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US 10,894,384 B2Granted
Laminate and method of making same
AssigneesReifenhaeuser GmbH & Co. KG Maschinenfabrik, Fibertex Personal Care A/S
InventorsSebastian Sommer, Morten Rise Hansen, Mikael Staal Axelsen
Life of this patent
Estimating the term…
Abstract
A laminate is made by first non-crimping or low-crimping continuous filaments to form a first spunbond layer and preconsolidating the first spunbond layer with a heated or calendering roller. Then continuous filaments with a greater crimp than the continuous filaments of the first spunbond layer are deposited as a second spunbond layer over the first spunbond layer to create a two-layer structure. Finally, the two-layer structure of the first and second spunbond layers is consolidated such that a total thickness of the laminate is 0.15 to 3 mm, preferably 0.2 mm to 2.5 mm and especially 0.2 mm to 2 mm.
Claims9
A method of making a laminate comprising the steps of:
- a) making a first spunbond layer by the substeps of
- a1) spinning non-crimping or low-crimping continuous first multi- or bi-component first filaments of symmetrical or coaxial configuration and having a titer of 1.0 to 2.5 den from a spinneret;
- a2) cooling the spun first filaments in a cooling chamber;
- a3) stretching the spun and cooled first filaments in a stretcher;
- a4) passing the spun, cooled, and stretched first filaments through a diffuser;
- a5) depositing the spun, cooled, and stretched first filaments downstream of the diffuser to form the first spunbond layer with a portion of the deposited first filaments extending in a machine direction;
- and
- a6) preconsolidating the first spunbond layer at a predetermined first contact pressure with a first roller heated to a predetermined temperature;
- b) making a second spunbond layer by the substeps of
- b1) spinning continuous second filaments with a greater crimp than the continuous first filaments and having a titer of 1.8 to 2.5 den from a spinneret;
- b2) cooling the spun second filaments in a cooling chamber;
- b3) stretching the spun and cooled second filaments in a stretcher;
- b4) passing the spun, cooled, and stretched second filaments through a diffuser;
- and
- b5) depositing the spun, cooled, and stretched second filaments downstream of the diffuser to form the second spunbond layer;
- c) applying the second spunbond layer over the preconsolidated first spunbond layer to create a two-layer structure with a smaller portion of the deposited second filaments extending in the machine direction than the portion of the first filaments extending in the machine direction, a filament diameter of the first filaments being smaller than a filament diameter of the second filaments;
- d) preconsolidating the second spunbond layer at a second contact pressure smaller than the first contact pressure with a second calendering roller heated to a predetermined temperature lower than the predetermined temperature of the first roller;
- and
- e) final-consolidating the two-layer structure into the laminate until
- a total thickness of the laminate is 0.15 to 1.0 mm, and
- a longitudinal stiffness of the laminate comprised of the first spunbond layer and the second spunbond layer is 20 to 80% of a longitudinal stiffness of a comparative nonwoven or laminate of the same grammage as and made of the filaments of the first spunbond layer.
18 more elements
A laminate comprising:
- a first spunbond layer essentially consisting of non-crimping or low-crimping continuous first multi- or bi-component filaments of symmetrical or coaxial configuration and having a titer of 1.0 to 2.5 den;
- and
- a second spunbond layer atop the first spunbond layer, forming therewith a two-layer structure, and essentially consisting of continuous second filaments that have a titer of 1.8 to 2.5 den and are more strongly crimping than the continuous first filaments of the first spunbond layer, a filament diameter of the first filaments being smaller than a filament diameter of the second filaments, a total thickness of the two-layer structure being 0.15 mm to 1.0 mm, a weight of the laminate per unit of area being 8 to 80 g/m2, a larger portion of the first filaments being oriented in a machine direction than of the second filaments, a ratio of a thickness of the first spunbond layer to a thickness of the second spunbond layer is 1.0:0.8 to 1.0:6.0, and a longitudinal stiffness of the laminate comprised of the first spunbond layer and the second spunbond layer is 20 to 80% of a longitudinal stiffness of a comparable nonwoven or laminate of the same grammage as and made of the filaments of the first spunbond.
Dependencies are inferred from the claim text.