US4449978A
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Nonwoven products having low residual free formaldehyde content
Assignee: Air Products and Chemicals Inc
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Filing: 1983-04-01
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Granted: 1984-05-22
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Expires: 2003-04-01
Abstract
Abstract A nonwoven product formed from a nonwoven web of fibers bonded together with a binder comprising an interpolymer of vinyl acetate/ethylene/N-methylol acrylamide/acrylamide, the interpolymer comprising about 5 to 40 wt % ethylene and an amount of N-methylol acrylamide and acrylamide which is about 3.0 to 10 wt % of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt % and the acrylamide about 1.25 to 8.25 wt %. Such nonwoven products have a low residual free formaldehyde content and good tensile properties.
Inventors
- 👤 John G. Iacoviello
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 04:20
CPC Classifications
D; D21; D21H; D21H17/00; D21H17/20; D21H17/33; D21H17/34; D21H17/41; D21H17/44; D21H17/45; A; A61; A61L; A61L15/00; A61L15/16; A61L15/22; A61L15/24; D04; D04H; D04H1/00; D04H1/40; D04H1/58; D04H1/587; D04H1/64; D21H17/35; D21H17/36; D21H17/37; D21H17/38; D21H17/39; Y; Y10; Y10T; Y10T442/00; Y10T442/20; Y10T442/2861; Y10T442/2885; Y10T442/2893
Claims Analysis
Total Claims: 52
Claim 1
Independent Claim
105 words
A nonwoven product comprising a nonwoven web of fibers bonded together with a binder which comprises an interpolymer of vinyl acetate/ethylene/an N-methylol acrylamide/an acrylamide, the interpolymer containing about 5 to 40 wt % ethylene and an amount of the N-methylol acrylamide and the acrylamide which is about 3 to 10 wt % of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt % and the acrylamide about 1.25 to 8.25 wt %, the nonwoven product characterized by a low free formaldehyde content after drying and curing at a binder add-on which is sufficient to bind the fibers together to form a self-sustaining web.
Claim 2
Dependent Claim
105 words
A nonwoven product comprising a nonwoven web of fibers bonded together with a binder which comprises an interpolymer of vinyl acetate/ethylene/an N-methylol acrylamide/an acrylamide, the interpolymer containing about 5 to 40 wt % ethylene and an amount of the N-methylol acrylamide and the acrylamide which is about 3 to 10 wt % of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt % and the acrylamide about 1.25 to 8.25 wt %, the nonwoven product characterized by a low free formaldehyde content after drying and curing at a binder add-on which is sufficient to bind the fibers together to form a self-sustaining web.
Claim 3
Dependent Claim
22 words
The nonwoven product of claim 1 in which the free formaldehyde content after drying and curing is less than about 50 ppm.
Claim 4
Dependent Claim
18 words
The nonwoven product of claim 2 having at least about 3 wt% binder add-on, on a dry basis.
Claim 5
Dependent Claim
16 words
The nonwoven product of claim 3 having about 50 wt% binder add-on, on a dry basis.
Claim 6
Dependent Claim
17 words
The nonwoven product of claim 1 in which the free formaldehyde content is less than 25 ppm.
Claim 7
Dependent Claim
17 words
The nonwoven product of claim 3 in which the free formaldehyde content is less than 25 ppm.
Claim 8
Dependent Claim
17 words
The nonwoven product of claim 6 having about a 50 wt% binder add-on, on a dry basis.
Claim 9
Dependent Claim
14 words
The nonwoven product of claim 3 in which the interpolymer is vinyl acetate/ethylene/N-methylol acrylamide/acrylamide.
Claim 10
Dependent Claim
36 words
The nonwoven product of claim 8 in which the interpolymer contains an amount of N-methylol acrylamide and acrylamide which is about 4 to 5 wt% of the interpolymer, the acrylamide being about 1.25 to 3.25 wt%.
Claim 11
Dependent Claim
20 words
The nonwoven product of claim 8 in which the interpolymer contains N-methylol acrylamide and acrylamide in about equal molar amounts.
Claim 12
Dependent Claim
12 words
The nonwoven product of claim 1 which is a paper nonwoven product.
Claim 13
Dependent Claim
15 words
The nonwoven product of claim 1 in which the fibrous web comprises synthetic polymeric fibers.
Claim 14
Dependent Claim
15 words
The nonwoven product of claim 1 in which the fibrous web comprises natural polymeric fibers.
Claim 15
Dependent Claim
29 words
The nonwoven product of claim 11 having a free formaldehyde content of less than about 10 ppm at about 20 wt% or less binder add-on, on a dry basis.
Claim 16
Dependent Claim
11 words
The nonwoven product of claim 8 which is a paper nonwoven.
Claim 17
Dependent Claim
15 words
The nonwoven product of claim 8 in which the fibrous web comprises synthetic polymeric fibers.
Claim 18
Dependent Claim
15 words
The nonwoven product of claim 8 in which the fibrous web comprises natural polymeric fibers.
Claim 19
Dependent Claim
29 words
The nonwoven product of claim 15 having a free formaldehyde content of less than about 10 ppm at about 20 wt% or less binder add-on, on a dry basis.
Claim 20
Dependent Claim
115 words
A nonwoven product formed from a nonwoven web of fibers bonded together by a binder deposited from an interpolymer latex comprising an aqueous medium having dispersed threrein a vinyl acetate/ethylene/an N-methylol acrylamide/an acrylamide interpolymer, the interpolymer containing about 5 to 40 wt% ethylene and an amount of the N-methylol acrylamide and the acrylamide which is about 3 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, the nonwoven product characterized by a free formaldehyde content after drying and curing of less than 50 ppm at a binder add-on which is sufficient to bind the fibers together to form a self-sustaining web.
Claim 21
Dependent Claim
115 words
A nonwoven product formed from a nonwoven web of fibers bonded together by a binder deposited from an interpolymer latex comprising an aqueous medium having dispersed threrein a vinyl acetate/ethylene/an N-methylol acrylamide/an acrylamide interpolymer, the interpolymer containing about 5 to 40 wt% ethylene and an amount of the N-methylol acrylamide and the acrylamide which is about 3 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, the nonwoven product characterized by a free formaldehyde content after drying and curing of less than 50 ppm at a binder add-on which is sufficient to bind the fibers together to form a self-sustaining web.
Claim 22
Dependent Claim
18 words
The nonwoven product of claim 19 having at least about 3 wt% binder add-on, on a dry basis.
Claim 23
Dependent Claim
16 words
The nonwoven product of claim 20 having a free formaldehyde content of less than 25 ppm.
Claim 24
Dependent Claim
17 words
A nonwoven product of claim 21 having about a 50 wt% binder add-on, on a dry basis.
Claim 25
Dependent Claim
16 words
The nonwoven product of claim 21 in which the binder is a vinyl acetate/ethylene/N-methylol acrylamide/acrylamide interpolymer.
Claim 26
Dependent Claim
36 words
The nonwoven product of claim 23 in which the interpolymer contains an amount of N-methylol acrylamide and acrylamide which is about 4 to 5 wt% of the interpolymer, the acrylamide being about 1.25 to 3.25 wt%.
Claim 27
Dependent Claim
20 words
The nonwoven product of claim 23 in which the interpolymer contains N-methylol acrylamide and acrylamide in about equal molar amounts.
Claim 28
Dependent Claim
16 words
The nonwoven product of claim 19 having a free formaldehyde content of less than 10 ppm.
Claim 29
Dependent Claim
106 words
A nonwoven fabric having a low residual free formaldehyde content comprising a loosely assembled web of fibers bonded together with a binder which comprises an interpolymer of vinyl acetate/ethylene/N-methylol acrylamide/acrylamide, the interpolymer containing about 5 to 40 wt% ethylene and an amount of N-methylol acrylamide and acrylamide which is about 3.0 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, the nonwoven fabric characterized by a free formaldehyde content after drying and curing of less than 50 to 60 ppm at a 10 to 100 wt% binder add-on, on a dry basis.
Claim 30
Dependent Claim
106 words
A nonwoven fabric having a low residual free formaldehyde content comprising a loosely assembled web of fibers bonded together with a binder which comprises an interpolymer of vinyl acetate/ethylene/N-methylol acrylamide/acrylamide, the interpolymer containing about 5 to 40 wt% ethylene and an amount of N-methylol acrylamide and acrylamide which is about 3.0 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, the nonwoven fabric characterized by a free formaldehyde content after drying and curing of less than 50 to 60 ppm at a 10 to 100 wt% binder add-on, on a dry basis.
Claim 31
Dependent Claim
35 words
The invention of claim 27 in which the interpolymer contains an amount of N-methylol acrylamide and acrylamide which is about 4 to 5 wt% of the interpolymer, the acrylamide being about 1.25 to 3.25 wt%.
Claim 32
Dependent Claim
19 words
The invention of claim 27 in which the interpolymer contains N-methylol acrylamide and acrylamide in about equal molar amounts.
Claim 33
Dependent Claim
14 words
The invention of claim 27 in which the nonwoven fabric is a disposable diaper.
Claim 34
Dependent Claim
33 words
The invention of claim 27 in which the nonwoven fabric is characterized by a residual free formaldehyde content of less than 30 ppm at a 20 wt% binder add-on, on a dry basis.
Claim 35
Dependent Claim
121 words
A nonwoven fabric having a low residual free formaldehyde content formed from a loosely assembled web of fibers bonded together by a binder deposited from a vinyl acetate/ethylene/N-methylol acrylamide/acrylamide interpolymer latex comprising an aqueous medium having colloidally suspended therein a vinyl acetate/ethylene/N-methylol acrylamide/acrylamide interpolymer, the interpolymer containing about 5 to 40 wt% ethylene and an amount of N-methylol acrylamide and acrylamide which is about 3.0 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, the nonwoven fabric characterized by a free formaldehyde content after drying and curing of less than 50 to 60 ppm at a 10 to 100 weight % binder add-on, on a dry basis.
Claim 36
Dependent Claim
121 words
A nonwoven fabric having a low residual free formaldehyde content formed from a loosely assembled web of fibers bonded together by a binder deposited from a vinyl acetate/ethylene/N-methylol acrylamide/acrylamide interpolymer latex comprising an aqueous medium having colloidally suspended therein a vinyl acetate/ethylene/N-methylol acrylamide/acrylamide interpolymer, the interpolymer containing about 5 to 40 wt% ethylene and an amount of N-methylol acrylamide and acrylamide which is about 3.0 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, the nonwoven fabric characterized by a free formaldehyde content after drying and curing of less than 50 to 60 ppm at a 10 to 100 weight % binder add-on, on a dry basis.
Claim 37
Dependent Claim
35 words
The invention of claim 32 in which the interpolymer contains an amount of N-methylol acrylamide and acrylamide which is about 4 to 5 wt% of the interpolymer, the acrylamide being about 1.25 to 3.25 wt%.
Claim 38
Dependent Claim
19 words
The invention of claim 32 in which the interpolymer contains N-methylol acrylamide and acrylamide in about equal molar amounts.
Claim 39
Dependent Claim
14 words
The invention of claim 32 in which the nonwoven fabric is a disposable diaper.
Claim 40
Dependent Claim
32 words
The invention of claim 32 in which the nonwoven fabric is characterized by a residual free formaldehyde content of less than 30 ppm at a 20% binder add-on, on a dry basis.
Claim 41
Independent Claim
130 words
A method for the preparation of a nonwoven product which comprises applying to a nonwoven mass of fibers a latex comprising an interpolymer of vinyl acetate/ethylene/an N-methylol acrylamide/an acrylamide dispersed in water, the interpolymer containing about 5 to 40 wt% ethylene and an amount of the N-methylol acrylamide and acrylamide which is about 3 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, heating to remove the water and to bond the fibers together with the interpolymer, the latex being applied to the nonwoven mass of fibers to provide a sufficient amount of interpolymer add-on to bind the fibers together to form a self-sustaining web, and the nonwoven product characterized by a low free formaldehyde content.
Claim 42
Independent Claim
130 words
A method for the preparation of a nonwoven product which comprises applying to a nonwoven mass of fibers a latex comprising an interpolymer of vinyl acetate/ethylene/an N-methylol acrylamide/an acrylamide dispersed in water, the interpolymer containing about 5 to 40 wt% ethylene and an amount of the N-methylol acrylamide and acrylamide which is about 3 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, heating to remove the water and to bond the fibers together with the interpolymer, the latex being applied to the nonwoven mass of fibers to provide a sufficient amount of interpolymer add-on to bind the fibers together to form a self-sustaining web, and the nonwoven product characterized by a low free formaldehyde content.
Claim 43
Dependent Claim
20 words
The method of claim 37 in which the nonwoven product has a free formaldehyde content of less than 50 ppm.
Claim 44
Dependent Claim
32 words
The method of claim 38 in which the latex is applied to the mass of fibers in an amount to provide at least about 3 wt% interpolymer add-on, on a dry basis.
Claim 45
Dependent Claim
20 words
The method of claim 39 in which the nonwoven product has a free formaldehyde content of less than 25 ppm.
Claim 46
Dependent Claim
19 words
The method of claim 39 in which the latex comprises an interpolymer of vinyl acetate/ethylene/N-methylol acrylamide/acrylamide dispersed in water.
Claim 47
Independent Claim
140 words
A method for the preparation of a nonwoven fabric having a low residual free formaldehyde content which comprises applying to a loosely assembled mass of fibers a latex comprising an interpolymer of vinyl acetate/ethylene/N-methylol acrylamide/acrylamide colloidally suspended in water, the interpolymer containing about 5 to 40 wt% ethylene and an amount of N-methylol acrylamide and acrylamide which is about 3.0 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, heating to remove the water and to bond the fibers together with the interpolymer, the latex being applied to the mass of fibers in an amount to provide a 10 to 100 weight % interpolymer add-on, on a dry basis, and the nonwoven fabric characterized by a free formaldehyde content of less than 50 to 60 ppm.
Claim 48
Independent Claim
140 words
A method for the preparation of a nonwoven fabric having a low residual free formaldehyde content which comprises applying to a loosely assembled mass of fibers a latex comprising an interpolymer of vinyl acetate/ethylene/N-methylol acrylamide/acrylamide colloidally suspended in water, the interpolymer containing about 5 to 40 wt% ethylene and an amount of N-methylol acrylamide and acrylamide which is about 3.0 to 10 wt% of the interpolymer, the N-methylol acrylamide being about 1.75 to 3.5 wt% and the acrylamide about 1.25 to 8.25 wt%, heating to remove the water and to bond the fibers together with the interpolymer, the latex being applied to the mass of fibers in an amount to provide a 10 to 100 weight % interpolymer add-on, on a dry basis, and the nonwoven fabric characterized by a free formaldehyde content of less than 50 to 60 ppm.
Claim 49
Dependent Claim
35 words
The invention of claim 42 in which the interpolymer contains an amount of N-methylol acrylamide and acrylamide which is about 4 to 5 wt% of the interpolymer, the acrylamide being about 1.25 to 3.25 wt%.
Claim 50
Dependent Claim
19 words
The invention of claim 42 in which the interpolymer contains N-methylol acrylamide and acrylamide in about equal molar amounts.
Claim 51
Dependent Claim
14 words
The invention of claim 42 in which the nonwoven fabric is a disposable diaper.
Claim 52
Dependent Claim
33 words
The invention of claim 42 in which the nonwoven fabric is characterized by a residual free formaldehyde content of less than 30 ppm at a 20 wt% binder add-on, on a dry basis.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-05-22 | 1987-11-21 | 1988-05-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-05-22 | 1991-11-21 | 1992-05-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-05-22 | 1995-11-21 | 1996-05-22 | $7700.00 | Window Closed / Lapsed |