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Improved elasticity and mechanical properties of Vistamaxx™ performance polymers / homopolymer blend elastic spunbond fabrics with multi-layer structure

IP.com Disclosure Number: IPCOM000248493D
Publication Date: 2016-Dec-08
Document File: 5 page(s) / 218K

Publishing Venue

The IP.com Prior Art Database

Abstract

VistamaxxTM performance polymers, a propylene-based elastomer, have good elastic properties and are used widely for elastic film applications in hygiene applications. However, Asia Pacific (AP) customers in the elastic film business who look for alternate solutions using other conversion techniques. Elastic spunmelt fabrics have received a lot of attention recently. It has been recently demonstrated that neat Vistamaxx 7050 can successfully make elastic spunbond fabrics with while overcoming previous processing challenges due to its higher MFR (48g/10min) and low ethylene content (13%). However, previous disclosures all focus on single layer spunbond due to easier process-ability, while the productivity and fabric uniformity is not good enough, especially at the lower basis weight. This is critical because Brandowners would like to save cost when making the switch. The Brandowners also preferred to have elastic spunbond fabric with better uniformity, which brings stronger mechanical properties, so that higher diaper line speed and less processing issue could be achieved. In this work, trials of multi-layer fabric on commercial lines were conducted, showing good processability. The test result indicated better elastic properties of multi layer elastic SB vs. monolayer at the same basis weight with higher elongation, stronger tensile strength, lower initial force while maintaining the retractive force and permanent set.

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Improved elasticity and mechanical properties of Vistamaxx™ performance polymers / homopolymer blend elastic spunbond fabrics with multi-layer structure

Abstract: VistamaxxTM performance polymers, a propylene-based elastomer, have good elastic properties and are used widely for elastic film applications in hygiene applications. However, Asia Pacific (AP) customers in the elastic film business who look for alternate solutions using other conversion techniques. Elastic spunmelt fabrics have received a lot of attention recently. It has been recently demonstrated that neat Vistamaxx 7050 can successfully make elastic spunbond fabrics with while overcoming previous processing challenges due to its higher MFR (48g/10min) and low ethylene content (13%). However, previous disclosures all focus on single layer spunbond due to easier process-ability, while the productivity and fabric uniformity is not good enough, especially at the lower basis weight. This is critical because Brandowners would like to save cost when making the switch. The Brandowners also preferred to have elastic spunbond fabric with better uniformity, which brings stronger mechanical properties, so that higher diaper line speed and less processing issue could be achieved. In this work, trials of multi-layer fabric on commercial lines were conducted, showing good processability. The test result indicated better elastic properties of multi layer elastic SB vs. monolayer at the same basis weight with higher elongation, stronger tensile strength, lower initial force while maintaining the retractive force and permanent set.

Background:
Elastic spunbond fabric is growing in popularity in AP because there is potential to replace more expensive incumbents such as Styrene Butadiene Copolymer, Olefin Block Copolymer, Thermoplastic Polyurethane, and SPANDEX in hygiene applications (waistband, bellyband). There is also potential for such spunbond fabrics to penetrate into medical (e.g., surgical masks, bandages) and cosmetics (masks). Due to the unsuitable viscosity and ethylene content, commercial Vistamaxx grades faced processing challenges (drips, stickiness, etc.) that prevent the usage of neat Vistamaxx in this application. Blending Vistamaxx with polypropylene (PP) helps to overcome processing issues but this resulted in insufficient elasticity for successful commercial penetration.

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