GB2387180A

GB2387180A - A lofted non-woven material with z orientated fibres

Info

Publication number: GB2387180A
Application number: GB0312834A
Authority: GB
Inventors: James Richard Neely; Edward Jason White; Kurtis Lee Brown; John Herbert Conrad; Richard Wallace Hoefer
Original assignee: Kimberly Clark Worldwide Inc; Kimberly Clark Corp
Current assignee: Kimberly Clark Worldwide Inc; Kimberly Clark Corp
Priority date: 1999-04-30
Filing date: 2000-04-21
Publication date: 2003-10-08
Anticipated expiration: 2020-04-21
Also published as: GB0312834D0; GB2387180B

Abstract

A lofty non-woven web 40,62 having x,y and z directions, which correspond to the machine direction, the cross machine direction, and the loft direction respectively, comprises a plurality of continuous fibres 46 which are orientated in the z-direction and are folded to form loops 48 that are'U'-shaped and which aggregate in the cross machine direction to form waves extending across the web with a succession of waves spaced apart in the machine direction. The bight of the "U" 50 may extend either in the machine direction (x) with the legs 52,54 extending to the upper and lower surfaces 42,44 of the web, or in the loft direction (z) with both legs 69 extending to the same surface 64 , preferably retrograde of the bight 68. The non-woven webs further comprise an absorbent.

Description

Y 23871 80

CONTROLLED LOFT AND DENSITY NONWOVE WEBS

AND METHOD FOR PRODUCING

BACKGROUND OF THE INVENTION

- Field of the Invention

This invention relates to a lofty, nonwoven material produced from continuous fibers in which the lofty character of the nonwoven material is the result of the 5 fibers compnsmg the web being oriented in a Indirection? that is outside of the plane of the orientation of the web, of the nonwoven material. These materials are particularly suitable for use in a broad wage of applications including fluid management (surge)? air and liquid filtration? acoustic and thermal insulation, paclcinc? material, absorbents, and cleaning materials. tvIore particularly, these materials are suitable for use as surge, spacer layers, 10 filtration materials and absorbent layers In personal care absorbent products including disposable diapers, incontinence,ments? and feminine care products such as salutary pads and Naples, and in face masks, surgical gowns, sterile wraps and surgical drapes. In addition, this invention relates to methods for producing such lofty, nonwoven materials.

DISCUSSION OF RELATE3:) ART

15 Absorbent personal care articles such as sanitary pads and redskins, disposable diapers? incontinent-care pads and the like are widely used, and much effort has been made to Improve their effectiveness and ffmcuonalitY. These aracles generally include a liquid absorbent material baclced by a liquid-impervious bamer sheet. To enhance the sense of comfort, the absorbent material has a facing of a material which masks at least the body 20 facing surface of the product The purpose of this cover material is to help structurally contain the absorbent material and to protect the wearer Dom continuous direct contact with moisture from previously wetted absorbent matenal. Lee cover material is typically of relatively low basis weight nonwoven fabric. Improved product performance has been obtained in these products through the ircoporation of a surge management material 95 - disposed between the cover material and the absorbent material. The surge management material is made Tom a relatively high basis weight, low density, that is, thick, nonwoven web material.

( In nonwoven webs, the fibers compusing the web are generally oriented in the x-y plane ofthe web and the resulting nonwoven web material is relatively thin, that is lacking in loft or significant thickness. LoD or thickness in a nonwoven web suitable for use in personal care absorbent articles promotes comfort (softness) to the user, surge 5 management and fluid distribution to adjacent layers.

In order to impart loft or thickness to a nonwoven web, it is generally desirable that at least a portion of the fibers comprising the web be oriented in the z direchon. Conventionally, such lofty nonwoven webs are produced mug staple fibers. See, for example, U.S. Patent 4,837,067 which teaches a nonwoven thermal insulating batt 10 comprising structural staple fibers and bonding staple fibers which are entangled and substantially parallel to the faces of the ball at the face portions and substantially perpendicular to the faces of the bay and U.S Patent 4,590, 114 which teaches a batt including a mayor percept oftheImo-mechanical wood pulp fibers stabilized by the inclusion of a mmor percent of thermoplastic fibers including staple length thermoplastic fibers.

15 Altenanvely, conventional high loft forming processes rely on preformino processes such as fiber crimp formed on a flat wire or drum, and post-fortrg processes such as creping or pleating of the formed web.

SUMMARY OF THE INVENTION

In contradistinction to the known art, the present invention does not first fonn 20 a web of material and pleat it. Rather, fibers are looped, or bent, on themselves without big first being formed into a material web. These fiber level loops, running between the .. major surfaces of the resultant web, are a,gregated m the cross machine direction to form structures running in the cross machine direction which are herein sometimes called "waves" or "folds" to distinguish them fiom 'pleats" which refer to structures in preformed web or 95 mesh material that has been folded on itself Accordingly, it is one object of this invention to provide a high loft, low density nonwoven web material comprisin, substantially continuous fibers as opposed to staple fibers traditionally used in the manufacture of such nonwoven materials.

This and other objects of this invention are addressed by a lofty, nonwoven 30 material comprising a nonwoven web comprising a plurality of substantially continuous

fibers, which may be cried or linear, oriented in a Correction of the nonwoven web. The substantially continuous fibers are preferably spunbond and/or meltblown. In accordance with one embodunent of this tnvennon, a support stincte may be attached to at least one face of the nonwoven web, thereby providing strength to the high loft nonwoven web. This 5 laminate structure provides support for the high loft structure, strength for winding, converting, etc., and a boundary layer to either enhance or retard fluid flow into the lofty absorbent structure in products such as disposable diapers, incontinence Moments, and absorbent fernmnne care products including sanitary pads and nap}cius.

- The lofty, nonwoven material ofthis invention is produced in accordance wit-in 10 one embodiment of this invention by a process in which a plurality of substantially continuous fibers are directed into a variable nip, resulting in bending of the fibers and formation of a nonwoven web. Within the nip the fibers may be subjected to a vacuum from both sides of the nip, either equally or differentially, producing a lofty, nonwoven web having a plurality of the substantially continuous fibers oriented in a z direction.

15 In accordance with another embodiment ofthis invention the logy, nonwoven material is produced by directing a plurality of continuous, substantially linear, filament fibers through a slot formed by two opposed surfaces whereby the substantially congruous fibers bend from contact with the two opposed surfaces, which may be differential speeds or vacuum' or both, thereby forming a lofty, nonwoven web having a plurality of as-formed 20 indirection fibers.

BRIEF DESCRIPTION OF TO DRAWINGS

These and other objects and features of this invention will be better understood from the following detailed description taken in conjunction with the drawings

wherein: 25 Fig. 1 is a diagram of a process for producing a lofty, nonwoven material in accordance with one embodiment of this invention; Fig. is a diagram of another process for producing a lofty, nonwoven material in accordance with another embodiment of this invention;

( Figs 3A and 3B are diagrammatic representations of a conventional nonwoven web and a high loft nonwoven web in accordance with this invention' respectively; Fig 4 is a photograph of a side view of a high loft nonwoven web produced in accordance with the method of this invention; 5 Figs. 5-7 illustrate a material made according to the method of Fig. 2 with equal speed on the opposing surfaces; and Figs. 8-10 illustrate a material made according to the method of Fig. 2 with differential speed on the opposing surfaces.

10 DETAILED DESCRIPTION OF THE

PRESENIIY PREFERRED EMBOI:)IMENTS

DEFINITIONS

As used herein, the term "nonwoven web" or "nonwoven material" means a 15 web having a structure of individual fibers, filaments or threads which are mterlaid, but not in a regular or identifiable manner, such as in a knitted fabric and films that have been fibrillated. Nonwoven webs or materials have been formed from many processes such as, for example, meltblowg processes, spunbonding processes, and bonded carded web processes. The basis weight of nonwoven webs or materials is usually expressed in ounces 20 of material per square yard (osy) or grams per square meter (gsm), and the fiber diameters usable are usually expressed in microns (Note that to convert from osy to gun multiply c\sy by 33.91.) As used herein, the term "z-direction-' refers to fibers disposed outside of the plane of orientation of a web. Fig. 3A is a diagraIn showing a nonwoven web without z 23 direction fibers. That is, all of Me fibers are generally oriented in the direction indicated by arrow 27. By comparison, Fig. 3B is a diagram showing a nonwoven web having Direction fibers in accordance with this invention. That is, in addition to fibers oriented in the direction of arrow 28, fibers are also oriented in the direction of arrows 29 and 30. The tenn "as formed z-direction fibers', as used herein refers to fibers that become oriented in the z 30 direction during forming of the nonwoven web as distinguished from fibers having a z direction component resultug from post-forming processin, of the nonwoven web, such as in the case of mechanically crunped or creped nonwoven webs.

t As used herein the term "spunbond fibers" refers to small diameter fibers Which are formed by exuding molten therrnoplasuc material as filaments fiom a pl8ty of fine, usually circular capillaries of a spinneret as taught, for example, by U.S. Patent 4,340,563 to Appel et al. and U.S. Patent 3,802,811 to Matsuki et al. 5 As used herein, the term "meltblown fibers" refers to fibers formed by exuding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging him velocity gas streams (for example, airstreams) which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Such a process is disclosed, for 10 example, by U.S. Patent 3,849,241 to Bum.

As used herein the term "microfibers" refers to small diameter fibers having an average diameter not greater than about 75 microns, for example, having an average diameter of Tom about 0.5 microns to about 50 microns, or more particularly, having an average diameter of from about 2 microns to about 40 microns.

15 As used herein the term "polymer" generally includes, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random and altematino copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically liruted, the term "polymer" also includes all possible eometuc configurations of the material. These configurations include, but are not limited to, isotactic, 20 syndiotactic, atactic and random symmetries.

As used herein, the term 'personal care absorbent article" means disposable diapers, training pants, absorbent underpants, adult incontinence products, fernne hygiene products and the like.

As used herein, the term "homofilament" refers to a fiber formed from only 25 one polymer. This is not meant to exclude fibers formed from one polymer to which small amounts of additives have been added for coloration, anti-static properties, lubrication, hydrophilicity, etc. As used herein, the tenn"bicomponent fibers" refers to fibers which have been formed Tom at least two polymers extruded Tom separate extenders but spun together 30 to form one fiber. Bicomponet fibers are also sometimes referred to as conjugate fibers or

multicomponent fibers. Bicomponent fibers are taught by U.S. Patent 5,382, 400 to Pike et al. As used herein, the teIlu "biconstituent fibers" refers to fibers which have been formed fiom at least two polymers extruded from the same excluder as a blend. The 5 term "blend" is defined below. Biconshtuent fibers are sometimes also referred to as multicortuent fibers. Fibers oftbis general type are discussed in, for example, U.S. Patent 5,108,827 to Gessner. AS used herein, the term 'lend" means a my of two or more polymers. As used herein, the term "substantially continuous fibers" refers to fibers, 10 including without limitation, spunbond and meltblown fibers, which are not cut from their original length prior to being formed into a nonwoven web or fabric. Substantially continuous fibers may have average lengths ranging from greater than about 15 centimeters to more than one meter, and up to the length of the web or fabric being forrneL The definition of"subsnhally continuous ilbers" includes fibers which are not cut prior to being 15 formed into a nonwoven web or fabric, but which are later cut when the nonwoven web or fabric is cut, and fibers which are substantially linear or cnmped.

The term "staple fibers" means fibers which are natural or cut from a manufactured filament prior to forming into a web, and which have an average length ranging from about 0.1-15 centimeters, more commonly about 0.2-7 cenneters.

20 As used herein, the term Rough-air bonding" or 'TAB" means the process of bonding a nonwoven, for example, a bicomponent fiber web in which air which is sufficiently hot to melt one ofthe polymers of which the fibers of the web are made is forced through the web.

Potential applications for the nonwoven web of this invention include 25 personal care absorbent articles such as diapers, training pants, incontinence garments.

feminine care products including sanitary pads and napkins, all surge materials, loop for hook and loop, air filtration, liquid filtranon, body scrub pads, oil sore, baby wipes, industrial wipes, insulation and packaging matenal. In the case of filtration materials, the method of this invention greatly increases the surface area and volume available for filtration. In 30 addition, the method of this invention may be suitable for producing coforms or composite materials incorporating high loaf surgelpulplsuperabsorbent material. And, for a continuous

roll of diapers. a composite material made by the present invention could be produced by edging or ruffling a high loft slgeipulp/superabsorbent material laminate and placing it in between an outer cover and a liner, which would produce a IaTnmate with all of the components of a diaper in a single step, which could be wound up and cut and placed later 5 on converting machines The lofty or high lob nonwoven material of this invention comprises a nonwoven web comprmug a plurality of substantially continuous fibers oriented in a z direchon of the nonwoven web. The substantially continuous fibers preferably are drawn in spmbond or meltblown processes. The substantially continuous fibers are preferably formed 10 with polymers selected from the group consisting of polyolefus, polyamides, polyesters, polyconates, polystyrenes, thermoplastic elastomers, fluoropolymers, vinyl polymers, and blends and copolnners thereof. Suitable polyolefins include, but are not limited to, polyethylene, polypropylene, polybutylene, and the lik e; suitable polyamides include, but are not limited to, nylon 6, nylon 6/6, nylon 10, nylon 19 and the lily; and suitable polyesters 15 include, but are not limited to, polyethylene terephthalate, polybutylene terephthalate, polytrimethyl terephthalate, polylactic acid and the like. Particularly suitable polymers for use in the present invention are polyolefs including polyethylene, for example, linear low density polyethylene, low density polyethylene, medium density polyethylene, high density polyethylene and blends thereof; polypropylene; polybutylene and copolymers as well as 90 blends thereof. Additionally, the suitable fiber forming polymers may have thermoplastic elastomers blended therein.

In accordance with one preferred embodiment of this invention, the substantially continuous fibers are bicomponent fibers. Particularly suitable polymers for forming the structural component of suitable bicomponent fibers include polypropylene and 25 copolymers of polypropylene and ethylene, and particularly suitable polymers for the adhesive component of the bicomponent fibers includes polyethylene, more particularly linear low density polyethylene, and high density polyethylene. In addition, the adhesive component may contain additives for enhancing the crimpability andfor lowering the bonding temperature of the fibers, and enhancing the abrasion resistance, strength and softness of the 30 resulting webs. The nonwoven web of the material of this invention has a basis weight in the lunge of about 0 95 osy to about 50 osy. To enhance the absorption characteristics ofthe ^

nonwoven material accordance with one embodiment of this invention the nonwoven web comprises an absorbent, for example, superabsorbent particles as a cofomt.

In accordance with one embodiment of this invention, a support structure is attached to at}east one face of the nonwoven web so as to pronde strength thereto. The 5 resulting Emanate structure provides support for the high loaf sincere, strength for wading, convlLig, etc., and a bomdary layer to either enhance or retard fluid flow into the lofty absorbent smacnre. The support structure may include spunbond webs of venous types including liners, perforated, mcrmLiber, creped, etc., spunbond-meltblownspunbond (SMS), meltblown, and/or films.

10 As used hereby the tend "coforrn" means a process in which at least one meltblown dichead is arranged near a chute through which other materials are added to the web while it is footing. Such other materials may be pulp, superabsorbent particles, cellulose or staple fibers, for example. CofoTm processes are shown in commonly assigned U.S. Patent 4, 818,4:64 to Lau I 5 In a method for producing a lofty, nonwoven material in accordance with one embodiment of this invention, Fi,. l, a plurality of substantially continuous fibers are conveyed into a variable nip 19, that is a nip in which one of the elements funning the nip is adjustable, thereby enabling adjustment of the size of the nip in which the fibers are subjected to a vacuum from both sides of the nip, resulting in a lofty, nonwoven web having, 20 a plurality of the substantially continuous fibers oriented in a Indirection. Such a lofty, nonwoven web is shown in Fig. 4 in which the individual fibers comprising the web can be seen. In accordance with the embodiment shown in Fig. l, a plurality of substantially continuous fibers 14 are generated by a fiber forming mit 11 and are deflected 25 by deflector 17 directly into a variable nip 19 formed by dam former 16 and forming surface 18. In accordance with We embodiment shown, the nip is varied by vertically adjusting drum former 16. Varying the nip in this fashion allows control over the density and loft of the nonwoven web. Within drum former 16 disposed above the nonwoven web, fanning box 15 disposed below the forming surface IS, are means for subjecting the substantially 30 continuous fibers 14 to a vacuum as the web passes through variable nip 19. The nonwoven web is thus formed in the variable nip l9, as opposed to upstream of the nip on a forming

i surface, is a high loft nonwoven web. Loft in the nonwoven web as it passes through the variable nip can be mainlined by application of the vacuum to both sides of the web. in accordance with one embodiment of this invention, the resulting lofty, nonwoven web is subjected to treat by a hot air knife 17 for the purpose of increasing the integrity of the nonwoven web. A hot air knife is used to bond the individual polymer fibers together at various locations so that the web has increased strength and structural integrity for subsequent Rents such as passage through a through-air bonding unit. A conventional hot air knife includes a mandrel with a slot that blows a jet of hot air onto the nonwoven web surface. Such hot air knives are taught, for example, by U.S. Patent 5, 707,468 to Amold 10 et al. Alternatively, the nonwoven web may be set by an adhesive sprayed onto the fibers prior to entering variable nip 19 by adhesive system 13, or by a combination thereof, e g., a thermally activated adhesive.

Although shown as a combination of dnun former 16 and forming surface 18, it will be apparent to those skilled in the art Hat variable nip 19 may be formed by other 15 means, such as two drum Dormers, two opposed moving hefts, etc. In order to vary the 3 dimensional structure of the nonwoven web for a:,iven fiber, the relative speeds of the dnun former 16 and moving forming surface 18, as well as the height of the nip, and amount of vacuum may be varied In accordance with one preferred embodiment of this invention, the speed of rotation of drain former 16 corresponds 20 to the speed at which moving forming surface 18 is Raveling. In accordance with another preferred embodiment of this invention the speed at which drum former 16 is rotating is different from the speed of travel of moving forming surface 18. After forming in variable nip 19, the nonwoven web is integrally fixed' i.e., its swcnlre is set by a hot air knife, adhesive, a calender, through-air-bonding unit, or the like and without laminate additions.

25 In accordance with one preferred embodiment of this invention, laminate structures are produced by unwinding andlor alternately producing and introducing one or more fabrics to be formed upon the web of the present invention. By either unwinding onto drain former 16 and/or web foImmg surface IS, applying adhesive in one or more possible places, and forming the lofty, nonwoven web as described hereinabove, a multi- layer 30 laminate structure can be produced.

Fig. 2 is a diagram showing an altemanve method for producing a lofty, nonwoven material in accordance with this invennom In the embodiment shown in Fig. 9, substantially continuous fibers 14 are directed in a first direction, in this instance vertically downward, through slot 35 Conned by two opposed surfaces, such as foramnous or perforate, 5 for-mm" wires 32, 33, whereby the substantially continuous fibers bend Mom contact with the two opposed surfaces, foxing a lofty, nonwoven web having a plurality of as-fonned Affection fibers. After passing through slot 35, the resulting lofty, nonwoven web may be passed through a calender tmit or some other downstream apparatus such as a through-air bonder for further processing Alternatively, as shown in Fig 2, where slot 35 is formed by 10 the two foraminous urines 32, 33, the high loll nonwoven web may be subjected to through air bonding, as at arrow 36, as the web passes through slot 35, thereby enabling the web to be formed in a single step.

lye loft and density of the nonwoven web produced in accordance with the method of this invention is defined m part by the distance between the two opposed surfaces 15 32, 33. The density of the nonwoven web maybe controlled by ad3ustnent of the speed at which the nonwoven web passes through slot 35 and/or by varying the width of slot 35. Slot 35 may be a faced plate slot, but the dual wire system shown in Fig. 2 is considered to be a more efficient method of web forming. Typically, adjustment of the distance between opposed surfaces formulas the nip or slot, the speed at which the material passes through the 20 nip or slot, and We relative speed of the moving surfaces forming the nip or slot and amount and direction of applied vacuum, are necessary to produce a nonwoven web with given characteristics. The Conning nip or slot may also have parallel, or converging, or a series of converging and expanding slots. Adjustment of any or all ofthese factors may result in great variations of web characteristics.

25 As stated above, spunbond and meltblown fibers can be used to produce the high loft nonwoven web of this invention. Single component (homofilament), bicomponent and biconstituent fibers can be used. Bicomponent fibers are preferred in accordance with one embodianent of this invention because they have the advance that thermal bonding fiber crimp can be used to enhance lofty material properties. The fibers can also be either 30 quenched (rapidly cooled), in which case the outer surface of the fibers is solidified, or unquenched in which case the outer surface of the fibers remains ac,iy. Unquenched fibers

Am have the advantage of bonding to each other without a further bonding requirement.

Thermoplastic fibers can be through-air bonded in a stuffed through-air bonder mat symbolically shown as arrow 36 in Fig. 2, thereby providing a one-step forming/bonding process. Other types of bonding, such as bonding rolls, may be placed after the sniffed 5 through-ar-bonder unit for material consolidation, including point-bondtng, hydra entangling, or needle punching.

Referencmg Figs. 7 a nonwoven material 40 made according to the method of Fig. 2 has first and second major surfaces 42, 44 the plane of the web, i. e., generally parallel to Me XY plane, and spaced apart in the Z direction. lithe continuous fibers, e., 46 10 are folded to form loops, e. g. 48, whose z direction terminii are fused into the first and second major surfaces 42, 44. Referencing Fig. 6, the major surfaces are substantially flat or planar, i.e., within the 'its of manufactunng and material tolerances. and may be preponderantly open or closed, i.e., majority air or fiber, respectively, dependent upon process parameters of belt speed, belt speed differential type of fiber, vacuum applied, etc. 15 The loops 48, generally form a succession of'lf'- - ped waveforms with the bitt '0 of the ' protruding in the machine, or X axis, direction and midway between the first and second major surfaces 42, 44. The legs 52, 54 of the Ad" extend retrograde of the bight 50 towards the major surfaces 49 44. The loops aggregate n the CTOSS machine direction, or Y axis to form waves or folds running, or extending, in the cross machine direction and being z 20 direction oriented to add loft to the nonwoven material. The periodicity of the waveforms may be regular or random and recurrent as seen in Fig. 5 where the loops are alternately more densely 56 and less densely 58 packed along the mac'nine direction. With this embodiment of low density material definite open channels 60 may be seen between the waves.

The fabric of Figs. 7 was made using no speed differential between Me 25 moving surfaces 32, 33 and with no vacuum applied to opposite sides of the slot 35.

As seen in Figs. 8-10, a lofty nonwoven material 62 has first major surface 64 which is substantially flat or planar, and a second major surface 66 which is ridged or waved. The fiber loops, e.g., 68 have teminii 69 fused into t'ne first major surface 64, but are not filsed and therefore protrude in the Z direction at the second major surface 66. The 30 terminii extend retrograde of t'ne loops, e.g., 68, owing to the differential speed of the formin, surfaces, or wires 32, 33. The loops a;, gregate in the cross machine direction to

( form serial successive waveforms, collectively 70 as in Fig. 9. In Ins case the first major surface 64 was formed on the slower moving of Me opposing surfaces. If vacuum is differenhaUy applied the first major surface would receive the greater vacuum In terms of gross morphology, the fist major surface 64 is substantially flat and preponderantly closed S m the given example. The waveforms are preponderantly regular m penodicity and length along the cross machine direction. The waves 70 at the second major surface may be crenelate as at 72 depending on the height of slot 35, type of fiber used and other [actors.

Of course, as stated above, the gross morphology may be easily altered by adjustment of a number of factors within the manufacturing process.

10 While in the foregoing specification this invention has been described in

relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illusions it will be apparent to those skilled in the ant that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing Tom the basic principles of the invention.

Claims

WE CLAW:

1. A lofted web oinonwoven material comprising: aplmalitv of substantially continuous fibers, the web having x, y and z dictions. edges, and fast and second major surfaces in an x-y plane, with x being a machine direction, y being a cross machine direction and z being a loft direction; the substantially continuous fibers oriented in the z direction and folded to form loops; the first and second major surfaces in the xy planes are spaced apart in the z .. direction; the loops form a waved material with a train of waves spaced along the machine direction, running from edge to edge in the cross direction and extending in the z direction; and the first major surface is flat; the second major surface is flat; the web is integrally fixed with the waves being substantially 'Q'-shaped wherein said fJ-snape has a bight protruding in the machine direction, and, midway between the first major surface and the second major surface, the legs of the "U" extend retrograde of the macnune direction towards the first and second major surfaces.

2. The material according to Claim 1 farther including the first major

surface being substantially open.

3. The material according to Claim 1 further including the first major surface being substantially closed.

4. The material acco ding to Clann 1 farther including the second major surface being substantially open.

5. The material according to Claun l fimher including the second major surface being substantially closed.

/ - 6. The material according to Claim I fi=her including the loops being random. 7. The material according to Claim 1 farther including the loops bemg regular. 8. The material according to Claim 1 filer including the waves being random and recurrent.

9. The material according to Claim 1 filer including the waves being regular. 1 O. A loRy mammal in accordance with Claim 10, wherein said nonwoven web fi=her comprises a composite material having an absorbent.

11. A lofted web of nonwoven material compnsing: a plurality of substantially continuous fibers, the web having x, y and z directions, edges, and a first major surface in an x-y plane, with x being a machine direction, y being a cross machine direction and z being a lop direction; the substantially continuous fibers oriented in the z-direction and folded to form loops; the loops form a waved material with a tram of waves spaced along the machine direction running from edge to edge the cross direction and extending in the z direction; and the first major surface is flat; and the web is integrally fixed with each wave being a substantially 'Q'-shaped wherein said U-shape has a bight protruding in Me lop direction and the legs of the 'AT' are spaced along the machine direction and extend towards the first major surface.

12. The material according to Claim 11 fiuther including the waves being oriented off the orthogonal Taxis and uniformly shaped

13. The matenal according to Claim 11 further including the waves being oriented ofithe orthogonal zaps and crenule.

14. The material according to Clann 11 further including the first m for surface bang substantially open.

13. The material according to Clans 1 I further lncludg the first major surface being substantially closed 16. The material according to Clann 11 further including the first major surface bemg substantially planar.

17. The Cal according to Claim 1 1 further including the second major surface being substantially ridged 18. The matenal according to Clann 1 1 fi=her including the loops being random. 19. The material according to Claim 1 1 fi=her including the loops berg regular. 20. The material according to Claun 11 further including the waves being random. 91. Me material according to Claim 1 1 fisher including the waves being regular. 20. Lee material according to Claim 1 1 fi=her including the legs of the AT' extending retrograde towards the first major surface.

23. A low material in accordance with Claim 11 farther composing a plurality of staple fibers as a binder.

24. A lofty material in accordance with Claim 11, wherein said substantially continuous fibers compose an adhesive.

25. A lofty martial in accordance with Clann 11, wherein said nonwoven web has a basis weight in a range of about D.25 osy to about 50 osy.

26. A lofty material in accordance with Claim 117 wherein said substantially continuous fibers are polymeric fibers.

27. A lofty material in accordance with Claim 11, wherein said substantially continuous fibers are selected fiom the group consisting of homofilament fibers, bicomponent fibers, biconstituent fibers and combinations thereof.

98. A lofty material in accordance with Claim 11, wherein said substantially continuous fibers are thermoplastic fibers.

29. A lofty material in accordance with Claim 11, wherein said substantially continuous fibers are cnmped.

30. A lofty material in accordance with Claim 11, wherein said substantially continuous fibers are substantially linear.

31. A lofty material in accordance with Claim 11, wherein a Support structure is attached to at least one face of said nonwoven web.

32. A lofty material in accordance with Claim 11, wherein said nonwoven web farther comprises a composite material having an absorbent

( / 33. A lofty material in accordance with Claim 11, wherein said substantially continuous fibers are selected Mom the group consisting of spunbond, meltblown, and commons thereof.

34. A lofty material in accordance with Claim 11, wherein said substantially continuous fibers are meltspun.

35. A method for producing a lofty, nonwoven material comprising the steps of: directing a plurality of substantially continuous fibers into a nip; and subjecting said substantially continuous fibers to a vacuum from both sides of said nip, producing a lofty, nonwoven web having indirection oriented fibers.

36. A method in accordance with Claim 35, wherein the nip is variable.

37. A method in accordance with Claim 35, further including integrally taring the z direction orientation of the fibers within the nonwoven material.

38. A method in accordance with Claim 37, wherein the fibers are thermally fixed.

39 A method in accordance with Clann 37, wherein the fibers are adhesively fixed 40 A method in accordance with Clann 357 wherein the substantially continuous fibers are nonfunctionally bonded 41. A method in accordance with Claim 35, wherein an adhesive is applied to said plurality of substantially continuous fibers prior to passing through said variable nip.

( 42. A method in accordance with Clean 35, wherein said vanable nip comprises two nip elements having a surface moving at a same linear speed in a machine direction. 43. A method in accordance win Claim 35, wherein said variable nip comprises two nip elements having a surface moving at different linear speeds in a machine direction. 44. A method in accordance with Claim 36, wherein said variable nip comprises a forming belt and a rotating drum.

45. A method in accordance with Claim 35, wherein said plurality of substantially continuous filament fibers are selected from the group consisting of homofiIament fibers, bicomponent fibers, biconstituent fibers, and combinations thereof.

46. A method m accordance with Claim 35, wherein said plurality of substantially continuous fibers are selected from the group consisting of spunbond fibers, meltblown fibers and combinations thereof.

47. A method in accordance with Claim 35, wherein said plurality of substantially continuous fibers are deposited onto a support layer, resulting in formation of a laminate.

48. A method in accordance with Claim 35, wherein said plurality of substantially continuous fibers are meltspun fibers.

( it 49. A method for producing a lofty, nonwoven material compnsmg the steps of: passing a plurality of substantially continuous fibers through a slot formed by two opposed surfaces whereby said substantially continuous fibers bend from contact with said two opposed surf and fixing the substantially continuous fibers in the bent position, thereby forming a lobby, nonwoven web hang a plurality of as-formed z direction funs.

50. A method in accordance with Claim 4g, wherein said slot is vertically oriented 51. A method in accordance with Claim 49, wherein said slot is formed between two foraminous wires.

52. A method in accordance with Claim S1, wherein said wires are moving. 53. A method in accordance with Claim 49, farther comprising integrally fixing the z direction of the fibers with heat.

54. A method m accordance with Claim 49, filer comprmug integrally fixing the z direction of the fibers with adhesive.

55. A method in accordance with Claim 49, wherein the substantially continuous fibers are nonfunctionally bonded before passing through the slot.

56. method in accordance with Claun 49 further comprising changing a width of said slot, whereby a density of said nonwoven web is changed.

57. method in accordance with Claim 49 higher comprising adjusting a speed at which said substantially continuous fibers pass through said slot, whereby a density of said nonwoven web is changed

SS A method in accordance with Claim 52 further cord moving the wires at a differential speed to produce a edged surface on the nonwoven web.

So. A method accordance With Claim 49, wherem scud substantially . continuous fibers are selected from the group Consoling of spunbond fibers, meltblown fibers and combinations thereof 60. A method in accordance with Claim 49, wherein a support material is applied to at least one face of said nonwoven web, forming a laTninate.

61. A personal care absorbent article comprising: a nonwoven web comprising a plurality of substantially continuous fibers oriented in a indirection of said nonwoven web.

62. A personal care absorbent article in accorlnce with Claim 61, wherein said nonwoven web furler comprises an absorbent.

63. A filtration material composing: a nonwoven web comprising a plurality of substantially continuous fibers oriented in a z direction of said nonwoven web.

64. A filtration material in accordance with Claim 63, wherem said substantially continuous fibers are crimper 65. A surgical garment composing: a nonwoven web comprising a plurality of substantially continuous fibers oriented in a z-direchon of said nonwoven web.

1\ Amendments to the claims have been filed as follows CLAIMS

1. A lofted web of nonwoven material comprising: a plurality of substantially continuous fibers, the web 5 having x, y and z directions, edges, and first and second major surfaces in an x-y plane, with x being a machine direction, y being a cross machine direction and z being a loft direction; the substantially continuous fibers oriented 10 in the zdirection and folded to form fibre level loops; the first and second major surfaces in the xy planes are spaced apart in the z direction; the loops aggregate in the cross direction to form waves with a succession of waves spaced along the 15 machine direction, running from edge to edge in the cross direction and extending in the z-direction; and the first major surface is flat; the second major surface is flat; the web is integrally fixed with the waves 20 being substantially "U"-shaped wherein said Ushape has a bight protruding in the machine direction, and, midway between the first major surface and the second major surface, the legs of the 'tO't extend retrograde of the machine direction towards the first and second major 25 surfaces; and wherein said nonwoven web further comprises a composite material incorporating an absorbent.

2. The material according to claim 1 further 30 including the first major surface being substantially open. 3. The material according to claim 1 further including the first major surface being substantially 35 closed.

4. The material according to claim 1 further ( . .

T: ( l al including the second major surface being substantially open. 5. The material according to claim 1 further 5 including the second major surface being substantially closed. 6. The material according to claim 1 further including the periodicity of the loops being random.

7. The material according to claim 1 further including the periodicity of the loops being regular.

8. The material according to claim 1 further 15 including the periodicity of the waves being random and recurrent. 9. The material according to claim 1 further including the periodicity of the waves being regular.

lo. A lofted web of nonwoven material comprising; a plurality of substantially continuous fibers, the web having x, y and z directions, edges, and a first major surface in an x-y plane, with x being a 25 machine direction, y being a cross machine direction and z being a loft direction; the substantially continuous fibers oriented in the zdirection and folded to form fibre level loops; the loops aggregate in the cross direction to 30 form waves with a succession of waves spaced along the machine direction running from edge to edge in the cross direction and extending in the z-direction; and the first major surface is flat; and the web is integrally fixed with each wave 35 being substantially "U''-shaped wherein said U-shape has a bight protruding in the loft direction and the legs of the "U" are spaced along the machine direction and .. <... c ..... ,.

extend towards the first major surface.

11. The material according to claim 10 further including the waves being oriented off an axis 5 orthogonal to the x-y plane and extending in the z-

direction and uniformly shaped.

12. The material according to claim 10 further including the waves being oriented off an axis 10 orthogonal to the x-y plane and extending in the z-

direction and crenelate.

13. The material according to claim 10 further including the first major surface being substantially open. 14. The material according to claim 10 further including the first major surface being substantially closed. 15. The material according to claim 10 further including the first major surface being substantially planar. 2516. The material according to claim 10 further including the second major surface being substantially ridged. 17. The material according to claim 10 further 30including the periodicity of the loops being random.

18.- The material according to claim 10 further including the periodicity of the loops being regular.

3519. The material according to claim 10 further including the periodicity of the waves being random.

a c c c 1 1 c c c. c c c. c c c c c c;

. : 20. The material according to claim 10 further including the periodicity of the waves being regular.

21. The material according to claim 10 further 5 including the legs' of the "U" extending retrograde of the,bight of the "U" towards the first major surface.

22. lofty material in accordance with claim 10 further comprising a plurality of staple fibers as a 10 binder.

23. A lofty material in accordance with claim 10, wherein said substantially continuous fibers comprise an adhesive. 24. A lofty material in accordance with claim 10, wherein said nonwoven web has a basis weight in a range of about 0.25 osy (34 gsm) to about 50 osy (1700 gem).

20 25. A lofty material in accordance with claim 10, wherein said substantially continuous fibers are polymeric fibers.

26. A lofty material in accordance with claim 10, 25 wherein said substantially continuous fibers are selected from the group consisting of homofilament fibers, bicomponent fibers, biconstituent fibers and combinations thereof.

30 27. A lofty material in accordance with claim 10, wherein said substantially continuous fibers are thermoplastic fibers.

28. A lofty material in accordance with claim 10, 35 wherein said substantially continuous fibers are _ _ crimped.

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i t i i .,.. t

Al is 29. A lofty material in accordance with claim 10, wherein said substantially continuous fibers are substantially linear.

5 30 A lofty material in accordance with claim 10, wherein a support structure is attached to at least one surface of said nonwoven web.

31. A lofty material in accordance with claim 10, 10 wherein said nonwoven web further comprises a composite material incorporating an absorbent.

32. A lofty material in accordance with claim 10, wherein said substantially continuous fibers are 15 selected from the group consisting of spunbond, melLblown, and combinations thereof.

33. A lofty' materiel in accordance with claim 10, wherein said substantially continuous fibers are 20 meltspun. 34. A personal care absorbent article comprising the lofted web of nonwoven material according to any preceding claim.

35. A personal care absorbent article in accordance with claim 34, wherein said nonwoven web further comprises an absorbent.

30 36. A filtration material comprising the lofted web of nonwoven material according to any preceding claim. 37. A filtration material in accordance with claim 35 36, wherein said substantially continuous fibers are crimped. ( ( c. c ( ( 1 c i c ( i

! 2(

_.....

. 38. A surgical garment comprising the lofted web or nonwoven material according to any preceding claim.

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