Method of making a nonwoven laminate

Patent metadata

Field	Value
Publication number	US-11897244-B2
Application number	US-202016828083-A
Country	US
Kind code	B2
Filing date	Mar 24, 2020
Priority date	Mar 26, 2019
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

A nonwoven laminate having at least two nonwoven layers is made by first spinning, cooling, and stretching, first crimped multicomponent filaments to form a first nonwoven web that is deposited on a deposition device. Then second continuous continuous filaments including an elastomer based on polypropylene are spun, cooled, and stretched to form a second nonwoven web that is deposited on the first nonwoven web and thereby forming the nonwoven laminate that it then consolidated.

First claim

We claim:

1. A method of making a nonwoven laminate having at least two nonwoven layers, the method comprising the steps of:
spinning, cooling, and stretching first crimped multicomponent filaments to form a first nonwoven web;
depositing the first nonwoven web on a deposition device; and
spinning, cooling, and stretching, second monocomponent continuous filaments consisting of only one elastomer based on polypropylene with a mesopentad fraction of more than 70% to form a second nonwoven web; and
depositing the second nonwoven web on the first nonwoven web and thereby forming the nonwoven laminate.

2. The method according to claim 1 , further comprising the step of:
spinning, cooling, stretching, third crimped multicomponent filaments to form a third nonwoven web; and
depositing the third nonwoven web on the second nonwoven web, whereby the laminate has three layers.

3. The method according to claim 2 , further comprising the step of:
spinning, cooling, and stretching a second set of the second continuous filaments including an elastomer based on polypropylene to form a second layer of the second nonwoven web; and
depositing both of the second nonwoven webs atop the first nonwoven web such that the third nonwoven web can be deposited atop them.

4. The method according to claim 2 , wherein the crimped filaments of the first spunbonded web or the third spunbonded web are formed as crimped filaments with side-by-side configuration or with a core-sleeve configuration.

5. The method according to claim 2 , wherein the crimped filaments of the first spunbonded web or the third spunbonded web have at least one component based on polypropylene.

6. The method according to claim 2 , wherein the crimped filaments of the first spunbonded web or the third spunbonded web have two components of polypropylene that differ in their melt-flow rate such the melt-flow rate of one component is preferably at least 1.2 times greater than the melt-flow rate of the other component.

7. The method according to claim 2 , wherein the crimped filaments of the first spunbonded web or the third spunbonded web have a degree of crimp of more than 2.5 loops per cm of their length.

8. The method according to claim 1 , wherein the continuous filaments of the second spunbonded woven web consist substantially of a copolymer of propylene and ethylene having a melting point between 50° C. and 170° C.

9. The method according to claim 1 , wherein the continuous second filaments of the second spunbonded web are manufactured with a titer of 10 μm to 50 μm.

10. The method according to claim 1 , further comprising the step of:
calendering the laminate formed by the first spunbonded web and the second spunbonded web with a pressing surface portion or welding surface portion of the calender of 8% to 15%.

11. The method according to claim 10 , wherein the calendering is effected by a calender with a figure density of 10 to 50 figures/cm 2 .

12. The method according to claim 10 , wherein the calendering is effected by a calender whose surface temperature is 60° C. to 90° C.

13. The method according to claim 1 , further comprising the step of:
stretching the laminate in a machine direction.

Assignees

• Wagner Tobias
• Bohl Patrick
• Frey Detlef
• Reifenhaeuser Masch

Inventors

• Wagner Tobias
• Bohl Patrick
• Frey Detlef

Classifications

• D04H3/005

  Synthetic yarns or filaments (D04H3/013 takes precedence) · CPC title

• B32B5/022 Primary

  Non-woven fabric · CPC title

• B32B5/26

  another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} · CPC title

• B32B27/32

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title

• B32B37/0076

  characterised in that the layers are not bonded on the totality of their surfaces · CPC title