A high pulp content nonwoven composite fabric is disclosed. The composite fabric contains 1) from more than about 0 to less than about 30 percent, by weight, of a nonwoven layer of conjugate spun filaments, the filaments containing at least one low-softening point component and at least one high-softening point component and having at least some exterior surfaces of the filaments composed of at least one low-softening point component; 2) more than about 70 percent, by weight, of pulp fibers; and 3) regions in which the low-softening point component at the exterior surfaces of the filaments is fused to at least a portion of the fibrous component. This high pulp content composite nonwoven fabric may be used as a heavy duty wiper or as a fluid distribution material, cover material, and/or absorbent material in an absorbent personal care product. Also disclosed is a method of making the high pulp content nonwoven composite fabric.

High pulp content nonwoven composite fabric

A dual-zoned, three-dimensional, resilient absorbent web is disclosed which is suitable as body-side liner for absorbent articles such as feminine pads, diapers and the like. When used as a liner in absorbent articles, the dual-zoned web combines the advantages of apertured films and soft, nonwoven cover layers in one structure while still being inherently hydrophilic. The liner comprises a web of wet-resilient, hydrophilic basesheet having a three-dimensional topography comprising elevated regions onto which hydrophobic matter is deposited or printed and a plurality of spaced apart depressed regions. In a preferred embodiment, the hydrophobic matter applied to the elevated regions of the basesheet comprises hydrophobic fibers in a contiguous nonwoven web which has been apertured or provided with slits or other openings, such that the apertures or openings overlay a portion of the depressed regions. The elevated hydrophobic regions enhance dry feel and promote fluid flow toward the lower hydrophilic regions, which comprise the exposed depressed regions of the basesheet. The basesheet is preferably in liquid communication with underlying absorbent material, most preferably a stabilized airlaid cellulosic material or compressed stabilized fluff such that the absorbent material can wick fluid out of the basesheet by capillary action. When soft, hydrophobic fibers are deposited on the elevated regions, the liner also has a soft, cloth-like feel in addition to a dry feel in use.

Dual-zoned absorbent webs

Disclosed is a composite elastic material adapted to provide improved tenacity in one direction and which includes (1) an anisotropic elastic fibrous web having at least one layer of elastomeric meltblown fibers and at least one layer of substantially parallel rows of elastomeric filaments autogenously bonded to at least a portion of the elastomeric meltblown fibers, and (2) at least one gatherable layer joined at spaced apart locations to the anisotropic elastic fibrous web so that the gatherable layer is gathered between the spaced-apart locations. The anisotropic elastic fibrous web has a strength index of at least about 2 or less than 0.5. The substantially parallel rows of elastomeric filaments in the elastic fibrous web may have an average diameter ranging from about 40 to about 750 microns and constitute at least about 20 percent, by weight, of the anisotropic elastic fibrous web.

Composite elastic material including an anisotropic elastic fibrous web and process to make the same

Disclosed is an elastic nonwoven web containing a coherent matrix of fibers formed from an extrudable blend composed of an elastomeric A-B-A-B tetrablock copolymer where A is a thermoplastic polymer block and where B is an isoprene monomer unit hydrogenated to substantially a poly(ethylene-propylene) monomer unit. The elastic nonwoven web adapted to have an elastic modulus of less than about 1.25 which is locally constant during elongation of the web up to about 250 percent. The elastic nonwoven web may also include at least one type of nonelastic fibers and/or particulate materials distributed within or on the matrix of elastomeric fibers. The elastic nonwoven web may be incorporated into a multilayer material and/or may be a component of a composite elastic material in which the elastic web is joined to a gatherable layer at spaced apart locations so that the gatherable layer is gathered between the spaced-apart locations.

High performance elastomeric nonwoven fibrous webs

Improved thermoplastic polymer blend compositions comprising an isotactic polypropylene component and an alpha-olefin and propylene copolymer component, said copolymer comprising crystallizable alpha-olefin sequences. In a preferred embodiment, improved thermoplastic polymer blends are provided comprising from about 35% to about 85% isotactic polypropylene and from about 30% to about 70% of an ethylene and propylene copolymer, wherein said copolymer comprises isotactically crystallizable propylene sequences and is predominately propylene. The resultant blends manifest unexpected compatibility characteristics, increased tensile strength, and improved process characteristics, e.g., a single melting point.

Propylene olefin copolymers

A composite nonwoven elastomeric web material, and method of forming such material, as well as a nonwoven elastomeric web material and method of forming such material, are disclosed. The composite web material is provided by hydraulically entangling a laminate of at least (1) a layer of meltblown fibers; and (2) at least one further layer, preferably of at least one of pulp fibers, staple fibers, meltblown fibers, and continuous filaments, with or without particulate material, with at least one of the layer of meltblown fibers and the further layer being elastic so as to form an elastic web material after hydraulic entanglement. The nonwoven elastomeric web material is provided by hydraulically entangling a layer of meltblown elastomeric fibers. The material formed can be cloth-like with smooth surfaces, and with isotropic elasticity and strength. Different texture properties, including a corrugated stretchable fabric, can be provided by pre-stretching and then hydraulically entangling while stretched.

Hydraulically entangled nonwoven elastomeric web and method of forming the same

Nonwoven fibrous elastomeric web material, including absorbent webs and fabric web material, and methods of forming the same, are disclosed. The elastomeric web material is a hydraulically entangled coform or admixture of (1) meltblown fibers, such as elastic meltblown fibers and (2) pulp fibers and/or staple fibers and/or meltblown fibers and/or continuous filaments, with or without particulate material; such coform can be hydraulically entangled by itself or with other materials, including, e.g., super absorbent particulate material. The use of meltblown fibers facilitates the hydraulic entangling, resulting in a high degree of entanglement and enabling the use of shorter staple or pulp fibers. The hydraulic entangling technique provides a nonwoven fibrous elastic material having increased web strength and integrity, and allows for better control of other product attributes, such as absorbency, wet strength and abrasion resistance. A smooth surfaced and/or highly absorbent elastic web material, with isotropic strength and recovery in both machine- and cross-directions, can be provided according to the present invention.

Nonwoven fibrous hydraulically entangled elastic coform material and method of formation thereof

Nonwoven fibrous non-elastic webs, reinforced nonwoven fibrous non-elastic webs and methods of forming the same are disclosed. The nonwoven fibrous non-elastic webs are a hydraulically entangled coform or admixture of non-elastic meltblown fibers and fibrous material, with or without particulate material. The fibrous material (e.g., non-elastic fibrous material) can be at least one of pulp fibers, staple fibers, meltblown fibers and continuous filaments. The use of meltblown fibers facilitates the hydraulic entangling, resulting in a high degree of entanglement and enabling the more effective use of shorter fibrous material. The hydraulic entangling technique provides a nonwoven fibrous material having increased web strength and allows for better control of other product attributes, such as absorbency, wet strength, printability and abrasion resistance. The coform can be hydraulically entangled with a reinforcing material, e.g., a melt-spun nonwoven, a scrim, screen, net, etc.

Nonwoven fibrous hydraulically entangled non-elastic coform material and method of formation thereof

Composite nonwoven non-elastic web materials and methods of forming the same are disclosed. The composite nonwoven non-elastic web materials are formed by hydraulically entangling a laminate of (a) at least one layer of meltblown fibers and (b) at least one layer of nonwoven material. The nonwoven material can comprise at least one of pulp fibers, staple fibers, meltblown fibers and substantially continuous filaments. The nonwoven material can also be a net, foam, etc. Each of the meltblown fiber layer and the nonwoven material layer is preferably made of non-elastic material.

Nonwoven hydraulically entangled non-elastic web and method of formation thereof

Nonwoven fibrous non-elastic webs, reinforced nonwoven fibrous non-elastic webs and methods of forming the same are disclosed. The nonwoven fibrous non-elastic webs are a hydraulically entangled coform or admixture of non-­elastic meltblown fibers and fibrous material, with or without particulate material. The fibrous material (e.g., non-elastic fibrous material) can be at least one of pulp fibers, staple fibers, meltblown fibers and continuous filaments. The use of meltblown fibers facilitates the hydraulic entangling, resulting in a high degree of entanglement and enabling the more effective use of shorter fibrous material. The hydraulic entangling technique pro­vides a nonwoven fibrous material having a high web strength and allows for good control of other product attributes, such as absorbency, wet strength, printability and abrasion, resistance. The coform can be hydraulically entangled with a reinforcing material, e.g., a melt-spun nonwoven, a scrim, screen, net, etc.

Nonwoven fibrous non-elastic material and method of formation thereof

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