Process for making fibrous structures

Patent metadata

Field	Value
Publication number	US-9926648-B2
Application number	US-201414475699-A
Country	US
Kind code	B2
Filing date	Sep 3, 2014
Priority date	Jul 17, 2007
Publication date	Mar 27, 2018
Grant date	Mar 27, 2018

Abstract

Processes for making fibrous structures and more particularly processes for making fibrous structures comprising filaments are provided.

First claim

What is claimed is:

1. A process for making a fibrous structure, the process comprising the steps of:
a. meltblowing a plurality of first filaments comprising a first polymer from a die comprising filament-forming holes such that the first filaments comprise single filaments each produced from a single filament-forming hole, wherein the first filaments are externally attenuated;
b. combining the plurality of first filaments with solid additives to form a mixture;
c. collecting the mixture of the first filaments and solid additives on a collection device to produce a formed fibrous structure; and
d. adding a layer of second filaments to at least one surface of the formed fibrous structure.

2. The process according to claim 1 wherein the process further comprises the step of:
e. supplying at least the first polymer to the die.

3. The process according to claim 1 wherein the die comprises one or more filament-forming holes, wherein one or more fluid-releasing holes are associated with one filament-forming hole such that a fluid exiting the fluid-releasing hole contacts an exterior surface of a filament exiting the filament-forming hole.

4. The process according to claim 1 wherein at least one row of filament-forming holes comprises two or more filament-forming holes.

5. The process according to claim 3 wherein more than one fluid-releasing hole is associated with a filament-forming hole.

6. The process according to claim 3 wherein one fluid-releasing hole is concentrically positioned around one filament-forming hole.

7. The process according to claim 1 wherein the first polymer comprises a synthetic polymer.

8. The process according to claim 7 wherein the synthetic polymer is selected from the group consisting of: polyvinyl alcohol, polyvinyl alcohol derivatives, polyesters, nylons, polyolefins, polylactic acids, polyhydroxyalkanoates, polycaprolactones and mixtures thereof.

9. The process according to claim 7 wherein the synthetic polymer comprises a polyolefin.

10. The process according to claim 9 wherein the polyolefin comprises polypropylene.

11. The process according to claim 1 wherein the first polymer comprises a natural polymer.

12. The process according to claim 11 wherein the natural polymer is selected from the group consisting of: starch, starch derivatives, cellulose, cellulose derivatives, hemicellulose, hemicellulose derivatives and mixtures thereof.

13. The process according to claim 1 wherein the first polymer comprises a compostable polymer.

14. The process according to claim 13 wherein the compostable polymer is selected from the group consisting of: polylactic acids, polyhydroxyalkanoates, polycaprolactones and mixtures thereof.

15. The process according to claim 1 wherein the solid additives comprise fibers.

16. The process according to claim 15 wherein the fibers comprise wood pulp fibers.

17. The process according to claim 1 wherein the second filaments comprise a second polymer.

18. The process according to claim 17 wherein the second polymer is the same as the first polymer.

Assignees

• Procter & Gamble

Inventors

• Barnholtz Steven Lee
• Trokhan Paul Dennis
• Suer Michael Donald
• Barkey Douglas Jay
• Brennan Jonathan Paul
• Gorley Ronald Thomas

Classifications

• D04H1/425

  Cellulose series · CPC title

• D04H1/4291

  Olefin series · CPC title

• D04H1/56

  in association with fibre formation, e.g. immediately following extrusion of staple fibres · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• D01D5/0985 Primary

  by means of a flowing gas (e.g. melt-blowing) · CPC title