Abstract: A process for producing a windable spunlaid material, and a product produced by the process, wherein minimal web compaction occurs and thermal, mechanical and chemical prebonding is not necessary. Filaments are produced and laid on a moving support to provide a web having a machine direction tensile strength of less than 5 N per 5 cm at a basis weight of 50 gsm. The web is then passed through a compacting calender. The filaments of the spunlaid web are not subjected to a temperature exceeding the melting point of the filaments. Preferably, the calender through which the web passes has a surface temperature of less than 130° C. at a calender nip pressure of 30 N/mm. The resulting web is windable under low tension, i.e., a tension of less than 40 N/m. The wound spunlaid material can then be stored and/or transport, to provide a nonwoven material.

Abstract: A lightweight nonwoven material is described. The nonwoven material includes at least three layers wherein a first layer is spunlaid, a second layer is meltblown, and a third layer is spunlaid, the first and third layers being external layers. The basis weight of the nonwoven material is 15.0 gsm or less and the weight of the second meltblown layer is about 5% or less of the total basis weight. The preferred polymer for the nonwoven material is polypropylene, in particular for the meltblown fibers is a resin having a molecular weight distribution Mw/Mn in a range of about 1.8-3.2. Hydrophilicity can be imparted to the nonwoven material by inclusion of a surfactant additive in an extrusion melt during formation of fibers, or by topical treatment following formation of the layers of the nonwoven material. The method of making the nonwoven material involves formation of the layers thereof as continuous fibers and forming the layers in a continuous sequential manner, i.e.

Abstract: A nonwoven material composed of hydrophobic material rendered hydrophilic through the inclusion of an internal additive is described. The nonwoven material includes at least one layer of which can be continuous filament spunmelt or meltblown. The layer can be provided alone or as one of a composite material. Hydrophilicity is imparted to the nonwoven material by inclusion of a surfactant additive in an extrusion melt during formation of fibers which will form a layer of nonwoven material. By controlling the internal additive utilized and modifying the type of fibers formed, e.g., continuous, non-continuous (staple), denier size, etc., the absorbency and barrier properties of a nonwoven material can be predetermined in view of the use to which the nonwoven material is to be applied.

Abstract: A process for making a single layer or multi-layer nonwoven material having improved cross-directional strength and feel, and the nonwoven material made thereby, is described. The process provides a nonwoven material including at least one layer formed of polymeric continuous filaments. The layer(s) are formed in a continuous sequential manner, i.e., a subsequent layer being formed on top of a preceding layer or layers. Thereafter, in the absence of any prebonding, the layer(s) are subjected to hydroentanglement. The basis weight of the nonwoven material is from about 17 to 150 gsm. The nonwoven material has improved properties based on treating the layer(s) by hydroentanglement. Varying the number of water jets and the pressure of the water allows variance in the properties obtained in the final product.

Abstract: A method of making spunmelt/film composite materials, as well as the product of the method, is described. The method is a continuous in-line process including in-line production of a continuous filament spunmelt web, placement of a film on the spunmelt web, optional placement of at least one nonwoven fabric on the film, joining or bonding of the formed layered structure by subjecting the layered structure to calendering using heated rolls. The basis weight of the continuous filament spunmelt web is from about 13.5 gsm to about 100 gsm and of the polyolefin film from about 10 gsm to about 40 gsm. The total composite basis weight tolerance ranges from about 25 gsm to about 150 gsm. No adhesive or secondary thermal bonding is utilized in the process.

Abstract: A lightweight nonwoven material having hydrophilic characteristics is described. The nonwoven material includes at least three layers wherein a first layer is spunlaid, a second layer is meltblown, and a third layer is spunlaid, the first and third layers being external layers. The basis weight of the nonwoven material is 13.5 gsm or less and the basis weight of the second meltblown layer is 3.5 gsm or less, preferably less than 3.0 gsm, and more preferably less than 2.5 gsm. Hydrophilicity is imparted to the nonwoven material by inclusion of a surfactant additive in an extrusion melt during formation of fibers, or by topical treatment following formation of the layers of the nonwoven material. The method of making the nonwoven material involves formation of the layers thereof as continuous fibers and forming the layers in a continuous sequential manner, i.e., a subsequent layer being formed on top of a preceding layer or layers.

Abstract: A composite nonwoven material having two external layers, formed of body fluid permeable nonwoven material, between which is arranged a synthetic fiber lap which is permeable to body fluids. The external layers are assembled between each other by thermal fusion according to a pattern forming a network of points and a central area of perforations. The composite nonwoven material can be used to make absorbent hygienic articles.

Abstract: The process and apparatus of the present invention involves treating a well-integrated woven or non-woven web of hydrophobic fibers to make selected areas hydrophilic. It also can be used to make a web of hydrophilic fibers selectively hydrophobic. It uses a plurality of selectively adjustable covers on an applicator roll rotating in a bath of liquid to place the liquid material on selected areas of the web as the web moves over the roll. In a preferred embodiment the web is non-woven and the fibers are hydrophobic in nature, e.g., dry-laid or melt-blown polypropylene or polyethylene fibers or spun-bonded hydrophobic filaments. A woven web made of cotton or other hydrophilic fibers may also be used if the end result is to create partially hydrophobic areas on a hydrophilic web. The areas of liquid are positioned on the web only where desired so as to eliminate the excessive cost of unwanted and unnecessary coating material. If the web is hydrophobic, the liquid makes that area hydrophilic.