Zoned spinneret and highly bulky nonwoven fabric

Abstract

A spinneret for melt spinning polymeric fibers is provided that includes a spinneret body including a plurality of spinneret orifices formed through a thickness of the spinneret body. The plurality of spinneret orifices includes (i) a plurality of multi-component spinneret orifices including a first multi-component opening and a separate second multi-component opening, and (ii) a plurality of single-component spinneret orifices including a single single-component opening. Non-woven fabrics having monocomponent and multicomponent fiber regions are provided, as well as methods of forming such non-woven fabrics using zoned spinnerets.

Description

[0001] Cross-references to related applications

[0002] This application claims priority under 35 U.S.C. §119(e) to U.S. Patent Application No. 63 / 357,196, filed on June 30, 2022, the entire disclosure of which is hereby expressly incorporated herein by reference. Technical Field

[0003] Embodiments of the disclosed invention generally relate to spinnerets and dies including spinnerets, wherein the spinnerets include a zone configured to simultaneously melt-spin a monocomponent fiber and a defined region of a multicomponent fiber. Embodiments of the disclosed invention also generally relate to nonwoven fabrics and methods of forming such nonwoven fabrics. Background Art

[0004] In nonwoven fabrics, the fibers forming nonwoven fabrics are usually oriented in the xy plane of the fiber web. Like this, the nonwoven fabric of gained is relatively thin, and lacks fluffy or significant thickness in the z-direction. The fluffiness or thickness of the nonwoven fabrics suitable for health-related products (such as personal care absorbent products) improves the user's comfort (softness), surge processing and fluid distribution to the adjacent parts of the products. In this respect, high-loft, low-density nonwoven fabrics are used for various end-use applications, such as for health-related products (such as, sanitary pads and napkins, disposable diapers, incontinence care pads, etc.). For example, high-loft and low-density nonwoven fabrics can be used in products such as towels, industrial wipes, incontinence products, baby care products (such as, diapers), absorbent women's care products and professional health products.

[0005] In order to impart bulkiness or thickness to nonwoven fabrics, it is generally desirable that at least a portion of the fibers constituting the web be oriented in the z direction. Typically, such bulky nonwoven webs are produced using crimped staple fibers or post-forming processes such as creping or pleating of formed fabrics. Although there are methods for producing high-loft and low-density fabrics, during conversion, fabrics are generally subjected to many processes of compression and / or deformation of materials. Compression of fabrics can reduce the total volume generated during a variety of conversion processes when conveying the fabric longitudinally, which may cause undesirable longitudinal elongation and / or necking (e.g., width reduction in the transverse direction), which adversely affects the ability of the conversion process due to the overall deformation of the fabric.

[0006] Therefore, there remains a need in the art for a bulky nonwoven fabric having improved resistance to deformation, such as longitudinal elongation and / or transverse width reduction due to external loads or tensions applied in the longitudinal direction on the nonwoven fabric, and / or resistance to lint formation via abrasion. There also remains a need in the art for an apparatus and method for making such a bulky nonwoven fabric. Summary of the invention

[0007] One or more embodiments of the present invention can solve one or more of the above problems. According to certain embodiments of the present invention, a spinneret for melt-spinning polymer fibers is provided, the spinneret comprising a spinneret body, the spinneret body comprising a plurality of spinneret holes formed through the thickness of the spinneret body, wherein the plurality of spinneret holes comprises (i) a plurality of multicomponent spinneret holes, which comprises a first multicomponent opening and a separate second multicomponent opening, and (ii) a plurality of monocomponent spinneret holes, which comprises a single monocomponent opening; wherein the plurality of monocomponent spinneret holes optionally comprises a plurality of polymer composition-A (PCA) monocomponent spinneret holes and a plurality of polymer composition-B (PCB) monocomponent spinneret holes.

[0008] On the other hand, the present invention also provides a die head, which includes (i) a spinneret as described and disclosed herein, (ii) a first polymer distribution path, which operably connects the first inlet to each of the first multicomponent openings of a plurality of multicomponent spinnerets of the spinneret, (iii) a second polymer distribution path, which operably connects the second inlet to each of the second multicomponent openings of the plurality of multicomponent spinnerets of the spinneret, (iv) a third polymer distribution path, which operably connects the third inlet to at least a first portion of the single component openings of a plurality of single component spinnerets of the spinneret, such as a plurality of PCA single component spinnerets; and (v) optionally, a fourth polymer distribution path, which operably connects the fourth inlet to at least a second portion of the single component openings of a plurality of single component spinnerets of the spinneret, such as a plurality of PCB single component spinnerets.

[0009] In another aspect, the present invention also provides a system comprising (i) a die as described and disclosed herein; (ii) a first polymer source comprising a first polymer composition, wherein the first polymer source is operatively connected to a first inlet of the die, (iii) a second polymer source comprising a second polymer composition different from the first polymer composition, wherein the second polymer source is operatively connected to a second inlet of the die, and optionally (iv) a third polymer source comprising a third polymer composition different from the first polymer composition and the second polymer composition, wherein the third polymer source is operatively connected to a third inlet of the die.

[0010] On the other hand, the present invention also provides a nonwoven fabric comprising a plurality of interwoven fibers and a plurality of curled multi-component fibers, the plurality of interwoven fibers comprising a plurality of monocomponent fibers, for example, a plurality of different types of monocomponent fibers optionally comprising a plurality of first type monocomponent fibers and a plurality of second type monocomponent fibers, wherein the nonwoven fabric comprises at least one first region and at least one second region, the at least one first region comprising at least a majority (e.g., all) of a first monocomponent fiber group of the plurality of monocomponent fibers, and the at least one second region comprising at least a majority (e.g., all) of a first multicomponent fiber group of the plurality of curled multi-component fibers.

[0011] In another aspect, the present invention provides a method for making a nonwoven fabric, such as those described and disclosed herein. According to certain embodiments of the present invention, the method may include the following steps: (i) simultaneously melt spinning a group of fibers, such as those described and disclosed herein, from a single spinneret, wherein the group of fibers comprises a plurality of monocomponent fibers, such as optionally a plurality of different types of monocomponent fibers, the plurality of different types of monocomponent fibers comprising a plurality of first type monocomponent fibers and a plurality of second type monocomponent fibers, and a plurality of multicomponent fibers, and wherein the group of fibers forms at least one first region and at least one second region, the at least one first region comprising at least a majority of the first monocomponent fiber group of the plurality of monocomponent fibers, the at least one second region comprising at least a majority of the first multicomponent fiber group of the plurality of multicomponent fibers; (ii) collecting the melt-spun group of fibers; and (iii) forming a plurality of crimped multicomponent fibers by actively and / or passively forming one or more crimped portions in at least a portion of the multicomponent fibers. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Various embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the present invention are shown. Indeed, these inventions may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable statutory requirements. Like numbers refer to like elements throughout, and wherein:

[0013] Figure 1A A spinneret according to some embodiments of the present invention is shown, the spinneret comprising a zone of multi-component spinnerets and a zone of single-component spinnerets;

[0014] Figure 1B A spinneret according to some embodiments of the present invention is shown, the spinneret comprising a zone of multi-component spinnerets and a zone of mono-component spinnerets, the zone of mono-component spinnerets comprising a plurality of polymer composition-A (PCA) mono-component spinnerets and a plurality of polymer composition-B (PCB) mono-component spinnerets;

[0015] Figure 1C Another spinneret including a zone of multi-component spinholes and a zone of mono-component spinholes according to certain embodiments of the present invention is shown, the zone of spinholes including a plurality of polymer composition-A (PCA) mono-component spinholes and a plurality of polymer composition-B (PCB) mono-component spinholes;

[0016] Figure 2A A spinneret according to certain embodiments of the present invention is shown, the spinneret comprising a zone of single-component spinnerets located adjacent to and between two zones of multi-component spinnerets;

[0017] Figure 2B A spinneret including a zone of monocomponent spinholes according to certain embodiments of the present invention is shown, the monocomponent spinholes including a plurality of polymer composition-A (PCA) monocomponent spinholes and a plurality of polymer composition-B (PCB) monocomponent spinholes located adjacent to and between the zones of two multicomponent spinholes;

[0018] Figure 3A A spinneret according to certain embodiments of the present invention is shown, the spinneret comprising a large region of multi-component spinnerets located adjacent to and between two smaller regions of single-component spinnerets;

[0019] Figure 3B A spinneret according to certain embodiments of the present invention is shown, the spinneret comprising a large region of multicomponent orifices located adjacent to and between two smaller regions of monocomponent orifices, wherein one of the smaller regions of monocomponent orifices comprises a plurality of polymer composition-A (PCA) monocomponent orifices, and the other smaller region of monocomponent orifices comprises a plurality of polymer composition-B (PCB) monocomponent orifices;

[0020] Figure 4 A spinneret according to certain embodiments of the present invention is shown, the spinneret comprising alternating zones of multicomponent orifices and monocomponent orifices along a length direction (L) of the spinneret, which length direction of the spinneret may be associated with a machine direction (MD) during operation;

[0021] Figure 5 A spinneret according to certain embodiments of the present invention is shown, the spinneret comprising alternating zones of multicomponent orifices and monocomponent orifices along a length direction (L) of the spinneret, the length direction (L) of the spinneret being associated with a machine direction (MD) when in operation, and the length direction (L) of the spinneret being associated with a cross-direction (CD) when in operation;

[0022] Figure 6Another spinneret according to certain embodiments of the present invention is shown, the spinneret comprising alternating regions of multicomponent orifices and monocomponent orifices along a length direction (L) of the spinneret, which may be associated with a machine direction (MD) when in operation, and which may be associated with a cross direction (CD) when in operation;

[0023] Figure 7 Another spinneret according to certain embodiments of the present invention is shown, the spinneret comprising alternating zones of multicomponent orifices and monocomponent orifices along a length direction (L) of the spinneret, which may be associated with a machine direction (MD) when in operation, and which may be associated with a cross direction (CD) when in operation;

[0024] Figure 8 A spinneret is shown comprising a plurality of separate regions of monocomponent orifices dispersed in a single zone or sea of ​​multicomponent orifices;

[0025] Figures 9A-9H Examples of cross-sectional views of some exemplary multicomponent fibers according to certain embodiments of the present invention are shown. DETAILED DESCRIPTION

[0026] Various embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the present invention are shown. Indeed, these inventions may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable statutory requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0027] The present invention generally relates to a spinneret having multiple "zones", which can be defined as, for example, spinnerets having different shapes, sizes and / or configurations (e.g., monocomponent spinnerets are configured to melt-spin monocomponent fibers, multicomponent spinnerets are configured to melt-spin one or more types of multicomponent fibers, etc.). For example, a group of multiple monocomponent spinnerets can define a first zone, while multiple multicomponent spinnerets can define a second zone. In this regard, a spinneret can include a generally unlimited number of different zones (e.g., from a single spinning beam), which can be positioned relative to each other to enable melt-spinning of fibers for producing nonwoven fabrics having a particularly desired structure, which can be defined by the corresponding positions of corresponding groups of melt-spun fibers present in a nonwoven fabric (e.g., a single-layer nonwoven fabric formed by a single spinning beam including a spinneret according to certain embodiments of the present invention). According to certain embodiments of the present invention, the spinneret can be combined with a melt spinning die and / or a melt spinning system, which can distribute and spin multiple polymer compositions (e.g., 2, 3, 4, 5, 6...different polymer compositions). For example, three separate polymer compositions can be melt spun simultaneously, wherein the first polymer composition can form the first component of a multi-component fiber, the second polymer composition can form the second component of a multi-component fiber, and the third polymer composition can form a mono-component fiber. However, according to certain embodiments of the present invention, a specific polymer composition can be distributed in the same die to form a mono-component fiber and one of the components of a multi-component fiber (e.g., a bi-component fiber).

[0028] According to certain embodiments of the present invention, nonwoven fabrics (e.g., bulky nonwoven fabrics formed with spinnerets as described and disclosed herein) incorporating a mixture of monocomponent fibers and multicomponent fibers (e.g., crimped multicomponent fibers) according to certain embodiments of the present invention can provide a beneficial reduction in machine direction (MD) and / or cross direction (CD) compared to similar or identical bulky nonwoven fabrics. Additionally or alternatively, nonwoven fabrics (e.g., bulky nonwoven fabrics formed with spinnerets as described and disclosed herein) incorporating a mixture of both monocomponent fibers and multicomponent fibers (e.g., crimped multicomponent fibers) according to certain embodiments of the present invention can provide a reduction in "fuzz" or fiber debris during wear compared to similar or identical bulky nonwoven fabrics.

[0029] According to certain embodiments of the present invention, by way of example only, the total number or weight percentage of monocomponent fibers present in the nonwoven fabric may be selected to occupy less than about, for example, 40% (e.g., less than 33%, less than 30%, less than 25%, less than 20%, less than 15%, or less than about 10%). According to certain embodiments of the present invention, a lower amount of monocomponent fibers may provide the benefit of reduced elongation and / or improved resistance to lint formation due to wear, while maintaining the desired loft / thickness by not removing too much crimped multicomponent fiber. According to certain embodiments of the present invention, the location selection of the monocomponent fibers (e.g., by the location selection of the monocomponent spinneret holes in the spinneret) may be important when providing improved resistance to lint or "fuzz" formation during wear. For example, a smaller amount of monocomponent fibers (e.g., consolidation) near the outermost surface of the contacting engraved roll may provide a "blanket" or "buffer" zone of non-crimped fibers that are less likely to become pulled out of plane during wear. However, with a smaller layer of these monocomponent fibers, the nonwoven fabric may maintain loft / thickness via the crimped multicomponent fibers located underneath. According to certain embodiments of the present invention, the level or degree of curl of the underlying multicomponent fibers can improve loft. For example, the degree of curl formation can be increased because a small amount of monocomponent fibers provide a "blanket" or "cushion" area.

[0030] The term "substantially" or "substantially" may encompass the total amount specified according to certain embodiments of the invention, or largely but not the total amount specified (e.g., 95%, 96%, 97%, 98% or 99% of the total amount specified) according to other embodiments of the invention.

[0031] The terms "polymer" or "polymeric", as used interchangeably herein, may include homopolymers, copolymers, such as block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof. In addition, unless otherwise specifically limited, the terms "polymer" or "polymeric" shall include all possible structural isomers; stereoisomers, including but not limited to geometric isomers, optical isomers or enantiomers; and / or any chiral molecular configuration of such polymer or polymeric material. These configurations include but are not limited to isotactic, syndiotactic and atactic configurations of such polymer or polymeric material. The terms "polymer" or "polymeric" shall also include polymers made from various catalyst systems, including but not limited to Ziegler-Natta catalyst systems and metallocene / single-site catalyst systems. According to certain embodiments of the present invention, the terms "polymer" or "polymeric" shall also include polymers produced by fermentation methods or from biological sources.

[0032] As used herein, the terms "nonwoven" and "nonwoven web" may include a web having a structure of individual fibers, filaments and / or threads, which are interwoven in an interlaced manner but not in a repetitive manner as identifiable in a knitted or woven fabric. According to certain embodiments of the present invention, a nonwoven fabric or web may be formed by any conventional method known in the art, such as meltblowing, spunbonding, needlepunching, hydraulic entanglement, air-laid web and bonded carding. As used herein, a "nonwoven web" may include multiple individual fibers that have not been subjected to a consolidation process. In some cases, a "nonwoven web" may include multiple layers, such as one or more spunbond layers and / or one or more meltblown layers. For example, a "nonwoven web" may include a spunbond-meltblown-spunbond structure.

[0033] As used herein, the terms "fabric" and "nonwoven fabric" may include a web of fibers in which a plurality of fibers are mechanically entangled or interconnected, fused together, and / or chemically bonded together. For example, a nonwoven web of individually laid fibers may be subjected to a bonding or consolidation process to bond at least a portion of the individual fibers together to form a bonded (e.g., united) web of interconnected fibers.

[0034] The terms "consolidated" and "consolidation" as used herein may include placing at least a portion of the fibers of a nonwoven web together so that they are closer together or attached thereto (e.g., heat-melted together, chemically bonded together, and / or mechanically entangled together) to form one or more bonding sites, which act to increase resistance to external forces (e.g., wear and tension) compared to an unconsolidated web. For example, one or more bonding sites may include discrete or localized areas of a web material that have been softened or melted, and optionally subsequently or simultaneously compressed to form discrete or localized deformations in the web material. In addition, the term "consolidated" may include an entire nonwoven web that has been processed so that at least a portion of the fibers are closer together or attached thereto (e.g., heat-melted together, chemically bonded together, and / or mechanically entangled together), such as by thermal bonding or mechanical entanglement (e.g., hydraulic entanglement), just as a few examples. According to certain embodiments of the present invention, such a web may be considered a "consolidated nonwoven material," a "nonwoven fabric," or simply a "fabric."

[0035] As used herein, the term "spunbond" may include fibers formed by extruding molten thermoplastic material as filaments from a plurality of fine, generally circular capillaries of a spinneret and then rapidly reducing the diameter of the extruded filaments. According to embodiments of the present invention, spunbond fibers are generally not tacky when deposited onto a collecting surface and may be generally continuous as disclosed and described herein. It is noted that the spunbond materials used in certain composite materials of the present invention may include those described in the literature as Spunbond fibers, for example, include continuous fibers.

[0036] As used herein, the term "continuous fibers" refers to fibers that are not cut from their original length prior to forming a nonwoven web or nonwoven fabric. The average length of the continuous fibers may be greater than about 15 centimeters to greater than one meter, and may be up to the length of the formed web or fabric. For example, the continuous fibers used herein may include fibers wherein the fiber length is at least 1,000 times the average fiber diameter, such as fibers wherein the fiber length is at least about 5,000, 10,000, 50,000, or 100,000 times the average fiber diameter.

[0037] As used herein, the term "layer" may include generally identifiable groups of similar material types and / or functions that exist in the XY plane.

[0038] As used herein, the term "multicomponent fiber" may include fibers formed from at least two different polymeric materials or compositions (e.g., two or more) that are extruded from separate extruders but spun together to form one fiber. As used herein, the term "bicomponent fiber" may include fibers formed from two different polymeric materials or compositions that are extruded from separate extruders but spun together to form one fiber. The polymeric materials or polymers are arranged in substantially constant positions in different regions on the cross-section of the multicomponent fiber and extend continuously along the length of the multicomponent fiber. The configuration of such a multicomponent fiber may be, for example, a sheath / core arrangement in which one polymer is surrounded by another polymer, an eccentric sheath / core arrangement, a side-by-side arrangement, a pie-shaped arrangement, or an "island in the sea" arrangement, each of which is a multicomponent fiber, including known in the art of bicomponent fibers.

[0039] As used herein, the term "machine direction" or "MD" includes the direction in which fabrics are produced or transported. As used herein, the term "cross direction" or "CD" includes the direction in which fabrics are substantially perpendicular to the MD.

[0040] As used herein, the term "high loft" includes materials having a z-direction thickness generally exceeding about 0.3 mm and a relatively low bulk density. The thickness of a "high loft" nonwoven material and / or layer may be greater than 0.3 mm (e.g., greater than 0.4 mm, greater than 0.5 mm, greater than 0.6 mm, or greater than 1 mm), such as using ProGage Thickness available from Thwig-Albert Instrument Co. (West Berlin, NJ 08091). Tester (model 89-2009), which uses a 2 "diameter foot and has an applied force of 1.45kPa during measurement. According to certain embodiments of the present invention, the thickness of the "high loft" nonwoven and / or layer can be up to about any of the following: 3, 2.75, 2.5, 2.25, 2, 1.75, 1.5, 1.25, 1.0, 0.75 and 0.5mm and / or at least about any of the following: 0.3, 0.4, 0.5, 0.75, 1.0, 1.25, 1.5, 1.75 and 2.0mm. As used herein, the "high loft" nonwoven and / or layer can also have a relatively low density (e.g., bulk density - weight / unit volume), for example, less than about 70kg / m 3 , such as up to about any of the following: 70, 60, 55, 50, 45, 40, 35, 30, and 25 kg / m 3 and / or at least about any of the following: 10.15, 20, 25, 30, 35, 40, 45, 50 and 55 kg / m 3 .

[0041] As used herein, the term "curl" or "curled" includes three-dimensional curls or bends, such as a folded or compressed portion having an "L" configuration, a wavy portion having a "zigzag" configuration, or a curled portion such as a spiral configuration. According to certain embodiments of the present invention, the term "curl" or "curled" does not include random two-dimensional ripples or undulations in the fiber, such as those associated with the normal laydown of fibers in a melt spinning process.

[0042] As used herein, the term "aspect ratio" includes the ratio of the length of the major axis to the length of the minor axis of the cross-section of the fiber in question.

[0043] When referring to melt flow rate (MFR) herein, the MFR value is determined according to standard procedure ASTM D1238 (2.16 kg, 230° C.).

[0044] According to certain embodiments of the present invention, a spinneret for melt-spinning polymer fibers is provided, the spinneret comprising a spinneret body, the spinneret body comprising a plurality of spinneret holes formed through the thickness of the spinneret body, wherein the plurality of spinneret holes comprises (i) a plurality of multi-component spinneret holes, which comprises a first multi-component opening and a separate second multi-component opening, and (ii) a plurality of mono-component spinneret holes, which comprises a single mono-component opening; wherein the plurality of mono-component spinneret holes optionally comprises a plurality of polymer composition-A (PCA) mono-component spinneret holes and a plurality of polymer composition-B (PCB) mono-component spinneret holes. For example, a plurality of PCA mono-component spinneret holes may be aligned with a polymer source different from a plurality of PCB mono-component spinneret holes. Additionally or alternatively, a plurality of PCA mono-component spinneret holes may have a geometric opening area and / or size different from a plurality of PCB mono-component spinneret holes. According to certain embodiments of the present invention, the spinneret body may have a length and a width greater than the length. In this regard, the plurality of spinnerets may define a plurality of rows that extend independently of one another along at least about 20% of the width, such as at least about any of 20, 30, 40, 50, 60, and 70% of the width, and / or, at most about any of 100, 95, 90, 80, and 70% of the width.

[0045] According to certain embodiments of the present invention, a plurality of multicomponent spinnerets may define at least one first zone, and a plurality of monocomponent spinnerets may define at least one second zone. For example, at least one first zone may include one or more rows of the first group, including the first outermost row extending along the width direction of the spinneret body. Additionally or alternatively, at least one first zone may include one or more rows of the second group, including the second outermost row extending along the width direction of the spinneret body. Additionally or alternatively, at least one second zone may include one or more rows of the third group, the third group extending along the width direction of the spinneret body and being directly or indirectly located between one or more rows of the first group and one or more rows of the second group.

[0046] For example, Figure 1A A spinneret 1 is shown, comprising a first zone comprising a first group of one or more rows of multicomponent spinholes 10, the first group comprising a first outermost row extending in the width direction of the spinneret body, and a second zone comprising a second group of one or more rows of monocomponent spinholes 20, the second group comprising a second outermost row extending in the width direction of the spinneret body. Figure 1B Shown with Figure 1A The spinneret 1 is similar to the spinneret 1, but according to some embodiments of the present invention, the plurality of single-component spinnerets 20 include a plurality of polymer composition-A (PCA) single-component spinnerets (i.e., Figure 1B and a plurality of polymer composition-B (PCB) single-component spinnerets (i.e., Figure 1BAs described above, the plurality of PCA monocomponent spinnerets may be aligned with a different polymer source than the plurality of PCB monocomponent spinnerets. Additionally or alternatively, the plurality of PCA monocomponent spinnerets may have a different geometric opening area and / or size than the plurality of PCB monocomponent spinnerets. Figure 1B In the particular embodiment shown, the plurality of PCA monocomponent orifices define a first outermost row of the plurality of orifices, while the plurality of PCB monocomponent orifices are located between and adjacent the plurality of PCA monocomponent orifices and the one or more rows of multicomponent orifices 10 . Figure 1C Another spinneret 1 is shown including a zone of multicomponent orifices 10 and a zone of monocomponent orifices 20 according to some embodiments of the present invention, the zone of monocomponent orifices including an alternating pattern of a plurality of PCA monocomponent orifices and a plurality of PCB monocomponent orifices.

[0047] Figure 2A A spinneret 1 according to some embodiments of the present invention is shown, comprising a first zone, the first zone comprising one or more rows of multicomponent spinnerets 10 of a first group and one or more rows of multicomponent spinnerets 15 of a second group. The spinneret of Fig. 2 comprises a relatively small second zone, the second zone comprising one or more rows of monocomponent spinnerets 20 of a third group, the one or more rows of multicomponent spinnerets of the third group being adjacent to and located between the one or more rows of multicomponent spinnerets 15 of the second group. In this regard, the resulting nonwoven fabric will have two outermost surfaces defined by multicomponent fibers (e.g., curled) and an inner portion formed by monocomponent fibers, the inner portion of which can provide enhanced strength and / or reduced elongation to the nonwoven fabric without adversely affecting the bulk of the nonwoven fabric. Figure 2B Shown with Figure 2A A similar spinneret 1, but according to certain embodiments of the present invention, the zone of the single-component spinneret hole 20 includes a plurality of PCA single-component spinneret holes and a plurality of PCB single-component spinneret holes, and the plurality of PCA single-component spinneret holes and the plurality of PCB single-component spinneret holes are located near and between the two zones of the multi-component spinneret holes. Figure 2B The particular embodiment shown includes an alternating pattern of PCA monocomponent orifices and PCB monocomponent orifices along the rows of orifices.

[0048] According to certain embodiments of the present invention, the spinneret body can have a total number of rows, and one or more rows of the first group include about 1 to about 45% of the total number of rows, such as at least about 1, 3, 5, 8, 10, 12, 15, 18 and 20% of the total number of rows, and / or at most about any of the following: 45, 40, 38, 35, 32, 30, 28, 25, 22 and 20% of the total number of rows. According to certain embodiments of the present invention, if at least most of the spinnerets are of a specific type (e.g., monocomponent or multicomponent), a given row can be classified in a specific zone. Additionally or alternatively, the spinneret body can have a total number of rows, and the second group of one or more rows includes about 1 to about 45% of the total number of rows, such as at least about 1, 3, 5, 8, 10, 12, 15, 18 and 20% of the total number of rows, and / or at most about any of the following: 45, 40, 38, 35, 32, 30, 28, 25, 22 and 20% of the total number of rows. According to certain embodiments of the present invention, if at least most of the spinnerets are of a specific type (e.g., monocomponent or multicomponent), a given row can be classified in a specific zone. Additionally or alternatively, the spinneret body may have a total number of rows, and one or more rows of the third group may constitute about 10 to about 99% of the total number of rows, such as at least about 10, 12, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of rows, and / or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number of rows. According to certain embodiments of the present invention, if at least most of the spinnerets are of a particular type (e.g., monocomponent or multicomponent), a given row may be classified in a particular zone.

[0049] According to certain embodiments of the present invention and Figure 3A As shown, the spinneret 1 may include at least one second zone (i.e., a single component spinneret hole), which may include one or more rows of single component spinneret holes 20 of the first group, and the first group includes the first outermost row extending in the width direction of the spinneret body. In addition, at least one second zone may also include one or more rows of single component spinneret holes 25 of the second group, which include the second outermost row extending in the width direction of the spinneret body. According to certain embodiments of the present invention, at least one first zone (i.e., a multicomponent spinneret hole) of the spinneret 1 may include one or more rows of multicomponent spinneret holes 10 of the third group, which extend in the width direction of the spinneret body and are directly or indirectly located between one or more rows of single component spinneret holes 20 of the first group and one or more rows of single component spinneret holes 25 of the second group. Figure 3B The invention shows some embodiments of the present invention. Figure 3A The spinneret is similar to spinneret 1, but wherein one of the smaller areas of monocomponent spinnerets includes a plurality of PCA monocomponent spinnerets, and the other smaller area of ​​monocomponent spinnerets includes a plurality of PCB monocomponent spinnerets.

[0050] According to certain embodiments of the present invention, the spinneret body can have a total number of rows, and one or more rows of the first group include about 1 to about 45% of the total number of rows, such as at least about 1, 3, 5, 8, 10, 12, 15, 18 and 20% of the total number of rows, and / or at most about any of the following: 45, 40, 38, 35, 32, 30, 28, 25, 22 and 20% of the total number of rows. According to certain embodiments of the present invention, if at least most of the spinnerets are of a specific type (e.g., monocomponent or multicomponent), a given row can be classified in a specific zone. Additionally or alternatively, the spinneret body can have a total number of rows, and the second group of one or more rows includes about 1 to about 45% of the total number of rows, such as at least about 1, 3, 5, 8, 10, 12, 15, 18 and 20% of the total number of rows, and / or at most about any of the following: 45, 40, 38, 35, 32, 30, 28, 25, 22 and 20% of the total number of rows. According to certain embodiments of the present invention, if at least most of the spinnerets are of a specific type (e.g., monocomponent or multicomponent), a given row can be classified in a specific zone. Additionally or alternatively, the spinneret body may have a total number of rows, and one or more rows of the third group constitute about 10 to about 99% of the total number of rows, such as at least about 10, 12, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of rows, and / or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number of rows. According to certain embodiments of the present invention, if at least most of the spinnerets are of a particular type (e.g., monocomponent or multicomponent), a given row may be classified in a particular zone.

[0051] According to some embodiments of the present invention, Figure 3A-3B As generally shown in FIG. 1 , at least one first region may include a plurality of first regions, and at least one second region may include a plurality of second regions. Figure 4 As shown, a plurality of first zones and a plurality of second zones can be arranged in an alternating pattern along the length direction of the spinneret. According to certain embodiments of the present invention, a plurality of first zones and a plurality of second zones can be arranged in an alternating pattern along the width direction. According to certain embodiments of the present invention and as Figure 5 As shown, a plurality of first regions (ie, 10a-10j) and a plurality of second regions (ie, 20a-20j) may be positioned in an alternating pattern along the length direction and the width direction. According to some embodiments of the present invention, Figure 4 and 5 An exemplary spinneret may include a plurality of PCA single-component spinnerets and a plurality of PCB single-component spinnerets, as described above.

[0052] Figure 6Another spinneret 1 according to certain embodiments of the present invention is shown, comprising alternating regions of multi-component spinnerets and mono-component spinnerets along the length direction (L) of the spinneret, which can be associated with the machine direction (MD) during operation, and the length direction (L) of the spinneret can be associated with the cross direction (CD) during operation. Figure 7 Another spinneret 1 according to certain embodiments of the present invention is shown, comprising alternating regions of multicomponent spinnerets and monocomponent spinnerets along the length direction (L) of the spinneret, which can be associated with the machine direction (MD) during operation, and the length direction (L) of the spinneret can be associated with the cross direction (CD) during operation. According to certain embodiments of the present invention, Figure 6 and 7 An example spinneret may include a plurality of PCA single-component spinnerets and a plurality of PCB single-component spinnerets, as described above.

[0053] According to certain embodiments of the present invention, at least one first zone (i.e., multicomponent spinholes) may include a continuous sea of ​​a plurality of multicomponent spinholes, and at least one second zone (i.e., monocomponent spinholes) may include a plurality of second zones comprising islands of monocomponent spinholes dispersed in the continuous sea of ​​a plurality of multicomponent spinholes. For example, Figure 8 A spinneret 1 is shown, which includes at least one first zone (i.e., multicomponent spinholes), the first zone including a continuous sea of ​​a plurality of multicomponent spinholes 10, and at least one second zone (i.e., monocomponent spinholes) including a plurality of second zones, the second zones including islands of monocomponent spinholes 20, 25, 28, the monocomponent spinholes being dispersed over the continuous sea of ​​a plurality of multicomponent spinholes 10. Alternatively, at least one second zone may include a continuous sea of ​​a plurality of monocomponent spinholes, and at least one first zone includes a plurality of first zones, the first zones including islands of multicomponent spinholes, the multicomponent spinholes being dispersed over the continuous sea of ​​a plurality of monocomponent spinholes. According to certain embodiments of the present invention, Figure 8 An example spinneret may include a plurality of PCA single component spin holes and a plurality of PCB single component spin holes, as described above. For example, the island of single component spin holes 25 may include PCA single component spin holes, while the islands of single component spin holes 20, 28 may include PCB single component spin holes. Alternatively, each of the islands of single component spin holes 20, 25, 28 may include a combination of a plurality of PCA single component spin holes and a plurality of PCB single component spin holes.

[0054] According to certain embodiments of the present invention, a plurality of multicomponent spinnerets may include a circular outermost cross section, a non-circular outermost cross section, or both. Additionally or alternatively, a plurality of multicomponent spinnerets may include an average opening area of ​​about 60% to about 95% at the discharge surface of the spinneret body, such as at least about any one of the following: 60, 65, 70 and 75%, and / or at most about any one of the following: 95%, 90%, 85%, 80% and 75%.

[0055] According to certain embodiments of the present invention, the plurality of multicomponent spinholes may include a circular outermost cross-section having an aspect ratio of 0.8 to 1.2, such as about 0.8, 0.9, and 1, and / or at most about 1.2, 1.1, and 1. Additionally or alternatively, the plurality of multicomponent spinholes include a non-circular outermost cross-section having an aspect ratio of at least 1.5, such as at least about any one of the following: 1.5, 2, 3, 4, and 5, and / or at most about any one of the following: 10, 9, 8, 7, 6, and 5.

[0056] According to certain embodiments of the present invention, the multicomponent spinneret, the first multicomponent opening and the separate second multicomponent opening may define a side-by-side configuration, a multi-lobal configuration, a sheath-and-core configuration, an island-in-the-sea configuration, or any combination thereof, wherein the separate second multicomponent opening comprises a plurality of such openings operatively connected to one another. According to certain embodiments of the present invention, the sheath-and-core configuration may comprise a core opening and a sheath opening, wherein the core opening defines at least a portion of the outermost periphery of the multicomponent spinneret having a circular outermost cross-section or at least a portion of the outermost periphery of the multicomponent spinneret having a non-circular outermost cross-section.

[0057] According to certain embodiments of the present invention, the multicomponent spinholes may include a combination of circular outermost cross-section multicomponent spinholes and non-circular outermost cross-section multicomponent spinholes.

[0058] According to the present invention, the circular outermost cross-section multicomponent spinholes may include 1% to about 99% of the total number of multicomponent spinholes, for example, at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45 and 50% of the total number of multicomponent spinholes, and / or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55 and 50% of the total number of multicomponent spinholes. Additionally or alternatively, the non-circular outermost cross-section multicomponent spinholes may comprise from 1% to about 99% of the total number of multicomponent spinholes, such as at least about any of 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of multicomponent spinholes, and / or at most about any of 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number of multicomponent spinholes. According to certain embodiments of the present invention, the multicomponent spinholes may all be circular or non-circular.

[0059] According to certain embodiments of the present invention, the plurality of monocomponent spinholes include a circular outermost cross-section having an aspect ratio of 0.8 to 1.2, such as about 0.8, 0.9, and 1, and / or at most about 1.2, 1.1, and 1. Additionally or alternatively, the plurality of monocomponent spinholes include a non-circular outermost cross-section having an aspect ratio of at least 1.5, such as at least about any one of the following: 1.5, 2, 3, 4, and 5, and / or at most about any one of the following: 10, 9, 8, 7, 6, and 5.

[0060] According to certain embodiments of the present invention, the monocomponent spinholes may include a combination of circular outermost cross-section monocomponent spinholes and non-circular outermost cross-section monocomponent spinholes. According to certain embodiments of the present invention, the circular outermost cross-section monocomponent spinholes may include 1% to about 99% of the total number of monocomponent spinholes, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45 and 50% of the total number of monocomponent spinholes, and / or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55 and 50% of the total number of monocomponent spinholes. Additionally or alternatively, the non-circular outermost cross-section monocomponent spinholes comprise from 1% to about 99% of the total number of monocomponent spinholes, such as at least about any of 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of monocomponent spinholes, and / or at most about any of 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number of monocomponent spinholes. Alternatively, the monocomponent spinholes may all be circular or non-circular.

[0061] According to certain embodiments of the present invention, the plurality of spinnerets of the spinneret may have or define a total number of spinnerets. According to certain embodiments of the present invention, about 1% to about 40% of the total number of spinnerets may be single-component spinnerets, for example, at least about any one of the following: 1, 2, 3, 5, 10, 12, 15, 18, and 20% of the total number of spinnerets may be single-component spinnerets, and / or at most about any one of the following: 40, 38, 35, 33, 30, 28, 25, 22, and 20% of the total number of spinnerets may be single-component spinnerets. Additionally or alternatively, from about 60% to about 99% of the total number of spinholes may be multicomponent spinholes, for example, at least about any of 60, 62, 65, 67, 70, 72, 75, 78, and 80% of the total number of spinholes may be multicomponent spinholes, and / or at most about any of 99, 98, 97, 95, 90, 88, 85, 82, and 80% of the total number of spinholes may be multicomponent spinholes.

[0062] On the other hand, the present invention also provides a die head, the die head comprising (i) a spinneret as described and disclosed herein, (ii) a first polymer distribution path, which operatively connects the first inlet to each of the first multicomponent openings of a plurality of multicomponent spinnerets of the spinneret, (iii) a second polymer distribution path, which operatively connects the second inlet to each of the second multicomponent openings of a plurality of multicomponent spinnerets of the spinneret, and (iv) a third polymer distribution path, which operatively connects the third inlet to at least a first portion of the single component openings of a plurality of monocomponent spinnerets of the spinneret, such as a plurality of PCA monocomponent spinnerets; and (v) optionally, a fourth polymer distribution path, which operatively connects the fourth inlet to at least a second portion of the single component openings of a plurality of monocomponent spinnerets of the spinneret, such as a plurality of PCB monocomponent spinnerets. According to certain embodiments of the present invention, the die head is a spunbond die head, which is configured to form continuous fibers.

[0063] In another aspect, the present invention also provides a system comprising (i) a die as described and disclosed herein; (ii) a first polymer source comprising a first polymer composition, wherein the first polymer source is operatively connected to a first inlet of the die, (iii) a second polymer source comprising a different polymer composition than the first polymer composition, wherein the second polymer source is operatively connected to a second inlet of the die, and optionally (iv) a third polymer source comprising a different polymer composition than the first polymer composition and the second polymer composition, wherein the third polymer source is operatively connected to a third inlet of the die. According to certain embodiments of the present invention, the first polymer source or the second polymer source may also be operatively connected to the third inlet of the die.

[0064] According to some embodiments of the present invention, their system also includes a third polymer source comprising a third polymer composition, wherein the third polymer source is operatively connected to the third inlet. For example, the third polymer composition may be different from the first polymer composition and the second polymer composition. Alternatively, the third polymer composition may be identical to the first polymer composition or the second polymer composition. Additionally or alternatively, the system may include a fourth polymer source comprising a fourth polymer composition, wherein the fourth polymer source is operatively connected to the fourth inlet; wherein, the fourth polymer composition is different from the third polymer composition, and the fourth polymer composition is identical or different to the first polymer composition and / or the second polymer composition.

[0065] According to certain embodiments of the present invention, a first polymer source comprises a first hopper, a first extruder, and a first metering pump, wherein the first hopper has a first hopper outlet operatively connected to the first extruder inlet, the first extruder has a first extruder outlet operatively connected to the first metering pump inlet, and the first metering pump has a first metering pump outlet operatively connected to the first inlet of the die. Additionally or alternatively, a second polymer source comprises a second hopper, a second extruder, and a second metering pump, wherein the second hopper has a second hopper outlet operatively connected to the second extruder inlet, and the second extruder has a second extruder outlet operatively connected to the second metering pump inlet, and the second metering pump has a second metering pump outlet operatively connected to the second inlet of the die. Additionally or alternatively, a third polymer source comprises a third hopper, a third extruder, and a third metering pump, wherein the third hopper has a third hopper outlet operatively connected to the third extruder inlet, and the third extruder has a third extruder outlet operatively connected to the third metering pump inlet, and the third metering pump has a third metering pump outlet operatively connected to the third inlet of the die. Additionally or alternatively, the system may include a fourth polymer source, the fourth polymer source comprising a fourth hopper, a fourth extruder, and a fourth metering pump, wherein the fourth hopper has a fourth hopper outlet operatively connected to a fourth extruder inlet, and the fourth extruder has a fourth extruder outlet operatively connected to a fourth metering pump inlet, and the fourth metering pump has a fourth metering pump outlet operatively connected to a fourth inlet of the die.

[0066] On the other hand, the present invention also provides a nonwoven fabric comprising a plurality of interwoven fibers and a plurality of crimped multicomponent fibers, the plurality of interwoven fibers comprising a plurality of monocomponent fibers, for example, a plurality of different types of monocomponent fibers optionally comprising a plurality of first type monocomponent fibers and a plurality of second type monocomponent fibers, wherein the nonwoven fabric comprises at least one first region and at least one second region, the at least one first region comprising at least a majority (e.g., all) of a first monocomponent fiber group of the plurality of monocomponent fibers, and the at least one second region comprising at least a majority (e.g., all) of a first multicomponent fiber group of the plurality of crimped multicomponent fibers. According to certain embodiments of the present invention, different types of monocomponent fibers can be distinguished from each other because of having different polymer compositions, different cross-sections, different average diameters, or any combination thereof. For example, a plurality of first type monocomponent fibers may contain or consist of a particular polymer composition (e.g., polymer composition 'A'), while a second type of monocomponent fibers may contain or consist of a different polymer composition (e.g., polymer composition 'B').

[0067] Regardless of the specific number and / or relative position of corresponding groups or regions of different types of fibers (e.g., monocomponent and multicomponent fibers), according to certain embodiments of the present invention, based on the total amount of fibers forming the nonwoven material, the total weight percentage of all monocomponent fibers may be from about 1% to about 40%, for example, at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18 and 20 wt%, and / or at most about any of the following: 40, 38, 35, 33, 30, 28, 26, 25, 24, 22 and 20 wt%. Additionally or alternatively, the total weight percentage of all multicomponent fibers, based on the total amount of fibers forming the nonwoven material, may be from about 60 to about 99 wt %, for example, at least about any of the following: 60, 62, 65, 67, 70, 72, 74, 75, 76, 78, 80 wt %, and / or at most about any of the following: 99, 98, 97, 95, 94, 92, 90, 88, 86, 85, 82 and 80 wt %.

[0068] According to certain embodiments of the present invention, the first monocomponent fiber group defines the first outermost surface of the nonwoven fabric. Additionally or alternatively, at least one first zone also includes a second monocomponent fiber group of a plurality of monocomponent fibers, and wherein the second monocomponent fiber group defines the second outermost surface of the nonwoven fabric. According to certain embodiments of the present invention, the first multicomponent fiber group may be adjacent to the first monocomponent fiber group, the second monocomponent fiber group, or both. Additionally or alternatively, the nonwoven fabric may have a total basis weight of about 10 grams per square meter (gsm) to about 200 gsm, for example, at least about any one of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 gsm, and / or at most about any one of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 gsm. Additionally or alternatively, the first monocomponent fiber group comprises from about 1 wt% to about 30 wt% of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14 and 15 wt% of the total basis weight, and / or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16 and 15 wt% of the total basis weight. Additionally or alternatively, the second monocomponent fiber group comprises from about 1 to about 30 wt% of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14 and 15 wt% of the total basis weight, and / or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16 and 15 wt% of the total basis weight. Additionally or alternatively, the first multicomponent fiber group comprises about 40 to about 98 wt % of the total basis weight, such as at least about any of the following: 40, 44, 48, 50, 52, 56, 60, 64, 68, and 70 wt % of the total basis weight, and / or at most about any of the following: 98, 96, 94, 90, 88, 84, 80, 76, 72, and 70 wt % of the total basis weight. According to certain embodiments of the present invention, the total weight percentage of all monocomponent fibers based on the total amount of fibers forming the nonwoven material can be about 1% to about 40%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, and 20 wt %, and / or at most about any of the following: 40, 38, 35, 33, 30, 28, 26, 25, 24, 22, and 20 wt %. Additionally or alternatively, the total weight percentage of all multicomponent fibers, based on the total amount of fibers forming the nonwoven material, may be from about 60 to about 99 wt %, for example, at least about any of the following: 60, 62, 65, 67, 70, 72, 74, 75, 76, 78, 80 wt %, and / or at most about any of the following: 99, 98, 97, 95, 94, 92, 90, 88, 86, 85, 82 and 80 wt %.

[0069] According to certain embodiments of the present invention, the first multi-component fiber group defines the first outermost surface of the nonwoven fabric. Additionally or alternatively, at least one second zone also includes a second multi-component fiber group of a plurality of multi-component fibers, and wherein the second multi-component fiber group defines the second outermost surface of the nonwoven fabric. Additionally or alternatively, the first monocomponent fiber group may be adjacent to the first multi-component fiber group, the second multi-component fiber group, or both. Additionally or alternatively, the nonwoven fabric has a total basis weight of about 10 grams per square meter (gsm) to about 200 gsm, for example, at least about any one of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45 and 50 gsm, and / or at most about any one of the following: 200, 180, 150, 120, 100, 80, 70, 60 and 50 gsm. Additionally or alternatively, the first multicomponent fiber group comprises from about 1 to about 45 wt % of the total basis weight, for example, at least about any of: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22 and 25 wt % of the total basis weight, and / or at most about any of: 45, 42, 40, 38, 35, 32, 30, 28, 26, 25, 24, 22, 20, 18, 16 and 15 wt % of the total basis weight. Additionally or alternatively, the second multicomponent fiber group comprises from about 1 to about 45 wt % of the total basis weight, for example, at least about any of: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22 and 25 wt % of the total basis weight, and / or at most about any of: 45, 42, 40, 38, 35, 32, 30, 28, 26, 25, 24, 22, 20, 18, 16 and 15 wt % of the total basis weight. Additionally or alternatively, the first monocomponent fiber group comprises from about 10 to about 98 weight percent of the total basis weight, for example, at least about any of: 10, 16, 20, 24, 30, 36, 40, 44, 48, 50, 52, 56, 60, 64, 68 and 70 weight percent of the total basis weight, and / or at most about any of: 98, 96, 94, 90, 88, 84, 80, 76, 72, 70, 64, 60, 56 and 50 weight percent of the total basis weight. According to certain embodiments of the present invention, the total weight percentage of all monocomponent fibers, based on the total amount of fibers forming the nonwoven material, may be from about 1% to about 30%, for example, at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14 and 15 wt %, and / or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16 and 15%.

[0070] According to some embodiments of the present invention, at least one first region includes multiple first regions, and the at least one second region includes multiple second regions. For example, multiple first regions and multiple second regions can be positioned in an alternating pattern along the longitudinal direction of nonwoven fabric, along the z direction perpendicular to the longitudinal and transverse direction, or both. Additionally or alternatively, multiple first regions and multiple second regions can be positioned in an alternating pattern along the transverse direction of nonwoven fabric, along the z direction perpendicular to the transverse and longitudinal direction, or both. According to some embodiments of the present invention, multiple first regions and multiple second regions can be positioned in an alternating pattern along the transverse and longitudinal direction. According to some embodiments of the present invention, multiple first regions and multiple second regions can also be positioned in an alternating pattern in the z direction of nonwoven fabric, wherein the z direction is perpendicular to the transverse and longitudinal direction. Additionally or alternatively, the nonwoven fabric can have a total basis weight of about 10 grams per square meter (gsm) to about 200 gsm, for example, at least about any of 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 gsm, and / or at most about any of 200, 180, 150, 120, 100, 80, 70, 60, and 50 gsm. Additionally or alternatively, the plurality of multicomponent fibers comprise from about 1 to about 95 wt % of a total basis weight, e.g., at least about any of 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, and 50 wt % of the total basis weight, and / or at most about any of 95, 90, 85, 80, 75, 70, 65, 60, and 50 wt % of the total basis weight. Additionally or alternatively, a plurality of monocomponent fibers comprise about 1 to about 95 wt % of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, and 50 wt % of the total basis weight, and / or at most about any of the following: 95, 90, 85, 80, 75, 70, 65, 60, and 50 wt % of the total basis weight. According to certain embodiments of the present invention, the total weight percentage of all monocomponent fibers, based on the total amount of fibers forming the nonwoven material, may be about 1% to about 30%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, and 15 wt %, and / or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15%.

[0071] According to certain embodiments of the present invention, at least one second region may include a continuous network of a plurality of crimped multicomponent fibers, and at least one first region includes a plurality of first regions, the plurality of first regions including separate islands of a plurality of monocomponent fibers dispersed in a continuous network of a plurality of crimped multicomponent fibers. Alternatively, the at least one first region includes a continuous network of a plurality of monocomponent fibers, and at least one second region includes a plurality of second regions, the plurality of second regions including separate islands of crimped multicomponent fibers dispersed in a continuous network of a plurality of monocomponent fibers. According to certain embodiments of the present invention, the nonwoven fabric may have a total basis weight of about 10 grams per square meter (gsm) to about 200 gsm, for example, at least about any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 gsm, and / or at most about any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 gsm. Additionally or alternatively, the plurality of multicomponent fibers comprise from about 1 to about 95 wt % of a total basis weight, e.g., at least about any of 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, and 50 wt % of the total basis weight, and / or at most about any of 95, 90, 85, 80, 75, 70, 65, 60, and 50 wt % of the total basis weight. Additionally or alternatively, a plurality of monocomponent fibers comprise about 1 to about 95 wt % of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, and 50 wt % of the total basis weight, and / or at most about any of the following: 95, 90, 85, 80, 75, 70, 65, 60, and 50 wt % of the total basis weight. According to certain embodiments of the present invention, the total weight percentage of all monocomponent fibers, based on the total amount of fibers forming the nonwoven material, may be about 1% to about 30%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, and 15 wt %, and / or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15%.

[0072] According to certain embodiments of the present invention, the plurality of crimped multicomponent fibers may include a circular outermost cross-section, a non-circular outermost cross-section, or both. The plurality of crimped multicomponent fibers may include a variety of cross-sectional geometries and / or deniers, such as circular or non-circular cross-sectional geometries. According to certain embodiments of the present invention, the plurality of crimped multicomponent fibers may include all or substantially all of the same cross-sectional geometries or a mixture of different cross-sectional geometries to adjust or control various physical properties.

[0073] Additionally or alternatively, the plurality of crimped multi-component fibers may have an average cross-section (e.g., the longest cross-section length perpendicular to the fiber length) of about 8 to about 40 microns, such as at least about any of the following: 8, 10, 12, 15, 18, and 10 microns, and / or at most about any of the following: 70, 38, 35, 32, 30, 28, 25, 22, and 20 microns. According to certain embodiments of the present invention, the plurality of crimped multi-component fibers may include round crimped multi-component fibers having any of the above average cross-section values ​​or ranges. Additionally or alternatively, the plurality of crimped multi-component fibers may include non-round crimped multi-component fibers having an average cross-section (e.g., the longest cross-section length perpendicular to the fiber length) of about 15 to about 40 microns, such as at least about any of the following: 15, 18, 20, 22, and 25 microns, and / or at most about any of the following: 40, 38, 35, 32, 30, 28, and 25 microns. By way of example only, non-round fibers may include trilobal crimped multicomponent fibers having an average cross-section (e.g., the longest cross-section length perpendicular to the length of the fiber) of about 20 to about 30 microns, such as at least about any of 20, 22, and 25 microns, and / or at most about any of 30, 28, and 25 microns. As another example, non-round fibers may include ribbon-shaped (e.g., rectangular) crimped multicomponent fibers having an average cross-section (e.g., the longest cross-section length perpendicular to the length of the fiber) of about 20 to about 30 microns, such as at least about any of 20, 22, 24, and 25 microns, and / or at most about any of 30, 28, 26, and 25 microns.

[0074] According to certain embodiments of the present invention, a plurality of crimped multicomponent fibers may include a circular outermost cross-section having an aspect ratio of 0.8 to 1.2, such as about 0.8, 0.9, and 1, and / or at most about 1.2, 1.1, and 1. Additionally or alternatively, a plurality of crimped multicomponent fibers may include a non-circular outermost cross-section having an aspect ratio of at least 1.5, such as at least about any of the following: 1.5, 2, 3, 4, and 5, and / or at most about any of the following: 10, 9, 8, 7, 6, and 5.

[0075] According to certain embodiments of the present invention, the curled multi-component fibers may include a side-by-side configuration, a multi-lobal configuration, a core-sheath configuration, an island-in-the-sea configuration, or any combination thereof. According to certain embodiments of the present invention, the core-sheath configuration may include an eccentric core-sheath configuration, wherein at least a portion of the outermost circumference of a curled multi-component fiber having a circular outermost cross-section, or at least a portion of the outermost circumference of a curled multi-component fiber having a non-circular outermost cross-section, is defined by a core component. According to certain embodiments of the present invention, the plurality of curled multi-component fibers include bicomponent fibers.

[0076] According to certain embodiments of the present invention, the plurality of curled multicomponent fibers include a combination of circular outermost cross-section multicomponent fibers and non-circular outermost cross-section multicomponent fibers. For example, the circular outermost cross-section multicomponent fibers may include 1 to about 99% of the total number of multicomponent fibers, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of multicomponent fibers, and / or up to about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number of multicomponent fibers. Additionally or alternatively, the non-circular outermost cross-section multicomponent fibers may comprise from 1% to about 99% of the total number of multicomponent fibers, such as at least about any of 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of multicomponent fibers, and / or at most about any of 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number of multicomponent fibers. According to certain embodiments of the present invention, the crimped multicomponent fibers may all be circular outermost cross-section multicomponent fibers, or may all be non-circular outermost cross-section multicomponent fibers.

[0077] Figures 9A-9H Examples of cross-sectional views of some non-limiting examples of multiple crimped multi-component fibers according to certain embodiments of the present invention are shown. Figures 9A-9H As shown, the crimped fiber 50 may include a first polymer component 52 of a first polymer composition A and a second polymer component 54 of a second polymer composition B. The first and second components 52 and 54 may be arranged in substantially distinct zones within the cross-section of the crimped fiber, the zones extending substantially continuously along the length of the crimped fiber. The first and second components 52 and 54 may be arranged in a side-by-side arrangement such as Fig.9A In circular cross-section fibers as shown, or arranged as Figure 9G and 9H In the ribbon-shaped (e.g., non-circular) cross-section fiber shown. Additionally or alternatively, the first and second components 52 and 54 can be arranged in a sheath / core arrangement, such as Fig. 9B and 9C Eccentric skin / core arrangement shown. Fig. 9B In the eccentric sheath / core crimped fiber shown, one component completely encloses or surrounds the other component, but is asymmetrically positioned in the crimped fiber to cause the fiber to be crimped (e.g., first component 52 surrounds component 54). Fig. 9C The eccentric sheath / core configuration shown includes a first component 52 (e.g., sheath component) that substantially surrounds a second component 54 (e.g., core component), but not completely because a portion of the second component may be exposed and form a portion of the outermost surface of the fiber 50. As another example, a plurality of crimped multicomponent fibers may include, for example, Fig.9D and9E The hollow fibers shown or Fig.9F Multilobal fibers shown. However, it should be noted that many other cross-sectional configurations and / or fiber shapes may be suitable according to certain embodiments of the present invention. In multicomponent fibers, according to certain embodiments of the present invention, the polymer components may be present in a ratio (by volume or mass) of about 85:15 to about 15:85. According to certain embodiments of the present invention, a ratio of about 50:50 (by volume or mass) may be ideal; however, the specific ratio used may vary as desired, such as up to about any of the following: 85:15, 80:20, 75:25, 70:30, 65:35, 60:40, 55:45 and 50:50 by volume or mass and / or at least about any of the following: 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80 and 15:85 by volume or mass.

[0078] According to certain embodiments of the present invention, the plurality of crimped multi-component fibers may include self-crimped fibers, wherein the crimped portion is formed during the layup process. In this regard, the plurality of crimped multi-component fibers may include (i) a first component including a first polymer material having a first melt flow rate (MFR), such as, optionally, less than 500 g / 10 min, less than 400 g / 10 min, less than 300 g / 10 min, less than 200 g / 10 min, less than 100 g / 10 min, or less than 50 g / 10 min, and (ii) a second component including a second polymer material different from the first component, wherein the plurality of crimped multi-component fibers include one or more three-dimensional crimped portions. Optionally, the second polymeric material may comprise a second melt flow rate (MFR), which is, for example, optionally less than 2000 g / 10 min, 1500 g / 10 min, 1000 g / 10 min, 500 g / 10 min, less than 400 g / 10 min, less than 300 g / 10 min, less than 200 g / 10 min, less than 100 g / 10 min, or less than 50 g / 10 min. Additionally or alternatively, the plurality of crimped multicomponent fibers may comprise non-self-crimping fibers that require a post-crimping forming operation (e.g., heat activation) to impart the desired crimped portion.

[0079] As described above, the plurality of multicomponent fibers may include a first component comprising a first polymer composition and a second component comprising a second polymer composition, wherein the first polymer composition is different from the second polymer composition. For example, the first polymer composition may include a first polyolefin composition, and the second polymer composition may include a second polyolefin composition, polyester or polyamide. According to certain embodiments of the present invention, the first polyolefin composition may include a blend of a first polypropylene or polypropylene, and the second polyolefin composition may include a second polypropylene and / or a second polyethylene, wherein the first polyolefin composition has, for example, a first melt flow rate, and the second polymer composition (for example, the second polyolefin composition) has a second melt flow rate, wherein the first melt flow rate is different from the second melt flow rate. Additionally or alternatively, the first polypropylene or a blend of polypropylene may have a lower crystallinity than the second polymer composition (for example, the second polyolefin composition). According to certain embodiments of the present invention, the second polymer composition may include polyester, polyamide or biopolymer (for example, polylactic acid).

[0080] According to certain embodiments of the present invention, the first polymer composition and the second polymer composition may be selected so that the multi-component fiber forms one or more curls therein, without in the diffusion section after the stretching unit but before laying, once the stretching force is relaxed, and / or post-processing, such as additional heat is applied after fiber laying and web formation. Therefore, the polymer composition may contain polymers that are different from each other because they have different stress or elastic recovery properties, crystallization rates and / or melt viscosities. According to certain embodiments of the present invention, the polymer composition may be selected to self-curl by relying on the melt flow rate of the first and second polymer compositions as described and disclosed herein (for example, after the fiber is deposited from the spinneret, the post-curling operation may not be necessary). According to certain embodiments of the present invention, the multi-component fiber may, for example, form or have a curled fiber portion having a spiral curl in a single continuous direction. For example, a polymer composition may be substantially continuously located on the inner side of the spiral formed by the curling properties of the fiber. As described above, a plurality of curled multi-component fibers may include non-self-curling fibers that require a post-curling forming operation (e.g., heat activation) to impart the desired curled portion.

[0081] According to certain embodiments of the present invention, the plurality of crimped multicomponent fibers may include (i) a first plurality of crimped multicomponent fibers having a first identifying characteristic (e.g., a first cross-sectional geometry, a first chemical configuration, or a first crimp percentage per given fiber length), and (ii) a second plurality of crimped multicomponent fibers having a second identifying characteristic (e.g., a second cross-sectional geometry, a second chemical configuration, or a second crimp percentage per given fiber length), wherein the first identifying characteristic is different from the second identifying characteristic. For example, the first plurality of crimped multicomponent fibers may include a polyolefin as at least a portion thereof (e.g., a component of the multicomponent fibers), and the second plurality of crimped multicomponent fibers may include a different polyolefin composition or a non-polyolefin as at least a portion thereof.

[0082] According to certain embodiments of the present invention, a plurality of crimped multicomponent fibers may include, for example, a first component (e.g., different phases) and a second component (e.g., different phases), the first component including or consisting of a polymer material including a polyolefin, such as a polypropylene homopolymer, and the second component including or consisting of a different polymer material including a different polyolefin, such as a polypropylene copolymer. The polypropylene copolymer may, for example, be a polypropylene random copolymer or a polypropylene block copolymer. For example, the polypropylene copolymer may include a small amount of wt% C2 or C 4- C8 α-olefin units are distributed throughout the polypropylene copolymer. For example, C2 or C 4- The C8 alpha-olefin units may comprise from about 1 to about 20 wt% of the propylene copolymer, such as at least about any of 1, 2, 3, 5, 6, 8, and 10 wt% of the propylene copolymer, and / or up to about any of 20, 18, 16, 15, 14, 12, and 10 wt% of the propylene copolymer. According to certain embodiments of the present invention, the first component (e.g., a polypropylene homopolymer) may comprise from about 20 to 80 wt% of the crimped multicomponent fiber, such as at least about any of 20, 25, 30, 35, 40, 45, 50, 55, and 60 wt% of the crimped multicomponent fiber, and / or up to about any of 80, 75, 70, 65, and 60 wt% of the crimped multicomponent fiber. Additionally or alternatively, the second component (e.g., a polypropylene copolymer) may comprise from about 20 to 80 wt % of the crimped multicomponent fiber, such as at least about any of 20, 25, 30, 35, 40, 45, 50, 55, and 60 wt % of the crimped multicomponent fiber, and / or at most about any of 80, 75, 70, 65, and 60 wt % of the crimped multicomponent fiber.

[0083] According to certain embodiments of the present invention, a plurality of monocomponent fibers may include, for example, a plurality of first-type monocomponent fibers, the first-type monocomponent fibers comprising a third polymer composition different from the first polymer composition and the second polymer composition. Alternatively, a plurality of monocomponent fibers may include, for example, a plurality of first-type monocomponent fibers, the first-type monocomponent fibers comprising a third polymer composition identical to the first polymer composition or the second polymer composition. For example, the third polymer composition may include a third polyolefin composition, polyester or polyamide. According to certain embodiments of the present invention, the third polyolefin composition may include a blend of a third polypropylene or polypropylene and / or a third polyethylene. Additionally or alternatively, the third polymer composition may include a biopolymer (e.g., polylactic acid). According to certain embodiments of the present invention, a plurality of monocomponent fibers may include, for example, a plurality of second-type monocomponent fibers, the second-type monocomponent fibers comprising a fourth polymer composition different from the third polymer composition, and wherein the fourth polymer composition may be different from the first polymer composition and the second polymer composition. Alternatively or additionally, a plurality of monocomponent fibers may include, for example, a plurality of second-type monocomponent fibers, the second-type monocomponent fibers comprising a fourth polymer composition different from the third polymer composition, and wherein the fourth polymer composition may be identical to the first polymer composition or the second polymer composition. For example, the 4th polymer composition can include the 4th polyolefin composition, polyester or polyamide. According to certain embodiments of the present invention, the 4th polyolefin composition can include the blend of the 4th polypropylene or polypropylene and / or the 4th polyethylene. Additionally or alternatively, the 4th polymer composition can include biopolymer (for example, polylactic acid).

[0084] According to certain embodiments of the present invention, a plurality of monocomponent fibers may include, for example, a polymer material comprising a polymer component, the polymer component comprising a polyolefin (e.g., a polypropylene homopolymer or a polypropylene copolymer) or consisting of a polyolefin. According to certain embodiments of the present invention, a plurality of monocomponent fibers may include, for example, a polymer material that is completely different from each of those polymers used in the multicomponent fibers or is the same as one of the polymer materials used in the multicomponent fibers. For example, a plurality of multicomponent fibers may include at least one component, the at least one component comprising a polypropylene copolymer as described above or consisting of a polypropylene copolymer as described above. According to certain embodiments of the present invention, a plurality of monocomponent fibers may include a polymer material having a polymer component, the polymer component comprising a polypropylene copolymer or consisting of a polypropylene copolymer (e.g., the same or different from that of the multicomponent fibers). The polypropylene copolymer of the plurality of monocomponent fibers may, for example, be a polypropylene random copolymer or a polypropylene block copolymer. For example, the polypropylene copolymer may include a small amount of wt % of C2 or C 4- C8 α-olefin units are distributed throughout the polypropylene copolymer. For example, C2 or C 4-The C8 α-olefin units may comprise from about 1 to about 20 wt % of the propylene copolymer, e.g., at least about any of 1, 2, 3, 5, 6, 8, and 10 wt % of the propylene copolymer, and / or up to about any of 20, 18, 16, 15, 14, 12, and 10 wt % of the propylene copolymer.

[0085] According to certain embodiments of the present invention, a plurality of monocomponent fibers may include all circular outermost cross-section monocomponent fibers or all non-circular outermost cross-section monocomponent fibers. Alternatively, a plurality of monocomponent fibers may include a combination of circular outermost cross-section monocomponent fibers and non-circular outermost cross-section monocomponent fibers. For example, the circular outermost cross-section monocomponent fibers may account for 1 to about 99% of the total number of monocomponent fibers, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of monocomponent fibers, and / or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number of monocomponent fibers. Additionally or alternatively, the non-circular outermost cross-section monocomponent fibers may comprise from 1% to about 99% of the total number of monocomponent fibers, for example at least about any of 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45 and 50% of the total number of monocomponent fibers, and / or at most about any of 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55 and 50% of the total number of monocomponent fibers.

[0086] According to certain embodiments of the present invention, the nonwoven fabric may have a weight of less than about 70 kg / m 3 Density, for example up to about any of the following: 70, 60, 55, 50, 45, 40, 35, 30 and 25 kg / m 3 and / or at least about any of the following: 10, 15, 20, 25, 30, 35, 40, 45, 50 and 55 kg / m 3 Additionally or alternatively, the nonwoven fabric may have a thickness in a z-direction perpendicular to the longitudinal and transverse directions of the nonwoven fabric, the thickness comprising about 0.3 mm to about 4 mm, for example, up to about any of 4, 3.8, 3.5, 3.2, 3, 2.75, 2.5, 2.25, 2, 1.75, 1.5, 1.25, 1.0, 0.75, and 0.5 mm and / or at least about any of 0.3, 0.4, 0.5, 0.75, 1.0, 1.25, 1.5, 1.75, and 2.0 mm.

[0087] According to certain embodiments of the present invention, the nonwoven fabric can have a bonding area of ​​about 1% to about 40%, such as at least about any of the following: 1.2, 3, 5, 6, 8, 10, 12, 15, 18, 20, 21 and 22%, and / or at most about any of the following: 40, 38, 35, 32, 30, 28, 25 and 22%. In this regard, the bonding area can be defined by a plurality of separate bonding sites, such as a plurality of thermal point bonding (e.g., via thermal calendering or ultrasonic bonding). Alternatively, the nonwoven fabric is hot air bonded.

[0088] According to certain embodiments of the present invention, the nonwoven fabric may have a ΔPillGrade value of about 0.05 to about 0.35 after 60 frictions (i.e., the PillGrade value before being worn through the Martindale abrasion tester minus the PillGrade value after being worn a predetermined number of times through the Martindale abrasion tester), for example, at least about any one of the following values: 0.05, 0.08, 0.1, 0.15 and 0.2, and / or at most about any one of the following: 0.35, 0.32, 0.3, 0.25 and 0.2. Additionally or alternatively, the nonwoven fabric can have a ΔPillGrade value of about 0.05 to about 0.6 after 120 rubs, e.g., at least about any of the following values: 0.05, 0.08, 0.1, 0.15, 0.2, 0.25, and 0.3, and / or at most about any of the following: 0.6, 0.55, 0.5, 0.45, 0.4, 0.35, 0.32, and 0.3. Additionally or alternatively, the nonwoven fabric can have a ΔPillGrade value of about 0.1 to about 0.8 after 180 rubs, e.g., at least about any of the following values: 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, and 0.4, and / or at most about any of the following: 0.8, 0.75, 0.7, 0.65, 0.6, 0.55, 0.5, 0.45, and 0.4.

[0089] On the other hand, the present invention provides a method for making a nonwoven fabric, such as those described and disclosed herein. According to certain embodiments of the present invention, the method may include the following steps: (i) melt spinning a group of fibers, such as those described and disclosed herein, from a single spinneret simultaneously, wherein the group of fibers comprises a plurality of monocomponent fibers, such as optionally a plurality of monocomponent fibers of different types, the plurality of monocomponent fibers of different types comprising a plurality of monocomponent fibers of a first type and a plurality of monocomponent fibers of a second type, and a plurality of multicomponent fibers, and wherein the group of fibers forms at least one first region and at least one second region, the at least one first region comprising at least a majority of a first monocomponent fiber group of a plurality of monocomponent fibers, the at least one second region comprising at least a majority of a first multicomponent fiber group of a plurality of multicomponent fibers; (ii) collecting a group of melt-spun fibers; and (iii) forming a plurality of crimped multicomponent fibers by actively and / or passively forming one or more crimped portions in at least a portion of the multicomponent fibers.

[0090] According to certain embodiments of the present invention, the step of forming a plurality of crimped multicomponent fibers may include allowing the multicomponent fibers to self-crimp during the deposition process prior to the step of collecting the melt-spun fibers. Additionally or alternatively, the step of forming a plurality of crimped multicomponent fibers may include actively subjecting the multicomponent fibers to a sufficient amount of heat to induce the formation of one or more crimped portions, wherein the step of actively subjecting the multicomponent fibers to heat is performed before and / or after the step of collecting the melt-spun group of fibers. According to certain embodiments of the present invention, the method may include a combination of passively allowing the multicomponent fibers to self-crimp during the deposition process prior to the step of collecting the melt-spun fibers, and further subjecting the fibers to an active crimp forming process.

[0091] According to certain embodiments of the present invention, the method may include a step of consolidating the melt-spun fibers (e.g., consolidating a melt-spun nonwoven web to form a nonwoven fabric). The consolidation method may include a thermal bonding operation, such as a thermal calendering operation, a hot zone bonding operation, or an ultrasonic bonding operation. Alternatively, the consolidation method may include a hot air bonding process.

[0092] Example

[0093] The present disclosure is further illustrated by the following examples, which should in no way be construed as limiting. That is, the specific features described in the following examples are merely illustrative and not limiting.

[0094] Various bulky and elastic spunbond nonwoven fabrics were prepared, which highlight some benefits associated with bulky and elastic spunbond nonwoven fabrics (e.g., increased abrasion resistance, as illustrated by PillGrade measurement as described below), the bulky and elastic spunbond nonwoven fabrics are formed by a spinneret including a combination of bicomponent spinnerets and monocomponent spinnerets, and the bicomponent spinnerets form crimped bicomponent spunbond fibers having a side-by-side configuration. Samples 1 and 2 are control samples, in which all fibers are crimped spunbond fibers, but different combinations of polymer materials (e.g., polymers) are used to form the corresponding components of the fibers. Samples 3-6 show fluffy spunbond nonwoven fabrics according to certain embodiments of the present invention, wherein the spinneret used to form the samples provides 70% of the crimped bicomponent fibers and 30% of the monocomponent fibers.

[0095] Each sample was prepared from one or more of the following polymers:

[0096] Polymer 1 is a polypropylene homopolymer (ie, Exxon PP3155 from Exxon Corporation) having an MFR of 36 g / 10 min as measured according to ASTM D1238 (230°C / 2.16 kg) and a melting temperature of 165°C.

[0097] Polymer 2 is a propylene random copolymer having an MFR of 32 g / 10 min as measured according to ASTM D1238 (230°C / 2.16 kg) and a melting temperature of 149°C.

[0098] Polymer 3 is a different propylene random copolymer having an MFR of 35 g / 10 min as measured according to ASTM D1238 (230°C / 2.16 kg) and a melting temperature of 143°C.

[0099] Sample 1:

[0100] Sample 1 is a first control in which the nonwoven fabric is composed of 100% crimped bicomponent fibers in which the first component is formed from polymer 1 and the second component is formed from polymer 2. Polymer 1 comprises 60 wt% and polymer 2 comprises 40 wt%.

[0101] Sample 2:

[0102] Sample 2 is a second control in which the nonwoven fabric is composed of 100% crimped bicomponent fibers in which the first component is formed from polymer 1 and the second component is formed from polymer 3. Polymer 1 comprises 60% by weight and polymer 3 comprises 40% by weight.

[0103] Sample 3:

[0104] Sample 3 represents an exemplary nonwoven fabric according to some embodiments of the present invention. The nonwoven fabric is formed by 70% of the number of crimped bicomponent fibers and 30% of the monocomponent fibers, and the monocomponent fibers are provided by the same spinneret. The bicomponent fibers are formed by polymer 1 and polymer 2, wherein polymer 1 accounts for 60% by weight of the bicomponent fibers and polymer 2 accounts for 40% by weight of the bicomponent fibers. The monocomponent fibers are made of polymer 1.

[0105] Sample 4:

[0106] Sample 4 represents another exemplary nonwoven fabric according to certain embodiments of the present invention. The nonwoven fabric is formed by 70% of the number of crimped bicomponent fibers and 30% of the monocomponent fibers, and the monocomponent fibers are provided by the same spinneret. The bicomponent fibers are formed by polymer 1 and polymer 3, wherein polymer 1 accounts for 60% by weight of the bicomponent fibers and polymer 3 accounts for 40% by weight of the bicomponent fibers. The monocomponent fibers are made of polymer 1.

[0107] Sample 5:

[0108] Sample 5 represents another exemplary nonwoven fabric according to certain embodiments of the present invention. The nonwoven fabric is formed by 70% of the number of crimped bicomponent fibers and 30% of the monocomponent fibers, and the monocomponent fibers are provided by the same spinneret. The bicomponent fibers are formed by polymer 1 and polymer 2, wherein polymer 1 accounts for 60% by weight of the bicomponent fibers and polymer 2 accounts for 40% by weight of the bicomponent fibers. The monocomponent fibers are made of polymer 2.

[0109] Sample 6

[0110] Sample 6 represents another exemplary nonwoven fabric according to certain embodiments of the present invention. The nonwoven fabric is formed by 70% of the number of crimped bicomponent fibers and 30% of the monocomponent fibers, and the monocomponent fibers are provided by the same spinneret. The bicomponent fibers are formed by polymer 1 and polymer 3, wherein polymer 1 accounts for 60% by weight of the bicomponent fibers and polymer 3 accounts for 40% by weight of the bicomponent fibers. The monocomponent fibers are made of polymer 3.

[0111] Test scheme representative of wear resistance

[0112] 1300 Martindale abrasion and pilling testers (Martindale Abrasion and Pilling Tester) with 9 test positions and PillGrade test devices commercially available from SDL ATLAS company are used to evaluate the wear resistance of each sample. In particular, the part of each sample is subjected to Martindale abrasion test according to ASTM D4970 or ISO 12945-2 on the embossing roller side, wherein Spec Setup B (9kPa ​​weight, 60 frictions, 120 frictions and 180 frictions, 47.5rpm speed) is carried out. In this regard, one side of the adjacent embossing roller of the nonwoven material is rubbed with the opposite side of the nonwoven material (for example, so any rubber is removed from the top, and the nonwoven material is directly placed on the supporting foam). In this regard, the Martindale abrasion test of 60 frictions is carried out on each part of each sample, and another part of each sample is subjected to 120 frictions, and another part of each sample is subjected to 180 frictions.

[0113] After each corresponding sample portion is subjected to the respective number of rubs of the Martindale abrasion test, the original sample portion of each sample (e.g., the sample portion before rubbing) and each corresponding sample portion subjected to the Martindale abrasion test are tested by a PillGrade unit according to ASTM D4970 or ISO 12945-2, which measures the effect of abrasion on a fabric, wherein a value of "5" is no abrasion, and lower values ​​or scores indicate that the fabric shows more "pilling" or entangled fibers or final "small balls" (e.g., increased abrasion). In other words, the sample portions of the sample are slightly different before the abrasion test and after the cycle (through 60, 120 and 180 rubs of the Martindale abrasion test) and then sent to the PillGrade test unit to measure "PillGrade" (e.g., a value of "5" is as low as zero abrasion, while values ​​closer to "0" indicate a greater amount or level of abrasion).

[0114] In this regard, the numerical ratings of "pilling" between different samples are compared to illustrate the improved wear resistance of nonwoven fabrics according to certain embodiments of the present invention. Ultimately, the score or value closer to the difference between the pre-wear value (i.e., not rubbed in the Martindale wear test device) and the post-rub value at different cycles determines the wear performance. In this regard, the smallest increment or difference between the pre-wear value (i.e., '0' times rubbed) and the numerical rub is the best performing material. Table 1 provides a summary of the various Pillgrade values.

[0115]

[0116] As shown in the data of Table 1, samples 3-6 all exhibit significantly improved abrasion resistance compared to the control (i.e., samples 1 and 2), which is evident by the reduction in the average difference values ​​(e.g., the average difference of the average loss after 60 rubs, the average loss after 120 rubs, and the average loss after 180 rubs) reported in the rightmost column of Table 1. Samples 5 and 6 each illustrate the unexpected results of forming monocomponent fibers from propylene random copolymers. The average difference values ​​reported in the rightmost column of Table 1 for sample 5 are '0.15', while those for sample 6 are '0.24', which are 30-50% of the values ​​for samples 3-4 and 20-35% of the values ​​for samples 1-2.

[0117] Without departing from the spirit and scope of the present invention, those of ordinary skill in the art may make these and other modifications and variations to the present invention, the spirit and scope of the present invention being more particularly set forth in the appended claims. In addition, it should be understood that the aspects of the various embodiments may be interchangeable in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is merely exemplary and is not intended to limit the present invention as further described in these appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein.

Claims

1. A spinneret for melt-spinning polymer fibers, comprising: a spinneret body comprising a plurality of spinneret holes formed through a thickness of the spinneret body; The plurality of spin holes include (i) a plurality of multi-component spin holes including a first multi-component opening and a separate second multi-component opening, and (ii) a plurality of single-component spin holes including a single single-component opening.

2. The spinneret according to claim 1, wherein The plurality of multicomponent spinholes define at least one first zone, and the plurality of monocomponent spinholes define at least one second zone.

3. The spinneret according to claim 2, wherein The at least one first region includes a plurality of first regions, and the at least one second region includes a plurality of second regions.

4. The spinneret according to claim 1, wherein The plurality of spinholes defines a total number of spinholes, and wherein the plurality of multicomponent spinholes account for about 60 to about 99% of the total number of spinholes and the plurality of monocomponent spinholes account for about 1 to about 40% of the total number of spinholes.

5. A nonwoven fabric comprising: A plurality of interwoven fibers, including a plurality of monocomponent fibers and a plurality of crimped multicomponent fibers, wherein the nonwoven fabric comprises at least one first region and at least one second region, the at least one first region comprising at least a majority of a first monocomponent fiber group of the plurality of monocomponent fibers, and the at least one second region comprising at least a majority of a first multicomponent fiber group of the plurality of crimped multicomponent fibers.

6. The nonwoven fabric according to claim 5, wherein: The first monocomponent fiber group defines a first outermost surface of the nonwoven fabric.

7. The nonwoven fabric according to claim 6, wherein: The at least one first region also includes a second monocomponent fiber group of the plurality of monocomponent fibers, and wherein the second monocomponent fiber group defines a second outermost surface of the nonwoven fabric, and wherein the first multicomponent fiber group is positioned adjacent to the first monocomponent fiber group, the second monocomponent fiber group, or both.

8. The nonwoven fabric according to claim 5, wherein: The first multicomponent fiber group defines a first outermost surface of the nonwoven fabric.

9. The nonwoven fabric according to claim 8, wherein: The at least one second region also includes a second multicomponent fiber group of the plurality of multicomponent fibers, and wherein the second multicomponent fiber group defines a second outermost surface of the nonwoven fabric, and wherein the first monocomponent fiber group is positioned adjacent to the first multicomponent fiber group, the second multicomponent fiber group, or both.

10. The nonwoven fabric according to claim 5, wherein: The at least one first region includes a plurality of first regions, and the at least one second region includes a plurality of second regions.

11. The nonwoven fabric according to claim 10, wherein: The plurality of first regions and the plurality of second regions are positioned in an alternating pattern along the longitudinal direction of the nonwoven fabric, along a z-direction perpendicular to the longitudinal and transverse directions, or both; or wherein the plurality of first regions and the plurality of second regions are positioned in an alternating pattern along the transverse direction of the nonwoven fabric, along a z-direction perpendicular to the transverse and longitudinal directions, or both.

12. The nonwoven fabric according to claim 10, wherein: The plurality of first regions and the plurality of second regions are positioned in an alternating pattern along the transverse and longitudinal directions; or wherein the plurality of first regions and the plurality of second regions are also positioned in an alternating pattern in the z direction of the nonwoven fabric, wherein the z direction is perpendicular to the transverse and longitudinal directions.

13. The nonwoven fabric according to claim 7, wherein: The at least one second region comprises a continuous network of the plurality of curled multicomponent fibers, and the at least one first region comprises a plurality of first regions comprising separate islands of a plurality of monocomponent fibers dispersed in the continuous network of the plurality of curled multicomponent fibers; or wherein the at least one first region comprises a continuous network of the plurality of monocomponent fibers, and the at least one second region comprises a plurality of second regions comprising separate islands of curled multicomponent fibers dispersed in the continuous network of the plurality of monocomponent fibers.

14. The nonwoven fabric according to claims 5-13, wherein: The nonwoven fabric has a total basis weight, and the plurality of monocomponent fibers comprises from about 1 to about 40 wt % of the total basis weight, and / or the plurality of multicomponent fibers comprises from about 60 to about 99 wt % of the total basis weight.

15. A method of producing a nonwoven fabric, comprising: (i) simultaneously melt spinning a group of fibers from a single spinneret, the group of fibers comprising a plurality of monocomponent fibers and a plurality of multicomponent fibers, wherein the group of fibers forms at least one first region and at least one second region, the at least one first region comprising at least a majority of a first monocomponent fiber group of the plurality of monocomponent fibers, and the at least one second region comprising at least a majority of a first multicomponent fiber group of the plurality of multicomponent fibers; (ii) collecting a group of melt-spun fibers; as well as (iii) forming a plurality of crimped multicomponent fibers by actively and / or passively forming one or more crimped portions in at least a portion of the multicomponent fibers.

Images