A shaped nonwoven fabric comprises continuous spunbond filaments made by directly forming the spunbond filaments into a web in a single process. The fabric has an array of discrete surface features such as apertures or projections, or both. The spunbond filaments are bonded together with an adhesive polymeric component so that the shape of the fabric is retained. The fabric can be engineered to have particular fluid handling properties, strength properties, abrasive properties and aesthetic properties. Articles such as personal care products, garments, medical products and cleaning products are also disclosed.
This application is a continuation of application Ser. No. 08/055,449 entitled "Shaped Nonwoven Fabric and Method for Making the Same" and filed in the U.S. Patent and Trademark Office on Apr. 29, 1993, now abandoned.
The present invention is directed to a nonwoven fabric which is formed from a network of interconnected multi-length, multi-denier thermoplastic fibers. The nonwoven fabrics of the present invention provide enhanced comfort and performance not found in conventional nonwoven fabrics and have been found to be particularly useful as cover materials in disposable sanitary absorbent articles.
A method for making a fluid transfer layer has steps of depositing a first non-woven layer on a support, depositing a second non-woven layer on the first layer, with the two layers having a different melting point. The two layers are then thermally bonded to one another in a heated calender nip, during which differential shrinkage occurs because of the two layers' different melting points. A micro-bulked profile results. The composite, micro-bulked web is then mechanically bulked to provide a macro-bulked profile. The resulting non-woven fabric has a high bulk, high resistance to pore structure collapse, high resistance to compression deformation, and is more economical to produce than prior art carded or bicomponent webs. An absorbent article has a porous topsheet, the fluid transfer layer of the invention underlying the topsheet, and an absorbent core.
A method for forming a web structure having a pore size gradient which utilizes a spunbond process for producing fibers. The fibers are deposited on a contoured collection surface. Preferably, the surface is shaped as an elongated dome, having the central zone at the apex and the peripheral zones along the curved sides. The fibers are deposited onto the central zone and accumulate until they flow down the sides onto the peripheral zones. Fibers deposited onto the central zone have greater average pore size and fibers deposited onto the peripheral zone have smaller average pore size and greater fiber alignment. In an alternative embodiment, a plurality of dies in a row is used, each providing extruded fibers of distinct composition. Pore size gradient formation permits improved control of wicking and absorption over a web structure, such as a diaper or similar absorptive article. An alternative embodiment comprises providing a meltblown source of attenuated fibers, preferably co-formed with fluff.
A filter production method produces a filter having a shape substantially identical to the shape of a forming surface by extruding semi-molten fibers to the forming surface. When the semi-molten fibers are extruded to the forming surface, the semi-molten fibers are gathered to upstanding surface portions of the forming surface. Therefore, a sufficient amount of fibers can be layered onto the upstanding surface portions, so that the layering amount of fibers on the upstanding surface portions of the forming surface will not be considerably reduced in comparison with the layering amounts on other portions of the forming surface.
A method and apparatus for the production of nonwovens. The nonwovens including a spunbonding apparatus for forming a first web of nonwoven material on a first belt, and a meltblowing apparatus for forming a second web of nonwoven material on a second belt. The second belt moves in a direction opposite the first belt and after formation, the second web is deposited on said first web to form a composite spunbond and meltblown web.
