Teabags and Coffee/Beverage Pouches Made From Mono-component, Mono-constituent Polylactic Acid (PLA) Fibers

Abstract

A non-woven mono-component, mono-constituent poly lactic acid (PLA) web is disclosed. The web material is useful for production of tea bags and other infusion beverages. The nonwoven network of PLA fibers in mono-component, mono-constituent configuration provides infusion properties, strength and weight properties that surpass current beverage bags and pouches because of its unique composition and structure.

What is claimed: 
     
         1 . A non-woven fabric composition web of mono-component, mono-constituent PLA fiber composition consisting of:
 a plurality of fiber layers made from a plurality of individual fibers that are blends of a mono-component, mono-constituent polylactic acid (PLA) fiber;   said polylactic acid (PLA) fiber having different deniers and blend percentages of high and low fibers having a melt flow temperature in a range of 145-175° C. and 105-165° C., respectively.   
     
     
         2 . The non-woven fabric composition web composition in  claim 1 , wherein the plurality of layers are sequenced by at least one of the following layer configurations: ABA, AAB, ABB, BAB, ABC, CBA, CAB, CCA, CCB, BBC, BBA, BCB, and BAC, wherein layer A is a first fiber blend layer, layer B is a second fiber blend layer, and layer C is a third fiber blend layer. 
     
     
         3 . The non-woven web composition in  claim 2 , wherein the layer configuration is made up of layers up to 7 layers. 
     
     
         4 . The non-woven web composition in  claim 3 , wherein the plurality of layers are sequenced by at least one of the following layer configurations: ABCDEFG; BCDEFGA; CDEFGAB; DEFGABC; EFGABCD; FGABCDE; GABCDEF and any combination thereof, wherein layer A is a first fiber blend layer, layer B is a second fiber blend layer, and layer C is a third fiber blend layer, layer D is a fourth fiber blend layer, layer E is a fifth fiber blend layer, and layer F is a sixth fiber blend layer and layer G is a seventh fiber blend layer. 
     
     
         5 . The non-woven fabric web composition in  claim 1 , wherein the non-woven fabric web has a weight from 10 gsm to 125 gsm. 
     
     
         6 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers have a cross section, said cross-section is in a non-circular shape, and more particularly said cross-section is in a shape selected from the group consisting of: a triangle, a mock hollow or “C” shape, a flat shape, a rectangular shape, a ribbon shape, a spiral shape, a helix shape, a square shape, an oval shape, a polygon shape, and a multi-dimensional shape. 
     
     
         7 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers further consists of a permanent hydrophilic fiber finish to enhance rapid infusion of water. 
     
     
         8 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers have a unit of weight that describes thickness in the range from 0.8 to 26 deniers. 
     
     
         9 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers have a unit of weight that describes thickness in the range from 1.0 to 6.0 deniers. 
     
     
         10 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers have a length in the range from 0.75 to 6 inches. 
     
     
         11 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers have a length in the range from 1.5 to 3 inches. 
     
     
         12 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers have a weight in the range from 12 to 120 grams per square meter (gsm). 
     
     
         13 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers have a weight in the range from 16 to 100 grams per square meter (gsm). 
     
     
         13 . The non-woven fabric web composition in  claim 1 , wherein the plurality of fibers have a weight in the range from 90 to 100 grams per square meter (gsm). 
     
     
         14 . The non-woven fabric web composition in  claim 1 , wherein the PLA fibers are blended with synthetic cellulose fibers selected from a group consisting of Rayon, Lyocell (Tencel®), regenerated cellulose, acetate or any combination thereof to make a blend. 
     
     
         15 . The non-woven fabric web composition in  claim 14 , wherein the blend consists of 40% to 95% PLA or CoPLA, and 5% to 60% synthetic cellulose fibers with deniers from 0.5 to 7.0 denier and a fiber length of 0.25 to 7″ in length. 
     
     
         16 . The non-woven fabric web composition in  claim 1 , wherein the nonwoven fabric web further includes a food grade and FDA compliant hydrophilic fiber finish. 
     
     
         17 . A nonwoven web for use in producing beverage infusion pouches and bags, said web consisting of:
 a plurality of mono-component mono-constituent Polylactic Acid (PLA) fibers forming said web by dry thermo-bonding without the use of plasticizers and other surface treatments, wherein said web provides for biodegradability after usage and recyclability of waste materials during each step of a manufacturing process of said web;   the mono-component mono-constituent Polylactic Acid (PLA) fibers having an amorphous portion and a crystalline portion;   said mono-component mono-constituent Polylactic Acid (PLA) fibers form pore sizes of the web that are maintained if infused with hot liquids to enhance flow; and.   the PLA fibers are blended with synthetic cellulose fibers selected from a group consisting of Rayon, Lyocell (Tencel®), regenerated cellulose, acetate or any combination thereof to make a blend.   
     
     
         18 . A web as in  claim 17  wherein the web fibers have a fiber length of between about 20 mm to 90 mm. 
     
     
         19 . A web as in  claim 17  wherein the web fibers have a length of 38 mm. 
     
     
         20 . A web as in  claim 17  wherein the web fibers are from between about 0.6 denier to 6.0 denier. 
     
     
         21 . A web as in  claim 17  wherein the web fibers are 3.0 denier. 
     
     
         22 . A web as in  claim 17  wherein the web fibers are 1.5 denier. 
     
     
         23 . A web as in  claim 17  wherein the web fibers are 1.2 denier. 
     
     
         24 . A web as in  claim 17  having a dry basis weight from between about 8 to 50 grams per square meter. 
     
     
         25 . A web as in  claim 17  wherein the PLA mono-component mono-constituent fibers have two different melting points for a crystalline portion and an amorphous portion that is 145-175° C. and 105-165° C. respectively. 
     
     
         26 . A web as in  claim 17  wherein the fibers are 100% of PLA fibers that melt at a temperature of between about 135° to 175° C. 
     
     
         27 . A web as in  claim 17  where a proportion of fibers are PLA fibers are between 0.8 to 26 Denier. 
     
     
         28 . A web as in  claim 27  wherein the web fibers consist of mono-component mono-constituent fibers having a melting point of 145° to 175° C. and the Co PLA fiber portion of the mono-component mono-constituent fiber is CoPLA with a melt temperature from 105° to 165° C. having a lower melting temperature than the melting temperature of other mono-component mono-constituent fibers. 
     
     
         29 . A web as in  claim 17  wherein the mono-component mono-constituent fibers further include a thermally active component that is 5% to 50% by weight, wherein percentages are based on weight of the web. 
     
     
         30 . A web as in  claim 17  usable as material for bags or pouches for: Lemonade, herbal sachets, coffee, tea, hot chocolate, soap powder, chemicals and chlorine for pools and spas, decontaminating liquids, coloring of liquids, dehumidifying chemicals, carriers for phase-change materials for heating or cooling, tobacco pouches, and all materials that can be placed in a heat and/or ultra sound activated sealable container. 
     
     
         31 . A bag or pouch formed at least in part from the web of  claim 17 . 
     
     
         32 . A bag or pouch as formed essentially entirely from the web of  claim 17 . 
     
     
         33 . A bag or pouch using a web as in  claim 17 , but made using randomizing rolls so that the fibers in the web are randomized. 
     
     
         34 . A web as in  claim 17  wherein the fibers are at least two mono-component mono-constituent fibers of PLA fibers, a first fiber and a second fiber, with different melting points for forming the web such that the first fiber melts at a higher temperature than the second fiber. 
     
     
         35 . A web as in  claim 17  wherein the web is a beverage infusion package for providing biodegradability after usage and recyclability of waste materials during each step of the manufacturing process from polymer to finished web. 
     
     
         36 . A web as in  claim 35  usable in bags or pouches for materials selected from the group consisting of: lemonade, herbal sachets, coffee, tea, hot chocolate, soap powder, chemicals and chlorine for pools and spas, decontaminating liquids, coloring of liquids, dehumidifying chemicals, carriers for phase-change materials for heating or cooling, tobacco pouches, and wherein said bags or pouches are sealable by heat or ultra sound. 
     
     
         37 . A web as in  claim 36  further including a string attached to each one of the bags, said string also made of the mono-component mono-constituent Polylactic Acid (PLA) fibers. 
     
     
         38 . A web as in  claim 35  wherein the crystallinity of the mono-component mono-constituent Polylactic Acid (PLA) fibers are controlled by drawing. 
     
     
         39 . A web as in  claim 35  further including a dry basis weight from between about 8 to 50 grams per square meter. 
     
     
         40 . A web as in  claim 35  wherein the pore size of the web if infused with hot liquids is substantially maintained to enhance flow.