EP-4735675-A1 - POLYOLEFIN BICOMPONENT FIBER WITH COMPATIBILIZER AND POST INDUSTIRAL POLYOLEFIN RESIN

Abstract

The present disclosure provides a fiber. In an embodiment, the fiber includes a first region and a second region. A component is present in at least one of the first region and the second region. The component is composed of (i) a post-industrial resin (PIR) and (ii) an acrylate-based compatibilizer.

Inventors

• SINGH, ANURIMA
• MARKS, SCOTT, B.
• BRUNETTO, Michel
• LIN, YIJIAN
• BITINIS, Georgia, Natacha Eftalie
• PATEL, RAJEN, M.
• THAKRE, Piyush, R.

Assignees

• DOW GLOBAL TECHNOLOGIES LLC

Dates

Publication Date

20260506

Application Date

20240531

Claims (1)

1. 85411-WO-PCT (10009.898) CLAIMS 1. A fiber comprising: a first region; a second region; and a component present in at least one of the first region and the second region, the component comprising (i) a post-industrial resin (PIR) and (ii) an acrylate-based compatibilizer. 2. The fiber of claim 1 wherein the first region is a polymer selected from the group consisting of a propylene-based polymer, an ethylene-based polymer, and combinations thereof. 3. The fiber of any of claims 1-2 wherein the second region is a polymer selected from the group consisting of a propylene-based polymer, an ethylene-based polymer, and combinations thereof. 4. The fiber of any of claims 1-3 wherein the PIR comprises from 20 wt% to 60 wt% of an ethylene-based polymer and from 80 wt% to 40 wt% of a propylene-based polymer, based on total weight of the PIR. 5. The fiber of any of claims 1-4 wherein the acrylate-based compatibilizer is selected from the group consisting of ethylene methacrylate copolymer, ethylene ethylacrylate copolymer, ethylene butylacrylate copolymer, and combinations thereof. 6. The fiber of any of claims 1-5 wherein the component comprises from 99 wt% to 80 wt% of the PIR and from 1 wt% to 20 wt% of the acrylate-based compatibilizer, based on total weight of the component. {02280269.DOCX / } 26 85411-WO-PCT (10009.898) 7. The fiber of any of claims 1-6 wherein the first region and the second region are arranged in a configuration selected from the group consisting of a core-sheath configuration, a side-by- side configuration, and an island-in-the-sea configuration. 8. The fiber of claim 7 wherein the first region and the second region are arranged in the core-sheath configuration; the first region is the sheath and is composed of a propylene-based polymer; and the second region is the core and is composed of (A) a propylene-based polymer; and (B) the component. 9. The fiber of claim 7 wherein the first region and the second region are arranged in the core-sheath configuration; the first region is the sheath and is composed of an ethylene-based polymer; and the second region is the core and is composed of (A) a propylene-based polymer; and (B) the component. 10. The fiber of claim 7 wherein the first region and the second region are arranged in the core-sheath configuration; the first region is the sheath composed of (A) an ethylene-based polymer, and (B) the recycled component; and the second region is composed of a propylene-based polymer. 11. The fiber of any of claims 1-10 having a density from 1 denier to 10 denier. 12. The fiber of any of claims 1-11 wherein the fiber comprises from 2 wt% to 35 wt% of the component based on total weight of the fiber. {02280269.DOCX / } 27 85411-WO-PCT (10009.898) 13. The fiber of claim 7 wherein the first region and the second region are composed of the same polymer. 14. The fiber of claim 13 wherein the first region is composed of a propylene-based polymer; and the second region is composed of the same propylene-based polymer present in the first region. 15. The fiber of claim 13 wherein the first region is composed of an ethylene-based polymer; and the second region is composed of the same ethylene-based polymer present in the first region. {02280269.DOCX / } 28

Description

85411-WO-PCT (10009.898) BICOMPONENT FIBER WITH COMPONENT BACKGROUND [0001] Bicomponent fibers are fibers composed of two regions and corresponding polymer compositions that are extruded from the same spinneret with both compositions contained within the same filament or fiber. When the fiber leaves the spinneret, it consists of non-mixed components that are in contact at the interface. The two polymer compositions can differ in their chemical and/or physical properties. Or the polymer composition can be same, and, in that case, it is a mono component fiber. [0002] Spunbond nonwoven fabrics are widely used in various applications, such as hygiene, medical, industrial, or automotive applications to provide low basis weight, economical, strong, and cloth-like fabrics. A common bicomponent configuration for spunbound nonwoven fabric is polyethylene (PE) spun with polypropylene (PP) in a bicomponent fiber configuration with the PP being the core and PE being the sheath for nonwoven web. However, it is a common industrial occurrence that the edges of the nonwoven web (10-15% of the production) need to be trimmed off due to poor fiber laydown quality. The trimmed edges of nonwoven web are usually scrapped. Recycling of the trimmed edges (“regrind”) into the spunbond production is desired by the spunbond converters. However, currently only low levels of regrind (typically 3% or less) can be incorporated back into commercial fiber production without sacrificing the spinning process, due to significant fiber breaks. Blending the trimmed edges with virgin olefin-based polymer has seen only limited success in increasing the amount of bicomponent fiber regrind that can be incorporated back into the fiber production process. [0003] Hence, a need exists for increasing the amount of fiber regrind (and PE/PP fiber regrind in particular) back into a fiber spinning without causing fiber breaks during spinning. SUMMARY [0004] The present disclosure provides a fiber. In an embodiment, the fiber includes a first region a second region. A component is present in at least one of the first region and the second region. The component is composed of (i) a post-industrial resin (PIR) and (ii) an acrylate-based compatibilizer. {02280269.DOCX / } 1 85411-WO-PCT (10009.898) BRIEF DESCRIPTION OF THE DRAWINGS [0005] FIG.1 is a schematic representation of a fiber spinning process. DEFINITIONS [0006] Any reference to the Periodic Table of Elements is that as published by CRC Press, Inc., 1990– 1991. Reference to a group of elements in this table is by the new notation for numbering groups. [0007] For purposes of United States patent practice, the contents of any referenced patent, patent application or publication are incorporated by reference in their entirety (or its equivalent US version is so incorporated by reference) especially with respect to the disclosure of definitions (to the extent not inconsistent with any definitions specifically provided in this disclosure) and general knowledge in the art. [0008] The numerical ranges disclosed herein include all values from, and including, the lower and upper value. For ranges containing explicit values (e.g., a range from 1, or 2, or 3 to 5, or 6, or 7), any subrange between any two explicit values is included (e.g., the range 1–7 above includes subranges 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.). [0009] Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percents are based on weight and all test methods are current as of the filing date of this disclosure. [0010] The terms “comprising”, “including”, “having” and their derivatives do not exclude the presence of any additional component or procedure. The term, “consisting essentially of” excludes any other component or procedure, except those essential to operability. The term “consisting of” excludes any component or procedure not specifically stated. [0011] The term “denier” is the linear mass density of a fiber. Denier is defined as the grams of the fiber per 9000 meters of the fiber length. [0012] An "ethylene-based polymer" is a polymer that contains more than 50 weight percent (wt%) polymerized ethylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer. Ethylene-based polymer includes ethylene homopolymer, and ethylene copolymer (meaning units derived from ethylene and one or more {02280269.DOCX / } 2 85411-WO-PCT (10009.898) comonomers). The terms "ethylene-based polymer" and "polyethylene" may be used interchangeably. Nonlimiting examples of ethylene-based polymer (polyethylene) include low density polyethylene (LDPE) and linear polyethylene. Nonlimiting examples of linear polyethylene include linear low density polyethylene (LLDPE), ultra low density polyethylene (ULDPE), very low density polyethylene (VLDPE), multi-component ethylene-based copolymer (EPE), ethylene/α-olefin multi-block copolymers (also known as olefi