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Process for producing fibers for high strength non-woven materials
| Details |
Inventors: Kozulla, Randall Earl;
Assignee: Fiberco, Inc. (Wilmington, DE)
Primary Examiner: Tentoni; Leo B.
Assistant Examiner:
Attorney, Agent or Firm: Greenblum & Bernstein P.L.C.
Process of producing a polypropylene containing fiber and the resulting fiber and non-woven articles. The process involves the extruding of polypropylene containing material having a broad molecular weight distribution to form a hot extrudate having a surface, and quenching the hot extrudate in an oxidative atmosphere so as to effect oxidative chain scission degradation of the surface to obtain a fiber having a higher average melt flow rate as compared to an average melt flow rate of an inner, non-degraded portion thereof, and containing at least 7 percent of molecules having a molecular weight greater than 5.times.10.sup.5. |
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As used herein, polypropylene is utilized in its ordinary commercial meaning wherein the polypropylene is a substantially linear molecule.
Further, as used herein, a polypropylene composition includes a material which contains a broad molecular weight distribution of linear polypropylene to enable the obtaining of fibers and filaments which have superior spinning and thermal bonding characteristics.
Moreover, the fibers and filaments of the present invention provide non-woven materials of exceptional cross-directional strength, elongation, uniformity, loftiness and softness, by utilizing the disclosed polypropylene compositions including the disclosed linear polypropylene components having a broad molecular weight distribution when subjected to delayed quenching, whether or not other components are present therein.
Further, as used herein, polypropylene includes homopolymers of propylene, various polymers containing propylene, such as copolymers and terpolymers of propylene, and polypropylene mixtures (including blends and alloys produced by mixing separate batches or forming a blend in situ) with other substances and polymers.
For example, the polymer can comprise copolymers of propylene, and these copolymers can contain various components.
Preferably, such copolymers include up to about 10 weight % of at least one of ethylene and butene, but can contain varying amounts thereof depending upon the desired fiber or filament.
By practicing the process of the present invention, utilizing spin compositions according to the present invention, fibers and filaments can be obtained which have superior spinning and thermal bonding characteristics.
Moreover, the fibers and filaments of the present invention provide non-woven materials of exceptional cross-directional strength, toughness, elongation, uniformity, loftiness and softness, by utilizing a material which contains a broad molecular weight distribution of linear polypropylene utilizing delayed quenching, whether or not other components are present therein
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