Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond
Patent
1991-10-30
1994-03-15
Withers, James D.
Stock material or miscellaneous articles
Structurally defined web or sheet
Discontinuous or differential coating, impregnation or bond
428284, 428286, 428288, 428296, 428298, 428373, 428374, 428903, B32B 2734, B32B 2736, D04H 104, D02G 300
Patent
active
052944824
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. In addition to such fabrics, laminates--made by combining nonwoven fabrics made from the materials and processes as described herein with films, paper, tissue, woven fabrics, or nonwoven fabrics such as meltblowns--are also contemplated. The fabric according to the invention readily bonds to other materials of the sorts mentioned, and is therefore suitable for use in filtration media, medical and clean room garments, CSR wrap, absorbent article backsheets, and other barrier structures.
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Fiberweb North America, Inc.
Withers James D.
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