Abstract: The invention is directed to a composite nonwoven fabric comprising a nonwoven web of spunbonded substantially continuous thermoplastic filaments, a nonwoven web of thermoplastic strands, and a nonwoven web of thermoplastic meltblown microfibers sandwiched between the nonwoven web of spunbonded substantially continuous filaments and the nonwoven web of thermoplastic strands. An adhesive agent is disposed between the nonwoven web of spunbonded filaments and the nonwoven web of meltblown microfibers and between the nonwoven web of thermoplastic strands and the nonwoven web of meltblown microfibers, adhering the respective nonwoven webs together to form a unitary composite nonwoven fabric.

Abstract: The invention provides composite elastic nonwoven fabrics and processes of making the same. The composite elastic fabrics of the invention include a plurality of longitudinally extending elastomeric filaments and at least one fibrous web including staple fibers and anchoring fibers entangled with the elastomeric filaments. The anchoring fibers strengthen the attachment of the staple fibers to the elastomeric filaments, so that the entire fibrous mass extends as a unit when the fabric is extended. The resultant product is a coherent, substantially unitary structure encompassing the elastomeric filaments.

Abstract: A process is disclosed for extruding fibers from ionomer resins that are not blended with polyolefins, monomers, solvents, or other conventional compounds typically used in connection with processing fibers that contain ionomers. The preferred ionomers are 90% neutralized metal salts of copolymers of from at least about 60 to 90% ethylene and from at least about 10 to 40% acrylic acid. Multivalent metal cations can be used to introduce cross linking for control of the solubility and swellability of the fibers. The fibers and webs produced therefrom can be produced by meltblowing and can be used to provide a less expensive alternative to superabsorbent powders.

Abstract: A slot draw attenuator apparatus and method are provided for producing webs of spunbonded thermoplastic filaments having improved cover even at low basis weights. The filaments are introduced to a slot draw attenuator having corona electrodes mounted in an elongate insulator bar and staggered and spaced along one wall of the attenuator slot near the exit end thereof. The corona electrodes are electrically connected to a high voltage source. The opposing wall of the slot is grounded. A corona is created in the attenuator slot so that the filaments are charged as they exit the attenuator. The electrostatic charge induces repelling forces in the filaments so that the filaments spread before they are randomly deposited upon a forming belt.

Abstract: The invention provides elastic fabrics which exhibit low extensibility in the machine direction and have substantial elastic properties in the cross-machine direction. The fabrics of the invention include an elastic layer and a fibrous layer which are combined together. The fibrous layer is composed of a plurality of thermally activated binder fibers or filaments oriented substantially in the machine-direction of the fibrous web. The fabrics of the invention can be manufactured and processed more readily than fabrics which are elastic in both the machine direction and the cross-machine direction.

Abstract: A nonwoven fabric comprising at least one layer of textile fibers or net of polymeric filaments and at least one web of melt blown microfibers, bonded together by hydroentangling. The nonwoven fabric may be apertured by hydroentangling or may have areas of higher density and areas of lower density. The fabric has a favorable combination of softness, dryness, tensile strength and hand. Several processes are provided for producing the nonwoven fabric of the invention.

Abstract: Antistatic spunbonded nonwoven fabrics are provided. The fabrics of the invention include a plurality of substantially continuous electrically nonconductive filaments formed of a thermoplastic polymer, a plurality of electrically conductive filaments distributed among the electrically nonconductive filaments throughout the fabric, and a multiplicity of discrete bond sites bonding together the electrically nonconductive and the electrically conductive filaments to form a coherent fabric.

Abstract: The invention provides composite elastic nonwoven fabrics and the process of making them. The composite elastic fabrics of the invention include an elastomeric net and at least one fibrous web including binder fibers and which is intimately hydroentangled with the elastomeric net. At least a portion of the binder fibers in the hydroentangled fibrous web have been thermally activated thereby bonding the hydro-entangled web into a coherent, substantially unitary structure encompassing the elastomeric net.

Abstract: The invention is directed to elastomeric meltblown webs having desirable strength and stretch/recovery properties which can be produced at relatively high throughputs and/or relatively low die pressures. The meltblown webs of the invention comprise a blend of (i) a fully hydrogenated diblock or triblock thermoplastic elastomer copolymer or mixtures thereof based on polystyrene and poly(ethylene-butylene) blocks; and (ii) from about 5% by weight up to about 50% by weight of a copolymer of ethylene and acrylic acid or ethylene and a lower alkyl ester of acrylic acid in which the ethylene content ranges from about 5% by weight up to about 50% by weight.

Abstract: The present invention provides a thermally-bonded nonwoven fabric that is made from a web which comprises from 100 to 5 percent by weight of multiconstituent fibers. The multiconstituent fibers are composed of highly dispersed blends of at least two different immiscible thermoplastic polymers and have a dominant continuous polymer phase with at least one noncontinuous phase dispersed therein. The noncontinuous phase exists as an elongated fibrillar polymer domain oriented generally in the direction of the fiber axis. No single polymer domain cross-section of the noncontinuous phase or phases is larger than 0.1% of the cross-sectional area of the fiber. The polymer of the noncontinuous phase or phases has a Polymer Melt Temperature (PMT) at least 30.degree. C. below the PMT of the continuous phase. The fiber is configured such that the noncontinuous phase or phases occupy a substantial portion of the fiber surface.

Abstract: An apparatus and method are disclosed for forming a nonwoven fabric web, such as a spunbond web. The apparatus comprises a spinneret for downwardly extruding a curtain of filaments, and an underlying air drawing unit for drawing and attenuating the filaments as they move downwardly therethrough. A conveyor belt receives the drawn filaments and forms the filaments into a nonwoven fabric web. In the drawing unit, the filaments pass downwardly through a slot, and a pair of air nozzles are positioned in the slot, with one nozzle being positioned adjacent each side wall of the slot. The nozzle outlets are oriented so as to introduce each of the air streams into the slot in a direction which is parallel to the side walls of the slot, and the introduced air streams act to draw additional air into the open upper end of the slot.

Abstract: A multi-layer, nonwoven fabric useful as an absorbent article top sheet, which is formed of a continuous first layer, comprising hydrophobic thermoplastic fibers, bonded to a second layer, comprising a blend of hydrophobic thermoplastic fibers and natural hydrophilic fibers.

Abstract: The invention is directed to composite nonwoven fabrics comprising a hydrophobic nonwoven web, a nonwoven web of thermoplastic meltblown microfibers and a hydrophilic nonwoven web comprising staple fibers. The nonwoven web of thermoplastic meltblown fibers is sandwiched between the hydrophobic nonwoven web and the hydrophilic nonwoven web and all of the layers are thermally bonded together via discontinuous thermal bonds distributed substantially throughout the composite nonwoven fabric.

Abstract: A method and apparatus for providing uniformly distributed filaments from a spun filament bundle and a process for forming spunbonded fabric having superior uniformity and a favorable ratio between machine and cross direction tensile strengths. The apparatus includes a fiber transfer tube and a pair of adjustable deflector plates. The deflector plates form a channel having a tapering width for transporting the filaments in a stream of high velocity air. The apparatus may also include an electrostatic charging means for applying an electrostatic charge to each individual filament after it exits the channel. The method for providing uniformly distributed filaments includes a first stage of separating the filament bundle by the high velocity stream of air and may also include a second stage of electrostatically charging the filaments to achieve a uniform filament separation.

Abstract: Disclosed is a process for making bulky nonwoven fabric suitable for use in diaper constructions that comprises the steps of (a) forming a web of one or more layers comprised at least in part of thermoplastic bicomponent fibers, (b) bonding said web by means of a thru-air system, (c) compressing--either in a nip or by winding--the resulting bonded web to increase its density, (d) transporting and/or otherwise manipulating the compressed web, and (e) subsequently transforming said compressed web, by means of exposure to heat, into the low density bulky nonwoven fabric. The bulky nonwoven fabrics are particularly useful as diaper coverstock and as diaper spacer fabrics.

Abstract: A nonwoven fabric having high performance aqueous fluid retention and wiping characteristics and a method of producing such fabric. The fabric comprises a reinforcing web of self-bonded continuous filament synthetic fibers having at least one surface with spaced clusters of synthetic staple fibers and short natural fibers generally surrounded by void areas having a concentration of synthetic staple fibers and short natural fibers which is lower than such concentration in the clusters. The desired pattern of clusters may be obtained by hydroentanglement using a coarse apertured forming surface.

Abstract: Disclosed is a process for making bulky nonwoven fabric suitable for use in diaper constructions that comprises the steps of (a) forming a web of one or more layers comprised at least in part of thermoplastic bicomponent fibers, (b) bonding said web by means of a thru-air system, (c) compressing--either in a nip or by winding--the resulting bonded web to increase its density, (d) transporting and/or otherwise manipulating the compressed web, and (e) subsequently transforming said compressed web, by means of exposure to heat, into the low density bulky nonwoven fabric. The bulky nonwoven fabrics are particularly useful as diaper coverstock and as diaper spacer fabrics.

Abstract: The present invention provides a thermally-bonded nonwoven fabric that is made from a web which comprises from 100 to 5 percent by weight of multiconstitutent fibers. The multiconstituent fibers are composed of highly dispersed blends of at least two different immiscible thermoplastic polymers and have a dominant continuous polymer phase with at least one noncontinuous phase dispersed therein. The noncontinuous phase exists as an elongated fibrillar polymer domain oriented generally in the direction of the fiber axis. No single polymer domain cross-section of said noncontinuous phase or phases is larger than 0.1% of the cross-sectional area of said fiber. The polymer of the noncontinuous phase or phases has a Polymer Melt Temperature (PMT) at least 30.degree. C. below the PMT of the continuous phase. The fiber is configured such that the noncontinuous phase or phases occupy a substantial portion of the fiber surface.

Abstract: An ultrasonically bonded fabric comprising a non-woven coverstock treated with an organosilicone material, e.g., an organosilicone fluid, prior to being ultrasonically bonded to another material. The ultrasonically bonded fabric as made by treating a non-woven coverstock with the organosilicone material and ultrasonically bonding the treated non-woven coverstock to the other material.

Abstract: A soft, nonwoven, fibrous coverstock having opposite faces and having a basis weight in a range of from about 5 grams per square yard to about 120 grams per square yard, machine direction tensile strength in a range of from about 100 grams per inch to about 18,000 grams per inch, cross direction tensile strength in a range of from about 100 grams per inch to about 18,000 grams per inch, cross direction neck-in in a range of about 2% to about 20%, and softness in a range of about 1.8 PSU to about 2.2 PSU. The soft coverstock is produced by a method of passing a fibrous web of thermally bondable fibers through a pair of heated calendar nips to engage each opposite face of the web successively with a patterned roller having raised, discontinuous lands and for fusing portions of the web in a pattern of bond areas.