# US 11,897,244 B2 · Method of making a nonwoven laminate

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- Number: US 11,897,244 B2
- Document ID: US11897244B2
- Status: Granted
- Kind: B2
- Application number: 16/828,083
- Filed: 2020-03-24
- Published: 2020-10-01
- Granted: 2024-02-13
- Earliest claimed: 2019-03-26
- Assignees: Reifenhaeuser GmbH & Co. KG Maschinenfabrik
- Applicants: Tobias Wagner; Patrick Bohl; Detlef Frey
- Inventors: Tobias Wagner; Patrick Bohl; Detlef Frey
- Web page: https://patentgrep.com/patent/US11897244B2

## CPC

- B32B 5/022: {Non-woven fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 37/0076: {characterised in that the layers are not bonded on the totality of their surfaces}
- B32B 37/06: characterised by the heating method
- B32B 37/156: {at least one layer is calendered and immediately laminated}
- D01D 5/0985: {by means of a flowing gas (e.g. melt-blowing)}
- D01D 5/22: with a crimped or curled structure; with a special structure to simulate wool (producing crimped or curled effects in filaments or threads after formation D02G1/00)
- D01F 6/06: from polypropylene
- D01F 6/30: comprising olefins as the major constituent
- D01F 8/06: with at least one polyolefin as constituent
- D04H 3/005: Synthetic yarns or filaments (D04H3/013 takes precedence)
- D04H 3/007: Addition polymers
- D04H 3/14: with bonds between thermoplastic yarns or filaments produced by welding
- D04H 3/147: Composite yarns or filaments
- D04H 3/16: with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
- B32B 2038/0028: {Stretching, elongating}
- B32B 2250/03: 3 layers
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2250/242: All polymers belonging to those covered by group B32B27/32
- B32B 2262/0253: Polyolefin fibres
- B32B 2305/20: in the form of a non-woven mat
- B32B 2307/51: Elastic
- B32B 2309/02: Temperature
- D10B 2321/022: polypropylene
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D01D: MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01F: CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES

## 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.

## Claims

### 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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 2)

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.

### Claim 4 (depends on 2)

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.

### Claim 5 (depends on 2)

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.

### Claim 6 (depends on 2)

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.

### Claim 7 (depends on 2)

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.

### Claim 8 (depends on 1)

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.

### Claim 9 (depends on 1)

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.

### Claim 10 (depends on 1)

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%.

### Claim 11 (depends on 10)

The method according to claim 10, wherein the calendering is effected by a calender with a figure density of 10 to 50 figures/cm2.

### Claim 12 (depends on 10)

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

### Claim 13 (depends on 1)

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