Nonwoven fabrics comprising polylactic acid having improved strength and toughness
Inventors
Novarino, Elena • Drews, Gary • Hamilton, Jason • Chester, Stephen • Izzo, Alfredo • Newkirk, David D.
Assignees
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Publication Number
US-11441251-B2
Publication Date
2022-09-13
Expiration Date
Abstract
Nonwoven fabrics having a plurality of fibers that are bonded to each other to form a coherent web, wherein the fibers comprise a blend of a polylactic acid (PLA) and at least one secondary alkane sulfonate are provided. The nonwoven fabrics exhibit increased tensile strengths, elongation and toughness.
Core Innovation
The invention relates to a spunbond nonwoven fabric in which a coherent web is formed by bonding fibers together. The fibers comprise a blend of polylactic acid (PLA) and at least one secondary alkane sulfonate, and the secondary alkane sulfonate is present in the fibers in an amount ranging from 0.00375 to 0.2 weight percent based on the total weight of the fiber.
The fabric is characterized by improved mechanical performance compared to an identical fabric that does not include the at least one secondary alkane sulfonate. In particular, the fabric exhibits at least one of an increase in tensile strength in at least one of the machine or cross direction and an increase in elongation in at least one of the machine direction or cross direction.
In described embodiments, the at least one secondary alkane sulfonate is associated with specific fiber configurations and locations, including bicomponent arrangements such as sheath/core. The sulfonate has an alkane chain with an alkane chain carbon number range of C10-C18, and the sulfonate moiety is present on a secondary carbon.
Claims Coverage
The provided independent claim is directed to the spunbond nonwoven fabric containing PLA fibers blended with a secondary alkane sulfonate at a defined loading range, together with performance improvements in tensile strength and/or elongation.
Pla/secondary alkane sulfonate spunbond nonwoven coherent web
A spunbond nonwoven fabric comprising a plurality of fibers bonded to each other to form a coherent web, wherein the fibers comprise a blend of a polylactic acid (PLA) and at least one secondary alkane sulfonate.
Secondary alkane sulfonate loading in fibers
The at least one secondary alkane sulfonate is present in an amount ranging from 0.00375 to 0.2 weight percent, based on the total weight of the fiber.
Increased tensile strength and/or elongation versus identical fabric without sulfonate
The fabric exhibits at least one of an increase in tensile strength in at least one of the machine or cross direction in comparison to an identical fabric that does not include the at least one secondary alkane sulfonate; and an increase in elongation in at least one of the machine direction or cross direction in comparison to an identical fabric that does not include the at least one secondary alkane sulfonate.
The claim coverage centers on a PLA spunbond nonwoven coherent web where fibers include a secondary alkane sulfonate at 0.00375 to 0.2 weight percent, producing at least one of increased tensile strength and increased elongation relative to an identical fabric lacking the sulfonate.
Stated Advantages
Increased tensile strength in at least one of the machine direction or cross direction compared to an identical fabric without the secondary alkane sulfonate.
Increased elongation in at least one of the machine direction or cross direction compared to an identical fabric without the secondary alkane sulfonate.
Documented Applications
Absorbent articles including the fabric described.
Diapers.
Feminine pads.
Multilayer composites including the fabric.
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