Abstract:
A spunbonded elastic nonwoven fabric comprises a web of bonded thermoplastic filaments of a thermoplastic elastomer. The spunbonded fabrics of the invention are prepared in a slot draw spunbonding process operated at a rate of less than about 2000 meters per minute. The elastic fabric is used in absorbent products, such as disposable diapers, adult incontinence pads, sanitary napkins and the like, and as coverstock for absorbent personal care products.
Abstract:
A nonwoven web (12) of meltblown microfibers formed of a composition of polyethylene and at least one component added to provide processing stability to the polyethylene component. The meltblown web (12) can be produced at high polymer throughputs and exhibits good barrier properties. The meltblown web (12) is useful as a component of a composite fabric (10), which can be used for barrier application in medical and industrial applications.
Abstract:
A nonwoven web (12) of meltblown microfibers formed of a composition of polyethylene and at least one component added to provide processing stability to the polyethylene component. The meltblown web (12) can be produced at high polymer throughputs and exhibits good barrier properties. The meltblown web (12) is useful as a component of a composite fabric (10), which can be used for barrier application in medical and industrial applications.
Abstract:
The invention is directed to a composite nonwoven fabric (10) comprising first and second nonwoven webs (11, 13) of spunbonded substantially continuous thermoplastic filaments, and a nonwoven hydrophobic microporous web (12) of thermoplastic meltblown microfibers sandwiched between the first and second nonwoven webs. The filaments of the nonwoven spunbond webs are formed of continuous multiconstituent filaments which include a lower melting gamma radiation stable polyethylene polymer component and one or more higher melting gamma radiation stable polymer constituents, wherein a substantial portion of the surfaces of the multiconstituent filaments consists of the lower melting gamma radiation stable polyethylene constituent. The nonwoven hydrophobic microporous web is formed from a gamma radiation stable polyethylene polymer. The webs are bonded together to form the composite nonwoven fabric by discrete point bonds in which the polyethylene constituent of said multiconstituent filaments and the polyethylene of said third nonwoven web are fused together.
Abstract:
The invention is directed to composite nonwoven fabrics comprising a hydrophobic nonwoven web, a nonwoven web of thermoplastic meltblown microfibers and a hydrophilic nonwoven web comprising staple fibers. The nonwoven web of thermoplastic meltblown fibers is sandwiched between the hydrophobic nonwoven web and the hydrophilic nonwoven web and all of the layers are thermally bonded together via discontinuous thermal bonds distributed substantially throughout the composite nonwoven fabric.
Abstract:
Multicomponent thermoplastic continuous filaments are provided, including hollow core multicomponent filaments. The filaments are at least partially splittable into smaller filaments in the absence of mechanical treatment or application of high pressure water jets. The surface energy of the components can be controlled to control separation of the multicomponent filaments. Sub-denier and micro-denier filaments of low orientation can be produced from relatively high molecular weight polymers to produce nonwovens of surprising strength, barrier, and cover.
Abstract:
An apparatus is disclosed for forming a nonwoven fabric web, such as a spunbond web. The apparatus comprises a spinneret for downwardly extruding a curtain of filaments, and an underlying air drawing unit for drawing and attenuating the filaments as they move downwardly therethrough. A conveyor belt receives the drawn filaments and forms the filaments into a nonwoven fabric web. In the drawing unit, the filaments pass downwardly through a slot, and a pair of air nozzles are positioned in the slot, with one nozzle being positioned adjacent each sidewall of the slot. The nozzle outlets are oriented so as to introduce each of the air streams into the slot in a direction which is parallel to the sidewalls of the slot, and the introduced air streams act to draw additional air into the open upper end of the slot. The drawn-in air and the air introduced by the two nozzles collectively form a substantially non-turbulent flow at their juncture and along the remainder of the vertical length of the slot, and this smooth air flow serves to draw the filaments without imparting turbulence to the filaments, which in turn produces filaments which are uniformly drawn and thus of uniform denier.
Abstract:
A nonwoven filamentary web having high loft is produced by extruding a molten thermoplastic polymer or polymer blend through a spinneret to form continuous filaments while maintaining extrusion conditions which induce melt-fracture of the extrudate; attenuating the thus extruded melt-fractured filaments to obtain filamentary material having a crimped structure; and depositing the melt-fractured filamentary material on a collection surface and forming a web therefrom.
Abstract:
A slot draw attenuator apparatus and method are provided for producing webs of spunbonded thermoplastic filaments having improved cover even at low basis weights. The filaments are introduced to a slot draw attenuator having corona electrodes mounted in an elongate insulator bar and staggered and spaced along one wall of the attenuator slot near the exit end thereof. The corona electrodes are electrically connected to a high voltage source. The opposing wall of the slot is grounded. A corona is created in the attenuator slot so that the filaments are charged as they exit the attenuator. The electrostatic charge induces repelling forces in the filaments so that the filaments spread before they are randomly deposited upon a forming belt.