Exxonmobil Chemical Patents Inc.

Reifenhauser Gmbh & Co Kg Maschinenfabrik

William Michael Ferry

Chia Yung Cheng

Antonios K Doufas

Galen Charles Richeson

Derek Wade Thurman

Cynthia Ann Mitchell

Jerome Sarrazin

Jeanne Marie MacDonald

Wen Li

Detlef Frey

Hans-Georg Geus

Bryan Robert Chapman

Bruce R Lundmark

Alistair Duncan Westwood

Chon Yie Lin

Claudio Cinquemani

Michael Brian Kelly

Peter Schlag

Rahul Ravindra Kulkarni

Don Allen Plank

Dina Marie Colucci

Charles James Ruff

Vincent Bernard Gallez

William M Chien

Luis A Sotomayor

Rahul Rameshrao Kulkarni

Gregory E Keys

Cynthia A Mitchell

Alistair D Westwood

A process for producing a nonwoven fabric comprising forming a polymer composition comprising a primary polypropylene and at least one secondary polyolefin; in a spunbond process, forming fibers then fabric from the polymer composition; and exposing the fabric to an heating environment within a range from 50&#xb0; C. to 250&#xb0; C.

Process for producing a non-woven fabric

This invention relates to polypropylene fibers and fabrics containing polypropylene fibers, the fibers comprising propylene polymers comprising at least 50 mol % propylene, said polymers having: a) a melt flow rate (MFR, ASTM 1238, 230&#xb0; C., 2.16 kg) of about 10 dg/min to about 25 dg/min; b) a dimensionless Stress Ratio/Loss Tangent Index R[defined by Eq. (8)] at 190&#xb0; C. from about 1.5 to about 30; c) an onset temperature of crystallization under flow, T, (as determined by SAOS rheology, 190&#xb0; C., 1&#xb0; C./min, where said polymer has 0 wt % nucleating agent present), of at least about 123&#xb0; C.; d) an average meso run length determined byC NMR of at least about 55 or higher; and e) optionally, a loss tangent, tan &#x3b4;, [defined by Eq. (2)] at an angular frequency of 0.1 rad/s at 190&#xb0; C. from about 14 to about 70.

Polypropylene fibers and fabrics

This invention relates in one aspect to propylene polymers comprising propylene, said polymers having a melt flow rate (MFR, ASTM 1238, 230&#xb0; C., 2.16 kg) of 10 dg/min to 25 dg/min; a Dimensionless Stress Ratio/Loss Tangent Index Rat 190&#xb0; C. from 1.5 to 28; an average meso run length determined byC NMR of at least 70 or higher; and an MFR MFR Ratio of at least 1.0 and optionally, a Loss Tangent, tan &#x3b4;, at an angular frequency of 0.1 rad/s at 190&#xb0; C. from 14 to 100. The inventive propylene polymer compositions are useful in in molded articles and non-woven fibers and fabrics.

Propylene polymers

The present invention is directed to fibers, nonwoven fabrics, and nonwoven laminates comprising a blend of at least one impact copolymer and at least one propylene-based elastomer. The blends comprise from about 45 to about 85 wt % of an impact copolymer, where the impact copolymer comprises a blend of a propylene homopolymer and a copolymer comprising from about 20 to about 80 wt % propylene-derived units and from about 20 to about 80 wt % ethylene-derived units. The blends further comprise from about 15 to about 55 wt % of a propylene-based elastomer, where the propylene-based elastomer comprises from about 5 to about 25 wt % units derived from one or more Cor C-Calpha-olefins and has a triad tacticity greater than about 90% and a heat of fusion less than about 75 J/g.

Fibers and nonwoven materials prepared therefrom

Disclosed is a process for producing spunbond fibers comprising melt blending a polypropylene having a melt flow rate (230/2.16) of from 10 to 30 dg/min with a peroxide visbreaker such that the resulting melt flow rate of the visbroken polypropylene is from 50 to 100 dg/min; melt extruding the visbroken polypropylene through a die block such that filaments of the visbroken polypropylene being produced are exposed to a cabin pressure of from 4500 to 7000 Pa; and forming fibers of from less than 6.0 denier. Nonwoven fabrics and multiple-layer structures can be made from the fibers described herein that are useful for filtering and absorption related articles.

Method of producing polypropylene spunbond fibers

Multilayer meltblown composites, articles made therefrom, and methods for making same. One method can include meltblowing a first material to form a first meltblown layer; meltblowing a second material to form a second meltblown layer; and meltblowing a third material to form a third meltblown layer, wherein each material is the same or different, each material includes at least one resin having a MFR of about 2,000 dg/min or less, as measured by ASTM D1238, 2.16 kg, 230&#xb0; C., and at least one of the first, second, and third materials comprises an elastomer having a recovery of at least 70% after 100% deformation, as determined by ASTM D412.

Multi-layered meltblown composite and methods for making same

Disclosed herein is a spunbond fiber of visbroken polypropylene having an M/Mof from 3.5 to 7.0, an M/Mof from greater than 2.0 and a melt flow rate (230/2.16) of from 50 to 100 dg/min. Also disclosed is a process for producing spunbond fibers comprising melt blending a polypropylene having a melt flow rate (230/2.16) of from 10 to 30 dg/min with a peroxide visbreaker such that the resulting melt flow rate of the visbroken polypropylene is from 50 to 100 dg/min; melt extruding the visbroken polypropylene through a die block such that filaments of the visbroken polypropylene being produced are exposed to a cabin pressure of from 4500 to 7000 Pa; and forming fibers of from less than 6.0 denier. Nonwoven fabrics and multiple-layer structures can be made from the fibers described herein that are useful for filtering and absorption related articles.

Polypropylene spunbond fibers and methods for making same

Disclosed is a method of imparting constraint in a biaxially elastic nonwoven laminate, and the constrained laminate itself, the method comprising providing a biaxially elastic nonwoven laminate comprising at least one meltspun elastic fabric and at least one extensible fabric or film; and fusing at least, or preferably, only a portion(s) of the at least one meltspun elastic fabric to at least one of the extensible fabrics to create at least one inelastic zone. Desirably, the at least one meltspun elastic fabric and at least one extensible fabric or film is biaxially elastic, and referred to as being 'nonwoven' due to the at least one layer of meltspun elastomer. The meltspun elastic fabric may comprise a polyolefin-based elastomer or blend of an elastomer with a thermoplastic.

Biaxially elastic nonwoven laminates having inelastic zones

The present invention relates to fibers and nonwovens made from plasticized polyolefin compositions comprising a polyolefin, a non-functionalized hydrocarbon plasticizer and a slip agent.

Polypropylene based fibers and nonwovens

Provided are fabrics, components thereof, and methods for making the same. Woven and nonwoven fabrics are composed of fibers composed of a polyolefin composition. The polyolefin composition is composed of a propylene polymer and up to about 50 wt. %, based on the weight of the fiber, of a hydrocarbon resin. Fibers prepared from polyolefin compositions exhibit favorable elongation properties. Such fibers exhibit advantageous processing and enhanced levels of softness, durability, and elasticity, even at high spinning speeds required for preparing fine fibers.

Synthetic fabrics, components thereof, and methods for making the same

This invention relates generally to novel fibers and fabrics. Specifically, these fibers are prepared using propylene impact copolymer compositions. Fabrics, particularly nonwoven fabrics, formed from these fibers exhibit improved elongation properties.

Growing community of inventors

Houston, TX, United States of America

William Michael Ferry