Nonwoven fabric having a pore size gradient and method of making

Details Nonwoven fabric having a pore size gradient and method of making Nonwoven fabric having a pore size gradient and method of making

1996-04-25

1997-10-21

Cannon, James C.

Fabric (woven, knitted, or nonwoven textile or cloth, etc.)

Nonwoven fabric

Including strand or fiber material which is of specific...

26 185, 156 84, 425 722, 425 831, 4283105, 42831151, 4283155, 442351, 442362, 442363, 442364, 442414, B32B 514, B32B 526, B32B 3126, D04H 305, D04H 316

Patent

active

056790422

ABSTRACT:
Methods and apparatus for forming a nonwoven fiber web containing a pore size gradient resulting in enhanced wicking properties. A first method utilizes a conventionally formed web having an average pore size and comprises selectively contacting the web with a heat source to shrink the fibers in selected areas. The smaller pore sizes have greater wicking ability. A second method utilizes a novel apparatus and comprises forming a nonwoven fiber web having zones of fibers, each zone having generally an average set of fiber structure and/or composition, the zones preferably overlapping. The zones of fibers are exposed to a heat source, which shrinks the fibers according to their denier and composition.
The apparatus uses a conventional meltblown or spunbond system and provides a plurality of resin sources which feed resin to a plurality of meltblowing dies. Each die produces fibers of a particular denier and/or composition which forms zones in a web collected on a collecting belt. The web moves underneath a manifold which blows heated air or sprays boiling water onto the fibers. The fibers shrink according to their structure and composition to form a web having a pore gradient.

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