Bicomponent fibers, textile sheets and their use

FIELD: textiles, paper.

SUBSTANCE: bicomponent fibers contain aliphatic polyester or a mixture of aliphatic polyesters, which form the first component, and polyolefin or a mixture of polyolefins, which form the second component. Polyolefin contains auxiliary material improving its biodegradation. Textile sheets include these bicomponent fibers and are comparable by mechanical properties to textile sheets based on polyolefin, while they are decomposed more efficiently under the action of microorganisms than the textile sheets based on polyolefin.

EFFECT: enhanced biodegradability, to textile sheets such as nonwoven materials comprising these fibers, which can be used in personal care products.

16 cl, 3 tbl, 2 ex

The scope of the invention

The present invention relates to two-component fiber type core-shell with improved ability to decomposition by microorganisms. Textile sheets, including these fibers can be used in various applications such as textile or industrial applications. Preferably, the textile sheets produced as non-woven materials that can be used in personal care products.

The level of invention

Biorazlagaemykh fiber and textile sheets obtained from them, are known. One approach to improve biodegradation is the use of polymers, which are known to show improved biological degradability compared with, for example, polyolefins. Another approach to improve biological decomposition of polymers is the addition of tools that enhance the rate of biological decomposition of the polymer in use.

Patents JP-A-2007-197857 and USA 6197237 reveal spunbond comprising fibers of a mixture of polyolefin and polylactic acid or a mixture of a polyolefin, a polymer of aliphatic polyester and agent combination for both polymers. The polyolefin is present in the form of microvas in the matrix polymer of aliphatic polyester.

U.S. patent 2006/0159918 A1 discloses a biodegradable fiber, shows the sources of strength, stable during storage. These fibers are pulled and/or twisted and include a biodegradable polymer, for example an aliphatic polyester such as polylactic acid, and show initial strength of at least 1.5 g/denier, which remains virtually unchanged during storage for 120 days at ambient conditions.

Patent JP 2006-030 905 reveal A sound absorber, which consists of a material fiber structure made of short fibers of polylactic acid, which are two-component fiber made from polylactic acid with a high molecular weight of the polylactic acid of low molecular weight. In addition, short fiber, polylactic acid can be made in the form of a type of core-shell with polylactic the core and the shell of an aromatic polyester.

Patent JP 2000-054 227 discloses A conjugate fiber-based polyolefin consisting of a first component which is a polymer-based polyolefin, such as polyethylene, and a second component which is a polymer based on polylactic acid, or a mixture of selected polymers in which the specified second component is positioned so as to be partially visible on the part of the fiber surface. Different configurations of the component fibers are disclosed, for example, the R, type the core and the cladding, with the core of a polyolefin and a sheath of the specified second component.

Improved ability to biodegradation of polyolefins by adding excipients, which accelerates the rate of decomposition in the application, it is disclosed, for example, in the following documents: JP2004-182 877 A; JP 2005-255 744 A; JP 05-345 836 A; KR 1002-88 054 B; KR 10-1995-0113 175 B; KR 10-2001-0113 577 B; KR 10-2003-0071 175 B; USA 3903029 A and WO 2001-39 807 A.

Excipients to improve the speed of decomposition of polyolefins when applying commercially available. Examples of such substances are the products Envirome (Envirocare (Ciba)), Addiflex (Addiflex (Add-X Biotech AB)and ECM 6.0204 (ECM Biofilms).

While known products can meet the requirements of biodegradation by microorganisms, these products are often not optimal in other aspects. Non-woven materials made from polylactic acid, for example, often have high shrinkage or narrow the window termowizyjne. Non-woven materials made from polyolefin, can avoid these disadvantages, but they are derived from oil and gas, and not from renewable primary products.

Due to lack of fossil resources products made from alternative plastics are increasingly becoming important now. Such alternative plastics include polymers made from renewable resources, or even polymers to which e can borosilicates microorganisms or to turn into compost. Usually, these plastics are classified as "biodegradable plastic". Typical examples of such plastics are starch, cellulose or polylactic acid (PLA). PMC combines the advantage of renewable resources and the ability to decomposition by microorganisms, offering a balanced ecobalance. Disposal of waste formed such biodegradable plastics can be made by composting. Due to the process of biological decay of such material will completely break down to carbon dioxide, water and biomass. Thus, the waste can be managed Compostela or burying garbage, no heat treatment is not necessary. In the spinning method from the melt PMK is known as a plastic with good processing. Threads with a wide range of subtleties can be spun. However, some weaknesses can be noted: the temperature window of binding fibers PMK is narrow. Normally, therefore, the strength of non-woven materials is lower than known conventional nonwoven materials made from polyester or polypropylene. Additionally, high shrinkage nonwovens PMC should be considered. Disadvantages nonwovens PMK can be overcome, for example, when the SQP in fiber covered. For example, can be made two-the thread contains biodegradable plastic (such as VIM) in the core and conventional plastics such as polyolefin) in the shell. Such two-component filaments offer a wider temperature window link. Also the shrinkage of the nonwoven materials can be successfully reduced in this way. Unfortunately, the advantages of non-woven materials made from bicomponent filaments with a biodegradable plastic in the core and a polyolefin in the membrane, combined with the loss of the ability to biodegradation or composting. The polyolefin in the membrane are non-biodegradable plastics, protecting biodegradable plastic in the core filaments. Therefore, the decomposition process is slowed down or, at least, difficult.

The invention

One of the purposes of the present invention is to provide fiber and textile sheets containing these fibers, which include a high proportion of renewable primary products and show properties, for example, the temperature window termowizyjne or shrinkage of the polyolefin fibers and textile sheets made from it.

Another object of this invention is to provide fiber and textile sheets containing these fibers, which are readily biodegradable.

Another object of this invention is to provide fiber, which can be p otvedeny on conventional spinning equipment, using the process parameters already used in the production of polyolefin fibers.

Further objectives of this invention will become apparent from the following description.

In one embodiment, the present invention relates to two-component fibers comprising aliphatic polyester or a mixture of aliphatic polyesters as a first component, and including a polyolefin or mixture of polyolefins as the second component and including a second component an effective amount of an excipient, which improves the ability to biodegrade specified polyolefin.

In another embodiment, the invention relates to a textile sheet comprising the above-mentioned two-component fiber.

It has been unexpectedly found that are formed readily biodegradable fibers, which show properties such as polyolefin fibers, Association predomi from the melt polymer in the first component, for example, in the core of the bicomponent fiber core and the cladding, and polyolefins with selected excipients as a second component, for example, in the shell of a two-component fiber core-shell.

Detailed description of the invention

The polymer component of the core-component fibers according to the invention is aliphatic n is liefer or their mixture. In addition, the first component may contain additives, such as fillers, pigments, matting means, processing means, antistatics or excipient to improve the ability to biodegradation by microorganisms.

Aliphatic polyester first component is a biodegradable, synthetic, predomi from a melt of the polymer.

The term "biodegradable" is used in the present description, to determine the product that decomposes or breaks down in the environment. Thus, the product is considered as biodegradable from the point of view of this description, if the lower limit of the tensile strength and/or the maximum elongation of the specified product is at least 50%, preferably at least 70% of their initial values, if it is subjected during the six days of testing, accelerated aging, using a dry chamber at 80°C. This test procedure for the process of biological decomposition described in U.S. patent 2007/0243350 A1.

The polymer of the first component derived from aliphatic component having one carboxyl group (or its derivative, forming a complex of the polyester, such as ester group and one hydroxyl group (or its derivative, forming a complex of the polyester, such as simple ester group) or receive from a combination of aliphatic component, having two carboxyl groups (or its derivative, forming a complex of the polyester, such as ester group) with aliphatic component having two hydroxyl groups (or its derivative, forming a complex of the polyester, such as ether group).

The term "complex aliphatic polyester covers, along with a complex polyesters, which are made from aliphatic and/or cycloaliphatic components exclusively also polyesters which contain, along with aliphatic and/or cycloaliphatic units, aromatic units, as long as they do not impact adversely on the ability to biodegrade these polyesters.

Polymers derived from aliphatic component having one carboxyl group and one hydroxyl group, an alternative called polyhydroxyalkanoate (GAA). Examples are polyhydroxybutyrate (FCB), poly(hydroxybutyrate-co-hydroxyvalerate) (PHBV), poly(hydroxybutyrate-co-hydroxyhexanoate) (PHBH), polyglycolic acid (PGA), poly(Epsilon-caprolactone) (PCL) and preferably polylactic acid (PLA).

Examples of polymers derived from a combination of aliphatic component having two carboxyl groups, with aliphatic component having two guide who axiline groups, are polyesters derived from aliphatic diols and aliphatic dicarboxylic acids, such as poliatilenaksida (PBS), poliatilenaksida (PASU), polybutylene (PBA), polyacyladipate (pea), poly(tetramethylnaphthalene) (PTMT).

The polymer component of the second component of the bicomponent fiber according to the invention is a polyolefin or a mixture. Along with this, the specified second component must contain at least an effective amount of an excipient, which improves the ability to biodegrade polyolefin. In addition, the second component may contain other additives, such as fillers, pigments, matting tools, tools that improve processing and/or antistatics.

The polyolefin used as the material of the second component, usually derived from alpha-olefins. Examples of polyolefins are polyethylene (PE) in any form, such as low density polyethylene (LDPE), high density polyethylene (HDPE), linear low density polyethylene (LINP (LLDPE), polyethylene, very low density (PAOP (VLDPE)and polyethylene-low density (PAOP (ULDPE), polypropylene (PP) in any form, poly(1-butene), poly(1-penten) or poly(4-methylpent-1-ene). In addition to homopolymers are also included copolymers. Examples are copolymers of e is Elena with one or more copolymerizes alpha-olefins, copolymers of propylene with one or more copolymerizes alpha-olefins, preferably copolymers of ethylene and/or propylene with higher 1-olefins such as 1-butene, 1-penten, 1-hexene, 1-hepten, 1-octene, 4-methylpent-1-ene or 1-mission.

Further representatives of the polyolefin is a mixture of polyolefins and/or polyolefins which contain plots obtained by grafting unsaturated monomers with double bonds on the basis of the polyolefin.

The polyolefin of the second component contains the excipient, promoting biodegradation specified polyolefin. These auxiliary substances known to experts in technology, as highlighted in the section "invention".

Preferably, the products Envirome (Envirocare (Ciba)), Addiflex (Addiflex (Add-X Biotech AB)and ECM 6.0204 (ECM Biofilms) can be used.

Excipient, promoting the Biodegradability of polyolefin, preferably, contains a nutrient for microorganisms, preferably, starch, crushed inorganic compound such as calcium carbonate, and a salt of a transition metal such as iron carboxylate, manganese, cobalt or copper. Examples of such auxiliary substances found in U.S. patent 2007/0243350A1.

The number of auxiliary substances, promoting biodegradation of polyolefin, can vary within wide is the limits. Because commercial considerations typically use such a low amount as possible to ensure that the received desired degree of Biodegradability of the polyolefin. If you use a higher amount of an excipient, an upper limit is set by the spinning process used in the formation of two-component fibers. Thus, any number of such auxiliary substances may be used as long as it does not slow down the process of formation of the fibers.

Preferred excipients used in the method of production of two-component fibers according to this invention, is used as a masterbatch (concentrate) with the polyolefin of the polymer carrier.

The amount of masterbatch used in the method of producing fibers according to this invention, is within the interval of 0.5-10 wt.%, preferably 1-6 wt.%, more preferably 3-5 wt.%, in the calculation of the total number of components forming the shell.

The concentration of excipients, promoting biodegradation of polyolefin, within the above masterbatch are in the range of 0.075 to 1.5 wt.%, in the calculation of the total number of masterbatch.

Preferred masterbatch used in the production method of the fiber according to the invention, the soda is separated by 25-85 wt.% polyolefin and an auxiliary substance, promoting biodegradation, which comprises 1-30 wt.% starch, 2-50 wt.% calcium carbonate and 0.5-15 wt.% metal salt. The percentages apply to the total composition of the masterbatch.

The total number of auxiliary substances, promoting biodegradation of polyolefin, the second component is usually in the range of 0.005-0.5 wt.%, preferably 0.01 to 0.3 wt.%, more preferably 0.03 to 0.25 wt.%, in the calculation of the total number of components forming the second component.

The preferred two-component fiber according to the invention have a first component, a polymer PMK, preferred as the core of the fiber core and the cladding.

Further preferred two-component fiber according to the invention have a second component, polyethylene and/or polypropylene, are preferred as the fiber cladding core-shell.

In another preferred embodiment according to the invention an auxiliary substance, which improves the ability to biodegrade polyolefin includes starch and the salt of the compound of the transition metal.

In an additional preferred embodiment according to the invention the first component of a two-component fiber includes a filler, preferably a carbonate, alkaline earth metal, particularly preferably calcium carbonate.

Two-component fiber is according to the invention can be endless fibers (filaments or fibers of finite length (staple fiber). Two-component fiber according to this invention typically have a denier between 1 and 10 dtex (decitex). But it doesn't matter, and smaller or higher denier can be provided. The preferred diameters of the fibers constitute more than 10 μm, preferably between 10 and 20 microns.

Two-component fiber according to the invention may contain various polymer parts in any form. Examples are the configuration of the core-sheath, side-by-side or island-in-sea. The configuration of the core and the shell are preferred.

Two-component fiber according to the invention can have a cross-section of any shape. Examples of cross-sections found in the book "Fiber 2. Structure" (encyclopedia Ullman); Hearle J., "Fibetrs, 2. Structure" (Ullmann''s Encyclopedia of Industrial Chemistry, Wiley-VCH: 2002, 1-85). Examples of preferred cross-sections are circular, ellipsoidal, three or multiplemode or three or multipartite.

The number of the first component and the second component may vary within wide limits. The intervals of the first component is from 10 to 90 wt.%. The intervals of the second component ranges from 90 to 10 wt.%. These percentages relate to the total number of fibers. Preferably the amount of the first component is higher than the number of the second component, for example, 55-90 wt.% the first component, such as heart the wine, and 45-10 wt.% the second component, such as a shell.

Two-component fiber according to the invention can be converted in the textile sheets or other forms of fiber strands, such as a secondary staple yarns or cords.

Textile sheet comprising fibers according to the invention can be of any nature. Examples of this are fabric, knitted fabric, knitted fabric, mesh, clutch, or preferably non-woven materials.

Textile sheets of the invention can be in the form known to the specialist. Non-woven materials, for example, can be formed by wet-laying or dry styling. Examples of these methods are Karlovacka process for the production of Canovanas tissue and spunbond processes for forming spunbonded materials (spunbonded). These latter non-woven materials are preferred.

Production of textile sheets of the invention typically includes the following stages:

a) exposure of a two-component fiber according to this invention and, optionally, together with other strands, such as staple fibers or filaments, textile technology of forming of sheet materials to get the initial textile sheet, and

b) optionally, placing the specified initial textile sheet stabilizing treatment, known technologist is I.

Depending on the type of textile technology of forming of sheet materials, such as weaving or knitting, getting enough stable initial textile sheet. In this case, stage b) is optional, but can be done. Thus, in these cases, the primary textile sheets can imagine the final textile sheets.

In other types of textile technology of forming of sheet materials, such as nonwoven materials, usually obtained initial textile sheet is not sufficiently stable. In most of these cases, stage b) is mandatory. Thus, in these cases, the primary textile sheets must be further processed to result in the final textile sheets.

In addition to nonwoven materials comprising or consisting of fibers according to this invention, there may be layers of non-woven materials made of other materials. These multi-layered non-woven materials are also subject of the present invention.

In addition, the textile sheets along with the fibers according to the invention can contain additional strands made from other materials such as other polymers. These additional strands made of other materials can be present in any form, such as staple fiber, filament or direct the and. Examples of polymers forming such additional strands are cellulose, starch, proteins and/or synthetic polymers, such as polyesters, polyamide or polyacrylonitrile.

Primary textile sheets described above, can be or should be stable after the process of forming the sheet in a known manner. This stabilization treatment can be machined by the action of the needles and/or getoperalang or can be stabilized by bonding fibers forming the primary textile sheet, for example, adding an adhesive to the primary textile sheet, and/or thermal processing of the initial textile sheet to cause the bonding fibers and/or any binders fibers, which can be further included in the specified initial textile sheet.

Other known methods of treatment of textile sheets can be performed during or after their production. For example, the textile sheet may be subjected to the print processing or textile sheet, preferably non-woven materials can be subjected to embossing, at least one of their surfaces, for example, by the action of the profiled calender drum to give the surface figure and additional curing of selected parts of textile sheet caused what desia melt elementary fibers in places the treatment of textile sheet.

One advantage of two-component fibers according to this invention is that they can be processed by the technology of forming of sheet materials known from textile sheets of polyolefin, without changing the process parameters in connection with the known methods of production of the sheet.

Textile sheets of the present invention typically have the share of 10-200 g/m²preferably 15-50 g/m².

Textile sheets of the present invention can be used for applications in personal care, for example, products for care of children (diapers, altorki), for women (pillows, sanitary towels, tampons), adult products to eliminate incontinence) or for cosmetic applications (air bags).

The invention also relates to the use of the above-mentioned textile sheets in medical applications, such as protective clothing or as a surgical floor, or cleaning products. In addition, the above-mentioned textile sheets can be used in products for filtering for acoustic protection in automotive applications, such as geotextiles, as coverage in agriculture, as the pot for the propagation of plants, such as non-woven materials for sheets, including seeds and/or nutrients, such as the bag, for example, as economic the I bag or as protection from the cold.

The following examples explain the invention without limiting it.

Comparative Example 1

Non-woven fabric was obtained by spinning from the melt bicomponent fibers with the configuration of the core-shell and forming a spunbond weight basis 15 g/m²in the pilot plant. The weight of the core is 75% and the weight of the shell is 25%. The core was made from PMC, and the shell was made of polypropylene. Neither the core nor the shell does not contain additives.

Comparative Example 2

Should the method of Comparative Example 1, but produce spunbond with the weight of the base 26 g/m².

Comparative Example 3

Should the method of Comparative Example 1, but the core of the PMK using 10 wt.% calcium carbonate (Omyalene 102M) based on the weight of the core.

Comparative Example 4

Should the method of Comparative Example 1, but produce spunbond with the weight of the base 26 g/m².

Example 1

Non-woven fabric was obtained by spinning from the melt bicomponent fibers with the configuration of the core-shell and forming a spunbond weight basis 15 g/m²in the pilot plant. The weight of the core is 75% and the weight of the shell is 25%. The core was made from PMC, and the shell was made of polypropylene. The core contained 10 wt.%, based on the weight of the core, Carbo is ATA calcium (Omyalene 102M). The shell contained 3 wt.% based on the weight of the shell, excipients, promoting biodegradation (Addiflex HE).

Example 2

Should the method of Example 1, but produce spunbond with the weight of the base 26 g/m².

The following table summarises the spunbond prepared in Comparative Examples 1-4 and Examples 1-2.

Tests decomposition

To test the decomposition of samples of nonwoven materials were tested for thermal aging. Test thermal ageing recommended Add-X (provider additives Addiflex) and correlates well with tests composting.

Samples of nonwoven materials cut to run tests, tensile and elongation, and the samples were placed in a dry chamber at 80°C. After a few days of processing the measured tensile properties.

The results are shown in the following tables./p>

Discussion of results

Spunbond (non-woven synthetic fabric)obtained from two-component fibers PMK-PP, showed the tensile strength, which remained almost unchanged during heat treatment. The values of elongation immediately fell in one day, but remained virtually unchanged afterwards.

Spunbond obtained from two-component fibers PMK-PP and containing the filler is calcium carbonate in the core showed the same behavior as unfilled samples. But adding filler greatly reduced values of tensile strength and elongation of untreated samples.

Spunbond obtained from two-component fibers PMK-PP and containing the filler is calcium carbonate in the core and containing excipient accelerator decomposition in the shell, showed the same tensile strength properties and elongation as filled with samples before heat treatment. After heat treatment for 4 days or more values of tensile strength and elongation decreased significantly, indicating that spunbond worse. Finally, some of these samples were disintegrated when touched.

These results demonstrate that it is possible to obtain a fully biodegradable bicomponent nonwoven material PMK-PP, shows the store properties tensile known nonwoven materials.

1. Two-component fiber having a denier between 1 and 10 dtex, and comprising an aliphatic polyester or a mixture of aliphatic polyesters as a first component, and including a polyolefin or mixture of polyolefins as a second component, and including a second component an effective amount of an excipient, which improves the ability to biodegrade specified polyolefin.

2. Two-component fiber according to claim 1, which is in the configuration of the core and the cladding, in which the first component forms a core and the second component forms the sheath.

3. Two-component fiber according to claim 1, in which the first component is made from polylactic acid.

4. Two-component fiber of claim 1, wherein the second component comprises polyethylene or polypropylene.

5. Two-component fiber of claim 1, wherein the auxiliary substance, which improves the ability to biodegrade specified polyolefin includes starch and the salt of the compound of the transition metal.

6. Two-component fiber of claim 1, wherein the first component includes a carbonate of alkaline earth metal, preferably calcium carbonate.

7. Textile sheet comprising a two-component fiber according to claim 1.

8. Textile sheet according to claim 7, wherein said textile sheet is a nonwoven material.

9. Textile l the article of claim 8, in which the nonwoven material is spunbond.

10. Textile sheet according to claim 7, in which in addition to the component fibers are fibers, preferably fibers selected from the group of polyolefin fibers, rayon fibers, polyester fibers and polyamide fibers.

11. The use of two-component fiber according to claim 1 in the personal care product.

12. The use of textile sheet according to claims 7 to 10 in the personal care product.

13. The application of claim 11, in which the personal care product is a diaper, rubbing, pad, sanitary towel or tampon.

14. The application indicated in paragraph 12, in which the personal care product is a diaper, rubbing, pad, sanitary towel or tampon.

15. The use of two-component fiber according to claim 1 for medical use, cleaning products, filtering for acoustic protection in automotive applications, such as geotextiles, as the awning in agriculture, as the pot for the propagation of plants, such as non-woven fabric sheet, including seeds and/or nutrients, as a bag or as a cover to protect from frost.

16. The use of textile sheet according to claim 7 for use as a medicine, cleaning products, filtering for acoustic protection in automotive applications, such as geotextiles, as the awning in rural households is iste, as the pot for the propagation of plants, such as non-woven fabric sheet, including seeds and/or nutrients, as a bag or as a cover to protect from frost.