Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
• • A—HUMAN NECESSITIES
  • A44—HABERDASHERY; JEWELLERY
  • A44B—BUTTONS, PINS, BUCKLES, SLIDE FASTENERS, OR THE LIKE
  • A44B18/00—Fasteners of the touch-and-close type; Making such fasteners
  • A44B18/0003—Fastener constructions
  • A44B18/0011—Female or loop elements
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F13/00—Bandages or dressings; Absorbent pads
  • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
  • A61F13/15577—Apparatus or processes for manufacturing
  • A61F13/15756—Applying tabs, strips, tapes, loops; Knotting the ends of pads
• • A—HUMAN NECESSITIES
  • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
  • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
  • A61F13/00—Bandages or dressings; Absorbent pads
  • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
  • A61F13/56—Supporting or fastening means
  • A61F13/62—Mechanical fastening means ; Fabric strip fastener elements, e.g. hook and loop
  • A61F13/622—Fabric strip fastener elements, e.g. hook and loop
  • A61F13/627—Fabric strip fastener elements, e.g. hook and loop characterised by the loop
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/0046—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by constructional aspects of the apparatus
  • B32B37/0053—Constructional details of laminating machines comprising rollers; Constructional features of the rollers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/08—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B38/06—Embossing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
  • B32B5/022—Non-woven fabric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
  • D04H1/43838—Ultrafine fibres, e.g. microfibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
  • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H11/00—Non-woven pile fabrics
  • D04H11/08—Non-woven pile fabrics formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
  • D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
  • D06C15/00—Calendering, pressing, ironing, glossing or glazing textile fabrics
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/20—All layers being fibrous or filamentary
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/02—Synthetic macromolecular fibres
  • B32B2262/0253—Polyolefin fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/10—Fibres of continuous length
  • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
  • B32B2309/16—Tension
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2555/00—Personal care
  • B32B2555/02—Diapers or napkins

Definitions

• the present disclosure relates a sheet of loop material adapted to be cut into pieces to form loop portions for fasteners of the type comprising releasably engageable hook and loop portions, to be incorporated into items such as disposable garments or diapers.
• sheets of loop materials are known that are adapted to be cut into pieces to form the loop portions for fasteners of the type comprising releasably engageable hook and loop portions.
• Such sheets of loop materials typically comprise a backing and a multiplicity of loops formed from longitudinally oriented polymeric fibers anchored in the backing and projecting from a front surface of the backing so that they may be releasably engaged with the hooks on the hook portion of such a fastener, and can be made by many methods including conventional weaving, or knitting techniques.
• Sheets of loop materials in which the loops are stitched into the backing are described in U.S. Pat. Nos. 4,609,581 and 4,770,917.
• 5,616,394 describes a sheet of loop material adapted to be cut into pieces to form loop portions for fasteners, which sheet of loop material includes a backing comprising a thermoplastic backing layer with generally uniform morphology, and a sheet of longitudinally oriented fibers having generally non-deformed, anchor portions bonded or fused in the thermoplastic backing layer at spaced bonding locations, and arcuate portions projecting from a front surface of the backing between the bonding locations.
• nonwoven fabrics including at least one spunbond web that can self-form loops because they have a shrinkage mismatch. This can be due to the raw materials chosen or the process conditions chosen so that the two webs differ in molecular orientation so that when exposed to latent heat one of the layers will shrink more than the other. Bonding the layers together before allowing latent heat to shrink the highly oriented web forces it to bow away from the other layer, forming loops. These loops can engage with hook constructions in a hook-and-loop fastener arrangement.
• the present disclosure provides a method of forming a nonwoven fabric, comprising providing a first layer comprising continuous or discontinuous oriented monocomponent thermoplastic fibers; providing a second layer; conveying the first and second layers through a nip comprising a first and a second roller wherein the first roller is a patterned roller, wherein the nip pattern creates bonded regions while leaving unbonded regions so as to bond the first and second layers into a nonwoven fabric, wherein the unbonded regions comprise between about 20% and 40% of the total area of the nonwoven fabric, and further wherein the nip introduces latent heat into the nonwoven fabric; and allowing the latent heat to cool while the first layer is held at a tension of less than 4 N/linear cm such that free loops are formed in the unbonded areas of the first layer.
• the continuous or discontinuous oriented monocomponent thermoplastic fibers within the first layer are spunbond polypropylene formed at a spinning speed of lower than 2400 m/min.
• the first and second layers are each formed of webs of indefinite length having a longitudinal direction and a cross direction
• the second layer further include a meltblown layer laminated to the continuous or discontinuous oriented monocomponent thermoplastic fibers.
• the meltblown layer is disposed between two spunbonded layers.
• the present disclosure provides a nonwoven fabric, comprising a first layer comprising continuous or discontinuous oriented uncrimped monocomponent thermoplastic fibers, and a second layer having a pattern of bonded regions and unbonded regions with the first layer, wherein the bonded regions comprise between about 20% and 40% of the total area of the nonwoven fabric, wherein the first layer displays raised loops in the unbonded areas, and wherein the first layer possesses a percent solidity of less than 12.
• the first and second layer comprise webs of indefinite length having a longitudinal direction and a cross direction perpendicular to the longitudinal direction.
• the second layer further include a meltblown layer laminated to the continuous or discontinuous oriented monocomponent thermoplastic fibers.
• the meltblown layer is disposed between two spunbonded layers.
• Embodiment A A method of forming a nonwoven fabric, comprising:
• thermoplastic fibers monocomponent thermoplastic fibers
• a nip comprising a first and a second roller wherein the first roller is a patterned roller, wherein the nip pattern creates bonded regions while leaving unbonded regions so as to bond the first and second layers into a nonwoven fabric, wherein the unbonded regions comprise between about 20% and 40% of the total area of the nonwoven fabric, and further wherein the nip introduces latent heat into the nonwoven fabric;
• Embodiment B The method according to Embodiment A wherein
• Embodiment C The method according to Embodiments A or B wherein the first and second layer comprise webs of indefinite length having a longitudinal direction and a cross direction perpendicular to the longitudinal direction, and wherein no bonded regions extend without interruption by unbonded regions in any line oriented in the cross direction.
• Embodiment D The method according to any of the above Embodiments wherein the bonded regions comprise between about 20% to 40% of the nonwoven fabric.
• Embodiment E The method according to claim any of the above Embodiments wherein the second layer further comprises a meltblown layer laminated to the continuous or discontinuous oriented monocomponent thermoplastic fibers.
• Embodiment F The method according to Embodiment E wherein the meltblown layer is disposed between two spunbonded layers.
• Embodiment G A nonwoven fabric, comprising:
• a first layer comprising continuous or discontinuous oriented uncrimped
• thermoplastic fibers and a second layer having a pattern of bonded regions and unbonded regions with the first layer
• bonded regions comprise between about 20% and 40% of the total area of the nonwoven fabric
• nonwoven fabric possesses a percent solidity of less than 12.
• Embodiment H The nonwoven fabric according to Embodiment G wherein
• the first and second layer comprise webs of indefinite length having a longitudinal direction and a cross direction perpendicular to the longitudinal direction, and wherein no bonded regions extend without interruption by unbonded regions in any line oriented in the cross direction.
• Embodiment I The nonwoven fabric according to Embodiments G or H wherein the bonded regions comprise between about 20% to 40% of the nonwoven fabric.
• Embodiment J The nonwoven fabric according to claim any of Embodiments G through I wherein the second layer further comprises a meltblown layer laminated to the continuous or discontinuous oriented monocomponent thermoplastic fibers.
• Embodiment K The nonwoven fabric according to Embodiment J wherein the meltblown layer is disposed between two spunbonded layers.
• FIG. 1 is a perspective side view of an exemplary nonwoven fabric according to the present disclosure.
• FIG. 2 is a schematic view of an apparatus for carrying out the method according to the present disclosure.
• FIG. 3 is a schematic view of an alternate apparatus for carrying out the method.
• the present disclosure describes a nonwoven fabric particularly suited to be the loop side of a hook-and-loop fastening system.
• the disclosed method is simpler than other methods for making loop fabric, reducing cost for e.g. user of infant diapers.
• (co)polymer or “(co)polymers” includes homopolymers and copolymers, as well as homopolymers or copolymers that may be formed in a miscible blend, e.g., by coextrusion or by reaction, including, e.g., transesterification.
• copolymer includes random, block and star (e.g. dendritic) copolymers.
• joining with reference to a particular layer means joined with or attached to another layer, in a position wherein the two layers are either next to (i.e., adjacent to) and directly contacting each other, or contiguous with each other but not in direct contact (i.e., there are one or more additional layers intervening between the layers).
• a viscosity of "about” 1 Pa- sec refers to a viscosity from 0.95 to 1.05 Pa-sec, but also expressly includes a viscosity of exactly 1 Pa-sec.
• a perimeter that is “substantially square” is intended to describe a geometric shape having four lateral edges in which each lateral edge has a length which is from 95% to 105% of the length of any other lateral edge, but which also includes a geometric shape in which each lateral edge has exactly the same length.
• a substrate that is “substantially” transparent refers to a substrate that transmits more radiation (e.g. visible light) than it fails to transmit (e.g. absorbs and reflects).
• a substrate that transmits more than 50% of the visible light incident upon its surface is substantially transparent, but a substrate that transmits 50% or less of the visible light incident upon its surface is not substantially transparent.
• Nonwoven fabric 20 includes a first layer 22 and a second layer 24. These layers comprise continuous or discontinuous oriented monocomponent thermoplastic fibers, but second layer 24 possesses increased stress induced crystallinity compared to first layer 22. First layer 22 and second layer 24 are bonded together at bond regions 26. Between bond regions 26, fibers within unbonded regions 28 from second layer 26 bulge upwards to provide loops 30.
• nonwoven fabric 20 is a portion of a web of indefinite length with a longitudinal direction "LD" (also called the machine direction in the art) defined by the indefinite length. This further defines a cross direction "CD" perpendicular to the longitudinal direction and spanning the width of the web.
• LD longitudinal direction
• CD cross direction
• any arbitrary straight line drawn across the web in the cross direction e.g. arbitrary lines 32 and 34
• bonded regions 26 cover between about 20% to 40% of the surface of nonwoven fabric 20.
• first layer 22 in the form of a web of indefinite length is unwound from a roll 102 on an unwind stand 104.
• First layer 22 is directed towards a flexible belt 106 operation around idler rollers 108 and motor 110. Supported by flexible belt 106, first layer 22 passes under spinning station 120 where the fibers that will form second layer 24 are applied.
• Spinning station 120 applies a stream 122 of continuous microfibers to first layer 22.
• stream 122 may optionally be supplemented by a secondary stream 124 of sub-micrometer fibers emanating from sub -micrometer fiber-forming apparatus 126.
• fiber-forming material is brought to an extrusion head 128 from a hopper 130, feeding an extruder 132 where the material is melted.
• a pump 134 brings the molten material to extrusion pressure at extrusion head 128.
• Extrusion head 128 may be a conventional spinnerette or spin pack, generally including multiple orifices arranged in a regular pattern, e.g., straight-line rows.
• Filaments 140 of fiber-forming liquid are extruded from the extrusion head and conveyed to a processing chamber or optional attenuator 142.
• quenching streams 144 of air or other gas are presented to filaments 140 to reduce their temperature of extruded filaments 140. It is considered within the scope of this disclosure, however for the streams of air or other gas to be heated to facilitate drawing of the fibers.
• the filaments 140 then pass through the attenuator 142, and eventually exit onto first layer 22 where they are collected as a mass of fibers forming second layer 24.
• the web with its first layer 22 and second layer 24 may be passed through pressing station 150 where a light nip is applied so that the layers will cling as they are conveyed along by flexible belt 106.
• a bonding station 160 which in the depicted embodiment includes a patterned roll 162 and a smooth roll 164. At least one, and in many convenient embodiments both, of patterned roll 162 and smooth roll 164 are heated. Besides enough heat to form bond regions 26, enough latent heat must be instilled into the nonwoven fabric 20 to bring the first and second layers 22 and 24 above their T g . It is desirable that nonwoven fabric 20 be kept at a low tension while the latent heat cools, so a tensioning station 170 is provided.
• a cooling span 180 is provided to allow the latent heat from bond station 160 to cool slowly. During this time, the differential shrinkage of first layer 22 with second layer 24 causes loops 30 to form in unbonded regions 28.
• the nonwoven fabric 20 is wound onto a roll 182 on wind-up station 184.
• first layer 22 in the form of a web of indefinite length is unwound from a roll 202 on an unwind stand 204.
• Second layer 24, also in the form of a web of indefinite length is unwound from a roll 203 on an unwind stand 205.
• the two layers 22 and 24 are then conveyed to a bonding station 260, which in the depicted embodiment includes a patterned roll 262 and a smooth roll 264. At least one, and in many convenient embodiments both, of patterned roll 262 and smooth roll 264 are heated.
• a cooling span 280 is provided to allow the latent heat from bond station 160 to cool slowly. During this time, the differential shrinkage of first layer 22 with second layer 24 causes loops 30 to form in unbonded regions 28.
• the nonwoven fabric 20 is wound onto a roll 282 on wind-up station 284.
• percent solidity is determined by dividing the measured bulk density of a fibrous web by the density of the materials making up the solid portion of the web.
• Bulk density of a web can be determined by first measuring the weight (e.g. of a 10-cm by 10-cm section) of a web. Dividing the measured weight of the web by the web area provides the basis weight of the web, which is reported in g/m 2 .
• Thickness of the web can be measured by obtaining (e.g., by die cutting) a 135 mm diameter disk of the web and measuring the web thickness with a 230 g weight of 100 mm diameter centered atop the web.
• the bulk density of the web is determined by dividing the basis weight of the web by the thickness of the web and is reported as g/m 3 .
• the solidity is then determined by dividing the bulk density of the web by the density of the material (e.g. polymer) comprising the solid fibers of the web. (The density of a polymer can be measured by standard means if the supplier does not specify material density.) Solidity is a
• FIG. 2 An apparatus was constructed generally as described in FIG. 2. A second layer was formed following the procedure of US. Patent 8,906,815, "Composite nonwoven fibrous webs and methods of making and using the same,” except that the starting material was polypropylene commercially available as LUMICE E M6823MZ from Total of Courbevoie, FR, and the spinning speed was 3200 m/min. This material was then wound up and the wound roll was placed on the unwind stand of the apparatus.
• M6823MZ polypropylene was spun bond onto the second layer with the spinning speed of the fibers being 1800 m/min, forming the first layer.
• the composite layers were then conveyed to the pressing station, where a light pressure of 300 pounds/linear inch (525 N/linear cm) was applied.
• the two layers were then conveyed to the bonding station where the patterned roll and the smooth roll were both heated to 260 °F (127 °C).
• the patterned roll had a pattern so as to form a bond pattern generally as depicted in Fig. 1.
• the bonded material was then conveyed to the tensioning station, where a tension regime of 2 pounds/linear inch (3.5 N/linear cm) was imposed, and loops were formed from the differential heating between the bonding zones and the non-bonding zones at the nip.
• the latent heat was slowly cooled over a cooling span of about 3 meters.
• the finished nonwoven fabric was wound up on a roll at a wind-up station.
• the finished fabric was then tested according to the Solidity Test, and a percent solidity of 11 was recorded.
• a first layer was formed following the procedure of US. Patent 8,906,815, except that the starting material was polypropylene commercially available as
• An apparatus was constructed generally as described in FIG. 2.
• S1202KR1BA01A from Fitesa of Simsonville, SC was placed on the unwind stand of the apparatus. From the unwind stand, the material was conveyed at a line speed of 139 ft/min (42.4 m/min) towards the spinning station. At the spinning station, LUMICE E M6823MZ polypropylene was spun bond onto the second layer with the spinning speed of the fibers being 1800 m/min, forming the first layer. The composite layers were then conveyed to the pressing station, where a light pressure of 300 pounds/linear inch (525 N/linear cm) was applied. The two layers were then conveyed to the bonding station where the patterned roll and the smooth roll were both heated to 260 °F (127 °C).
• the patterned roll had a pattern so as to form a bond pattern generally as depicted in Fig. 1.
• the bonded material was then conveyed to the tensioning station, where a tension regime of 2 pounds/linear inch (3.5 N/linear cm) was imposed.
• the latent heat was slowly cooled over a cooling span of about 3 meters. During this time, loops appeared in the second layer.
• the finished nonwoven fabric was wound up on a roll at a wind-up station.
• the finished fabric was then tested according to the Solidity Test, and a percent solidity of 10.8 was recorded

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• Health & Medical Sciences (AREA)
• Biomedical Technology (AREA)
• Epidemiology (AREA)
• Heart & Thoracic Surgery (AREA)
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• Manufacturing & Machinery (AREA)
• Nonwoven Fabrics (AREA)
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• 2018
  • 2018-02-09 EP EP18707428.1A patent/EP3582648A1/en not_active Withdrawn
  • 2018-02-09 JP JP2019543750A patent/JP2020507688A/ja not_active Ceased
  • 2018-02-09 US US16/484,338 patent/US20190360135A1/en not_active Abandoned
  • 2018-02-09 WO PCT/IB2018/050812 patent/WO2018150306A1/en not_active Ceased

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