US4769279A
Expired / Lapsed
US
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Low viscosity ethylene acrylic copolymers for nonwovens
Assignee: University of Tennessee Research Foundation
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Filing: 1986-09-22
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Granted: 1988-09-06
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Expires: 2006-09-22
Abstract
Abstract Low viscosity ethylene acrylic copolymers and blends thereof with other fiber-forming polymers for spunbond and melt blown nonwoven applications. Ethylene/alkyl (meth) acrylate, especially ethylene/methyl acrylate copolymers are found to be suitable for fiber-forming operations, especially melt blowing when the melt index is at least about 10. Blends of the copolymer with other fiber-forming polymers are especially suitable for fiber-forming operations. The nonwoven products of the copolymers and blends of the invention show a good degree of elongation making them especially suitable for certain fabric applications and new uses. The nonwoven fabrics are comprised of fibers of the copolymers and blends, having a diameter of about 1-40 microns. Larger fibers may also be formed by various techniques.
Inventors
- 👤 Blair A. Graham
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 22:54
CPC Classifications
D; D01; D01F; D01F6/00; D01F6/28; D01F6/36; D01F6/30; D04; D04H; D04H1/00; D04H1/40; D04H1/54; D04H1/56; Y; Y10; Y10S; Y10S428/00; Y10S428/903; Y10T; Y10T428/00; Y10T428/29; Y10T428/2913; Y10T428/298; Y10T442/00; Y10T442/60; Y10T442/608; Y10T442/68
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
51 words
A melt-blown fiber of about 1-50 microns diameter comprised of an ethylene acrylic copolymer having a melt flow rate of at least about 10 and an ethylene comonomer content of about 35-99 weight percent, or being formed of a 30-70 weight percent blend of said copolymer with a second fiber-forming polymer.
Claim 2
Dependent Claim
51 words
A melt-blown fiber of about 1-50 microns diameter comprised of an ethylene acrylic copolymer having a melt flow rate of at least about 10 and an ethylene comonomer content of about 35-99 weight percent, or being formed of a 30-70 weight percent blend of said copolymer with a second fiber-forming polymer.
Claim 3
Dependent Claim
13 words
The fiber of claim 1 wherein said melt flow rate is about 20-500.
Claim 4
Dependent Claim
13 words
The fiber of claim 2 wherein said melt flow rate is about 25-200.
Claim 5
Dependent Claim
10 words
The fiber of claim 1 of about 1-40 microns diameter.
Claim 6
Dependent Claim
10 words
The fiber of claim 4 of about 1-15 microns diameter.
Claim 7
Dependent Claim
15 words
The fiber of claim 1 wherein said ethylene acrylic copolymer is an ethylene/alkyl (meth) acrylate.
Claim 8
Dependent Claim
14 words
The fiber of claim 6 wherein said alkyl (meth) acrylate is an alkyl acrylate.
Claim 9
Dependent Claim
14 words
The fiber of claim 7 wherein said alkyl acrylate is a lower alkyl acrylate.
Claim 10
Dependent Claim
13 words
The fiber of claim 8 wherein said lower alkyl acrylate is methyl acrylate.
Claim 11
Dependent Claim
11 words
The fiber of claim 1 comprised of an ethylene acrylic copolymer.
Claim 12
Dependent Claim
10 words
The fiber of claim 10 comprised of ethylene-methyl acrylate copolymer.
Claim 13
Dependent Claim
20 words
The fiber of claim 1 wherein said ethylene acrylic copolymer has an acrylic comonomer content of about 10-40 weight percent.
Claim 14
Dependent Claim
18 words
The fiber of claim 12 wherein said copolymer has an acrylic comonomer content of about 20-40 weight percent.
Claim 15
Dependent Claim
14 words
The fiber of claim 13 wherein said acrylic comonomer is an alkyl (meth) acrylate.
Claim 16
Dependent Claim
13 words
The fiber of claim 14 wherein said alkyl (meth) acrylate is methyl acrylate.
Claim 17
Dependent Claim
21 words
The fiber of claim 1 comprising a 30-70 weight percent blend of an ethylene acrylic copolymer and a second fiber-forming polymer.
Claim 18
Dependent Claim
13 words
The fiber of claim 16 wherein said second fiber-forming polymer is a polyolefin.
Claim 19
Dependent Claim
14 words
The fiber of claim 17 wherein said polyolefin is a polypropylene homopolymer or copolymer.
Claim 20
Dependent Claim
14 words
The fiber of claim 17 wherein said polyolefin is a polyethylene homopolymer or copolymer.
Claim 21
Dependent Claim
16 words
The fiber of claim 17 wherein said polyolefin comprises about 50 weight percent of said blend.
Claim 22
Dependent Claim
25 words
The fiber of claim 17 of about 1-40 microns diameter, wherein said copolymer component of the blend has a melt flow rate of about 20-500.
Claim 23
Dependent Claim
59 words
A nonwoven web of melt-blown fibers having a diameter of about 1-40 microns, said fibers being formed of an ethylene acrylic copolymer having a melt flow rate of at least about 10 and an ethylene comonomer content of about 35-99 weight percent, or being formed of a 30-70 weight percent blend of said copolymer with a second fiber-forming polymer.
Claim 24
Dependent Claim
59 words
A nonwoven web of melt-blown fibers having a diameter of about 1-40 microns, said fibers being formed of an ethylene acrylic copolymer having a melt flow rate of at least about 10 and an ethylene comonomer content of about 35-99 weight percent, or being formed of a 30-70 weight percent blend of said copolymer with a second fiber-forming polymer.
Claim 25
Dependent Claim
24 words
The nonwoven web of claim 22 wherein said fibers are formed of an ethylene acrylic copolymer having a melt flow rate of about 20-500.
Claim 26
Dependent Claim
17 words
The nonwoven web of claim 23 wherein said copolymer has a melt flow rate of about 25-200.
Claim 27
Dependent Claim
16 words
The nonwoven web of claim 22 wherein said fibers have a diameter of about 1-15 microns.
Claim 28
Dependent Claim
35 words
The nonwoven web of claim 22 wherein said web has a base weight of about one ounce per square yard has an elongation at break in the cross direction of at least about 50 percent.
Claim 29
Dependent Claim
24 words
The nonwoven web of claim 26 wherein said web has an elongation at break in the cross direction of at least about 90 percent.
Claim 30
Dependent Claim
17 words
The nonwoven web of claim 22 wherein said ethylene acrylic copolymer is an ethylene alkyl (meth) acrylate.
Claim 31
Dependent Claim
16 words
The nonwoven web of claim 28 wherein said alkyl (meth) acrylate is a lower alkyl acrylate.
Claim 32
Dependent Claim
14 words
The nonwoven web of claim 29 wherein said lower alkyl acrylate is methyl acrylate.
Claim 33
Dependent Claim
21 words
The nonwoven web of claim 22 wherein said ethylene acrylic copolymer has an acrylic comonomer content of about 10-40 weight percent.
Claim 34
Dependent Claim
15 words
The nonwoven web of claim 31 wherein said comonomer content is about 20-40 weight percent.
Claim 35
Dependent Claim
22 words
The nonwoven web of claim 22 comprising a 30-70 weight percent blend of an ethylene acrylic copolymer and a second fiber-forming polymer.
Claim 36
Dependent Claim
14 words
The nonwoven web of claim 33 wherein said second fiber-forming polymer is a polyolefin.
Claim 37
Dependent Claim
26 words
The nonwoven web of claim 33 wherein said web consists essentially of a 30-70 weight percent blend of an ethylene-methyl acrylate copolymer and polyethylene or polypropylene.
Claim 38
Dependent Claim
139 words
In a process for producing a melt-blown nonwoven product wherein a fiber-forming thermoplastic polymer resin or resin blend is extruded in molten form from orifices of a heated nozzle into a stream of gas which attenuates said molten resin or blend into fibers and said fibers are collected on a receiver to form said nonwoven web, the improvement comprising: extruding from said nozzle orifices a fiber-forming ethylene acrylic copolymer having a melt flow rate of at least about 10 and about 35-99 weight percent ethylene comonomer content, or a 30-70 weight percent blend of said copolymer with a second fiber-forming polymer; and forming a nonwoven web of said copolymer or blend, said web having a base weight of about one ounce per square yard and an elongation at break in the cross direction of at least about 50 percent.
Claim 39
Dependent Claim
139 words
In a process for producing a melt-blown nonwoven product wherein a fiber-forming thermoplastic polymer resin or resin blend is extruded in molten form from orifices of a heated nozzle into a stream of gas which attenuates said molten resin or blend into fibers and said fibers are collected on a receiver to form said nonwoven web, the improvement comprising: extruding from said nozzle orifices a fiber-forming ethylene acrylic copolymer having a melt flow rate of at least about 10 and about 35-99 weight percent ethylene comonomer content, or a 30-70 weight percent blend of said copolymer with a second fiber-forming polymer; and forming a nonwoven web of said copolymer or blend, said web having a base weight of about one ounce per square yard and an elongation at break in the cross direction of at least about 50 percent.
Claim 40
Dependent Claim
59 words
The process of claim 36 wherein said molten resin is extruded at about 400-650° F. at the rate of about 0.2 grams per minute per orifice, said resin is attenuated to fibers with said stream of gas at at least about 150 SCFM, and said fibers are collected on said receiver at about 8-15 inches from said heated nozzle.
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) | 1991-09-06 | 1992-03-07 | 1992-09-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-09-06 | 1996-03-07 | 1996-09-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-09-06 | 2000-03-07 | 2000-09-06 | $7700.00 | Window Closed / Lapsed |