Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

Abstract: The present invention provides a composite nonwoven fabric with a superior combination of extensibility, tensile properties and abrasion resistance. The composite nonwoven fabric (10) comprises at least one layer containing multipolymer fibers, with a plurality of bonds bonding the fibers together to form a coherent extensible nonwoven web (11). This coherent extensible nonwoven web (11) has a Taber surface abrasion value (rubber wheel) of greater than 10 cycles and an elongation at peak load in at least one of the machine direction or the cross-machine direction of at least 70%. A second extensible layer (12) is laminated to this coherent extensible nonwoven web (11).

Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

Abstract: A spunbonded elastic nonwoven fabric comprises a web of bonded thermoplastic filaments of a thermoplastic elastomer. The spunbonded fabrics of the invention are prepared in a slot draw spunbonding process operated at a rate of less than about 2000 meters per minute. The elastic fabric is used in absorbent products, such as disposable diapers, adult incontinence pads, sanitary napkins and the like, and as coverstock for absorbent personal care products.

Abstract: A fabric comprising at least two layers wherein at least one layer is an extensible, bonded non-woven composed of a fiber comprising multiple different polymers such as a fiber comprising isotactic polypropylene, polyethylene and a block or grafted polyolefin copolymer or terpolymer which is at least partially miscible with said polypropylene and polyethylene.

Abstract: The present invention provides composite nonwoven fabric laminates and processes for producing such. The fabric is comprised of a web of thermoplastic filaments laminated to at least one other web. Preferably, the filaments are spunbonded continuous polyolefin filaments which have an oxidatively degraded outer sheath portion to promote better interfilamentary bonding and improved fabric laminate strength. In a preferred embodiment, two outer nonwoven webs comprise oxidatively degraded spunbonded filaments and are positioned around and laminated to a web of meltblown microfibers thus forming an spunbond/meltblown/spunbond fabric. Additionally, a stretch compatible fabric may be formed in which a web of oxidatively degraded filaments is laminated to an elastic web. The fabrics of the invention may be advantageously used in numerous applications such as medical garments and disposable adsorbent products.

Abstract: A nonwoven web of meltblown microfibers formed of a composition of polyethylene and at least one component added to provide processing stability to the polyethylene component. The meltblown web can be produced at high polymer throughputs and exhibits good barrier properties. The meltblown web is useful as a component of a composite fabric, which can be used for barrier application in medical and industrial applications.

Abstract: Improved meltspinning productivity is achieved by employing polyolefin resins having key molecular weight distribution and rheological property parameters within predetermined ranges. These parameters include the molecular weight distribution breadth parameter, M.sub.z /M.sub.n ; and rheological property parameters of flow rate ratio, I.sub.10 /I.sub.2, and the power law index, n, of the regression analysis viscosity equation. These parameters additionally include one or both of the z-average molecular weight, M.sub.z, of the resin, or the second order constant, b.sub.2, of the regression analysis viscosity equation, and unless both of the latter two parameters are met, the parameters further include the die swell and the spinnability factor (determined from the relationship between die swell and MFR) of the resin.

Abstract: The present invention provides a nonwoven fabric laminate comprising a thermally-bonded multiconstituent fiber nonwoven web. The multiconstituent fiber is composed of a highly dispersed blend of at least two different thermoplastic polymers which are present as a dominant continuous phase and 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. The polymer of the noncontinuous phase has a melting temperature below that of said continuous phase, and the lower melting noncontinuous phase comprises from about 2.5 to about 20 percent by weight of the fiber. The fabric laminate also comprises at least one other web bonded to the multiconstituent fibers of the thermally bonded nonwoven web and a multiplicity of thermal bonds formed from the polymer of said multiconstituent fibers and bonding the multiconstituent fibers of said thermally bonded web to said at least one other web.

Abstract: Improved meltspinning productivity is achieved by employing polyolefin resins having key molecular weight distribution and rheological property parameters within predetermined ranges. These parameters include the molecular weight distribution breadth parameter, M.sub.z /M.sub.n ; and rheological property parameters of flow rate ratio, I.sub.10 /I.sub.2, and the power law index, n, of the regression analysis viscosity equation. These parameters additionally include one or both of the z-average molecular weight, M.sub.z, of the resin, or the second order constant, b.sub.2, of the regression analysis viscosity equation, and unless both of the latter two parameters are met, the parameters further include the die swell and the spinnability factor (determined from the relationship between die swell and MFR) of the resin.

Abstract: A composite nonwoven fabric having at least one hydrophobic microporous layer and at least one other layer formed of multicomponent fibers. The multicomponent fibers comprise a lower melting thermoplastic resin component and one or more higher melting thermoplastic resin components, wherein a substantial proportion of the surfaces of the multicomponent fibers consists of the lower melting thermoplastic resin component. The microporous layer is composed in substantial part of at least one thermoplastic resin which is thermally miscible with and adherent, upon thermal activation, to the lower melting thermoplastic resin component of the multicomponent fibers.

Abstract: The invention is directed to a composite nonwoven fabric comprising first and second nonwoven webs of spunbonded substantially continuous thermoplastic filaments, and a nonwoven hydrophobic microporous web of thermoplastic meltblown microfibers sandwiched between the first and second nonwoven webs. The filaments of the nonwoven spunbond webs are formed of continuous multiconstituent filaments which include a lower melting gamma radiation stable polyethylene polymer component and one or more higher melting gamma radiation stable polymer constituents, wherein a substantial portion of the surfaces of the multiconstituent filaments consists of the lower melting gamma radiation stable polyethylene constituent. The nonwoven hydrophobic microporous web is formed from a gamma radiation stable polyethylene polymer.

Abstract: A spunbonded elastic nonwoven fabric comprises a web of bonded thermoplastic filaments of a thermoplastic elastomer. The spunbonded fabrics of the invention are prepared in a slot draw spunbonding process operated at a rate of less than about 2000 meters per minute. The elastic fabric is used in absorbent products, such as disposable diapers, adult incontinence pads, sanitary napkins and the like, and as coverstock for absorbent personal care products.

Abstract: A process for producing nonwoven webs having improved strength properties at high throughputs is provided. In the process, a non-uniform blend of a polyolefin and a prodegradant is formed. The non-uniform blend is then rapidly heated to cause the substantially immediate thermal degradation of the prodegradant, thus providing a non-uniformly degraded polyolefin having a fraction substantially reduced in molecular weight and a fraction substantially unaffected in molecular weight as compared to the starting polyolefin.

Abstract: The invention provides elastic fabrics which are substantially non-extensible in the machine direction and have substantial elastic properties in the cross-machine direction. The process stable fabrics of the invention include a net and a fibrous layer which are secured together. The net is composed of a plurality of continuous machine direction strands and a plurality of cross-direction strands. The machine direction strands are substantially non-extensible and the cross-direction strands are substantially elastic. 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.