Soft extensible nonwoven webs containing fibers with high melt flow rates

a nonwoven web and high melt flow technology, applied in the field of soft extensible nonwoven webs, can solve the problems of significant challenge in the production of low denier fibers with high elongation, and achieve the effect of high extensibility, enabling the formation of nonwoven webs, and high extensibility

Inactive Publication Date: 2005-08-04
PROCTER & GAMBLE CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0006] The present invention provides nonwoven webs comprising fibers comprising a polymer composition that enables the nonwoven web to possess high extensibility. Additionally, the present invention provides low denier fibers that possess softness and enable the formation of nonwoven webs with high extensibility.

Problems solved by technology

For strong, low denier fibers with low elongation, this is not a problem, but producing low denier fibers with high elongation remains a significant challenge.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0048] This example demonstrates synergistic properties resulting from melt spinning a blend of a conventional spunbond grade polypropylene and a high melt flow rate polypropylene. Specifically, a 50:50 blend by weight of the polypropylenes from Comparative Example 1 and Comparative Example 2 is spun and bonded into nonwoven handsheets. The blend is pre-compounded in a twin-screw extruder prior to spinning. Table 1 shows the average strain at peak load for the handsheets made from the blend (1) are higher than that for either of the individual constituents (C1, C2), indicating synergistic elongation behavior.

TABLE 1Handsheets Made From Monocomponent Fibers - Neat PolypropyleneResins and a High MFR / Low MFR Polypropylene BlendSTRAIN ATEXAM-MFRPEAK LOADEXTENSIONPLE #RESIN(g / 10 min)(%)RATIOC1Profax PH8353572—C2Valtec HH44140098—150% Profax1181682.3PH835 50%Valtec HH441

[0049] The melt flow rate of a blend is calculated using the logarithmic additivity rule, such as described by Abraham...

example 2

[0052] This example illustrates the synergistic properties resulting from melt spinning a blend of a high melt flow rate polypropylene and a polyolefin copolymer. Specifically, an 80:20 blend by weight of the polypropylene from Comparative Example 2 and the polyolefin copolymer from Comparative Example 3 is spun and bonded into nonwoven handsheets. The blend is pre-compounded in a twin-screw extruder prior to spinning. Table 2 shows the average strain at peak load for the handsheets made from the blend (2) are higher than that for either of the individual constituents (C2, C3), indicating synergistic elongation behavior.

TABLE 2Handsheets Made From Monocomponent Fibers - Neat Polypropyleneand Polyolefin Copolymer Resins and Polypropylene / PolyolefinCopolymer BlendsSTRAIN ATEXAM-MFRPEAK LOADEXTENSIONPLE #RESIN(g / 10 min)(%)RATIOC1Profax PH8353572—C2Valtec HH44140098—C3Adflex Z104S25120—C480% Profax33880.7PH835 20%Adflex Z104S280% Valtec2301601.3HH441 20%Adflex Z104S

[0053] The melt flo...

example 3

[0055] This example demonstrates synergistic properties resulting from melt spinning a blend of a conventional spunbond grade polypropylene and a high melt flow rate polypropylene. Fibers of the present invention are prepared from a pre-compounded blend of 50 wt % ProFax PH835 and 50 wt % Valtec HH441 (400 MFR polypropylene resin available from Basell Polyolefins Company, Wilmington, Del.) at a mass throughput of 0.3 grams per hole per minute on a pilot-scale spunbond nonwoven line. Unbonded fiber bundles are collected for single fiber property evaluation. Table 3 shows the resultant diameters and average strain at break of the fibers. At equivalent or even at smaller diameters, fibers prepared from the blend of the present invention exhibit higher extensibility than fibers prepared from the neat 35 MFR polypropylene resin (C5).

TABLE 3Monocomponent Fiber Data - Neat Polypropylene Resin anda High MFR / Low MFR Polypropylene BlendDiameterStrain atExample #Resin(microns)Break (%)C5ProF...

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Abstract

The present invention provides a polymer composition that enables a nonwoven web to possess high extensibility. The polymer composition comprises a polypropylene having a melt flow rate of from about 100 to about 1000 grams per 10 minutes and a second polymer having a melt flow rate of from about 10 to about 80 grams per 10 minutes. Additionally, the present invention provides low denier fibers that possess softness and enable the formation of nonwoven webs with high extensibility.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 60 / 539,369, filed Jan. 27, 2004.FIELD OF THE INVENTION [0002] The present invention relates to soft extensible nonwoven webs comprising low denier fibers and disposable articles comprising such nonwoven webs. BACKGROUND [0003] Nonwoven webs formed by nonwoven extrusion processes such as, for example, meltblowing and spunbonding processes may be manufactured into products and components of products so inexpensively that the products could be viewed as disposable after only one or a few uses. Representatives of such products include disposable absorbent articles, such as diaper, incontinence briefs, training pants, feminine hygiene garments, wipes, and the like. [0004] There is an existing consumer need for nonwovens that can deliver softness and extensibility when used in disposable products. Softer nonwovens are gentler to the skin and help to provide a more garment...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C08L23/10C08L23/12D04H1/00D04H1/42D04H3/16D04H13/00
CPCC08L23/10C08L2205/02D01D5/0985D01F8/06D04H1/42D04H3/007D04H13/002D04H3/16B29D7/01C08L2666/06D04H3/14D04H3/147Y10T442/697Y10T442/637Y10T442/641Y10T442/681Y10T442/60Y10T442/699
Inventor MELIK, DAVID HARRYARORA, KELYN ANNEAUER, JEFFREY ALLEN
Owner PROCTER & GAMBLE CO
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