KR20070017164A - Nonwoven fabrics comprising strata with differing levels or combinations of additives and process of making the same - Google Patents

Abstract

The present invention is directed to a first layer comprising a first fiber comprising a polyolefin and a first amount of wettability improving additive or additive combination; And a second layer comprising a second fiber comprising a second amount of wettability improving additive or additive combination that is essentially zero weight percent or less than the first amount. In one preferred embodiment, the wettability of the nonwoven is temperature-dependent and can decrease with decreasing temperature. Such a nonwoven can be useful as a component of an absorbent article, for example as a liner and surge management layer, by providing a component that is wettable upon initial contamination but which reduces wettability as the contaminant cools, thereby inhibiting backflow of contaminants.

Wettability, nonwovens, polyolefins, ethoxylated hydrocarbons, ethoxylated siloxanes

Description

TECHNICAL FIELD Nonwoven fabrics comprising laminates with different layers or additive combinations and methods for manufacturing the same.NONWOVEN FABRICS COMPRISING STRATA WITH DIFFERING LEVELS OR COMBINATIONS OF ADDITIVES AND PROCESS OF MAKING THE SAME

The present invention relates to nonwovens, in particular wettable bicomponent nonwovens and methods of making such wettable bicomponent nonwovens. Generally, nonwovens made from polyolefin resins are not wetted by body fluids such as urine and menses. Polyolefin-based nonwovens have been partially treated with an aqueous surfactant and treated with an internal melt additive so that they can be better wetted and used as a component of disposable personal hygiene absorbent products such as diapers. The surge management layer is designed to quickly absorb and temporarily hold large quantities of fluid, such as urine.

While various methods of improving or modifying the surface properties of polymer fibers are known in the art, there remains a need for providing nonwovens with the desired physical properties that can be produced more efficiently and / or economically. This is especially true when the nonwoven is used as a disposable product such as, for example, wipes, absorbents, medical supplies, personal care products, or the like. It would be desirable to provide wet nonwovens that do not need to add wet chemistry, and improved methods of making such nonwovens that do not need to be treated after the nonwovens have been formed. It is also desirable to provide a nonwoven fabric that retains wettability even after multiple contaminations, and thus has a constant wettability.

Summary of the Invention

The present invention provides a nonwoven fabric comprising a first layer of a first fiber and a second layer of a second fiber, wherein the first fiber comprises a polyolefin and a first amount of a wettability improving additive or additive combination, the second fiber A second amount of wettability improving additive or additive combination that is less than the first amount. In one or more embodiments, the second layer is essentially free of wettability improving additives or additive combinations. In another embodiment, the second layer comprises a second fiber that is substantially similar in composition to the first fiber except that it includes less wettability improving additives or additive combinations than the first fiber. In an exemplary embodiment, the first fiber comprises from about 0.1 to about 5 weight percent of the blend of the first polyolefin and the wettability improving additive or additive, and from about 0.1 to the second polyolefin and the wettability improving additive or additive combination. A multicomponent fiber comprising a second component comprising about 5% by weight blend. In another embodiment, the first fiber comprises from about 0.1 to about 5 weights of a wettability improving additive or additive combination selected from the group consisting of a first polyolefin, ethoxylated hydrocarbons and derivatives thereof, ethoxylated siloxanes and derivatives thereof, and combinations thereof. About 0.1 to about 5 wettability enhancing additives or additive combinations selected from the group consisting of a first component comprising% blend, a second polyolefin, an ethoxylated hydrocarbon and derivatives thereof, an ethoxylated siloxane and derivatives thereof, and combinations thereof A multicomponent fiber comprising a second component comprising a weight percent blend. The multicomponent fiber may be a bicomponent fiber. The first component may be a substantially homogeneous melt blend of the combination of the first polyolefin and an ethoxylated hydrocarbon surfactant or ethoxylated hydrocarbon surfactant, the second component being a second polyolefin and an ethoxylated hydrocarbon surfactant or ethoxylated hydrocarbon interface It may be a substantially homogeneous melt blend of the combination of active agents. The first polyolefin and the second polyolefin may be independently selected from the group consisting of homopolymers and copolymers of ethylene and homopolymers and copolymers of propylene. Preferably, the first polyolefin is selected from the group consisting of homopolymers and copolymers of ethylene, and the second polyolefin is selected from the group consisting of homopolymers and copolymers of propylene. In another embodiment, the first fiber comprises a first component comprising from about 0.5 to about 3 weight percent of an ethoxylated hydrocarbon surfactant and a second component comprising from about 0.5 to about 3 weight percent of an ethoxylated siloxane surfactant. Include. The present invention provides a nonwoven fabric having a first surface and a second surface, wherein the first surface of the nonwoven fabric is heat treated to provide a nonwoven fabric having a wettability gradient in the z-direction such that the first surface of the nonwoven fabric is the second surface of the nonwoven fabric. More wettable than

The present invention provides a nonwoven fabric comprising a first level or stratum and a second layer or laminate, wherein the first layer comprises a first polyolefin, an ethoxylated hydrocarbon or derivative thereof, an ethoxylated siloxane or its About 0.1 to about 5 weight percent of a derivative, or a combination thereof, or a blend of about 0.1 to about 5 weight percent of a first component, and a second polyolefin, an ethoxylated siloxane or derivative thereof, or a combination thereof A first multicomponent fiber comprising a second component comprising the first component (the first component forms at least a portion of the outer surface of the first multicomponent fiber, and the second component of the outer surface of the first multicomponent fiber To form at least a portion); The second layer comprises a first component comprising less than about 0.1 weight percent of a blend of the first polyolefin, an ethoxylated hydrocarbon or derivative thereof, an ethoxylated siloxane or derivative thereof, or a combination thereof, a second polyolefin, and an ethoxylated siloxane Or derivatives thereof, or a combination thereof, and a second multicomponent fiber comprising a second component comprising less than about 0.1 weight percent blend. As mentioned above, the multicomponent fiber may be a bicomponent fiber, for example a bicomponent fiber having a side-by-side configuration. Exemplary ethoxylated siloxanes are poly [dimethylsiloxane-co-methyl (3-hydroxypropyl) siloxane] -graft-poly (ethylene glycol) methyl ethers and exemplary ethoxylated hydrocarbons are poly (ethylene glycol) 600 dioles It is eight.

In addition to use as a liner, the present invention provides a surge management layer for use in disposable personal hygiene absorbent products, wherein the surge management layer or liner comprises about 80 to about 99.9 weight percent polyethylene resin and ethoxylated hydrocarbons or derivatives thereof, ethoxylated siloxanes. Or a derivative comprising, or a blend comprising from about 0.1% to about 5% by weight of the first component, and from about 80% to about 99.9% by weight of a polypropylene resin and an ethoxylated hydrocarbon or derivative thereof, ethoxylated siloxane or Or a spunbonded nonwoven comprising a first layer of a bicomponent fiber comprising a second component comprising a derivative comprising about 0.1 to about 5 weight percent of a derivative thereof, or a combination thereof. The second component is in parallel.

In another embodiment, the present invention provides fibers, nonwovens, or personal hygiene products comprising such fibers or nonwovens having a first wettability at 35 ° C., and a second wettability at 21 ° C. that is slower than the first wettability. . For example, the fibers and nonwovens of one or more embodiments may wet in less than about 10 seconds at 35 ° C., but not less than about 60 seconds at 21 ° C. In one example, the nonwoven fabric comprises a first component comprising a blend comprising about 80 to about 99.9 wt% polyethylene resin and about 0.1 to about 5 wt% ethoxylated hydrocarbon, and about 80 to about 99.9 wt% polypropylene resin and ethoxy Bicomponent fibers comprising a second component comprising a blend comprising from about 0.1 to about 5 weight percent of silicified hydrocarbons.

In many embodiments, the first surface of the nonwoven can be heat treated to provide a nonwoven with a wettability gradient in the z-direction such that the first surface of the nonwoven is more wettable than the second surface of the nonwoven.

1 illustrates a process for providing a lofty nonwoven in accordance with one embodiment of the present invention and one particular multibank apparatus.

The invention is not limited in its application to the arrangement of details or components of the structures described in the detailed description below or shown in the drawings. The invention may be another embodiment or may be practiced or carried out in various other ways. Also, it is to be understood that the terminology and terminology used herein is for the purpose of description and illustration, and does not limit the invention. Similar reference numerals are used to indicate similar components.

Definition of Terms

As used herein, "nonwoven" or "nonwoven" refers to a web in which the individual fibers, filaments, or yarns have a structure that is entangled together in a manner that is not a regular or definable manner, such as how fabrics are knitted. And fibrillated films. Nonwovens or nonwovens can be manufactured through many processes, such as, for example, meltblowing processes, spunbonding processes, and bonded carded web processes. The basis weight of a nonwoven or nonwoven is typically expressed in ounces per square yard (osy) or grams per square meter (gsm), and the fiber diameter is typically expressed as microns. Another commonly used representation of fiber diameter is denier, which is defined as grams per 9000 meters of fiber, and can be calculated by multiplying polymer density (g / cc) by the square of the fiber diameter (microns (μm)) multiplied by 0.00707. have. Smaller deniers mean that the fibers are finer, and larger deniers mean that the fibers are thicker or heavier. For example, in order to convert the diameter of 15 micron (micrometer) polypropylene fiber into denier, the diameter is squared, multiplies the result by 0.89 g / cc, and then multiplies by 0.00707. Thus, 15 micron (μm) polypropylene fiber has a denier of about 1.42 (15 ² x 0.99 x 0.00707 = 1.415). In countries other than the United States, a unit called "tex" is more commonly used, which is defined as grams per kilometer of fiber. The text can be calculated as denier / 9 (note that to convert osy to gsm, multiply osy by 33.91).

As used herein, "z-direction" means that the fiber lies outside of the orientation plane of the fabric. The fabric is thought to have an x-axis in the machine direction, a y-axis in the machine direction and a z-axis in the swollen direction, with the main plane or surface of the fabric lying parallel to the x-axis and y-axis. Lose. “z-directional fibers” herein refers to the z- during molding of the nonwovens, as distinguished from fibers having z-directional components made in the post-molding process of the nonwovens, as in the case of mechanically crimped, creped or otherwise corrugated nonwovens. Used to refer to fibers oriented in a direction.

As used herein, "wetting agent" means any that causes the fiber surface to exhibit increased hydrophilicity by reducing the contact angle of the aqueous fluid in contact with the fiber surface and / or reducing the surface tension of the aqueous fluid in contact with the fiber surface. Refers to a chemical, compound, or composition.

As used herein, “internal processing” refers to the addition of any chemical, compound, or composition internally to a polymer, for example by blending or extruding with a molten polymer, to form a composition comprising the polymer and additives. .

As used herein, “integratedly bonded” refers to bonding a layer of material without attaching a particular fabric to an additional fabric.

As used herein, "low machine orientation" and "high machine orientation" refer to the extent to which the fibers of the nonwoven are dispersed in the molding surface, for example, in the transverse direction of the porous wire. Low machine orientation fibers are oriented such that the longer axis points laterally to a higher degree than the group of fibers that exhibits a higher machine orientation orientation less oriented laterally of the forming surface during fabrication of the fabric.

As used herein, "substantially continuous fibers" refers to fibers that are not cut in their original length before being formed into a nonwoven or nonwoven. Substantially continuous fibers may have an average length of greater than about 15 cm to greater than 1 m, and up to the length of the formed nonwoven or nonwoven. “Substantially continuous fibers” include fibers that are not cut before being formed into a nonwoven or nonwoven, but are later cut when the nonwoven or nonwoven is cut, and substantially linear or crimped fibers.

As used herein, "through-air bonding" or "TAB" means a fabric (eg, 2) that forces air through the fabric sufficiently hot to melt one of the polymers making up the fabric of the fabric. Refers to any process of integrally bonding the nonwoven fabric by adhering the fibers of the component fiber cloth) together.

As used herein, “parallel fiber” belongs to the class of bicomponent or conjugate fibers. "Bi-component fiber" refers to fibers made from two or more polymer components that are extruded in separate extruders but spun together to form one fiber. Bicomponent fibers are sometimes referred to as composite fibers or multicomponent fibers. Bicomponent fibers are taught, for example, in US Pat. No. 5,382,400 (Pike et al.), Incorporated herein by reference in its entirety. Some composite fibers may be monocomponent fibers, but typically the polymers of the composite fibers differ from one another. Composite fibers are taught in US Pat. No. 5,108,820 (Kaneko et al.), US Pat. No. 4,795,668 (Krueger et al.) And US Pat. No. 5,336,552 (Strack et al.) Incorporated herein by reference in their entirety. Composite fibers can be used to form crimps in fibers using different expansion and shrinkage rates of two (or more) polymers.

As used herein, "machine direction" or "MD" means the length of the nonwoven fabric, that is, the direction in which the nonwoven fabric is made. By "cross machine direction" or "CD" is meant the width of the nonwoven fabric, ie the direction generally perpendicular to the MD.

"Personal hygiene products" as used herein includes, but is not limited to, bandages and wound care products, diapers, training pants, swimwear, absorbent underwear, adult incontinence products, feminine hygiene products, and mortuary and veterinary products. It does not include products that are not.

The word “degree”, such as “about”, “substantially” and the like, is used herein as the meaning of “just or almost that of a particular manufacturing method, design, material and test tolerance inherent in the environment mentioned,” To help the understanding of the present invention, an exact or absolute numerical value is used to prevent an unscrupulous infringer from taking advantage of the present disclosure.

All percentages, proportions, and proportions used herein are by weight unless otherwise indicated.

Description of the Preferred Embodiments

In general, the present invention provides a personal care article and a nonwoven fabric comprising at least two levels, stratums or layers of fibers, wherein one of the layers, laminations or layers is a layer, lamination or Additives or additive combinations that improve the wettability of the layers and / or nonwovens, and another second layer, stack or layer comprise a smaller amount of additives or additive combinations or another additive or another additive combination. The amount of the second additive or the second additive combination present in the fibers of the second layer may be the same or different from the amount of the first additive or the first additive combination present in the fibers of the first layer, laminate or layer. As used herein, "fiber of the second layer" refers to a group of fibers adjacent to another "fiber of the first layer", which differs in composition from the fibers of the first layer, but is apparently different from the fibers of the first layer. It does not have to be distinguished. For example, the layers of the fibers may not be apparent from one another on the microscopic level.

In one preferred embodiment, the invention comprises a fiber of a first layer comprising a blend of a first polyolefin and a first amount of a first surfactant and a blend of a polyolefin and a second amount of a first surfactant different from the first amount It provides a nonwoven fabric comprising a second component. In certain embodiments, the second amount of the first surfactant may be 0 or essentially 0% by weight relative to the weight of the second component. In an exemplary embodiment, the fibers of the first and second layers are bicomponent fibers having a parallel structure. Other bicomponent and multicomponent structures are possible. When only two polymer compositions are used to form the individual components of the multicomponent fiber, each polymer component A and B has a volume ratio of about 90/10 to about 10/90, preferably about 75/25 to about 25/75, or It may be present as a weight ratio. Although the ratio of about 50/50 is often particularly preferred, the specific ratio used may be varied as desired.

Multicomponent fibers are well known and include, but are not limited to, bicomponent fibers, tricomponent fibers, and the like. Multi-component fibers of various structures are also well known and include sheath-core fibers, striped fibers, pie-components including parallel bicomponent fibers, concentric and eccentric sheath-core fibers (pie-component) fibers and the like, but is not limited thereto. Preferably, the multicomponent fiber should have at least two components that form an outer surface on the multicomponent fiber. Multicomponent refers to fibers formed from two or more polymer streams and extruded to make up one fiber. The individual components of the multicomponent fiber are arranged in different regions within the fiber cross section and extend substantially continuously along the length of the fiber. The cross-sectional structure of a multicomponent fiber has two or more different components that comprise part of the outer surface of the fiber. Multicomponent fibers may have three, four or more exposed segments forming the outer surface of the fiber. As mentioned above, two or more segments of individual polymer components together form the outer surface of the multicomponent fiber.

In another preferred embodiment, the present invention comprises a fiber of a first layer comprising at least one additive that improves the wettability of the fiber or nonwoven and a second additive different in chemical structure and / or composition from the first additive. Provided is a fibrous nonwoven comprising the fibers of the second layer. Preferably the first additive or additive combination provides different wettability or wetting properties than the second additive or additive combination. For example, the present invention includes fibers of a first layer comprising a first component comprising a blend of a first polyolefin and a first additive and fibers of a second layer comprising a blend of a second polyolefin and a second additive. Wherein the first additive is a fast wetting agent and the second additive is a slow wetting agent compared to the first additive.

The additives shown include, but are not limited to, ethoxylated siloxanes and hydrocarbons. Ethoxylated hydrocarbons are defined as compounds containing hydrocarbon (HC) chains linked to poly (ethylene oxide) (PEO) chains, wherein the bond between the two chains is ether, ester, amide, sulfonamide, terephthalate or any other It may be a suitable coupler. This can involve a number of HC and PEO chains. Suggested examples of ethoxylated hydrocarbons include, but are not limited to, poly (ethylene glycol) 600 dioleate, CAS registry number [9005-07-6], for example MAPEG 600 DO. Mappe 600 DO is a poly (ethylene glycol) available from BASF Corporation of Mount Olive, NJ. Another example of a commercially available ethoxylated hydrocarbon is CHROMASIST 188-A. Chromastist 188-A is also a PEG 600 DO and may be obtained from Cognis Corporation, Amble, PA. Other presented examples of ethoxylated hydrocarbon surfactants include, but are not limited to, polyethylene glycol (PEG) derivatives of one or more fatty acid or alcohol chains, wherein the PEG molecular weight is about 200 to about 5000, and fatty acid alkyl chains. The length can vary in the range of about 4 to about 22 carbons. Also possible are PEG derivatives of acids and synthetic alcohols having alkyl chains longer than 22 carbons, which may or may not contain unsaturated bonds.

Ethoxylated siloxanes are defined as compounds containing polydimethylsiloxane (PDMS) backbones to which one or multiple poly (ethylene oxide) (PEO) chains can be bound. PEO can be bound to the PDMS backbone through hydrocarbon spacers (eg ethyl groups, etc.) extended by the PEO chain. One presented example of an ethoxylated siloxane surfactant is, but is not limited to, Siltech MFF-184-SW, a dimethyl, methyl, hydroxypropyl ethoxylated siloxane obtained from Siltech Corporation, Toronto, Canada. . Other shown examples of ethoxylated siloxane surfactants include poly [dimethylsiloxane-co-methyl (3-hydroxypropyl) siloxane] -graft-poly (ethylene glycol) methyl ether, for example from BASF, Gunni, Ill. Drinks (MASIL® SF 19), and DC 193 and DC 5103, manufactured by Dow Corning, Midland, Michigan, USA, are not limited thereto. Other ethoxylated siloxane surfactants are described in US Pat. No. 6,300,258, which is incorporated herein by reference in its entirety. Additional materials that are compatible that do not significantly degrade the performance of certain additives may optionally be added to one or more polymer components and extruded with it. As one example, one or more individual components of the multicomponent fiber may optionally include additional surfactants, dyes, stabilizers, processing aids, pigments, fragrances, and the like.

In another preferred embodiment, the present invention provides fibers, nonwovens, or personal hygiene products comprising such fibers or nonwovens having a first wettability at 35 ° C., and a second wettability at 21 ° C. that is slower than the first wettability. do. In a more preferred embodiment, the fibers and nonwovens may wet in less than about 10 seconds at 35 ° C., but not less than about 60 seconds at 21 ° C. In one example, the nonwoven fabric comprises a first component comprising a blend comprising about 80 to about 99.9 wt% polyethylene resin and about 0.1 to about 5 wt% ethoxylated hydrocarbon, and about 80 to about 99.9 wt% polypropylene resin and ethoxy And a layer made of or comprising bicomponent fibers comprising a second component comprising a blend comprising about 0.1 to about 5 weight percent of the silicified hydrocarbons. Accordingly, the present invention provides a nonwoven fabric that can allow " selected wettability " in personal hygiene products such as diapers or training pants. Non-woven fabrics of selected wetting properties are liner or surge management layers that provide high wettability at body temperature, so that they rapidly suck and distribute fluid at body temperature, but draw fluid more slowly at lower temperatures, or liner or surge management that provides such a liner or surge management layer. It can be used as one component of the layer. As the contaminants penetrate the personal care product, the contaminants begin to cool, and as the contaminants cool, the contaminants are more likely to form a wettable liner and / or surge management layer than when initially contacted with the liner and / or surge management layer. Suppose you can't find it anymore. Since the effective capillary affinity for aqueous fluids of such wicking materials, such as liners and surge management layers, is lowered as the temperature decreases, the fluid may not be absorbed by any absorbent material adjacent to or near these layers. There will be no. The result is a wicking system and product that allows fluid to pass through a liner and / or surge management layer that is in intimate contact with the skin, thereby allowing more fluid to travel to the lower absorbent layer. The temperature-dependent wettability of the liner and / or surge management layer is said to prevent or at least reduce the rewetting of the liner or surge management layer, thereby more effectively reducing the rewet of the wearer's skin and helping to prevent contaminants from leaking out of the diaper. Assume Due to the reduced rewet, the trans epidermal water level (TEWL) of the skin can be reduced. Reduced TEWL and reduced leakage are desirable in personal care products.

The fibers may have a denier (g / 9000m) of less than about 4, more preferably less than about 1, even more preferably less than about 0.5. In further embodiments, the fibers may have an average cross sectional diameter of less than about 25 μm, preferably from about 10 to about 20 μm, even more preferably from about 15 to about 20 μm. As used herein, the average fiber size is determined using the largest dimension of the fiber cross section. The fibers are typically manufactured as a solid round structure, but the multicomponent fibers of the present invention are, for example, hollow, multilobal or flat (for example in the form of ribbons) in addition to the solid round fibers. Note that they may have various fiber shapes, such as fibers.

The component forming the fiber may comprise one or more melt-processable polymers. Individual fibers may comprise the same, similar or different polymers. However, two or more of the individual components are different from one another in that they are selected and contain different amounts of active material. The fibers and nonwovens of the present invention are polyolefins (e.g. polypropylene and polyethylene), polycondensates (e.g. polyamides, polyesters, polycarbonates and polyacrylates), polyols, polydienes, polyurethanes, poly It can be prepared from known processable polymers or resins used to form fibers and nonwovens, including but not limited to ethers, polyacrylates, polyacetals, polyimides, cellulose esters, polystyrenes, and the like. As a specific example, the polymer component may be polyethylene, polypropylene, poly (1-butene), poly (2-butene), poly (1-pentene), poly (2-pentene), poly (1-methyl-1-pentene) , Poly (3-methyl-1-pentene), poly (4-methyl-1-pentene), and the like. Many nonwovens are made from polyolefins. Polyolefins shown include, but are not limited to, homopolymers and copolymers of ethylene and homopolymers and copolymers of propylene. In one group of preferred embodiments, the first polyolefin is selected from the group consisting of homopolymers and copolymers of ethylene, and the second polyolefin is selected from the group consisting of homopolymers and copolymers of propylene.

The at least one layer of nonwoven fabric includes a first component comprising about 0.1 to about 5 weight percent of the fiber and an additive or additive combination that improves the wettability of the nonwoven made from the fiber, and a second, different from the first additive or additive combination It is contemplated to include a fiber further comprising a second component comprising from about 0.1 to about 5 weight percent of the additive or combination of additives. For example, the first component may contain about 0.1 to about 5 weight percent of ethoxylated hydrocarbons or a combination of ethoxylated hydrocarbons, and the second component may contain about 0.1 to about 5 weight percent of ethoxylated siloxane or a combination of ethoxylated siloxanes. It may contain. The fibers of the present invention may comprise a first component comprising about 0.5 to about 3 weight percent ethoxylated hydrocarbon and a second component comprising about 0.5 to about 3 weight percent ethoxylated siloxane. Preferably, the first component is a substantially homogeneous melt blend comprising a first polyolefin and an ethoxylated hydrocarbon surfactant and the second component is a substantially homogeneous melt blend comprising a second polyolefin and an ethoxylated hydrocarbon surfactant. to be. Methods of blending polymers with various additives are well known and include, but are not limited to, melt blending, coextrusion through the addition of additives directly to the extruder during melt processing, masterbatch methods, and the like. The fibers of the second layer can have similar or different compositions. Preferably, the fibers of the second layer may have the same or similar composition but differ in terms of the amount of additives or the composition of the additives. More preferably, the fibers of the second layer are less wettable than the fibers of the first layer and / or do not wet as quickly as the fibers of the first layer, thus providing a wettability gradient in the nonwoven fabric.

The nonwovens of the present invention can be produced through a variety of known nonwoven fabrication methods, including but not limited to spunbonding and meltblowing processes, in particular methods of making nonwovens from bicomponent or other multicomponent fibers. . Exemplary methods and apparatus for making multicomponent nonwovens are described in U.S. Patent Nos. 3,425,091 (Ueda et al.), U.S. Patent Nos. 3,981,650 (Page), U.S. Patents 5,601,851 (Terakawa, et al. US Pat. No. 5,344,297 (Hills) and US Pat. No. 5,382,400 (Pike et al.). It is also possible to heat treat one surface of the nonwoven fabric of the present invention more than the other to provide a nonwoven fabric having a larger wettability gradient in the z-direction such that one surface of the nonwoven is more wettable than the other surface of the nonwoven.

In certain preferred embodiments, the present invention can provide wettable fibers and wettable nonwovens that can be prepared by simple processes that do not require drying. Drying can negatively affect the appearance of the nonwoven by making the fibers more stiff, reduce the tensile strength and ultimately adversely affect the conversion process. In certain preferred embodiments, the present invention relates to wettable fibers, which may be prepared by a simple process that does not require wet chemical treatment (eg, bathing, spraying and foaming) after the fibers and / or nonwovens have been produced and Provides wettable nonwovens. Such wet chemical treatments typically involve the use of aqueous solutions containing one or more surfactants in solution or suspension, which can cause difficulties during processing. Advantageously, the fibers and nonwovens of certain preferred embodiments of the present invention are wettable immediately upon production and do not require additional processing or treatment to improve their wettability.

In one particularly preferred embodiment, the present invention provides fibers and nonwovens that include a synergistic blend of internal melt additives that exhibits rapid fluid wicking and confer unique wettability to durable nonwovens when exposed to multiple aqueous fluids. . Such fibers and nonwovens are useful in a variety of products, including but not limited to personal care products and other absorbent products such as diapers. Thus, in one embodiment, the present invention provides a surge management layer for use in disposable personal hygiene absorbent articles, wherein the surge management layer comprises components comprising about 0.1 to about 5 weight percent of polyethylene resin and ethoxylated hydrocarbon, and A first layer of bicomponent fiber comprising a component comprising a polypropylene resin and a blend comprising a blend comprising from about 0.1 to about 5 weight percent of ethoxylated siloxane, and a relatively small amount of no ethoxylated hydrocarbon or ethoxylated siloxane Spunbonded nonwoven fabrics comprising fibers of a second layer comprising ethoxylated hydrocarbons and ethoxylated siloxanes.

As mentioned above, many methods of making nonwovens are known. Only one advantageous method of spunbonding to produce nonwovens is illustrated and described herein. 1 illustrates a preferred method and apparatus for making a highly swelled low density nonwoven fabric in accordance with one embodiment of the present invention by making a substantially continuous crimping bicomponent parallel structure fiber. In FIG. 1, the figures show an exemplary method and multibank apparatus of the present invention for producing highly swelling low density nonwovens by making substantially continuous crimping bicomponent parallel structure fibers and crimping them in a non-constrained environment. . The two polymers A and B are spun using a known thermoplastic fiber spinning device 21 to form a bicomponent parallel structure or A / B polymer filament 23 of the first layer. The polymer filament 23 is then passed through a fiber drawing device (FDU) 25 to form a drawn fiber 24. According to one embodiment of the present invention, the FDU is not heated but is kept at room temperature (eg 65 ° F.). Thus, while the polymer is recognized to be heated to extrude the polymer mass, the actual fibers formed at the FDA at room temperature are referred to and understood herein as being deposited on the molding surface, without further heating of the fibers prior to the deposition of the fibers. will be. Fiber 24 is in a substantially continuous state and is deposited on a moving forming wire or surface 27. A vacuum under the wire supplied by the negative pressure device or an exhaust 29 under the wire is used to assist in the deposition of the fibers 24.

The two polymers A and B are spun through a second thermoplastic fiber spinning device 61 to form a bicomponent parallel structure of the second layer or polymer filament 63 of A / B. The second stretched fiber 64 is then formed by passing the polymer filament 63 through the second fiber drawing device (FDU) 65. The fibers 64 of the second layer are in a substantially continuous state and are deposited on the fibers 24 of the first layer on the moving forming wire or surface 27.

Subsequently, the composite layer of fibers including the first layer of fibers 24 and the second layer of fibers 64 is either one of a hot air knife (HAK) 31 or a hot air diffuser 33 (both in the drawing). Although shown, under normal circumstances one of them is used), it can be heated. Typical hot air knives include a mandrel having a slot for blowing hot air jets onto the nonwoven surface. Such hot air knife is taught, for example, by US Pat. No. 5,707,468 to Arnold et al., Which is incorporated by reference in its entirety herein. The hot air diffuser 33 is a similar but operates at a lower air velocity on a larger surface area and is a substitute for using a correspondingly lower air temperature. The group or layer of fibers may thus undergo melting or some non-functional bonding of the outer skin while passing through the first heating zone. "Nonfunctional bond" is a weak bond that is sufficient to hold the fibers in place during the process according to the method of the present invention but not to hold the fibers together to the extent that they can be manipulated by hand. This combination is incidental and can be eliminated if desired.

The fiber will then cool once it passes through the first heating zone of hot air knife 31 or hot air diffuser 33. In order not to destroy the crimp, the exhaust 29 under the wire can be removed. In a particular preferred embodiment, the nonwoven fabric comprises fibers that are crimped out of the z-direction, i. The fabric 37 is then conveyed to an air permeation (TAB) device 39 to fix or fix the fabric to the desired degree of swelling and density. On the one hand, the TAB device 39 is banded to provide a first heating zone, followed by a cooling zone, followed by a second heating zone sufficient to fix the fabric instead of the hot air knife 31 or the hot air diffuser 33. Can provide. The settled fabric 41 can then be continued for collection or further processing on the take-up roll 43 or the like for later use.

According to one preferred embodiment of the invention, the one or two layers of fibers are substantially continuous fibers and are bicomponent fibers. Preferably, the two layers of fibers are substantially continuous bicomponent fibers. The fabric of the present invention may contain a single denier structure (ie one fiber size) or a mixed denier structure (ie multiple fiber sizes). Particularly suitable polymers for forming the structural component of suitable bicomponent fibers include polypropylene and copolymers of propylene and ethylene, and polymers particularly suitable for the adhesive component of bicomponent fibers are polyethylene, more particularly linear low density polyethylene and high density polyethylene. It includes. In addition, the adhesive component may contain additives for improving crimping properties and / or lowering the bonding temperature of the fibers as well as for improving the wear resistance, strength and flexibility of the resulting fabric. Particularly suitable bicomponent polyethylene / polypropylene fibers for the process according to the invention are described in US Pat. No. 5,336,552 (Strack et al.) And US Pat. No. 5,382,400 (Pike et al.). The fabrics prepared according to the invention further comprise fibers having a resin which is capable of replacing PP / PE, for example poly (ethylene terephthalate), poly (butylene terephthalate), poly (trimethylene terephthalate), copoly- And may further contain fibers including, but not limited to, PP + 3% PE, poly (lactic acid), nylon, and the like. The fibers can have a variety of alternative forms and symmetry, including pentabal, tri-T, hollow, striped, cat's eye ribbons, X, Y, H and asymmetric cross sections. .

Polymers useful in the preparation of the nonwovens of the present invention may further include thermoplastic polymers such as polyolefins, polyesters and polyamides. Elastomers may also be used, which are block copolymers, for example polyurethanes, copolyether esters, polyamide polyether block copolymers, ethylene vinyl acetate, block copolymers having an ABA 'or AB structure, for example nasal Poly (styrene / ethylene-butylene), styrene-poly (ethylene-propylene) -styrene, styrene-poly (ethylene-butylene) -styrene, (polystyrene / poly (ethylene-butylene) / polystyrene, poly (styrene / Ethylene-butylene / styrene) and the like.

Polyolefins may also be used in conjunction with single reaction site catalysts, sometimes referred to as metallocene catalysts. Many polyolefins are used for making fibers, for example polyethylenes such as ASPUN7 6811A linear low density polyethylene, 2553 LLDPE and 25355 and 12350 high density polyethylene from Dow Chemical. These polyethylenes have a melt index of about 27, 40, 25 and 12 g / 10 min, respectively, at conditions of 190 ° C. and 2.16 kg forces. Fiber-forming polypropylenes include 3155 polypropylenes from Exxon Chemical Company and PF-304 from Montel Chemical Company. Many other polyolefins are commercially available.

Biodegradable polymers may also be used in the manufacture of fibers, suitable polymers include polylactic acid (PLA), and blends of BIOOLL® (BIONOLLE®) and adipic acid and UNIITHOX® (BAU). PLA is not a blend but a pure polymer such as polypropylene. BAU is a blend containing different percentages of Bionol, Adipic Acid and Unitox. Typically, the blend for short fibers contains 44.1% Bionol 1020, 44.1% Bionol 3020, 9.8% adipic acid and 2% Unitox 480, while spunbonded BAU fibers typically contain about 15% Use adipic acid. Bionol 1020 is a polybutylene succinate, Bionol 3020 is a polybutylene succinate adipate copolymer and Unitox 480 is an ethoxylated alcohol. Bionol is a trademark of Showa Highpolymer Co., Japan. Unitox is a trademark of Baker Petrolite, a subsidiary of Baker Hughes International.

Since the nonwovens of the present invention are wettable as manufactured, there is no need to post-heat the nonwovens to induce the nonwovens to be wettable with aqueous fluids. However, the nonwovens and / or fibers may be heated after molding. For example, in a HAK 31, hot air diffuser 33, or banded TAB (not shown) in a first heating zone, the polyethylene crystalline region relaxes its originally oriented molecular chain. It can be heated to a temperature that starts and starts to melt. The air temperature shown is about 110-260 ° F. This temperature range is the temperature before melting, ie higher than the glass transition temperature (Tg) or softening point but lower than the melting point, and the temperature at which the molecular chain can be relaxed before reaching the melting point of the polymer. The heat of the air stream from the HAK 31 may be hotter due to the short residence time of the fibers in the narrow heating zone. Also, when heat is applied to the oriented molecular chain of the fiber, the mobility of the molecular chain increases. The chains prefer to relax in an irregular state rather than oriented. Thus, the chains are bent and folded to cause further contraction. Heat may be applied to the fabric using hot air, IR lamps, microwaves or any other heat source that can be relaxed by heating the semi-crystalline region of polyethylene.

The fabric is then passed through a cooling zone that lowers the polymer temperature below its crystallization temperature. Because polyethylene is a semicrystalline material, the polyethylene chains recrystallize and shrink upon cooling. This shrinkage forces the one side of the parallel fiber to crimp or twist, unless there are other major forces that inhibit the fiber from moving freely in any direction. By using a low temperature FDU, the fiber is structured so as not to be crimped as a dense spiral that is common in the case of fibers that have passed through a high temperature FDU. Instead, the fibers are crimped more loosely and irregularly, causing the fabric to swell more in the z-direction.

Factors that may affect the amount and type of crimp include the residence time of the fabric in the first heating zone. Other factors that may affect the crimp may include material properties such as fiber denier, polymer type, cross sectional shape and basis weight. Inhibiting the fibers by vacuum, blowing air, or bonding also affects the amount of crimping, which, if achieved in the highly swollen low density fabric of the present invention, will affect the swelling or bulk desired. Thus, once the fiber enters the cooling zone, no vacuum is applied to hold the fiber to the forming wire 27. The cooling zone likewise controls or removes the blowoff air to a substantial or desired extent.

By controlling the amount of vacuum under the wire, the FDU pressure, the wire speed, and the forming height from the FDU to the wire surface, fibers with the desired degree of MD orientation can be deposited on the forming wire. As will be further described later, a high degree of MD orientation can be used to obtain a very bulging fabric. In addition, depending on the specific fiber and processing parameters, the air jet of the FDU will exhibit natural frequencies that can help provide specific morphological properties, such as shingling effects on the swelling of the fabric.

The following examples were prepared using the method as described below and generally shown in FIG. 1. Although the examples presented below are highly swelling low density nonwovens of one preferred embodiment, the present invention includes non-wovens of other multicomponent fibers as well as less swelling lower density nonwovens. The nonwoven fabric prepared in the examples had a basis weight of 77 gsm (about 2.3 osy), a bulk of 3.3 mm (about 0.1 inch) and a density of 0.023 g / cc. The average denier was about 3.3 dpf (denier / fiber). All fibers were parallel bicomponent fibers characterized by polymer A of Dow 61800.41 polyethylene (PE) and polymer B of exon 3155 polypropylene (PP). Prior to extrusion, a TiO ₂ additive, trade name SCC-4837 from Standridge Color Corporation, Social Circle, Georgia, USA, was added to the polymer in an amount of 2% by weight to impart white and opacity to the fabric. The fibers were spun in an A / B parallel structure (s / s) at a melting point of 410 ° F. through a 96 hole / inch spin pack.

The yield was balanced so that the two polymers were at 50/50 ratio and the total yield was 0.7 grams / hole / minute (ghm). The quench air temperature was 55 ° F. Fiber spinning length was 48 inches. The fibers were drawn to 4.0 pounds per square inch / gram (psig) in bank 1 and 4.5 psig in bank 2 using air at room temperature (eg, about 65 ° F.). The bottom of the fiber drawing device (FDU) was 12 inches above the forming wire, which moved at a rate of 229 ft / min when measured on the forming wire. Hot air knife (HAK) was set at a pressure above 5.0 inches from the forming wire, at 250 ° F. and 5.0 inch H ₂ O pressures in Bank 1, and at 240 ° F. and 3.5 inch H ₂ O pressures in Bank 2. The wire exhaust below the FDU was set to a vacuum of about 1.6 inches H ₂ O in bank 1 and a vacuum of 3.8 inches H ₂ O in bank 2. The fabric was bound at about 262 to 269 ° F. in a ventilator coupler (TAB).

Those skilled in the art will be familiar with alternative methods of forming the nonwovens of the present invention. For example, those skilled in the art can make the nonwoven fabric described above using a process such that the first layer does not contain internal additives that improve wettability and the fibers of the second layer include internal additives that improve wettability. You will know that you can. Other alternative methods include, for example, methods of forming bicomponent fibers or nonwovens that do not need to be heavily swollen and / or have high density, as well as other methods of making multicomponent fibers and nonwovens, such as more than two components. Including but not limited to methods of making multicomponent fibers and / or nonwovens. The invention will now be described with reference to the following specific examples.

Comparative Example A

Using the spunbonding process described above and shown in FIG. 1, a parallel bicomponent fiber and a nonwoven fabric of the bicomponent fiber were produced. This process is generally described and described in co-pending US patent applications Ser. Nos. 10 / 037,467 and 10 / 749,805. The bicomponent fibers and nonwovens of this Comparative Example A do not include any internal surfactants that increase the wettability of the nonwovens. However, this nonwoven fabric of Comparative Example A was surface treated with an aqueous foaming solution containing a surfactant that improved the wettability of the nonwoven surface. This aqueous solution contains 2% by weight of a mixture of ACOBEL Base N-62, Glucophone 220 UP, and Drinkable SF-19 in a weight ratio of 3: 1: 1. It was. Acobell Base N-62 (simply referred to as "Acobell") is a blend of hydrogenated ethoxylated perme oil and sorbitan monooleate. Glucophone 220 up (collectively referred to as "glucophone") is an alkyl polyglycoside, specifically octyl polyglycoside, commercially available from Cognis Corporation, Amble, PA. And Drinkable SF-19 is an ethoxylated siloxane surfactant, specifically ethoxylated trisiloxane, available from BASF, Gunni, Ill.

The polypropylene component (A) of the parallel bicomponent fibers consisted of a melt blend of about 98% by weight exon 3155 polypropylene (PP) resin and 2% by weight titanium dioxide opacifier obtained from ExxonMobil. The polyethylene component (B) of the parallel bicomponent fiber consisted of a melt blend of about 98% Dow 61800.41 polyethylene (PE) resin and 2% by weight titanium dioxide opacifier.

Using non-woven fabrics, the foam coating process generally described and described in co-pending US patent application Ser. No. 10/327828, the Acobell-based N-62 and Glucophone 220 up and the SF-19 to drink of 3: 1: 1 The mixture was treated off-line as 2% by weight of the mixed mixture by weight.

Example 1

Using the spunbonding process described above and generally shown in FIG. 1, a nonwoven fabric comprising multiple layers of bicomponent fibers and two layers of bicomponent fibers was prepared. The bicomponent fibers and nonwovens of the first layer of this Example 1 included an ethoxylated hydrocarbon surfactant in one component and an ethoxylated siloxane surfactant in the other components of the bicomponent fiber. The polypropylene component (A) comprises about 96% by weight of Exxon 3155 polypropylene resin obtained from ExxonMobil, 2% by weight titanium dioxide opacifier, and about 2 MFF 184 SW ethoxylated siloxane obtained from Siltech Corporation, Toronto, Canada. Consisting of wt.% Melt blend. Polyethylene component (B) comprises about 96% by weight of Dow 61800.41 polyethylene resin, 2% by weight titanium dioxide opacifier, and the polys sold under the trade name Chromastist 188-A by Cognis Corporation of Amble, PA. Ethylene glycol) 600 dioleate (abbreviated PEG 600 DO) of about 2% by weight melt blend. The fibers of the second layer did not contain any internal additives that improved wettability. Specifically, the fibers of the second layer comprise 50% by weight polypropylene component (A) consisting of about 98% by weight exon 3155 polypropylene resin and about 2% by weight titanium dioxide, and about 98% by weight Dow 61800.41 polyethylene resin. And 50% by weight of polyethylene component (B) consisting of a melt blend of about 2% by weight titanium dioxide opacifier.

Example 2

Using the spunbonding process described above, a nonwoven fabric, called a first layer, was prepared from parallel bicomponent fibers, wherein the polypropylene (A) component was about 96% by weight of exon 3155 polypropylene resin obtained from ExxonMobil. And a melt blend of 2% by weight titanium dioxide opacifier and about 2% by weight PEG 600 DO; the polyethylene (B) component comprises about 96% by weight Dow 61800.41 polyethylene resin, 2% by weight titanium dioxide opacifier and PEG 600 DO 2 wt% of the melt blend.

A second layer was formed on the first layer using a process similar to the process used in Example 1 above. For example, a second layer of parallel bicomponent fibers formed under the same conditions but without any internal additives that improve wettability can be formed on the first layer. Specifically, the second layer comprises 50% by weight polypropylene component (A) consisting of about 98% by weight exon 3155 polypropylene resin obtained from ExxonMobil and about 2% by weight titanium dioxide opacifier, and Dow 61800.41 poly It may consist of a bicomponent fiber consisting of 50% by weight polyethylene component (B) consisting of a melt blend of about 98% by weight of ethylene resin and 2% by weight of titanium dioxide opacifier.

The first layer of Example 2 was tested for wettability at various temperatures. Specifically, the nonwoven sample of this Example 2 was placed in a pan containing about 35 ° C. water without any pressure (non-forced flow), so that the sample at a temperature close to body temperature (37 ° C. or 98.6 ° F.) was obtained. The wettability of the sample at room temperature (about 70 ° F.) was determined by determining the wettability and likewise placing the second nonwoven sample of Example 2 into a pan containing about 21 ° C. water without any pressure (non-forced flow). Was determined. The sample was wet completely and usually immediately at 35 ° C. The term "wetting" of a nonwoven is known in the art and refers to a state in which the nonwoven is suspended in water, where the nonwoven no longer floats on the surface of the water and the fibers are in contact with water, resulting in a more transparent nonwoven. Samples placed in 21 ° C. water did not wet immediately, more specifically samples did not wet within the first minute (60 seconds) at 21 ° C. and typically did not wet within the first 2 minutes at 21 ° C. Thus this example provides fibers and nonwovens having temperature-dependent wettability. More specifically, this embodiment is wettable at body temperature (about 35-37 ° C. or 95-98.6 ° F.), but not wettable at lower temperatures such as room temperature or about 21 ° C. (about 70 ° F.). To provide.

This embodiment provides a nonwoven fabric that can allow " selected wettability " in personal hygiene products such as diapers or training pants. For example, a non-woven fabric with selected wettability is rapidly wetted by the fluid secreted by the body at body temperature, so a liner or surge management layer capable of rapidly drawing and dispensing fluid, or a liner or surge providing such liner or surge management layer It can be used as one component of the management layer. However, as the fluid cools in the liner or surge management layer, the fluid less wets the liner or layer, so the fluid is more likely to be transferred to any underlying absorbent layer. This reduces backflow of the fluid and / or rewet of the skin, thus keeping the skin dry.

Those skilled in the art will recognize that specific modifications may be made to the apparatus and methods disclosed herein with reference to the illustrated embodiments without departing from the spirit of the invention. While the present invention has been described with respect to the preferred embodiments, it will be appreciated that the present invention can be rearranged, modified and altered in numerous ways, and such rearrangement, adaptation and alteration embodiments also fall within the scope of the appended claims. As long as the claims set forth below are means and function claims, this does not imply that the invention or specification is not to include those that are not structurally identical to those described in the embodiments disclosed in the specification.

Claims (20)

A first layer of a first fiber comprising a polyolefin and a first amount of wettability improving additive or additive combination, and A second layer of the second fiber comprising a second amount of the wettability improving additive or additive combination that is from 0 wt% to less than the first amount Non-woven comprising a. The nonwoven fabric of claim 1, wherein the second layer is essentially free of wettability improving additives or additive combinations. The nonwoven fabric of claim 1, wherein the second layer comprises a second fiber substantially similar in composition to the first fiber and comprises less than a wettability improving additive or combination of additives that the first fiber contains. The method of claim 1, wherein the first fiber, A first component comprising from about 0.1 to about 5 weight percent of a blend of the first polyolefin and a wettability improving additive or additive, and A second component comprising from about 0.1 to about 5 weight percent blend of a second polyolefin with a wettability improving additive or additive combination Nonwoven fabric which is a multicomponent fiber comprising a. The method of claim 1, wherein the first fiber, A first component comprising from about 0.1 to about 5 weight percent of a blend of the first polyolefin and a wettability improving additive or additive, and A second component comprising from about 0.1 to about 5 weight percent blend of a second polyolefin with a wettability improving additive or additive combination Nonwoven fabric which is a bicomponent fiber comprising a. The method of claim 1, wherein the first fiber, A first component comprising from about 0.1 to about 5 weight percent of a blend of a first polyolefin with an ethoxylated hydrocarbon and derivatives thereof, an ethoxylated siloxane and derivatives thereof, and a combination thereof; And A second component comprising from about 0.1 to about 5 weight percent of a second polyolefin and a wettability improving additive or additive combination selected from the group consisting of ethoxylated hydrocarbons and derivatives thereof, ethoxylated siloxanes and derivatives thereof, and combinations thereof Nonwoven fabric which is a multicomponent fiber comprising a. 7. The substantially homogeneous melt blend of claim 6, wherein the first component is a substantially homogeneous melt blend comprising a first polyolefin and an ethoxylated hydrocarbon surfactant, and the second component is a substantially homogeneous comprising a second polyol lepin and an ethoxylated hydrocarbon surfactant. Non-woven fabric which is a melt blend. The nonwoven fabric of claim 1 wherein the first polyolefin and the second polyolefin are independently selected from the group consisting of homopolymers and copolymers of ethylene and homopolymers and copolymers of propylene. The nonwoven fabric of claim 1 wherein the first polyolefin is selected from the group consisting of homopolymers and copolymers of ethylene. The nonwoven fabric of claim 1 wherein the second polyolefin is selected from the group consisting of homopolymers and copolymers of propylene. The nonwoven fabric of claim 1 wherein the first polyolefin is selected from the group consisting of homopolymers and copolymers of ethylene and the second polyolefin is selected from the group consisting of homopolymers and copolymers of propylene. The method of claim 1, wherein the first fiber, A first component comprising from about 0.5 to about 3 weight percent of an ethoxylated hydrocarbon surfactant, and A second component comprising from about 0.5 to about 3 weight percent of an ethoxylated siloxane surfactant Non-woven comprising a. The nonwoven fabric of claim 1, wherein the nonwoven fabric has a first surface and a second surface, and the first surface of the nonwoven fabric is heat treated to provide a nonwoven fabric having a wettability gradient in the z-direction so that the first surface of the nonwoven fabric is the second surface of the nonwoven fabric. More wettable nonwovens. A first layer and a second layer; The first layer, A first component comprising from about 0.1 to about 5 weight percent of a blend of the first polyolefin with an ethoxylated hydrocarbon or derivative thereof, an ethoxylated siloxane or derivative thereof, or a combination thereof, and a second polyolefin with an ethoxylated hydrocarbon or A first multicomponent fiber comprising a second component comprising from about 0.1 to about 5 percent by weight of a derivative, an ethoxylated siloxane or derivative thereof, or a combination thereof, The first component forms at least a portion of the outer surface of the first multicomponent fiber and the second component forms at least a portion of the outer surface of the first multicomponent fiber; The second layer, A first component comprising less than about 0.1 weight percent of a blend of a first polyolefin with an ethoxylated hydrocarbon or derivative thereof, an ethoxylated siloxane or derivative thereof, or a combination thereof, and a second polyolefin with an ethoxylated hydrocarbon or derivative thereof, A nonwoven comprising a second multicomponent fiber comprising a second component comprising less than about 0.1% blend by weight of an ethoxylated siloxane or derivative thereof. 15. The nonwoven fabric of claim 14, wherein the multicomponent fiber is a bicomponent fiber. 15. The bicomponent fiber of claim 14, wherein the multicomponent fiber is a bicomponent fiber, and the first component and the second component are parallel structures. 15. The process of claim 14 wherein the ethoxylated siloxane is poly [dimethylsiloxane-co-methyl (3-hydroxypropyl) siloxane] -graft-poly (ethylene glycol) methyl ether and the ethoxylated hydrocarbon is poly (ethylene glycol) 600 Non-woven fabric which is dioleate. A first component comprising a blend comprising about 80 to about 99.9 weight percent polyethylene resin and about 0.1 to about 5 weight percent ethoxylated hydrocarbon or derivative thereof, ethoxylated siloxane or derivative thereof, or a combination thereof, and A second component comprising a blend comprising about 80 to about 99.9 weight percent polypropylene resin and about 0.1 to about 5 weight percent ethoxylated hydrocarbon or derivative thereof, ethoxylated siloxane or derivative thereof, or a combination thereof A spunbonded nonwoven fabric comprising a first layer of bicomponent fibers comprising a, And wherein said first component and said second component are suitable for use in a disposable personal hygiene absorbent article having a parallel structure. 19. The surge management layer of claim 18 wherein the wettability of the spunbonded nonwoven at 21 [deg.] C. is lower than that of the spunbonded nonwoven at 35 [deg.] C. 19. The nonwoven fabric of claim 18, wherein the nonwoven fabric has a first surface and a second surface, and the first surface of the nonwoven fabric is heat treated to provide a nonwoven fabric having a wettability gradient in the z-direction such that the first surface of the nonwoven fabric is the second surface of the nonwoven fabric. A more wettable surge management layer.

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