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 present invention provides composite nonwoven fabric laminates and processes for producing such. The fabric is comprised of a web of thermoplastic filaments laminated to at least one other web. Preferably, the filaments are spunbonded continuous polyolefin filaments which have an oxidatively degraded outer sheath portion to promote better interfilamentary bonding and improved fabric laminate strength. In a preferred embodiment, two outer nonwoven webs comprise oxidatively degraded spunbonded filaments and are positioned around and laminated to a web of meltblown microfibers thus forming an spunbond/meltblown/spunbond fabric. Additionally, a stretch compatible fabric may be formed in which a web of oxidatively degraded filaments is laminated to an elastic web. The fabrics of the invention may be advantageously used in numerous applications such as medical garments and disposable adsorbent products.
Abstract:
The present invention provides a thermally-bonded nonwoven fabric that is made from a web which comprises from 100 to 5 percent by weight of multiconstituent fibers. Said multiconstituent fibers are composed of highly dispersed blends of at least two different immiscible thermoplastic polymers and have a dominant continuous polymer phase with at least one noncontinuous phase dispersed therein. The noncontinuous phase exists as an elongated fibrillar polymer domain oriented generally in the direction of the fiber axis. No single polymer domain cross-section of said noncontinuous phase or phases is larger than 0.1% of the cross-sectional area of said fiber. The polymer of the noncontinuous phase or phases has a Polymer Melt Temperature (PMT) at least 30 DEG C below the PMT of the continuous phase. The fiber is configured such that said noncontinuous phase or phases occupy a substantial portion of the fiber surface. In addition to such fabrics, laminates --made by combining nonwoven fabrics made from the materials and processes as described herein with films, paper, tissue, woven fabrics, or nonwoven fabrics such as meltblowns-- are also contemplated. The fabric according to the invention readily bonds to other materials of the sorts mentioned, and is therefore suitable for use in filtration media, medical and clean room garments, CSR wrap, absorbent article backsheets, and other barrier structures.
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.