Compostable nonwoven with polyhydroxyalkanoate continuous filaments

Abstract

According to one or more embodiments, a compostable fabric includes a nonwoven fabric that includes continuous filaments with a polymeric composition that is fully biodegradable and includes about 51 weight percent to about 100 weight percent of a polyhydroxyalkanoate. The compostable fabric is biodegradable and demonstrates about 90% to about 100% conversion of organic carbon to carbon dioxide (CO2) after 180 days as measured by ASTMD 5338 test method.

What is claimed is: 
     
         1 . A compostable fabric comprising:
 a nonwoven fabric comprising continuous filaments comprising polymeric composition that is fully biodegradable and comprises about 51 weight percent to about 100 weight percent of a polyhydroxyalkanoate;   wherein the compostable fabric is biodegradable and demonstrates about 90% to about 100% conversion of organic carbon to carbon dioxide (CO 2 ) after 180 days as measured by ASTMD 5338 test method.   
     
     
         2 . The compostable fabric of  claim 1 , wherein the compostable fabric:
 demonstrates about 90% to about 100% conversion of organic carbon to carbon dioxide (CO 2 ) after 162 days in the absolute as measured by ASTMD 5338 test method; or   demonstrates about 90% to about 100% conversion of organic carbon to carbon dioxide (CO 2 ) after 143 days compared to a cellulosic control as measured by ASTMD 5338 test method.   
     
     
         3 . The compostable fabric of  claim 1 , wherein the compostable fabric is compostable in industrial aerobic facilities by demonstrating disintegration, wherein about 0% to about 10% of the compostable fabric's original dry weight remains after sieving on a 2.0 millimeter sieve after 84 days in a controlled composting test as measured in accordance with ISO 16929 with a minimum vessel volume of 35 Liters, or ISO 20200 under thermophilic aerobic composting conditions. 
     
     
         4 . The compostable fabric of  claim 1 , wherein the compostable fabric:
 is compostable in industrial aerobic facilities by demonstrating a concentrations of regulated metals less than 50% of those prescribed for sludges or composts in a country where the compostable fabric is sold; or   is compostable in industrial aerobic facilities by demonstrating a germination rate and a plant biomass of the compostable fabric composts shall are at least 90% that of corresponding blank composts for two different plant species following OECD Guideline 208 with the modifications found in Annex E of EN 13432.   
     
     
         5 . The compostable fabric of  claim 1 , wherein the polymeric composition further comprises:
 a polylactic acid, a polycaprolactone, a polybutylene succinate, a polybutylene succinate adipate, a polybutylene adipate terephthalate, a starch, or any combination thereof; or   an antioxidant, an ultraviolet (UV) stabilizer, or a combination thereof.   
     
     
         6 . The compostable fabric of  claim 1 , wherein the polymeric composition comprises 100% polyhydroxyalkanoate. 
     
     
         7 . The compostable fabric of  claim 1 , wherein the polyhydroxyalkanoate has a molecular weight of about 50,000 Daltons to about 2.5 million Daltons. 
     
     
         8 . The compostable fabric of  claim 1 , wherein the nonwoven fabric is formed by spunbonding, hydroentangling, needlepunching, thermal bonding, point bonding, or a combination thereof. 
     
     
         9 . The compostable fabric of  claim 1 , wherein the continuous filaments have an average diameter of about 10 to about 100 microns. 
     
     
         10 . The compostable fabric of  claim 1 , wherein the nonwoven fabric has a basis weight of about 20 to about 1,000 grams/square meter (gsm). 
     
     
         11 . The compostable fabric of  claim 1 , wherein the polymeric composition has a melt flow index (MFI) of about 1 to about 50 grams per 10 minutes as measured by ASTM D1238 test. 
     
     
         12 . The compostable fabric of  claim 1 , wherein the compostable fabric is an agricultural fabric. 
     
     
         13 . A method of making a compostable fabric, the method comprising:
 extruding a polymeric composition to form continuous filaments, the polymeric composition being fully biodegradable and comprising about 51 weight percent to about 100 weight percent of a polyhydroxyalkanoate; and   entangling the continuous filaments to form a nonwoven fabric.   
     
     
         14 . The method of  claim 13 , wherein extruding is by a melt spinning process at a temperature of about 120 to about 200 degrees Celsius. 
     
     
         15 . The method of  claim 13 , wherein entangling is hydroentangling and performed at a pressure of about 50 to about 300 Bars. 
     
     
         16 . The method of  claim 13 , wherein the polymeric composition comprises 100% polyhydroxyalkanoate; or the polyhydroxyalkanoate has a molecular weight of about 50,000 Daltons to about 2.5 million Daltons. 
     
     
         17 . The method of  claim 13 , wherein the entangling is by spunbonding, hydroentangling, needlepunching, thermal bonding, point bonding, or a combination thereof. 
     
     
         18 . The method of  claim 13 , wherein the continuous filaments have an average diameter of about 10 to about 100 microns; or the nonwoven fabric has a basis weight of about 20 to about 1,000 grams/square meter (gsm). 
     
     
         19 . The method of  claim 13 , wherein the polymeric composition has a melt flow index (MFI) of about 3 to about 50 grams per 10 minutes as measured by ASTM D1238 test. 
     
     
         20 . The method of  claim 13 , wherein the compostable fabric is an agricultural fabric.