on the first layer having multicomponent or bicomponent filaments as a cover layer and formed by
a first component on an outer surface of the filaments of the second layer consisting or substantially consisting of a polyolefin, and
a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the second layer, a polyolefin portion of the first component of the filaments of the second layer being greater than a polyolefin portion of the first component of the filaments of the first layer, a degree of crimp of the filaments of the second layer being equal to or less than a degree of crimp of the filaments of the first layer.

2. The spunbond nonwoven laminate according to claim 1 , wherein a titer of the filaments of the second outermost layer is less than a titer of the filaments of the first layer.

3. The spunbond nonwoven laminate according to claim 1 , wherein the second component of the filaments of the first layer consists or substantially consists of polypropylene or polyester.

4. The spunbond nonwoven laminate according to claim 1 , wherein the polyolefin portion of the filaments of the first layer is less than 40% by weight.

5. The spunbond nonwoven laminate according to claim 1 , wherein the filaments of the first layer have a titer of 1.5 den to 2.5 den.

6. The spunbond nonwoven laminate according to claim 1 , wherein the polyolefin of the first component of the filaments of the first layer is polyethylene having a melt flow rate of less than 35 g/10 min.

7. The spunbond nonwoven laminate according to claim 1 , wherein the second component of the filaments of the first layer consists or substantially consists of polypropylene having a melt flow rate of more than 25 g/10 min.

8. The spunbond nonwoven laminate according to claim 1 , wherein the multicomponent or bicomponent filaments of the second spunbond nonwoven layer are crimped filaments.

9. The spunbond nonwoven laminate according to claim 1 , wherein the second component of the filaments of the second layer consists or substantially consists of polypropylene.

10. The spunbond nonwoven laminate according to claim 1 , wherein the polyolefin portion of the filaments of the second layer is 40 wt. % to 65 wt. %.

11. The spunbond nonwoven laminate according to claim 1 , wherein the filaments of the second layer have a titer of less than 1.7 den.

12. The spunbond nonwoven laminate according to claim 1 , wherein the multicomponent or bicomponent filaments of the second layer have an eccentric core-sheath configuration or a side-by-side configuration.

13. The spunbond nonwoven laminate according to claim 1 , wherein the first component on the outer surface of the filaments of the second layer consists or substantially consists of polyethylene having a melt-flow rate greater than 15 g/10 min.

14. The spunbond nonwoven laminate according to claim 9 , wherein the melt flow rate of the polypropylene of the second component of the second layer is more than 25 g/10 min.

15. The spunbond nonwoven laminate according to claim 1 , wherein a weight per unit area of the second layer is less than a weight per unit area of the first layer.

16. The spunbond nonwoven laminate according to claim 1 , wherein a basis weight of the spunbond nonwoven laminate is less than 30 g/m 2 .

17. The spunbond laminate according to claim 1 , wherein a strength of the spunbond nonwoven laminate in a machine direction is greater than 25 N/5 cm, the spunbond nonwoven laminate having a basis weight of 12 to 50 g/m 2 .

18. The spunbond laminate according to claim 1 , wherein a thickness of the spunbond nonwoven laminate is more than 0.50 mm, and the spunbond nonwoven laminate has a basis weight from 12 to 50 g/m 2 .

19. The spunbond nonwoven laminate according to claim 1 , wherein a difference between a titer of the filaments of the first layer and a titer of the filaments of the second layer is at least 0.2 den.

20. The spunbond laminate according to claim 1 , wherein crimped multicomponent or bicomponent filaments are used for the filaments of the second spunbond nonwoven layer.

21. A spunbond nonwoven laminate comprising:
a first spunbond nonwoven layer having crimped multicomponent or bicomponent filaments in an eccentric core-sheath configuration and formed by
a first component on an outer surface of the filaments of the first layer consisting or substantially consisting of a polyolefin, and
a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the first layer; and

a second outermost spunbond nonwoven layer on the first layer having multicomponent or bicomponent filaments as a cover layer and formed by
a first component on an outer surface of the filaments of the second layer consisting or substantially consisting of a polyolefin, and
a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the second layer, a polyolefin portion of the first component of the filaments of the second layer being greater than a polyolefin portion of the first component of the filaments of the first layer, sheaths of the filaments of the first layer having over at least 20% of their circumferences a substantially constant thickness d.

22. A spunbond nonwoven laminate comprising:
a first spunbond nonwoven layer having crimped multicomponent or bicomponent filaments formed by
a first component on an outer surface of the filaments of the first layer consisting or substantially consisting of a polyolefin, and
a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the first layer; and

a second outermost spunbond nonwoven layer on the first layer having multicomponent or bicomponent filaments as a cover layer and formed by
a first component on an outer surface of the filaments of the second layer consisting or substantially consisting of a polyolefin, and
a second component consisting or substantially consisting of a plastic having a higher melting point than the polyolefin of the first component of the filaments of the second layer, a polyolefin portion of the first component of the filaments of the second layer being greater than a polyolefin portion of the first component of the filaments of the first layer, the multicomponent filaments or the bicomponent filaments of the second layer having an eccentric core-sheath configuration and the sheaths of the filaments having a constant thickness d or a substantially constant thickness d over at least 20% of a filament circumference.

Assignees

• Wagner Tobias
• Sommer Sebastian
• Bohl Patrick
• Roesner Andreas
• Geus Hans Georg
• Linke Gerold
• Kunze Bernd
• Reifenhaeuser Masch

Inventors

• Wagner Tobias
• Sommer Sebastian
• Bohl Patrick
• Roesner Andreas
• Geus Hans-Georg
• Linke Gerold
• Kunze Bernd

Classifications

• B32B2310/0454

  Hot air · CPC title

• B32B2309/08

  Dimensions, e.g. volume · CPC title

• B32B38/0036

  Heat treatment (for heating or cooling of layers during lamination B32B37/06, B32B37/08) · CPC title

• B32B37/144

  using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding (constructional features for tensioning B32B38/1825) · CPC title

• B32B2323/10

  Polypropylene · CPC title