Nonwoven fabric having a single layer with multiple different fiber types, and apparatus, systems and methods for producing same

Abstract

One or more aspects of the present disclosure provide a nonwoven fabric comprising a single fiber layer, where each fiber type comprises a plurality of different fibers having a desired functionality. In one aspect, a system is provided for preparing a nonwoven fabric having a single woven layer, where the single woven layer comprises a plurality of different fiber types. The system includes a spin beam having a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate having a plurality of distribution openings disposed in a plurality of zones, each zone constructed and arranged to extrude a plurality of polymer streams to the spinneret that are a different polymer type than the polymer streams extruded by an adjacent zone.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 136,122, filed January 11, 2021, the contents of which are incorporated by reference in their entirety herein.

[0002] The presently disclosed invention relates generally to nonwoven fabrics, and more particularly to nonwoven fabrics having stratified woven layers having two or more regions of desired functionality. [Background technology]

[0003] Nonwoven fabrics are used in a variety of applications, including apparel, disposable medical products, and absorbent articles (e.g., diapers and personal hygiene products), among others. New products being developed for these applications require stringent performance requirements, including comfort, conformity to the body, freedom of body movement, good softness and drape, adequate tensile strength and durability, and resistance to surface abrasion, pilling, or fuzzing. Thus, nonwoven fabrics used in these types of products must be designed to meet these performance requirements.

[0004] In some situations, it may be desirable for the nonwoven to also exhibit different properties or a combination of properties within the nonwoven. To achieve this goal, it is typically necessary to combine multiple layers of nonwoven to form a composite structure. This typically involves the use of multiple spin beams to prepare multiple nonwoven layers, with each individual layer imparting a desired property to the resulting composite nonwoven.

[0005] In addition to the use of multiple spin beams, the individual layers must also be adhered together using, for example, thermal, mechanical or chemical lamination techniques.

[0006] The use of multiple spin beams necessarily increases the complexity and cost associated with producing a nonwoven fabric that exhibits different properties in different areas of the nonwoven fabric. Summary of the Invention [Problem to be solved by the invention]

[0007] Although much effort has gone into the development of nonwoven fabrics, there remains a need for products that exhibit multiple properties and functionalities. [Means for solving the problem]

[0008] One or more embodiments of the present invention provide a nonwoven fabric comprising a single layer comprising a plurality of different fibers, each fiber type having a desired functionality.

[0009] In one embodiment, aspects of the invention are directed to a system for preparing a nonwoven fabric having a single woven layer, the single woven layer comprising a plurality of different fiber types, the system comprising: a first polymer source configured to provide a stream of a molten or semi-molten first polymer; a second polymer source configured to provide a stream of a molten or semi-molten second polymer, where the first polymer and the second polymer are of different types; a spin beam in fluid communication with the first polymer source and the second polymer source, the spin beam comprising a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone constructed and arranged to extrude a plurality of polymer streams to the spinneret, the polymer streams being of a different polymer type than the polymer streams extruded by an adjacent zone; and a collecting surface disposed below the spinneret, the collecting surface having continuous filaments deposited thereon to form a single layer comprising two or more types of fibers, the two or more types being of different types from one another.

[0010] In some embodiments, the zoned distribution plate includes 2 to 10 zones, such as 2 to 4 zones, or 2 to 3 zones.

[0011] In some embodiments, the zoned distribution plate comprises a first zone configured to produce multicomponent filaments and a second zone configured to produce monocomponent filaments, hi some embodiments, the first polymer source comprises polypropylene and the second polymer source comprises a different polypropylene.

[0012] In some embodiments, the zoned distribution plate comprises a first zone configured to produce crimped filaments and a second zone configured to produce non-crimped or low crimped filaments. In a preferred embodiment, the first polymer source comprises metallocene catalyzed propylene and the second polymer source comprises Ziegler-Natta catalyzed polypropylene. In some embodiments, the first polymer source comprises a blend of standard spunbond polypropylene (e.g., melt flow rate of 20-40 g / 10 min) with a polypropylene-based additive, such as a high melt flow rate polypropylene (e.g., melt flow rate of about 500 to about 2000 g / 10 min) or a polypropylene with low isotacticity.

[0013] In some embodiments, the zoned distribution plate comprises a plurality of zones extending longitudinally in a cross direction of the spin beam, hi some embodiments, the zoned distribution plate comprises a plurality of zones extending transversely in a machine direction of the spin beam.

[0014] In some embodiments, the system further includes a third polymer source and / or a fourth polymer source in fluid communication with the spin beam, where the third polymer source and / or the fourth polymer source are configured to provide a stream of molten or semi-molten third polymer and / or fourth polymer.

[0015] In some embodiments, the first polymer source comprises a first polypropylene polymer and the second polymer source comprises a second polypropylene polymer that is different from the first polypropylene polymer.

[0016] In some embodiments, the first distribution zone is configured to extrude a polymer stream comprising monocomponent filaments, and the second distribution zone is configured to extrude a polymer stream having a sheath / core configuration comprising the first polypropylene polymer and the second polypropylene polymer.

[0017] In some embodiments, the first polymer source comprises a first polymer, and the second polymer source comprises a second polymer that is blended with a functional additive that is not blended with the first polymer. Examples of functional additives may include colorants, UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblock agents, slip agents, optical brighteners, flame retardants, and antimicrobial agents.

[0018] In one embodiment, the first distribution zone has about 20 to about 40 rows of distribution apertures arranged in the cross direction of the spin beam, and the second distribution zone has about 20 to about 40 rows of distribution apertures arranged in the cross direction of the spin beam.

[0019] In some embodiments, the ratio of the number of rows of distribution openings in the first distribution zone to the number of rows of distribution openings in the second distribution zone is 10:90 to 90:10, particularly 30:70 to 70:30, and more particularly about 50:50.

[0020] In some embodiments, the zoned distribution plate comprises a third distribution zone, and the second distribution zone is sandwiched between the first distribution zone and a third distribution zone.

[0021] In some embodiments of the invention, the first distribution zone and the third distribution zone are in fluid communication with the first polymer source. In one embodiment, the first distribution zone and the second distribution zone are configured to produce low crimp or non-crimp filaments, and the second distribution zone is configured to produce crimped filaments.

[0022] In some embodiments, the system is configured to produce a stratified textile layer having two or more regions of different fiber types. In these embodiments, the stratified textile layer is extruded from the spin beam as a single layer.

[0023] In some embodiments, the system may be configured to produce a nonwoven layer having multiple fiber types, where the multiple fiber types are intermingled throughout the thickness of the woven layer.

[0024] In some embodiments, the system may also include a bonding unit for bonding the fibers together to form a coherent web. Examples of bonding include thermal, mechanical, and chemical bonding. In one embodiment, the bonding unit includes a calendar bonding unit.

[0025] Embodiments of the present invention are also directed to the use of the system and the zoned distribution plate of the present invention in the manufacture of nonwoven fabrics.

[0026] In one embodiment, the present invention is directed to the use of a nonwoven fabric having multiple different fiber types in the manufacture of absorbent articles. In particular, an embodiment of the present invention may be directed to the use of the system having the zoned distribution plate in the manufacture of absorbent articles.

[0027] An embodiment of the present invention is also directed to the zoned distribution plate for use in a spunbond system for preparing spunbond nonwoven fabrics having multiple different fiber types within a single woven layer.

[0028] In one embodiment, the present invention is directed to a system for preparing a nonwoven fabric having a stratified woven fabric layer, the system comprising: a first polymer source configured to provide a stream of a molten or semi-molten first polymer; a second polymer source configured to provide a stream of a molten or semi-molten second polymer, where the first polymer and the second polymer are of different types; a spin beam in fluid communication with the first polymer source and the second polymer source, the spin beam comprising a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone constructed and arranged to extrude a plurality of polymer streams to the spinneret that are of a different polymer type than the polymer streams extruded by an adjacent zone; and a collection surface disposed below the spinneret, onto which continuous filaments are deposited to form a stratified nonwoven fabric. The collecting surface forms a layered nonwoven fabric, where the layered nonwoven fabric includes a single layer having two or more regions where adjacent regions are different fiber types.

[0029] In one embodiment of a system for preparing a stratified woven fabric layer, the zoned distribution plate includes a first zone configured to produce multicomponent filaments and a second zone configured to produce monocomponent filaments. In some embodiments, the zoned distribution plate includes between 2 and 10 zones.

[0030] In some embodiments of the system for preparing a stratified woven fabric layer, the zoned distribution plate comprises a first zone configured to produce crimped filaments and a second zone configured to produce non-crimped or low crimped filaments. In one embodiment, the zoned distribution plate comprises a plurality of zones extending longitudinally in a cross direction of the spin beam. In some embodiments, the zoned distribution plate comprises a plurality of zones extending transversely in a machine direction of the spin beam.

[0031] In certain embodiments of the system for preparing a stratified woven fabric layer, the system further comprises a third polymer source or a fourth polymer source in fluid communication with the spin beam, wherein the third polymer source and / or the fourth polymer source are configured to provide a stream of a molten or semi-molten third polymer and / or fourth polymer.

[0032] Aspects of the invention are also directed to a method of preparing a nonwoven fabric having a single woven layer, the single woven layer comprising a plurality of different fiber types, the method including: providing a first polymer source configured to provide a stream of a molten or semi-molten first polymer; providing a second polymer source configured to provide a stream of a molten or semi-molten second polymer, where the first polymer and the second polymer are of different types; introducing the first polymer stream and the second polymer stream into a spin beam in fluid communication with the first polymer source and the second polymer source, where the spin beam is coupled to a zoned distribution plate (or stack of distribution plates) disposed upstream of a spinneret. the zoned distribution plate having a plurality of distribution openings arranged in a plurality of zones, each zone constructed and arranged to extrude a plurality of polymer streams into the spinneret, the polymer streams being a different polymer type than the polymer streams extruded by an adjacent zone; extruding a first stream of the first polymer from the spinneret as first continuous filaments; extruding a second stream of the second polymer from the spinneret as second continuous filaments; and collecting the first and second continuous filaments on a collection surface disposed below the spinneret to form a single layer comprising the first and second continuous filaments of different types.

[0033] In some embodiments of the present invention, the zoned distribution plate comprises between 2 and 10 zones.

[0034] In one embodiment of the method, the zoned distribution plate includes a first zone configured to produce multicomponent filaments and a second zone configured to produce monocomponent filaments. In one embodiment, the first polymer source comprises polypropylene and the second polymer source comprises polypropylene. The polypropylene of the first polymer source and the polypropylene of the second polymer source can be different or the same.

[0035] In one embodiment of the method, the zoned distribution plate includes a first zone configured to produce monocomponent filaments and a second zone configured to produce monocomponent filaments, where the polymer may be the same or different in each polymer stream.

[0036] In some embodiments, the method includes extruding a stream of the first polymer through a first zone of the zoned distribution plate to produce crimped filaments, and extruding a stream of the second polymer through a second zone of the zoned distribution plate to produce non-crimped or low crimp filaments.

[0037] In some embodiments, the method includes extruding the first polymer stream and the second polymer stream through a first zone comprising a side-by-side, IOS, segmented pie, or sheath / core (concentric or non-concentric) configured cross section of the zoned distribution plate to produce crimped filaments, while simultaneously extruding the first polymer stream and / or the second polymer stream through a second zone of the zoned one or more distribution plates configured to produce non-crimped or low crimped filaments.

[0038] In some embodiments of the present invention, the zoned distribution plate comprises a plurality of zones extending longitudinally in a cross direction of the spin beam.

[0039] In one embodiment of the method, the zoned distribution plate includes a plurality of zones extending transverse to the machine direction of the spin beam.

[0040] In one embodiment, the method further comprises providing a third polymer source in fluid communication with the spin beam, wherein the third polymer source is configured to provide a stream of molten or semi-molten third polymer. In yet another embodiment, the method comprises providing a fourth polymer source in fluid communication with the spin beam, wherein the fourth polymer source is configured to provide a stream of molten or semi-molten third polymer.

[0041] In certain embodiments of the method, the first polymer source comprises a first polypropylene polymer and the second polymer source comprises a second polypropylene polymer different from the first polypropylene polymer.

[0042] In one embodiment, the first distribution zone is configured to extrude a polymer stream comprising monocomponent filaments, and the second distribution zone is configured to extrude a polymer stream having a sheath / core configuration comprising the first polypropylene polymer and the second polypropylene polymer.

[0043] In one embodiment of the method, the first polymer source comprises a first polymer, and the second polymer source comprises a second polymer that is blended with a functional additive that is not blended with the first polymer.

[0044] Examples of functional additives that may be incorporated into one or more of the polymer sources include colorants, UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblock agents, slip agents, optical brighteners, flame retardants, and antimicrobial agents.

[0045] In some embodiments of the invention, the first distribution zone has about 10 to about 50 rows, e.g., about 20 to about 40 rows, of distribution openings arranged in the transverse direction of the spin beam, and the second distribution zone has about 10 to about 50 rows, e.g., about 20 to about 40 rows, of distribution openings arranged in the transverse direction of the spin beam.

[0046] In one embodiment, the ratio of the number of rows of distribution openings in the first distribution zone to the number of rows of distribution openings in the second distribution zone is 10:90 to 90:10, for example 30:70 to 70:30, in particular about 50:about 50.

[0047] In one embodiment of the method, the zoned distribution plate comprises a third distribution zone, and the second distribution zone is sandwiched between the first distribution zone and the third distribution zone. In one embodiment, the first distribution zone and the third distribution zone are in fluid communication with the first polymer source.

[0048] In one embodiment of the method, the first distribution zone and the second distribution zone are configured to produce low crimp or non-crimped filaments, and the second distribution zone is configured to produce crimped filaments.

[0049] In one embodiment, the method is configured to produce a stratified woven layer having two or more regions of different fiber types.

[0050] In some embodiments of the invention, the spin beam is configured to produce a nonwoven layer having multiple fiber types, where the multiple fiber types are intermingled throughout the thickness of the woven layer.

[0051] In some embodiments, the method includes the step of bonding, for example thermally, mechanically, or chemically, the fibers of the fabric to form a coherent fabric.

[0052] In one embodiment, aspects of the invention are directed to the use of the methods described herein in the manufacture of nonwoven fabrics.

[0053] In a further aspect, a spunbond nonwoven fabric is provided having a single woven layer including a plurality of continuous filaments bonded to one another to form a coherent web, wherein the plurality of continuous filaments include a first fiber type and a second fiber type different from the first fiber type.

[0054] In some embodiments, the fiber types are intermingled throughout the thickness of a single fabric layer. In some embodiments, the single fabric layer is a stratified fabric layer, where the first fiber type is predominantly disposed in a first region of the stratified fabric layer and the second fiber type is predominantly disposed in a second region of the stratified fabric layer.

[0055] In some embodiments, the single woven layer of the spunbond nonwoven fabric may include a third fiber type.

[0056] In some embodiments, the first fiber type comprises multicomponent filaments and the second fiber type comprises monocomponent filaments. In one embodiment, the first fiber type comprises polypropylene and the second fiber type comprises polypropylene. In one such embodiment, the first fiber type comprises crimped filaments and the second fiber type comprises non-crimped or low crimped filaments.

[0057] In some embodiments, the first fiber type comprises a first polypropylene polymer and the second fiber type comprises a second polypropylene polymer that is different from the first polypropylene polymer.

[0058] In some embodiments, the first fiber type comprises multicomponent filaments having a sheath / core configuration comprising the first polypropylene polymer and the second polypropylene polymer, and the second fiber type comprises monocomponent filaments comprising the first polypropylene polymer. In some embodiments, the multicomponent filaments comprise bicomponent fibers having a side-by-side configuration, an eccentric sheath / core configuration, or a D-centric sheath / core configuration.

[0059] In one embodiment of the spunbond nonwoven fabric, the first fiber type comprises a first polymer, and the second fiber type comprises a second polymer that is blended with a functional additive that is not blended with the first polymer. Examples of functional additives may include colorants, UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblock agents, slip agents, optical brighteners, flame retardants, and antimicrobial agents.

[0060] In a still further aspect, an embodiment of the present invention is directed to a multi-layered composite sheet material, the sheet material comprising at least one spunbond layer according to an embodiment of the present invention, i.e., a spunbond fabric having a single layer having a plurality of different fiber types.

[0061] In some embodiments, the composite sheet material comprises a spunbond fabric of the present invention and at least one meltblown fabric layer adhered to a surface of the spunbond fabric. For example, in some embodiments, a composite sheet material is provided in which a spunbond fabric layer of the present invention is sandwiched between two meltblown layers.

[0062] In other embodiments, the composite sheet material comprises at least one meltblown layer sandwiched between two spunbond layers, at least one of the spunbond layers individually comprising the single woven layer comprising a first fiber type and a second fiber type different from the first fiber type.

[0063] In one embodiment of the composite sheet material, the spunbond fabric layer having a single fabric layer comprises both crimped and non-crimped or low crimped filaments.

[0064] Having thus described the invention in general terms, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0065] [Figure 1] FIG. 1 illustrates a nonwoven fabric having a single layer in accordance with at least one embodiment of the present invention. [Diagram 2] FIG. 2 illustrates a nonwoven fabric having stratified woven layers in accordance with at least one embodiment of the present invention. [Diagram 3] FIG. 3 illustrates a system for preparing a nonwoven fabric having stratified woven layers in accordance with an embodiment of the present invention. [Figure 4] FIG. 4 shows a spin pack for use in the system shown in FIG. [Diagram 5] FIG. 5 illustrates various zoned distribution plates in accordance with embodiments of the present invention. [Figure 6] FIG. 6 illustrates various zoned distribution plates in accordance with embodiments of the present invention. [Figure 7] FIG. 7 illustrates various zoned distribution plates in accordance with embodiments of the present invention. [Figure 8] FIG. 8 illustrates various zoned distribution plates in accordance with embodiments of the present invention. [Figure 9] FIG. 9 illustrates various zoned distribution plates in accordance with embodiments of the present invention. [Figure 10] FIG. 10 illustrates a various zoned distribution plate according to an embodiment of the present invention. [Figure 11] FIG. 11 illustrates various zoned distribution plates in accordance with embodiments of the present invention. [Figure 12] FIG. 12 is a cross-sectional view of a nonwoven fabric, each fabric having layered woven layers, in accordance with at least one embodiment of the present invention. [Figure 13] FIG. 13 is a cross-sectional view of a nonwoven fabric, each fabric having layered woven layers, in accordance with at least one embodiment of the present invention. [Figure 14] FIG. 14 is a cross-sectional view of a nonwoven fabric, each fabric having layered woven layers, in accordance with at least one embodiment of the present invention. [Figure 15] FIG. 15 is a cross-sectional view of a nonwoven fabric, each fabric having layered woven layers, in accordance with at least one embodiment of the present invention. [Figure 16] FIG. 16 is a cross-sectional view of a nonwoven fabric, each fabric having layered woven layers, in accordance with at least one embodiment of the present invention. [Figure 16a] FIG. 16a is a cross-sectional view of a multicomponent fiber according to one embodiment of the present invention. [Figure 17] FIG. 17 is a cross-sectional view of a nonwoven fabric, each fabric having layered woven layers, in accordance with at least one embodiment of the present invention. [Figure 18A] FIG. 18A illustrates various composite fabric structures in accordance with one or more embodiments of the present invention. [Figure 18B] FIG. 18B illustrates various composite fabric structures in accordance with one or more embodiments of the present invention. [Figure 18C] FIG. 18C illustrates various composite fabric structures in accordance with one or more embodiments of the present invention. [Figure 18D] FIG. 18D illustrates various composite fabric structures in accordance with one or more embodiments of the present invention. [Figure 19]FIG. 19 is a magnified image of the surface of a spunbond nonwoven fabric having a single fiber type. [Figure 20] FIG. 20 is a close-up of the surface of a spunbond nonwoven fabric having two different types of fiber types. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0066] The present invention will now be described in more detail with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied 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 legal requirements. Like numbers refer to like elements throughout.

[0067] The words "first," "second," "primary," "exemplary," "secondary," and the like do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Further, the words "a," "an," and "the" do not denote a limitation of quantity, but rather denote the presence of "at least one" of the referenced item.

[0068] It is contemplated that each embodiment disclosed herein is applicable to each other disclosed embodiment. All combinations and subcombinations of the various elements described herein are within the scope of the present invention.

[0069] Where a parameter range is provided, it is to be understood that all integers within that range, and tenths and hundredths thereof, are also provided by the present invention. For example, "5-10%" includes 5%, 6%, 7%, 8%, 9%, 10%, 5.0%, 5.1%, 5.2%......9.8%, 9.9%, and 10.0%; and 5.00%, 5.01%, 5.02%......9.98%, 9.99%, and 10.00%.

[0070] As used herein, the words "about," "approximately," and "substantially" in the context of a numerical value or range mean ±10% of the stated or claimed numerical value or range, and specifically encompass values ​​within the standard measurement error (e.g., SEM) of the stated value, or a variation of ±0.5%, ±1%, ±5%, or ±10% from the specified value.

[0071] For purposes of this application, the following terms shall have the following meanings:

[0072] The term "fiber" can refer to fibers of finite length or filaments of infinite length.

[0073] As used herein, the term "monocomponent" refers to fibers formed from one polymer or a single blend of polymers. Of course, this does not exclude fibers that have additives added for pigments, antistatic properties, lubricity, hydrophilicity, liquid repellency, etc.

[0074] As used herein, the term "multicomponent" refers to a fiber formed from at least two polymers (e.g., bicomponent fiber) extruded from separate extruders. The at least two polymers may each be independently the same or different from one another, or may be a blend of polymers. The polymers are arranged in distinct zones that are substantially uniformly spaced across the cross section of the fiber. The components may be arranged in any desired configuration, such as sheath-core, side-by-side, pie, island-in-the-sea, etc. Various methods for forming multicomponent fibers are described in U.S. Pat. No. 4,789,592 to Taniguchi et al., U.S. Pat. No. 5,336,552 to Strack et al., U.S. Pat. No. 5,108,820 to Kaneko et al., U.S. Pat. No. 4,795,668 to Kruege et al., U.S. Pat. No. 5,382,400 to Pike et al., U.S. Pat. No. 5,336,552 to Strack et al., and U.S. Pat. No. 6,200,669 to Marmon et al., which are incorporated herein by reference in their entireties. Multicomponent fibers having various irregular shapes are also described in U.S. Pat. No. 5,277,969 to Hogle et al., U.S. Pat. No. 5,162,074 to Hills, U.S. Pat. No. 5,466,410 to Hills, U.S. Pat. No. 5,069,970 to Largman et al., and U.S. Pat. No. 5,057,368 to Largman et al., which are incorporated by reference in their entireties.

[0075] As used herein, the terms "nonwoven," "nonwoven web," and "nonwoven fabric" refer to a structure or web of material that is formed without the use of a weaving or knitting process to produce a structure of individual fibers or threads that are intertwined but not in a discernible repeating manner. Nonwoven webs have been formed in the past by a variety of conventional processes, such as meltblown processes, spunbond processes, and staple fiber carding processes.

[0076] As used herein, the term "meltblowing" refers to a process in which fibers are formed by forcing a molten thermoplastic material through a plurality of fine, usually circular, die capillaries into a high velocity gas (e.g., air) stream that elongates the molten thermoplastic material to form fibers that can be of microfiber diameter. The meltblown fibers are then carried by the gas stream and deposited on a collecting surface to form a web of random meltblown fibers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,244 to Buntin.

[0077] As used herein, the term "laminate" refers to a nonwoven comprising two or more layers directly or indirectly bonded together to form a composite sheet material.

[0078] As used herein, the term "machine direction" or "MD" refers to the direction of travel of a nonwoven web during manufacture.

[0079] As used herein, the term "cross direction" or "CD" refers to the direction perpendicular to the machine direction and extending laterally across the width of the nonwoven web.

[0080] As used herein, unless otherwise indicated, the term "molecular weight" refers to weight average molecular weight (Mw) and is expressed in grams / mole. Weight average molecular weight can be determined using commonly known techniques, such as gel permeation chromatography (GPC).

[0081] As used herein, the term "spunbond" refers to a process in which molten thermoplastic material is extruded as filaments through a plurality of fine, usually circular, spinnerets, which are then mechanically or pneumatically attenuated and drawn. The filaments are deposited on a collecting surface to form a web of randomly oriented, substantially continuous filaments, which can then be bonded to form a coherent nonwoven fabric. The manufacture of spunbond nonwoven webs is shown in patents such as U.S. Pat. Nos. 3,338,992, 3,692,613, 3,802,817, 4,405,297, and 5,665,300. Generally, these spunbond processes include extruding the filaments through a spinneret, quenching the filaments with an air stream to hasten solidification of the molten filaments, attenuating the filaments by applying a draw tension by pneumatically entraining the filaments with an air stream or by winding the filaments around a mechanical draw roll, depositing the drawn filaments onto a foraminous collecting surface to form a web, and bonding the web of loose filaments to a nonwoven fabric by any thermal or chemical bonding treatment, typically thermal point bonding.

[0082] As used herein, "thermal point bonding" involves passing the materials to be bonded, such as one or more fibrous webs to be bonded, between a heated calender roll and an anvil roll, which is typically patterned so that the fabric is not bonded over its entire surface, but rather at discrete point bond sites.

[0083] As used herein, the term "through air bonded" or "through air bonding" refers to a type of thermal bonding in which the materials to be bonded, e.g., fibrous webs, are subjected to a supply of heated gas, e.g., air, whose temperature is greater than the softening or melting temperature of at least one polymer component of the materials to be bonded. The heated gas causes the at least one polymer component to soften, and in some cases to a semi-molten state, causing the polymers of adjacent fibers to fuse together to form a thermal bond. Air thermal bonding also includes passing the materials through a heated oven.

[0084] As used herein, the term "polymer" generally includes, but is not limited to, homopolymers, copolymers, such as block copolymers, graft copolymers, random and alternating copolymers, terpolymers, and the like, as well as blends and modifications thereof. Furthermore, unless otherwise limited, the term "polymer" includes all possible geometric configurations of the material, such as those possible above, including isotactic, syndiotactic, and random symmetries.

[0085] I. Nonwoven Layers Having Multiple Different Types of Fibers

[0086] Some embodiments of the present invention are directed to spunbond nonwoven fabrics comprising at least two different fiber types arranged in a single woven fabric layer. By "different fiber types" or "different fiber types", it is meant that, for example, one of the fibers in the single woven fabric layer is different from, for example, the different types of fibers in the single woven fabric layer in one or more of the following: 1) structure or cross-section (e.g., monocomponent or bicomponent), 2) compositional differences, for example, compositions with different polymers, chemicals, or functional additives, and 3) properties, for example, thickness, average fiber diameter, porosity, density, loft, denier, hydrophilicity / hydrophobicity, color properties. For example, in some embodiments, the single woven fabric layer may comprise a first fiber type comprising multicomponent fibers and a second fiber type comprising primarily monocomponent fibers.

[0087] In some embodiments, the different fiber types of the single woven layer may be homogeneously or heterogeneously mixed / intermingled to form the woven layer. For example, in some embodiments, the single woven layer includes at least two different fiber types where the different fiber types are intermingled together such that the different fiber types are substantially intermingled throughout the thickness of the single woven layer. In this regard, FIG. 1 shows a cross-section of a nonwoven fabric 2 having a single woven layer 4 including first fibers 6 and second fibers 8, where the first fibers 6 and the second fibers 8 are intermingled together throughout the thickness of the single woven layer. In the illustrated embodiment shown in FIG. 1, the first fibers 6 include monocomponent filaments of a first fiber type, and the second fibers 8 include crimped bicomponent fibers of a fiber type different from the first fibers. As will be described in more detail below, the crimped fibers typically have a side-by-side configuration, an eccentric sheath / core configuration, or a D-centric sheath / core configuration.

[0088] The first fibers 6 and second fibers 8 of the single woven fabric layer 12 are extruded from a single melt spin beam and deposited such that the fibers are formed as a single layer, even though the two different fiber types (first fibers 6 and second fibers 8) are different types from each other (e.g., two or more). The nonwoven fabric also has a first outer surface 9a and a second outer surface 9b.

[0089] In the embodiment of FIG. 1, the first fibers 6 and the second fibers 8 are shown substantially intermingled throughout the thickness "T" of the single woven layer 4. However, it should be recognized that there may be one or more regions where one of the multiple fiber types is the predominant fiber in the region. For example, in some embodiments, one fiber type may be found more prevalently near one of the multiple surfaces of the single woven layer 4. In some embodiments, there may be a gradient where one of the multiple fiber types is found more prevalently near one surface and then less prevalent near the opposing surface of the single woven layer 4.

[0090] As mentioned above, the degree of mixing of different types of fibers may be substantially uniform or non-uniform. In some embodiments, the degree of mixing / intermingling of the different types of fibers may be 0-100%, particularly 10-90%, more particularly 25-75%, where 0% means that there is substantially no mixing / intermingling of the different types of fibers, and 100% means that the different types of fibers are homogeneously mixed throughout the thickness of the single woven fabric layer 4.

[0091] In some embodiments, a single woven layer containing multiple different fiber types can contain from about 2 to about 12 different fiber types, more typically from about 2 to about 6 different fiber types, and more specifically from about 2 to about 4 different fiber types. In a preferred embodiment, the single woven layer of the nonwoven fabric has 2 to 3 different fiber types.

[0092] In some embodiments, each different type of fiber may be predominantly disposed within a discrete region of the single woven fabric layer. Thus, the nonwoven fabric has at least one single fabric layer, where the single fabric layer includes two or more regions in which the fibers in at least one region are a different type of fiber than the fibers in another region of the layered woven fabric layer.

[0093] Some embodiments of the present invention are directed to a spunbond nonwoven fabric having at least one layered woven layer, where the layered woven layer includes two or more regions in which the fibers in at least one region are a different type of fiber than the fibers in another region of the layered woven layer. In the layered woven layer, the different types of fibers are not substantially intermixed such that a region of the single woven layer contains primarily a single type of fiber, while a different region of the single woven layer contains a different fiber type than one or more other regions of the single woven layer. For example, in some embodiments, the layered woven layer may include a first region containing primarily multicomponent fibers and a second region containing primarily monocomponent fibers.

[0094] Referring to FIG. 2, an example of a nonwoven fabric having stratified woven layers is illustrated and generally designated by reference character 10. Nonwoven fabric 10 comprises a stratified woven layer 12 having a first region 14 and a second region 16 in which the fibers of the first region 14 and the second region 16 are of different types. The fibers of stratified woven layer 12 are extruded from a single melt spin beam and deposited such that the fibers of stratified woven layer 12 are formed as a single layer, despite having multiple regions (e.g., two or more) in which the fibers of the multiple regions are of different types. In the embodiment shown in FIG. 2, second region 16 overlies first region 14 at interface 18. Nonwoven fabric 10 comprises a first outer surface 20 and a second outer surface 22.

[0095] Because the stratified woven fabric layer 12 is deposited as a single layer, the interface 18 defines a boundary region within the stratified woven fabric layer where the first region 14 (containing primarily a first type of fiber) transitions to the second region 16 (containing primarily a second type of fiber). In some embodiments, some intermixing of different types of fibers from adjacent regions may occur at the boundary region near the interface 18. Typically, each region contains primarily a single type of fiber. For example, each region may contain at least 75% by weight of one type of fiber, based on the total weight of the region, particularly at least 80% by weight of one type of fiber, and more particularly at least about 90% by weight of one type of fiber, based on the total weight of the region.

[0096] Although Figure 2 illustrates a layered woven fabric layer having two regions of different fiber types, it should be appreciated that the layered woven fabric layer may include multiple regions of different fiber types. For example, the layered woven fabric layer may include 2-10 regions where adjacent regions include different fiber types. In a preferred embodiment, the layered woven fabric layer may include 2-4 regions, particularly 2-3 regions, of different fiber types.

[0097] In some embodiments, the regions of different fiber types may extend in the cross direction of the nonwoven web, while in other embodiments, the regions of different fiber types may extend in the machine direction of the nonwoven web.

[0098] As described in more detail below, the single woven fabric layer is formed as a single layer in which fibers of at least two different fiber types are extruded from the same melt spin beam. A nonwoven fabric having two different fiber types in a single woven fabric layer may provide several advantages. In particular, a single spin beam can be used to prepare a single woven fabric layer with multiple functionalities. In comparison, to achieve a similar result in a conventional spunbond system, it is typically necessary to have multiple spin beams, where each spin beam produces a single woven fabric layer with desired properties. These individually produced woven fabric layers are then laminated together to form a composite (multi-layer) nonwoven fabric. The use of multiple spin beams to achieve a desired functionality typically increases the complexity and cost associated with preparing a nonwoven fabric.

[0099] Further advantages include the ability to impart desired functionality to only selected regions of the nonwoven fabric. For example, in some embodiments, different polymers or blends of polymers can be used in the fibers of different regions of the layered woven fabric layer. In yet other embodiments, additives can be included in the fibers of one region, while one or more other regions of the layered woven fabric layer may not contain such additives or may contain different additives. In this way, a single nonwoven fabric layer can be prepared that includes two or more regions that have different functionality or properties compared to other regions of the nonwoven fabric.

[0100] Examples of suitable additives include one or more colorants (e.g., pigments (e.g., TiO), UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblock agents, slip agents, optical brighteners, flame retardants, antimicrobial agents (e.g., silver, copper oxide, and zinc oxide), polymer rheology modifiers, and the like. In some embodiments, one or more of the polymer streams may include a polypropylene rheology modifier comprising a polypropylene having low isotacticity, such as L-MODU available from Idemitsu. 商標 , may be included.

[0101] II. SYSTEMS, APPARATUS AND METHODS FOR PREPARING WOVEN FABRIC LAYERS OF MULTIPLE FIBER TYPES

[0102] Certain implementations of the present invention are also directed to apparatus and methods for producing nonwoven fabrics containing multiple different fiber types in a single layer. In particular, embodiments of the present invention also provide a distribution plate for use in a spunbond spin beam to produce a nonwoven fabric having a woven layer of the present invention. Additional embodiments of the present invention are also directed to articles comprising the woven layer of the present invention and to the use of the woven layer of the present invention in the manufacture of absorbent articles.

[0103] As described in more detail below, nonwoven fabrics having a single woven layer containing multiple fiber types may be prepared using a spunbond spinning system, where a spin pack includes a zoned distribution plate having multiple distribution zones configured and arranged to feed a polymer stream to a spinneret, where the polymer stream in one distribution zone is of a different type than the polymer stream in one or more other distribution zones of the zoned distribution plate. As with the "different types of fibers" discussed above, the term "different types" or "different polymer types" in reference to polymer streams means, for example, that the polymer stream in one distribution zone differs in one or more of the following: 1) structure or cross-section (e.g., monocomponent or multicomponent), 2) compositional differences, e.g., compositional differences having different polymers, chemicals, or functional additives, and 3) properties, e.g., hydrophilicity / hydrophobicity, color differences, as compared to the polymer streams in the second and / or third distribution zones of the zoned distribution plate.

[0104] Referring to FIG. 3, for example, a system for preparing a spunbond nonwoven fabric comprising a single woven layer having a plurality of different fiber types is shown generally and designated by the reference character 30.

[0105] As shown, the system includes a first polymer source (i.e., hopper 32) in fluid communication with a spin beam 36 via an extruder 38, and a second polymer source (i.e., hopper 40) in fluid communication with the spin beam 36 via an extruder 42. In one embodiment, the spin beam 36 includes a spin beam assembly 44 for delivering a molten polymer stream to a spin pack 46, a quenching station 48, and a drawing station 50.

[0106] When present, the spin beam assembly 44 includes a number of meters and pumps that supply two or more polymer streams to the spin pack. In some embodiments, the spin beam assembly may include one or more heating elements to maintain the molten polymer streams at a desired temperature. An example of a spin beam assembly that may be used in certain embodiments of the present invention is described in U.S. Patent No. 7,7740,777, the contents of which are incorporated herein by reference.

[0107] In the spinpack 46, at least two molten polymer streams of different types are distributed to a plurality of orifices (e.g., spinnerets) from which the molten polymer streams are extruded as a curtain of continuous or semi-continuous filaments. In some embodiments, the extruded filaments are then introduced into a quenching station where they are exposed to a quenching air stream directed at the filaments. The filaments are then drawn into a drawing station 50, which draws and attenuates the filaments. The drawn and attenuated filaments 51 are then deposited on a collecting surface 52 to form a nonwoven web 53. In some embodiments, the attenuated filaments may be introduced into a diffuser (not shown) before being deposited on the collecting surface.

[0108] In some embodiments, the nonwoven web may be passed through a bonding station 54 where the filaments are bonded to form a coherent web. A wide variety of bonding methods may be used in accordance with the present invention, including those described above, including thermal bonding (e.g., by air or calendar bonding), mechanical bonding (e.g., by hydroentanglement or needle punching), and chemical bonding (e.g., using adhesive resins). In one embodiment, the bonding station includes a thermal bonding unit including a pair of opposed calendar rolls.

[0109] In one embodiment, the bonding unit comprises a chamber in which the nonwoven fabric is exposed to a stream of heated gas, e.g., air, and in which the temperature of the heated gas is above the softening or melting temperature of at least one polymer component of the nonwoven fabric.

[0110] In some embodiments, the bonding unit may include a hot air knife configured to subject the nonwoven fabric to a stream of heated air that thermally bonds adjacent fibers together.

[0111] In further embodiments, the bonding unit may comprise one or more hydraulic entanglement units configured to apply a stream of high pressure water to the nonwoven fabric to entangle and mechanically bond the fibers.

[0112] In some embodiments, the system may also include a pair of cooperating rolls (not shown) (also referred to herein as "press rolls") disposed downstream from the exit of the spin beam. In this regard, the press roll may be configured to stabilize the web of filaments by compressing the web of fibers prior to delivery of the web from the exit of the spin beam toward the bonding unit. In some embodiments, for example, the press roll may include a ceramic coating deposited on its surface. In some embodiments, for example, one roll of the pair of cooperating rolls may be disposed above collecting surface 52, and a second roll of the pair of cooperating rolls may be disposed below collecting surface 52.

[0113] In some embodiments, and as shown in FIG. 3, the system may include a vacuum source 58 disposed below collection surface 52 to draw multiple continuous filaments from the exit of the spin beam onto collection surface 52 before being delivered to the bonding unit.

[0114] Finally, the bonded spunbond nonwoven fabric moves to a winder 56 where the nonwoven fabric is wound into a roll.

[0115] 3 shows only two polymer sources (e.g., two hoppers / extruders) for feeding two molten polymer streams to the spin beam, it should be appreciated that the system may include additional polymer sources (additional hoppers and extruders) for feeding additional molten polymer streams to the spin beam. In one embodiment, the system may include three polymer sources for feeding three molten polymer streams to the spin beam.

[0116] In some embodiments, the system may include additional devices to further modify or treat the nonwoven fabric. For example, the system may include a kiss roller or similar device to apply a topical treatment, such as a surfactant, to the surface of the nonwoven fabric. In some embodiments, the system may also include one or more devices to incrementally stretch the nonwoven fabric. One example of such a device is a ring roller, which includes multiple interlocking rings that stretch selected areas of the nonwoven fabric.

[0117] The system illustrated in FIG. 3 may be configured to produce a single woven layer with a homogeneous or heterogeneous mixture of multiple fibers of different types. In some embodiments in the preparation of a stratified woven layer, such as the stratified woven layer illustrated in FIG. 2, the collection surface may be operated at a higher speed to help facilitate the distribution of different types of fibers into discrete regions within the single woven layer. Alternatively or in combination, the stream of continuous filaments extruded by the spin beam may be deposited on a rotating cylinder. In some embodiments, the surface of the rotating cylinder may be equipped with a screen, which may be equipped with a vacuum source.

[0118] 4 is a schematic diagram of a spinpack 46 in accordance with at least one embodiment of the present invention. The spinpack 46 typically includes multiple plates sandwiched together in this order: a top plate 60, a polymer melt screen 62, a zoned distribution plate 64, and a spinneret 66. The spinpack essentially regulates the flow of the molten polymer stream to 1) form a desired type of fiber (e.g., monocomponent or multicomponent fibers, where the fibers have a particular cross-sectional geometry, etc.), 2) form a desired number of fibers that are continuously extruded by the system, and 3) distribute the molten polymer to the desired distribution zones based on the type of polymer.

[0119] A polymer melt screen 62 is provided with a filter for filtering the polymer stream prior to introduction into the zoned distribution plate 64 .

[0120] The spinneret is located downstream of the polymer melt screen 62 and the zoned distribution plate 64. The spinneret comprises a plurality of spinnerets arranged in an array extending transversely of the spin beam. For example, the spinnerets may be arranged in a substantially horizontal rectangular array, typically with 1,000 to 6,000 orifices per meter of spinneret length. As used herein, the term "spinneret" refers to the bottom of the spinpack that feeds the molten polymer to and through orifices for extrusion into the quenching station. The spinneret can be implemented by drilling or etching holes in a plate or other structure capable of providing the necessary fiber streams.

[0121] Additionally, the spinnerets may have a variety of different shapes (e.g., circular, square, oval, keyhole, multilobal (e.g., trilobal), etc.) resulting in a wide variety of fiber cross-sectional shapes. An exemplary spinpack for use with system 30 is described in U.S. Patent No. 5,162,040 to Hills, the disclosure of which is incorporated herein by reference in its entirety. However, it should be noted that any conventional or other spinpack for spinning fibers may be utilized with system 30.

[0122] The zoned distribution plate 64 includes an upper surface 70 and a lower surface 72. The upper surface 70 is disposed opposite the polymer melt screen 62 and includes a plurality of etched channels that are arranged and configured to receive two or more polymer melt streams and then distribute the polymer streams to desired distribution zones. Additionally, the zoned distribution plate 64 may include a plurality of channels that are constructed and arranged to combine two or more different polymer melt streams into a desired configuration (e.g., bi-component (side-by-side, core / sheath, off-center core / sheath, D-centric core / sheath, segmented pie, islands in the sea, etc.), ternary, etc.).

[0123] The lower surface 72 of the zoned distribution plate is disposed opposite the spinneret and includes a plurality of distribution openings through which the distributed polymer streams are introduced into corresponding spinning orifices of the spinneret and subsequently extruded as molten or semi-molten filaments.

[0124] In some embodiments of the invention, the zoned distribution plate is configured to distribute, combine, and extrude multiple polymer streams of different types, particularly between two and four polymer streams of different types. For example, the zoned distribution plate may be configured to extrude a polymer stream that includes four different polymers (e.g., polymers A, B, C, and D). Polymers A, B, C, and D may be distributed and extruded as monocomponent filaments or may be combined to form multicomponent filaments that include combinations of two or more polymers A, B, C, and D, where the polymers are disposed as separate polymer components across the cross-section of the polymer stream and thus in the resulting multicomponent fiber.

[0125] It should be appreciated that references to polymers A, B, C and D in the following description are used generally and are not limited to specific polymers. It should also be appreciated that polymers A, B, C and D are not limited to single polymers, but can include blends of polymers, blends of additives and polymers, and combinations thereof. In this regard, it should be noted that when one or more of polymers A, B, C and D are blends, the blends are typically first prepared in an extruder before being introduced into the spin beam. For example, polymer A is typically provided by a first extruder, polymer B is typically provided by a second extruder, and polymer C is typically provided by a third extruder.

[0126] In the embodiment shown in Figure 3, only a single zoned distribution plate is shown. It should be appreciated that the zoned distribution plate 64 may comprise two or more distribution plates stacked on top of one another and configured to cooperate to provide multiple molten polymer streams to the distribution openings. As described in more detail below, the distribution openings are arranged in multiple distribution zones across the lower surface of the distribution plate, where each distribution zone is configured to extrude a different type of polymer stream than the polymer streams of the adjacent zones.

[0127] III. A typical zoned distribution plate

[0128] Figures 5-11 show partial views of the underside of a zoned distribution plate according to various embodiments of the present invention. Given the number of distribution apertures typically present on a distribution plate, the number of rows and columns illustrated in Figures 5-11 have been reduced for simplicity and are not meant to limit in any way the actual number of distribution apertures.

[0129] Similar to the spinneret, the distribution apertures 82 shown in Figures 5-11 are arranged in a rectangular array with a plurality of rows (designated by reference letter "R") extending longitudinally in the cross direction of the spin beam between the proximal end 78a and the distal end 78b of the zoned distribution plate. In some embodiments, the distribution apertures are also arranged as a plurality of columns (designated by reference letter "C") extending transversely in the machine direction of the spin beam. While the zoned distribution plate is not limited to a particular number of distribution apertures, the zoned distribution plate typically comprises about 1,000 to about 6,000 distribution apertures per meter.

[0130] In some embodiments, the spin beam may comprise about 20 to about 80 rows of spinneret orifices and therefore 20 to 80 rows of corresponding distribution apertures extending longitudinally in the transverse direction of the spin beam. In some embodiments of the zoned distribution plate having two distribution zones, the ratio of the number of rows of distribution orifices per zone may be 8:72 to 72:8. For example, in a zoned distribution plate having two zones (wherein each zone has about the same number of rows (R)), the first distribution zone may comprise 10 to 50, e.g., 20 to 40, rows, and the second distribution zone may also comprise 10 to 50, e.g., about 20 to about 40, rows. In one embodiment, the zoned distribution plate comprises a first distribution zone having 25-30 rows of distribution openings extending longitudinally of the spin beam and a second distribution zone having 25-30 rows of distribution openings extending longitudinally.

[0131] In one embodiment, the zoned distribution plate has at least 4 rows, at least 5 rows, at least 6 rows, at least 7 rows, at least 8 rows, at least 9 rows, at least 10 rows, at least 11 rows, at least 12 rows, at least 13 rows, at least 14 rows, at least 15 rows, at least 16 rows, at least 17 rows, at least 18 rows, at least 19 rows, at least 20 rows, at least 21 rows, at least 22 rows, at least 23 rows, at least 24 rows, at least 25 rows, at least 26 rows, at least 27 rows, at least 28 rows, at least 29 rows, at least 30 rows, at least 31 rows, at least 32 rows, at least 33 rows, at least 34 rows, at least 35 rows, at least 36 rows, at least 37 rows, at least 38 rows, at least 39 rows, at least 40 rows, at least 41 rows, at least a first distribution zone having at least 42 rows, at least 43 rows, at least 44 rows, at least 45 rows, at least 46 rows, at least 47 rows, at least 48 rows, at least 49 rows, at least 50 rows, at least 51 rows, at least 52 rows, at least 53 rows, at least 54 rows, at least 55 rows, at least 56 rows, at least 57 rows, at least 58 rows, at least 59 rows, at least 60 rows, at least 61 rows, at least 62 rows, at least 63 rows, at least 64 rows, at least 65 rows, at least 66 rows, at least 67 rows, at least 68 rows, at least 69 rows, at least 70 rows, at least 71 rows, at least 72 rows, at least 73 rows, at least 74 rows, at least 75 rows, at least 76 rows, at least 77 rows, at least 78 rows, at least 79 rows, and at least 80 rows.

[0132] Additionally, the first distribution zone may include less than 80 rows of distribution openings, less than 79 rows, less than 78 rows, less than 77 rows, less than 76 rows, less than 75 rows, less than 74 rows, less than 73 rows, less than 72 rows, less than 71 rows, less than 70 rows, less than 69 rows, less than 68 rows, less than 67 rows, less than 66 rows, less than 65 rows, less than 64 rows, less than 63 rows, less than 62 rows, less than 61 rows, less than 60 rows, less than 59 rows, less than 58 rows, less than 57 rows, less than 56 rows, less than 55 rows, less than 54 rows, less than 53 rows, less than 52 rows, less than 51 rows, less than 50 rows, less than 49 rows, less than 48 rows, less than 47 rows, less than 46 rows, less than 45 rows, less than 44 rows, less than 43 rows, less than 42 rows, , 41 rows, 40 rows, 39 rows, 38 rows, 37 rows, 36 rows, 35 rows, 34 rows, 33 rows, 32 rows, 31 rows, 30 rows, 29 rows, 28 rows, 27 rows, 26 rows, 25 rows, 24 rows, 23 rows, 22 rows, 21 rows, 20 rows, 19 rows, 18 rows, 17 rows, 16 rows, 15 rows, 14 rows, 13 rows, 12 rows, 11 rows, 10 rows, 9 rows, 8 rows, 7 rows, 6 rows, 5 rows, 4 rows, 3 rows, and 2 rows.

[0133] In some embodiments, the first distribution zone may comprise 2-78 rows, 3-77 rows, 4-76 rows, 5-75 rows, 6-74 rows, 7-73 rows, 8-72 rows, 9-71 rows, 10-70 rows, 11-69 rows, 12-68 rows, 12-67 rows, 13-66 rows, 14-65 rows, 15-64 rows, 16-63 rows, 17-62 rows, 18-61 rows, 19-60 rows, 20-59 rows, 21-58 rows, 22-57 rows, 23-56 rows, 24-55 rows, 23-54 rows, 24-53 rows, or 25-52 rows of distribution apertures. In some embodiments, the first distribution zone may comprise 20-35 rows, 21-34 rows, 22-33 rows, 23-32 rows, 24-31 rows, 25-30 rows, 26-29 rows, or 27-28 rows of distribution openings.

[0134] Similarly, in this embodiment, the zoned distribution plate also has at least 4 rows, at least 5 rows, at least 6 rows, at least 7 rows, at least 8 rows, at least 9 rows, at least 10 rows, at least 11 rows, at least 12 rows, at least 13 rows, at least 14 rows, at least 15 rows, at least 16 rows, at least 17 rows, at least 18 rows, at least 19 rows, at least 20 rows, at least 21 rows, at least 22 rows, at least 23 rows, at least 24 rows, at least 25 rows, at least 26 rows, at least 27 rows, at least 28 rows, at least 29 rows, at least 30 rows, at least 31 rows, at least 32 rows, at least 33 rows, at least 34 rows, at least 35 rows, at least 36 rows, at least 37 rows, at least 38 rows, at least 39 rows, at least 40 rows, at least 41 rows, at least 42 rows, at least 43 rows, at least 44 rows, at least 45 rows, at least 46 rows, at least 47 rows, at least 48 rows, at least 49 rows, at least 50 rows, at least 51 rows, at least 52 rows, at least 53 rows, at least 54 rows, at least 55 rows, at least 56 rows, at least 57 rows, at least 58 rows, at least 59 rows, at least 60 rows, at least 61 rows, at least 62 a second distribution zone having at least 63 rows, at least 64 rows, at least 65 rows, at least 66 rows, at least 67 rows, at least 68 rows, at least 69 rows, at least 70 rows, at least 71 rows, at least 72 rows, at least 73 rows, at least 74 rows, at least 75 rows, at least 76 rows, at least 77 rows, at least 78 rows, at least 79 rows, and at least 80 rows.

[0135] Additionally, the second distribution zone may have less than 80 rows of distribution openings, less than 79 rows, less than 78 rows, less than 77 rows, less than 76 rows, less than 75 rows, less than 74 rows, less than 73 rows, less than 72 rows, less than 71 rows, less than 70 rows, less than 69 rows, less than 68 rows, less than 67 rows, less than 66 rows, less than 65 rows, less than 64 rows, less than 63 rows, less than 62 rows, less than 61 rows, less than 60 rows, less than 59 rows, less than 58 rows, less than 57 rows, less than 56 rows, less than 55 rows, less than 54 rows, less than 53 rows, less than 52 rows, less than 51 rows, less than 50 rows, less than 49 rows, less than 48 rows, less than 47 rows, less than 46 rows, less than 45 rows, less than 44 rows, less than 43 rows, less than 42 rows, 31, 32, 31, 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, and 2.

[0136] In some embodiments, the second distribution zone may comprise 2-78 rows, 3-77 rows, 4-76 rows, 5-75 rows, 6-74 rows, 7-73 rows, 8-72 rows, 9-71 rows, 10-70 rows, 11-69 rows, 12-68 rows, 12-67 rows, 13-66 rows, 14-65 rows, 15-64 rows, 16-63 rows, 17-62 rows, 18-61 rows, 19-60 rows, 20-59 rows, 21-58 rows, 22-57 rows, 23-56 rows, 24-55 rows, 23-54 rows, 24-53 rows, or 25-52 rows of distribution apertures. In some embodiments, the second distribution zone may comprise 20-35 rows, 21-34 rows, 22-33 rows, 23-32 rows, 24-31 rows, 25-30 rows, 26-29 rows, or 27-28 rows of distribution apertures.

[0137] 5 shows the underside 72 of the zoned distribution plate 64. In this embodiment, the zoned distribution plate 64 includes a first distribution zone 74 and a second distribution zone 76. In this illustrated embodiment, the first distribution zone and the second distribution zone extend longitudinally in a cross direction of the spin beam. In one embodiment, a first polymer melt stream is distributed by the zoned distribution plate 64 to the first distribution zone 74, and a second polymer melt stream of a different type is distributed by the zoned distribution plate 64 to the second distribution zone 76.

[0138] The number of rows (R) per distribution zone may vary depending on the desired properties of the single woven fabric layer. Typically, the number of rows (R) of distribution openings in the first distribution zone may be about 20 to about 80% based on the total number or number of rows of distribution openings on the zoned distribution plate, and the number of rows (R) of distribution openings in the second distribution zone may be about 20 to about 80% based on the total number or number of rows of distribution openings on the zoned distribution plate. That is, the ratio of the number of rows of the first distribution zone to the number of rows of the second distribution zone may be about 20: about 80 to about 80: about 20, with a ratio of about 30: about 70 to about 30: about 70 being more preferred. In some embodiments, the ratio of the number of rows of the first distribution zone to the number of rows of the second distribution zone may be about 50: about 50.

[0139] 6 includes the zoned distribution plate 80 having a first distribution zone 84 and a second distribution zone 86. In this illustrated embodiment, the first distribution zone and the second distribution zone extend longitudinally in a cross direction of the spin beam. In one embodiment, a first polymer melt stream is distributed by the zoned distribution plate 80 to the first distribution zone 84, and a second polymer melt stream of a different type is distributed by the zoned distribution plate 80 to the second distribution zone 86.

[0140] The number of rows (R) per distribution zone may vary depending on the desired properties of the single woven fabric layer. Typically, the number of rows (R) of distribution openings in the first distribution zone may be about 10 to about 90% based on the total number or number of rows of distribution openings on the zoned distribution plate, and the number of rows (R) of distribution openings in the second distribution zone may be about 10 to about 90% based on the total number or number of rows of distribution openings on the zoned distribution plate. That is, the ratio of the number of rows of the first distribution zone to the number of rows of the second distribution zone may be about 10:90 to about 90:10, with a ratio of 20:80 to 80:20 being more preferred. In some embodiments, the ratio of the number of rows of the first distribution zone to the number of rows of the second distribution zone may be about 30:70.

[0141] In one embodiment, the zoned distribution plate 80 includes a first distribution zone 84 configured to extrude monocomponent filaments comprising one of a polymer A, a polymer B, a blend of polymer A and polymer B, or a third polymer C different from polymers A and B, and a second distribution zone 86 configured to extrude multicomponent filaments comprising a first polymer component (polymer A) and a second polymer component (polymer B).

[0142] In a preferred embodiment, the ratio of first distribution zone 84 to second distribution zone 86 is from 15:85 to 30:70, and the first distribution zone is configured to extrude monocomponent fibers comprising a first polymer A, and the second distribution zone is configured to extrude bicomponent fibers having a side-by-side, eccentric, or D-centric configuration, where one of the polymer components comprises polymer A and the second polymer component comprises a second polymer B. In a preferred embodiment, the second distribution zone is configured to extrude bicomponent fibers having a side-by-side configuration.

[0143] In further embodiments of the zoned distribution plate of FIG. 6, the first distribution zone and the second distribution zone may be configured to extrude polymer streams that are substantially the same except for changes in composition, structure, or cross-section. For example, in one embodiment, the first distribution zone 84 and the second distribution zone 86 may be configured to extrude polymer streams that include the same polymer (e.g., polymer A), but one of the polymer streams to be extruded by either the first distribution zone or the second distribution zone may include a functional additive blended with the polymer to impart a desired property to one of multiple regions of the resulting single woven fabric layer. In some embodiments, a stratified woven fabric layer is provided in which a functional additive is provided in one or more desired regions of the single woven fabric layer. In this manner, it is possible to produce a nonwoven fabric having a desired functionality in a desired region within a single layer of the nonwoven fabric.

[0144] Examples of representative nonwoven layers having stratified woven layers that may be prepared using the zoned distribution plate according to FIG. 5 are described in more detail below.

[0145] 7 illustrates a further example of a zoned distribution plate 90 that may be used in accordance with an embodiment of the present invention. In this embodiment, the zoned distribution plate 90 includes a first distribution zone 92 configured to extrude bicomponent filaments having a side-by-side configuration and a second distribution zone 94 configured to extrude bicomponent filaments having an eccentric sheath / core configuration or a D-centric sheath / core configuration. Advantageously, each of the first distribution zone 92 and the second distribution zone 94 may be configured to produce crimped filaments having different crimp types. For example, one zone may produce a helical crimp and the other zone may produce a crimp having a sinusoidal shape.

[0146] Similar to the embodiment shown in FIG. 6, the number of rows (R) per distribution zone can vary depending on the desired properties of the single woven fabric layer. Typically, the number of rows (R) of distribution openings in the first distribution zone 92 can be about 10 to about 90% based on the total number of distribution openings or rows on the zoned distribution plate, and the number of rows (R) of distribution openings in the second distribution zone 94 can be about 10 to about 90% based on the total number of distribution openings or rows on the zoned distribution plate. That is, the ratio of the number of rows in the first distribution zone to the number of rows in the second distribution zone can be about 10:about 90 to about 90:about 10, with a ratio of about 20:about 80 to about 80:about 20 being more preferred. In some embodiments, the ratio of the number of rows in the first distribution zone to the number of rows in the second distribution zone can be about 50:about 50.

[0147] In a preferred embodiment, the ratio of the first distribution zone to the second distribution zone is from 15:85 to 30:70.

[0148] In one embodiment, the first distribution zone 92 of the zoned distribution plate illustrated in FIG. 7 is configured to extrude bicomponent fibers having an eccentric or D-centric sheath / core configuration in which one of the polymer components is one of polymer A and the other polymer component is one of polymer B or C, and the second distribution zone 94 is configured to extrude bicomponent fibers having a side-by-side configuration in which one of the polymer components is polymer A and the other polymer component is polymer B.

[0149] An example of a representative nonwoven layer having a stratified woven layer that can be prepared using the zoned distribution plate according to FIG. 7 is described in more detail below.

[0150] 8 shows another example of a zoned distribution plate 100 that may be used in accordance with an embodiment of the present invention. In this embodiment, the zoned distribution plate 100 includes a first distribution zone 102, a second distribution zone 104, and a third distribution zone 106 sandwiched between the first distribution zone 102 and the second distribution zone 104. Each of the distribution zones extends longitudinally in a cross direction of the spin beam. In one embodiment of the zoned distribution plate, the first distribution zone 102 and the second distribution zone 104 are configured to form an outer region of the layered nonwoven fabric, and the third distribution zone 106 is configured to form an inner region of the layered nonwoven fabric.

[0151] In certain embodiments of the zoned distribution plate shown in Figure 8, the first distribution zone 102 and the second distribution zone 104 may be configured to extrude polymer streams that are the same type, or alternatively, each may be configured to extrude different polymer streams from the other. In some embodiments, the first distribution zone 102 and the second distribution zone 104 may be configured to extrude polymer streams that form homopolymer fibers.

[0152] In some embodiments, the third distribution zone 106 is configured to extrude a polymer stream having a multicomponent configuration in which at least two polymer components form a resultant multicomponent fiber, which may have a side-by-side configuration, a sheath / core configuration, an eccentric sheath / core configuration, a D-centric sheath / core configuration, a tricomponent configuration, or a bico-segmented pie configuration.

[0153] As with the previously described embodiments, the number of rows (R) per distribution zone may vary depending on the desired properties of the single woven fabric layer. Typically, the number of rows (R) of distribution openings in each of the first distribution zone 102 and the second distribution zone 104 may be about 10 to about 40% based on the total number or number of rows of distribution openings on the zoned distribution plate, and the number of rows (R) of distribution openings in the third distribution zone may be about 20 to about 80% based on the total number or number of rows of distribution openings on the zoned distribution plate. In a preferred embodiment, the ratio of the number of rows (R) of the third distribution zone to the number of rows (R) of the first and second distribution zones combined is about 20: about 80 to about 80: about 20, more preferably about 40: about 60 to about 60: about 40. In some embodiments, the ratio is about 45: about 55 to about 55: about 45, with a ratio of about 50: about 50 being more preferred.

[0154] In some embodiments, the first distribution zone 102 and the second distribution zone 104 may be configured to extrude monocomponent fibers, and the third distribution zone 106 may be configured to extrude bicomponent fibers having a side-by-side configuration, an eccentric sheath-core configuration, or a D-centric sheath / core configuration. In such embodiments, the bicomponent polymer stream of the third distribution zone may include polymer A and polymer B, and the polymer streams of the first distribution zone and the second distribution zone may include one or more of polymer A, polymer B, or polymer C, and blends thereof.

[0155] An example of a representative nonwoven fabric layer having a stratified woven fabric layer that can be prepared using the zoned distribution plate according to FIG. 8 is described in more detail below.

[0156] 9 illustrates another example of a zoned distribution plate 110 that may be used in accordance with embodiments of the present invention. In this embodiment, the zoned distribution plate 110 includes a first distribution zone 112, a second distribution zone 114, and a third distribution zone 116 sandwiched between the first distribution zone 112 and the second distribution zone 114. In some embodiments, the first distribution zone 112 and the second distribution zone 114 may be configured to form an outer region of the layered nonwoven fabric, and the third distribution zone 116 may be configured to form an inner region of the layered nonwoven fabric.

[0157] In some embodiments, the first distribution zone 112 and the second distribution zone 114 may be configured to extrude multicomponent polymer streams in which the resulting multicomponent fibers have a side-by-side configuration, a sheath / core configuration, an eccentric sheath / core configuration, a D-centric sheath / core configuration, a tricomponent configuration, or a bipartite pie configuration. In such embodiments, the third distribution zone 116 may be configured to extrude a multicomponent polymer stream in which the resulting multicomponent fibers may have a side-by-side configuration.

[0158] In a preferred embodiment, the first distribution zone 112 and the second distribution zone 114 are configured to extrude bicomponent polymer streams having a quarter pie configuration in which polymer A and polymer B each comprise two alternating segments of the stream, and the third distribution zone is configured to extrude a bicomponent fiber having a side-by-side configuration in which the two components are different from each other and may be one of polymer A, polymer B or polymer C.

[0159] As with the previously described embodiments, the number of rows (R) per distribution zone may vary depending on the desired properties of the single woven fabric layer. Typically, the number of rows (R) of distribution openings in each of the first distribution zone 112 and the second distribution zone 114 may be about 10 to about 20% based on the total number or number of rows of distribution openings on the zoned distribution plate, and the number of rows (R) of distribution openings in the third distribution zone may be about 60 to about 80% based on the total number or number of rows of distribution openings on the zoned distribution plate. In a preferred embodiment, the ratio of the number of rows (R) of the first and second distribution zones combined to the number of rows (R) of the third distribution zone is about 20:80 to about 40:60, more preferably about 22:78 to about 24:76, with a ratio of about 28:72 being more preferred.

[0160] An example of a representative nonwoven fabric layer having stratified fabric layers that can be prepared using the zoned distribution plate according to FIG. 9 is described in more detail below.

[0161] 10 shows another example of a zoned distribution plate 120 that may be used in accordance with an embodiment of the present invention. In this embodiment, the zoned distribution plate 120 includes multiple series of multiple distribution zones, where adjacent distribution zones are configured to extrude different types of polymer streams from each other, and alternating pairs of distribution zones are configured to extrude polymer streams of the same type of polymer. For example, distribution zones 122a and 122b are configured to extrude multiple polymer streams of the same type (i.e., same structure and composition), and distribution zones 124a and 124b are also configured to extrude multiple polymer streams of the same type (i.e., same structure and composition).

[0162] In the embodiment shown in FIG. 10, a total of four distribution zones are illustrated, however, it should be appreciated that the zoned distribution plate may have any number of alternating distribution zones, such as from about 2 to about 40, from about 5 to about 30, or from about 10 to about 20.

[0163] The alternating distribution zones may be configured to extrude monocomponent filaments or multicomponent filaments.

[0164] As with the previously described embodiments, the number of rows (R) per distribution zone can vary depending on the desired properties of the stratified woven fabric layer. Typically, the number of rows (R) of each distribution opening can be about 10 to about 30% based on the total number of rows of distribution openings on the zoned distribution plate, and in particular, about 15 to about 25% based on the total number or number of rows of distribution openings on the zoned distribution plate. It should be appreciated that the proportion of rows in each distribution zone does not have to be the same and can vary depending on the desired properties of the resulting stratified woven fabric layer.

[0165] FIG. 11 shows another example of a zoned distribution plate 130 that may be used in accordance with an embodiment of the present invention. In this embodiment, the distribution zones (e.g., 132a, 134a, 132b, 134b, ...) extend in the machine direction of the zoned distribution plate 130. Similar to the distribution plate of FIG. 10, the zoned distribution plate 130 includes multiple distribution zones where adjacent distribution zones are configured to extrude different types of polymer streams from each other and alternating distribution zones are configured to extrude polymer streams of the same type of polymer. For example, distribution zones 132a, 132b, 132c, and 132d are configured to extrude polymer streams where the polymer is of the same type (i.e., identical structure and composition) and where the polymer stream is of a different type than that extruded by distribution zones 134a, 134b, and 134c. Similarly, distribution zones 134a, 134b, and 134c are also configured to extrude a polymer stream, where the polymer is of the same type (i.e., identical structure and composition) and where the polymer stream is of a different type than that extruded by distribution zones 132a, 132b, 132c, and 132d.

[0166] In one embodiment of the zoned distribution plate 130, a first series of the plurality of alternating distribution zones (e.g., 132a, 134a, 132b, 134b) is configured to extrude a polymer stream having a bicomponent configuration, e.g., side-by-side, eccentric sheath / core, D-centric sheath / core, etc., where polymer A and polymer B comprise the two polymer components. In this embodiment, a second series of the plurality of alternating distribution zones (e.g., 134a, 134b, and 134c) is configured to extrude a polymer stream having a monocomponent configuration comprising one of polymers A, B, or C.

[0167] In one embodiment, the first series of alternating distribution zones (e.g., 132a, 134a, 132b, 134b) comprises about 60 to about 85% of the number of rows of distribution openings (C) based on the total number of rows of distribution openings on the zoned distribution plate, particularly about 70 to about 80% based on the total number of rows of distribution openings on the zoned distribution plate. In one embodiment, the ratio of the first series of alternating distribution zones to the second series of alternating distribution zones is about 80: about 20 to about 70: about 30, with a ratio of 75: 25 being more preferred. It should be appreciated that the proportion of rows of each distribution zone need not be the same and can be varied depending on the desired properties of the resulting stratified woven fabric layer.

[0168] IV. Representative examples of layered woven fabric layers

[0169] Figures 1 and 12-17 show representative nonwoven fabrics having stratified woven layers according to various embodiments of the present invention. It should be appreciated that the representative examples are provided to illustrate various embodiments that may be prepared according to embodiments of the present invention, and are not intended to limit the present invention in any manner. In particular, it should be understood that a wide variety of nonwoven fabrics having stratified woven layers are encompassed within the present invention.

[0170] Embodiments of the present invention are particularly useful for preparing spunbond nonwoven fabrics that contain crimped fibers.

[0171] Crimped fibers can be particularly useful in hygiene applications because they tend to improve the loft and softness of the nonwoven fabric. However, crimped fibers have the drawback of typically having low mechanical strength and dimensional stability. As a result, the crimped nonwoven fabric tends to have significant neck-in, which in turn results in fabric shrinkage in the cross direction of the nonwoven fabric under MD stress. To address this issue, U.S. Patent Publication No. 2016 / 0221300 (hereinafter "'300") describes a composite laminate in which a crimped spunbond fabric is deposited on a non-crimped spunbond fabric. The non-crimped spunbond fabric provides dimensional stability to the crimped spunbond fabric. However, the system and method described in '300 has drawbacks. In particular, it requires at least two separate spunbond fabric layers, which requires two separate spin beams and equipment associated with each spin beam. This increases the complexity and cost of preparing the composite laminates described in the '300 publication.

[0172] Advantageously, the inventors have discovered that the use of a single woven layer having two different fiber types provides a crimped fabric with improved dimensional stability without the need for multiple spunbond spin beams.

[0173] Returning to Figure 1, the nonwoven fabric 2 includes a single woven fabric layer 4 having two different fiber types 6 and 8, where a first fiber includes monocomponent filaments that are non-crimped or low crimp, and a second fiber 8 includes crimped bicomponent fibers of a different fiber type than the first fiber. As previously described, the single woven fabric layer 4 is extruded from the spin beam as a single layer.

[0174] In one embodiment, the second fiber 8 comprising the crimped continuous filaments comprises bicomponent fibers in which one of the polymeric components is different from the other polymeric component (e.g., differences in crystallinity, melting temperature, polydispersity index, flexural modulus, heat of fusion, and / or melt flow rate (MFR)), and thus the bicomponent fiber advantageously develops or has a natural crimp. In some embodiments, the crimped continuous filaments have a bicomponent configuration selected from the group including side-by-side, eccentric sheath / core, D-centric sheath / core, or any other configuration that can develop or retain a crimp. The crimped continuous filaments of the second fiber provide improved loft and softness. Polymers for preparing crimped fibers are described above.

[0175] In a preferred embodiment, the second crimped fiber has a helical crimp comprising a plurality of loops along the length of the filament. Typically, the number of helical loops per cm can be from about 2 to about 100, particularly from about 5 to about 75. In a preferred embodiment, the crimped fiber has at least 10 helical loops per cm, more particularly at least about 15 helical loops per cm. In a preferred embodiment, the number of crimps per cm is from about 2 to about 20 helical loops. The number of crimps of the crimped fiber according to the present invention can be determined according to JIS L 1015.

[0176] The first fibers 6 are non-crimping or low crimping filaments and typically comprise monocomponent or multicomponent fibers that do not develop a helical crimp, e.g., a centric sheath / core configuration. The first fibers provide strength to the nonwoven fabric and provide the nonwoven fabric with improved dimensional stability.

[0177] In some embodiments, the first fibers 6 can include a polyolefin, such as polyethylene, polypropylene, and combinations thereof. In a preferred embodiment, the first fibers 6 include a Ziegler-Natta catalyzed homopolymer polypropylene having an MFR of about 20 to about 40 g / 10 min, particularly about 25 to about 35 g / 10 min.

[0178] Further embodiments provide nonwoven fabrics having a stratified woven layer comprising crimped filaments. In this regard, FIG. 12 shows an embodiment of a nonwoven fabric 200 having a stratified woven layer 210 having a first region 220 comprising crimped continuous filaments and a second region 230 of non-crimped or low crimped filaments. In some embodiments, the stratified woven layer illustrated in FIG. 12 can be prepared using the zoned distribution plate illustrated in FIG. 5 or FIG. 6 previously described. As illustrated, the first region 220 and the second region 230 extend in the cross direction of the nonwoven fabric such that one region overlaps the other. Low crimp or non-crimped fibers typically have less than 2 loops per cm of fiber length.

[0179] As previously described, the stratified woven fabric layer 210 is extruded from the spin beam as a single layer.

[0180] In one embodiment, the first region 220 comprising the crimped continuous filaments comprises bicomponent fibers in which one of the polymeric components differs from the other polymeric component (e.g., differences in crystallinity, molecular weight, melting temperature, polydispersity index, flexural modulus, heat of fusion, melt flow rate (MFR), and crimp-inducing polymeric additives (e.g., blends with meltblown resins and / or polymers with low isotacticity, etc.)) and thus the bicomponent fibers advantageously develop or have a natural crimp. In some embodiments, the crimped continuous filaments have a bicomponent configuration selected from the group including side-by-side, eccentric sheath / core, D-centric sheath / core, or other configurations that can develop or retain a crimp. The crimped continuous filaments of the first region 220 provide improved loft and softness.

[0181] In a preferred embodiment, the crimped continuous filaments of the first region have a helical crimp comprising a plurality of loops along the length of the filament. Typically, the number of helical loops per cm can be from about 2 to about 100, particularly from about 5 to about 75. In a preferred embodiment, the crimped continuous filaments have at least 10 helical loops per cm, more particularly at least about 15 helical loops per cm. In a preferred embodiment, the number of crimps per cm is from about 2 to about 20 helical loops.

[0182] A wide variety of different polymers can be used in producing the crimped continuous filaments. In particular, the bicomponent fibers can include polyolefins, such as polypropylene, polyethylene, and combinations thereof.

[0183] In one embodiment, the crimped continuous filaments comprise a side-by-side configuration in which the first polymer component of the bicomponent fiber comprises a metallocene-catalyzed polypropylene having an MFR of 19-40 g / min and the second polymer component comprises a Ziegler-Natta-catalyzed polypropylene having an MFR of about 20-35 g / 10 min. Unless otherwise specified, MFR is measured according to ISO 1133, 230°C / 2.16 kg force.

[0184] Additional polymer compositions that may be used to prepare crimped continuous filaments for use in certain embodiments of the present invention are described in U.S. Patent Application Publication No. 2016 / 0221300, U.S. Pat. No. 6,454,989, EP 2,343,406 B1, and European Patent Applications Nos. 3,121,314 and 3,246,443, the entire contents of which are incorporated herein by reference.

[0185] The ratio of the first polymer component to the second polymer component may be from about 55:about 45 to about 80:about 20, with a ratio of 70:30 being more preferred.

[0186] In addition to the polymer compositions described above, blends of various polymers and polymer additives may be used to produce crimped filaments. In one such embodiment, a polypropylene having a MFR of 15-50 g / 10 min may be blended with a high MFR polypropylene resin (e.g., about 500-2,000 g / 10 min), or a low isotactic polypropylene.

[0187] In one embodiment, the second region 230 of non-crimp or low crimp filaments typically comprises monocomponent or multicomponent fibers that do not develop a helical crimp, e.g., a centric sheath / core configuration. The filaments of the second region 230 provide strength to the nonwoven and provide the nonwoven with improved dimensional stability.

[0188] The filaments comprising the second region 230 may comprise polyolefins, such as polyethylene, polypropylene, and combinations thereof. In a preferred embodiment, the filaments of the second region 230 comprise a Ziegler-Natta catalyzed homopolymer polypropylene having an MFR of about 20 to about 40 g / 10 min, particularly about 25 to about 35 g / 10 min. In one embodiment, the polymer comprising the filaments of the second region 230 is the same Ziegler-Natta catalyzed polypropylene used as the second polymer component in the bicomponent filaments of the first region 220.

[0189] In some embodiments, the nonwoven fabric 200 can have a basis weight of about 8 to about 65 grams per square meter (gsm), particularly about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 200 has a basis weight of about 15 to about 30 gsm.

[0190] The ratio of first regions 220 to second regions 230 (based on the number of rows of distribution apertures) is from about 40:about 60 to about 90:about 10, with a ratio of about 30:about 70 being more preferred.

[0191] Referring now to Figure 13, there is illustrated a further embodiment of a nonwoven fabric having a stratified woven layer that can be produced in accordance with an embodiment of the present invention. As illustrated, the nonwoven fabric 300 comprises a stratified woven layer 310 having a first region 320 and a second region 330, where the fibers in the two regions are of different types from each other. As previously described, the stratified woven layer 310 is extruded from a spin beam as a single layer. In some embodiments, the stratified woven layer illustrated in Figure 13 can be prepared using the zoned distribution plate illustrated in Figure 5, Figure 6, or Figure 7, as previously described.

[0192] In one embodiment, one of the first region 320 or the second region 320 contains a functional additive that is not present in the other region. In this manner, a nonwoven fabric can be prepared in which the layered woven fabric layer contains targeted functionality that is not present in the other region. As previously described, functional additives that can be included in one or more regions include colorants (e.g., pigments), UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblock agents, slip agents, optical brighteners, flame retardants, antimicrobial agents (e.g., copper oxide and zinc oxide), and the like.

[0193] In addition to pigments, the first and second regions may include different polymers and polymer blends to impart desired functionality to one region of the nonwoven fabric 300 .

[0194] In some embodiments, the nonwoven fabric 300 can have a basis weight of about 8 to about 65 grams per square meter (gsm), specifically about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 300 has a basis weight of about 15 to about 30 gsm.

[0195] 14, there is shown another embodiment of a nonwoven fabric 400 having a stratified woven layer 410. The nonwoven fabric 400 comprises a stratified woven layer 410 having a first region 420 and a second region 430, where the fibers in the two regions are of different types from each other. The nonwoven fabric 400 of FIG. 14 may be prepared using the zoned distribution plate according to the embodiment shown in FIG. 7 and specifically described above.

[0196] In one embodiment, the first region comprises crimped continuous filaments having a bicomponent configuration, and the second region comprises non-crimped or low crimped filaments having a bicomponent sheath / core configuration. As will be appreciated, this embodiment is similar to the nonwoven fabric shown in Figure 12 in that the first region of both stratified woven fabric layers is composed of crimped continuous filaments, which provide loft and softness to the nonwoven fabric.

[0197] The first region 420 of the layered woven fabric layer 410 may comprise the same materials, structures, and configurations as the first region 220 of the nonwoven fabric 200 described above. In a preferred embodiment, the crimped continuous filaments of the first region 420 comprise bicomponent filaments having a side-by-side configuration, where a first polymer component of the bicomponent fibers comprises a metallocene catalyzed polypropylene having an MFR of 19-40 g / min, and a second polymer component comprises a Ziegler-Natta catalyzed polypropylene having an MFR of about 20-35 g / 10 min.

[0198] With respect to the second region 430 of the layered woven layer 410, in this embodiment, the fibers may include bicomponent filaments having a sheath-core configuration, where the sheath includes a metallocene polypropylene having an MFR of about 15 to about 40 g / 10 min, particularly about 20 to about 35 g / 10 min, and the core includes a Ziegler-Natta catalyzed polypropylene having an MFR of about 20 to about 35 g / 10 min. In this embodiment, bicomponent fibers having a sheath / core configuration may help provide improvements in mechanical properties, such as improvements in CD and MD tensile strength and CD and MD elongation.

[0199] In some embodiments, the sheath to core ratio in the bicomponent filaments of the second region 430 may be from about 90:10 to about 10:90, with a ratio of 30:70 being preferred.

[0200] In yet a further embodiment of the layered woven fabric layer 410, the second region 430 may include continuous filaments having a sheath / core configuration, where the sheath includes a polyethylene polymer and the core includes a polypropylene polymer, such as one of the metallocene or Ziegler-Natta catalyzed polypropylenes previously described. The second region 430 including bicomponent filaments with a polyethylene sheath may provide a region of the nonwoven fabric with improved softness and drape, while also enhancing the flexibility of the nonwoven fabric 400.

[0201] In some embodiments, the nonwoven fabric 400 can have a basis weight of about 8 to about 65 grams per square meter (gsm), specifically about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 400 has a basis weight of about 15 to about 30 gsm.

[0202] Referring to FIG. 15, another embodiment of a nonwoven fabric having the layered woven layer 410 is shown. In this embodiment, the nonwoven fabric 500 comprises the layered woven layer 510 having a first region 520, a second region 530, and a third region 540 sandwiched between the first region 520 and the second region 530. In one embodiment, the first region 520 and the second region 530 are the same fiber type, and the third region 540 is a different fiber type compared to the first region 520 and the second region 530. In some embodiments, the first region 520 and the second region 530 may also be different fiber types. In some embodiments, the first region 520 comprises a first outer surface 525, and the second region 530 comprises a second outer surface 535.

[0203] As with the previously described embodiment of the stratified woven fabric layer, the nonwoven fabric 500 having the stratified woven fabric layer 510 is produced from a single spin beam. The nonwoven fabric 500 of Figure 15 can be prepared using the zoned distribution plate according to the embodiment shown in Figure 8 and described above.

[0204] In one embodiment of the nonwoven fabric 500, the third region 540 includes crimped continuous filaments, as described above in connection with the embodiment shown in Figure 12. As with the previous embodiment, the crimped continuous filaments serve to enhance the loft and softness of the nonwoven fabric 500.

[0205] Advantageously, first region 520 and second region 530 may comprise non-crimped or less crimped filaments, with the non-crimped and less crimped filaments sandwiching a third region 540 of crimped continuous filaments between the non-crimped and less crimped filaments. In this manner, first region 520 and second region 530 serve to improve the strength, abrasion resistance and dimensional stability of the nonwoven fabric.

[0206] In further embodiments, the first region 520 and the second region 530 may define an outer surface of the nonwoven. In some embodiments, functional additives may be added to one or more of the polymer streams from which the fibers of the first region 520 and the second region 530 are formed. In particular, the functionality of the first outer surface 525 and the second outer surface 535 of the first region 520 and the second region 530 may be selectively targeted to have desired properties. For example, in one embodiment, the first region 520 may include a colorant, e.g., a pigment, while the second region may include the same colorant, may be colorant-free, or may include a different colorant than the first region.

[0207] In some embodiments, the first region and the second region may be identical to one another (i.e., both are the same polymer type), while the third region 540 defines the interior of the layered woven fabric layer. In a preferred embodiment, the third region 540 may be composed of crimped continuous filaments, as previously described, while the first region and the second region may be composed of non-crimped or low crimped filaments. Advantageously, this embodiment provides an exterior surface on both sides of the crimped continuous filaments, thus improving the overall strength and dimensional stability of the layered woven fabric layer.

[0208] In addition, all three regions 520, 530 and 540 may each be of a different fiber type. In this embodiment, the layered woven fabric layers will provide two different outer surfaces with different properties. In some embodiments, one or more fiber types of the first region 520 and the second region 530 can be selected to be combined with an additional polymer layer, such as an additional nonwoven or film. This can be advantageous in many applications, such as providing a compatible surface polymer in a laminated composite structure or providing a bio-based polymer that is intended to be a body contact surface.

[0209] In some embodiments, the nonwoven fabric 500 can have a basis weight of about 8 to about 65 grams per square meter (gsm), specifically about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 500 has a basis weight of about 15 to about 30 gsm.

[0210] 16, a nonwoven fabric 600 is shown having three regions of different fiber types, where each region extends in a cross direction of the nonwoven fabric. In some embodiments, nonwoven fabric 600 can be prepared using the zoned distribution plate illustrated in FIG. 9 previously described.

[0211] The nonwoven fabric 600 comprises a stratified woven fabric layer 610 formed as a single layer from a single spin beam. The stratified woven fabric layer comprises a first region 620 of one fiber type, a second region 630 of one fiber type, and a third region 640 of one fiber type that is a different fiber type than both the first region 620 and the second region 630. In one embodiment, the first region 620 is a different fiber type than the second region 630. In other embodiments, the first region 620 and the second region 630 may be the same fiber type.

[0212] The first region comprises an outer surface 625 of the nonwoven fabric 600, and the second region 630 comprises an outer surface 635 of the nonwoven fabric.

[0213] Similar to the previously described embodiments, each of the first, second, and third regions of the layered woven fabric layer may have a variety of different structures (e.g., monocomponent or multicomponent), different compositions (e.g., polymers, chemicals, or functional additives), and different properties (e.g., loft, density, basis weight, hydrophilicity / hydrophobicity, etc.).

[0214] In some embodiments, the first region 620 and the second region 630 may be identical to one another (i.e., both are of the same polymer type), while the third region 640 defines the interior of the layered woven fabric layer. In a preferred embodiment, the third region 640 may be composed of crimped continuous filaments, as previously described, while the first region and the second region are composed of non-crimped or low crimped filaments. Advantageously, this embodiment provides exterior surfaces on both sides of the crimped continuous filaments, thus improving the overall strength, abrasion resistance, and dimensional stability of the layered woven fabric layer.

[0215] In one particular embodiment, the first region 620 and the second region 630 each comprise a multicomponent filament having a segmented pie cross-section. In this regard, FIG. 16a illustrates a cross-section of a multicomponent filament 650 having a plurality of pie segments 652, 654, 656, 658. In a preferred embodiment, the multicomponent filament 650 comprises a first pair of opposing segments (e.g., 652, 656) that are the same polymer type as each other, and a second pair of opposing segments (e.g., 654, 658) that are the same polymer type as each other, with the first pair of segments being a different polymer type than the second pair of segments.

[0216] Advantageously, the region containing multicomponent filaments with segmented pie cross-sections can be treated (e.g., by needle punching, hydroentanglement, or chemical methods) to break the segments and form individual segment filaments having reduced denier compared to unbroken filaments. For example, a 2.0 denier filament with five segments can be broken to form five 0.4 denier filaments. This results in a single woven layer having a mixture of fine denier from the first region 620 and the second region 630, and a region having a coarser denier from the third region 640. Such a woven fabric can be particularly useful in filtration applications or as a surge layer in absorbent articles.

[0217] This embodiment having an opposing pair of segments provides the advantage that filaments can be formed from immiscible polymers. For example, in one embodiment, a first pair of segments comprises a polypropylene polymer and a second pair of segments comprises a polyethylene polymer.

[0218] Additionally, the third region 640 may include crimped continuous filaments to help improve the loft and softness of the nonwoven. The third region 640 of the layered woven fabric layer 610 may have the same materials, structures, and configurations as the first region 220 of the nonwoven fabric 200 described above. In a preferred embodiment, the crimped continuous filaments of the third region 640 include bicomponent filaments having a side-by-side configuration, where a first polymer component of the bicomponent fiber includes a metallocene-catalyzed polypropylene having an MFR of 19 to 40 g / min, and another second polymer component includes a Ziegler-Natta catalyzed polypropylene having an MFR of about 20 to about 35 g / 10 min.

[0219] In some embodiments, the nonwoven fabric 600 can have a basis weight of about 8 to about 65 grams per square meter (gsm), specifically about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 600 has a basis weight of about 15 to about 30 gsm.

[0220] In some embodiments, the first and second regions may each comprise about 10 to about 20 weight percent, and more particularly about 12 to about 18 weight percent, of nonwoven fabric 600, based on the total weight of the nonwoven fabric. The third region 640 may comprise about 60 to 80 weight percent, and more particularly about 64 to 76 weight percent, of nonwoven fabric 600, based on the total weight of the nonwoven fabric.

[0221] 17, a nonwoven fabric 700 is shown having multiple regions of different fiber types extending in the machine direction of the nonwoven fabric. In one embodiment, nonwoven fabric 700 can be prepared using the zoned distribution plate illustrated in FIG. 11, previously described.

[0222] In the illustrated embodiment, the nonwoven fabric 700 comprises a stratified woven fabric layer 710 having a first series of alternating regions of one fiber type extending in the machine direction (e.g., 720a, 720b, 720c, 720d...) and a second series of alternating regions of a different fiber type extending in the machine direction (e.g., 730a, 730b, 730c...), where the first series and the second series comprise filaments of different fiber types.

[0223] In one particular embodiment, a first series of alternating regions of fiber type comprises crimped continuous filaments and a second series of alternating regions of fiber type comprises non-crimped or low crimped filaments.

[0224] Examples of crimped continuous filaments that may be used in this embodiment are as described above. For example, the crimped continuous filaments may include bicomponent filaments having a side-by-side configuration, where a first polymer component of the bicomponent fiber includes a metallocene catalyzed polypropylene having a MFR of 19-40 g / min, and another second polymer component includes a Ziegler-Natta catalyzed polypropylene having a MFR of about 20-35 g / 10 min.

[0225] Examples of non-crimp or low crimp filaments that may be used in the second series of the plurality of alternating regions (e.g., 730a, 730b, 730c...) are as described above. For example, the non-crimp or low crimp filaments may comprise monocomponent or multicomponent fibers that typically do not develop crimps, e.g., a central sheath / core configuration. In one embodiment, the filaments in the second series of the plurality of alternating regions (e.g., 730a, 730b, 730c...) may comprise a Ziegler-Natta catalyzed homopolymer polypropylene having an MFR of about 20 to about 35 g / 10 min, particularly about 25 g / 10 min. In one embodiment, the polymer comprising the filaments of the second series of the plurality of alternating regions may be a Ziegler-Natta catalyzed polypropylene which may be the same as the second polymer component used in the bicomponent filaments of the first series of the plurality of alternating regions (e.g., 720a, 720b, 720c, 720d...).

[0226] Advantageously, nonwoven fabric 700 can serve to improve the dimensional stability of the fabric in the cross direction via strain-resistant or low-crimp filaments in the second series of alternating regions (e.g., 730a, 730b, 730c...).

[0227] Nonwoven fabric 700 may be useful in preparing nonwoven fabrics with zoned regions of hydrophilic / hydrophobicity as well as other functional enhancements.

[0228] In some embodiments, the nonwoven fabric 700 can have a basis weight of about 8 to about 65 grams per square meter (gsm), particularly about 10 to about 30 gsm. In a preferred embodiment, the nonwoven fabric 700 has a basis weight of about 15 to about 40 gsm.

[0229] The above examples are provided to illustrate various embodiments within the scope of the invention and should not be construed as limiting the invention to the specific embodiments disclosed. It should be appreciated that a variety of different nonwoven fabrics having the stratified woven fabric layer 410 can be prepared in accordance with embodiments of the invention.

[0230] In addition to the polypropylene and polyethylene polymers mentioned above, embodiments of the present invention may also be prepared using a wide variety of different polymers and polymer blends. Examples of polymers suitable for preparing fibers include polyolefins, such as polypropylene and polyethylene and their copolymers; polyesters, such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT) and polybutylene terephthalate (PBT); nylon; polystyrene; polyurethane; copolymers; and blends thereof, as well as other synthetic polymers that may be used in the preparation of fibers.

[0231] In the embodiment that includes crimped filaments, polypropylene, polypropylene blends, and copolymers thereof can be advantageously employed.In some embodiments, the propylene polymer is a crystalline propylene polymer based on propylene, where examples are propylene homopolymer and propylene / α-olefin random copolymers of propylene and one or more α-olefin ethylene (for example, ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene and 4-methyl-1-hexene), such as propylene / ethylene random copolymers and propylene / ethylene / 1-butene random copolymers.

[0232] In further embodiments, the nonwoven fabric having the stratified woven layers containing a plurality of different fiber types can be prepared from sustainable polymers. In contrast to polymers derived from petroleum sources, sustainable polymers are generally derived from bio-based materials. In some embodiments, sustainable polymers can also be considered biodegradable. A special class of biodegradable products made from bio-based materials can be considered compostable if they can be decomposed in a composting environment. European Standard EN 13432 "Proof of Compostability of Plastic Products" can be used to determine whether a fabric or film composed of sustainable content is compostable.

[0233] In one such embodiment, the nonwoven fabric having a stratified woven fabric layer comprises fibers that include sustainable polymers. In some embodiments, the fibers are substantially free of synthetic materials, such as petroleum-based materials and polymers. For example, the fibers that make up the nonwoven fabric may have less than 25% by weight of non-biologically based materials, more preferably less than 20% by weight, less than 15% by weight, less than 10% by weight, and even more preferably less than 5% by weight of non-biologically based materials, based on the total weight of the nonwoven fabric.

[0234] In one embodiment, sustainable polymers for use include aliphatic polyester-based polymers, such as polylactic acid, and bio-based polyethylene.

[0235] Aliphatic polyesters useful in the present invention include homopolymers and copolymers of poly(hydroxyalkanoates), and homopolymers and copolymers of aliphatic polyesters derived from the reaction product of one or more polyols and one or more polycarboxylic acids, which are typically formed from the reaction product of one or more alkanediols and one or more alkanedicarboxylic acids (or acyl derivatives). Polyesters can also be derived from multifunctional polyols, such as glycerin, sorbitol, pentaerythritol, and combinations thereof, to form branched, star, and graft homopolymers and copolymers. Polyhydroxyalkanoates are generally formed from hydroxy acid monomer units or their derivatives. These include, for example, polylactic acid, polyhydroxybutyrate, polyhydroxyvalerate, polycaprolactone, and the like. Miscible and immiscible blends of aliphatic polyesters with one or more semi-crystalline or amorphous polymers can also be used.

[0236] One useful class of aliphatic polyesters are the poly(hydroxyalkanoates) obtained by condensation or ring-opening polymerization of hydroxy acids, or derivatives thereof. Suitable poly(hydroxyalkanoates) may be represented by the formula: H(O--R--C(O)--). nOH, where R is an alkylene moiety, which may be linear or branched, having 1 to 20 carbon atoms, preferably 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms, optionally substituted with catenary oxygen atoms (attached to a carbon atom in the carbon chain); n is a number such that the ester is polymerizable, preferably such that the molecular weight of the aliphatic polyester is at least 10,000 daltons, preferably at least 30,000 daltons, and most preferably at least 50,000 daltons. In some embodiments, the molecular weight of the aliphatic polyester is typically less than 1,000,000, preferably less than 500,000, and most preferably less than 300,000 daltons. R may further include one or more catenary (i.e., linear) ether oxygen atoms. Generally, the R group of the hydroxy acid is such that the pendant hydroxyl group is a primary or secondary hydroxyl group.

[0237] Useful poly(hydroxyalkanoates) include, for example, homopolymers and copolymers of poly(3-hydroxybutyrate), poly(4-hydroxybutyrate), poly(3-hydroxyvalerate), polylactic acid (also known as polylactide), poly(3-hydroxypropanoate), poly(4-hydropentanoate), poly(3-hydroxypentanoate), poly(3-hydroxyhexanoate), poly(3-hydroxyheptanoate), poly(3-hydroxyoctanoate), polydioxanone, polycaprolactone, and polyglycolic acid (i.e., polyglycolide). Copolymers of two or more of the above hydroxy acids can also be used, including, for example, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), poly(lactate-co-3-hydroxypropanoate), poly(glycolide-co-p-dioxanone), and poly(lactic acid-co-glycolic acid). Blends of two or more of the poly(hydroxyalkanoates) may also be used, as well as blends with one or more semi-crystalline or amorphous polymers and / or copolymers.

[0238] The aliphatic polyester may be a block copolymer of poly(lactic-co-glycolic acid). Aliphatic polyesters useful in the compositions of the present invention include homopolymers, random copolymers, block copolymers, star-branched random copolymers, star-branched block copolymers, dendritic copolymers, hyperbranched copolymers, graft copolymers, and combinations thereof.

[0239] Another useful class of aliphatic polyesters includes those derived from the reaction product of one or more alkanediols with one or more alkanedicarboxylic acids (or acyl derivatives). Such polyesters have the general formula: [ka]

[0240] wherein R' and R" each represent an alkylene moiety, which may be linear or branched, having 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms; and m is a number such that the ester is polymerizable, preferably such that the molecular weight of the aliphatic polyester is at least 10,000, preferably at least 30,000, and most preferably at least 50,000 Daltons, but less than 1,000,000, preferably less than 500,000, and most preferably less than 300,000 Daltons. Each n is independently 0 or 1. R' and R" may further include one or more catenary (i.e., linear) ether oxygen atoms.

[0241] Examples of aliphatic polyesters include (a) homo- and copolymers derived from one or more of the following diacids (or derivatives thereof): succinic acid; adipic acid; 1,12-dicarboxydodecane; fumaric acid; glutaric acid; diglycolic acid; and maleic acid; and (b) homo- and copolymers derived from one or more of the following diols: ethylene glycol; polyethylene glycol; 1,2-propanediol; 1,3-propanediol; 1,2-propanediol; 1,2-butanediol; 1,3-butanediol; 1,4-butanediol; 2,3-butanediol; 1,6-hexanediol; 1,2-alkanediols having 5 to 12 carbon atoms; diethylene glycol; 3 and (c) homo- and copolymers derived from one or more of: polyethylene glycol having a molecular weight of 00 to 10,000 daltons, preferably 400 to 8,000 daltons; propylene glycol having a molecular weight of 300 to 4,000 daltons; block or random copolymers derived from ethylene oxide, propylene oxide or butylene oxide; dipropylene glycol; and polypropylene glycol, optionally with minor amounts, i.e., 0.5 to 7.0 mole %, of homo- and copolymers derived from polyols having a functionality greater than 2, such as glycerol, neopentyl glycol, and pentaerythritol.

[0242] Such polymers may include polybutylene succinate homopolymer, polybutylene adipate homopolymer, polybutylene adipate-succinate copolymer, polyethylene succinate-adipate copolymer, polyethylene glycol succinate homopolymer, and polyethylene adipate homopolymer.

[0243] Commercially available aliphatic polyesters include poly(lactide), poly(glycolide), poly(lactide-co-glycolide), poly(L-lactide-co-trimethylene carbonate), poly(dioxanone), poly(butylene succinate), poly(butylene adipate).

[0244] The term "aliphatic polyester" includes polyesters made exclusively from aliphatic and / or cycloaliphatic components as well as polyesters that contain aromatic units in addition to aliphatic and / or cycloaliphatic units, so long as the polyesters have a substantially sustainable content.

[0245] In addition to the PLA-based resin, the nonwoven fabric according to the embodiment of the present invention may contain other polymers derived from aliphatic components having one carboxylic acid group and one hydroxyl group, alternatively called polyhydroxyalkanoates (PHAs). Examples are polyhydroxybutyrate (PHB), poly-(hydroxybutyrate-co-hydroxyvalerate) (PHBV), poly-(hydroxybutyrate-co-polyhydroxyhexanoate) (PHBH), polyglycolic acid (PGA), poly-(epsilon-caprolactone) (PCL), and preferably polylactic acid (PLA).

[0246] Examples of additional polymers that may be used in embodiments of the present invention include polymers derived from a combination of an aliphatic component having two carboxylic acid groups and an aliphatic component having two hydroxyl groups, and polyesters derived from aliphatic diols and aliphatic dicarboxylic acids, such as polybutylene succinate (PBSU), polyethylene succinate (PESU), polybutylene adipate (PBA), polyethylene adipate (PEA), polytetramethylene adipate / terephthalate (PTMAT).

[0247] Useful aliphatic polyesters include those derived from semicrystalline polylactic acid. Polylactic acid or polylactide (PLA) is the main degradation product of lactic acid, which is commonly found in nature, non-toxic, and widely used in the food, pharmaceutical, and medical industries. The polymer can be prepared by ring-opening polymerization of lactide, a dimer of lactic acid. Lactic acid is optically active, and the dimer occurs in four different forms: L,L-lactide, D,D-lactide, D,L-lactide (meso-lactide), and a racemic mixture of L,L- and D,D-. By polymerizing these lactides as pure compounds or blends, poly(lactide) polymers with different stereochemical characteristics and different physical properties, including crystallinity, can be obtained. L,L- or D,D-lactide yields semicrystalline poly(lactide), while poly(lactide) derived from D,L-lactide is noncrystalline.

[0248] Typically, polylactic acid-based polymers are prepared from dextrose, a sugar source obtained from field corn. In North America, corn is used because it is the most economical source of plant starch for ultimate conversion to sugar. However, it should be recognized that dextrose can be obtained from sources other than corn. Sugar is converted to lactic acid or lactic acid derivatives by fermentation through the use of microorganisms. The lactic acid is then polymerized to form PLA. Other agricultural sugar sources can be used, such as those listed above, including rice, sugar beet, sugar cane, wheat, and cellulosic materials such as xylose recovered from wood pulping.

[0249] Polylactic acid preferably has a high enantiomeric ratio to maximize the inherent crystallinity of the polymer. The crystallinity of polylactic acid is based on the regularity of the polymer backbone and its ability to crystallize with other polymer chains. When a relatively small amount of one enantiomer (e.g., D-) is copolymerized with the opposite enantiomer (e.g., L-), the polymer chain becomes irregularly shaped and crystallinity decreases. For these reasons, when crystallinity is preferred, it is desirable to have polylactic acid that is at least 85% of one isomer, at least 90% of one isomer, or at least 95% of one isomer to maximize crystallinity.

[0250] In some embodiments, a near equimolar blend of D-polylactide and L-polylactide is also useful, which forms a unique crystalline structure that has a higher melting point (about 210° C.) than D-poly(lactide) and L-poly(polylactide) alone (about 190° C.), and has improved thermal stability.

[0251] Copolymers such as those mentioned above, including block and random copolymers of polylactic acid with other aliphatic polyesters, may also be used. Useful comonomers include glycolide, beta-propiolactone, tetramethylglycolide, beta-butyrolactone, gamma-butyrolactone, pivalolactone, 2-hydroxybutyric acid, alpha-hydroxyisobutyric acid, alpha-hydroxyvaleric acid, alpha-hydroxyisovaleric acid, alpha-hydroxycaproic acid, alpha-hydroxyethylbutyric acid, alpha-hydroxyisocaproic acid, alpha-hydroxy-beta-methylvaleric acid, alpha-hydroxyoctanoic acid, alpha-hydroxydecanoic acid, alpha-hydroxymyristic acid, and alpha-hydroxystearic acid.

[0252] Blends of polylactic acid with one or more other aliphatic polyesters or one or more other polymers may also be used. Examples of useful blends include polylactic acid and polyvinyl alcohol, polyethylene glycol / polysuccinate, polyethylene oxide, polycaprolactone, and polyglycolide.

[0253] In a preferred embodiment, the aliphatic polyester component comprises a PLA-based resin. A wide variety of different PLA resins may be used to prepare nonwoven fabrics according to embodiments of the present invention. The PLA resin should have suitable molecular properties to be spun in a spunbond process. Suitable examples include PLA resins such as 6752D grades, 6100D grades and 6202D grades supplied by NatureWorks LLC, Minnetonka, Minn. 55345, which are believed to be generally manufactured according to the disclosures of U.S. Patents 5,525,706 and 6,807,973 to Gruber et al. Other examples of suitable PLA resins may include L130, L175 and LX175 from Corbion, Arkelsedijk 46, 4206 AC Gorinchem, The Netherlands.

[0254] In some embodiments, the nonwoven fabrics of the present invention may comprise a biodegradable sustainable polymer component derived from an aliphatic component having one carboxylic acid group (or a polyester-forming derivative thereof, such as an ester group) and one hydroxyl group (or a polyester-forming derivative thereof, such as an ether group), or may be derived from a combination of an aliphatic component having two carboxylic acid groups (or a polyester-forming derivative thereof, such as an ester group) together with two hydroxyl groups (or a polyester-forming derivative thereof, such as an ester group).

[0255] Additional non-limiting examples of biobased polymers include polymers produced directly from living organisms, such as polyhydroxyalkanoates (e.g., poly(beta-hydroxyalkanoates), poly(3-hydroxybutyrate-co-3-hydroxyvalerate), NODAX 商標 ), and bacterial cellulose; polymers extracted from plants and biomass, such as polysaccharides and their derivatives (e.g., gums, cellulose, cellulose esters, chitin, chitosan, starch, chemically modified starches), proteins (e.g., zein, whey, gluten, collagen), lipids, lignin, natural rubber; and current polymers derived from naturally occurring monomers and derivatives, such as bio-polyethylene, bio-polypropylene, polytrimethylene terephthalate, polylactic acid, NYLON 11, alkyd resins, succinic acid-based polyesters, and bio-polyethylene terephthalate.

[0256] In some embodiments, the bio-based polymer may include bio-based polyethylene, which is derived from a living organism. For example, bio-based polyethylene can be prepared from sugar that is fermented to produce ethanol, which is dehydrated to provide ethylene. One example of a suitable sugar cane-derived polyethylene is available from Braskem SA under the product name PE SHA7260.

[0257] As previously discussed, nonwoven embodiments may include one or more regions in the stratified woven fabric layer 410 where the fibers are multicomponent. In some embodiments, the fibers include multicomponent fibers having at least two polymeric components arranged in structured domains across the cross-section of the fiber. As is generally well known to those skilled in the art, the polymeric domains or components are arranged in substantially continuously arranged zones across the cross-section of the multicomponent fiber and extend continuously along the length of the multicomponent fiber. More than two components may be present in the multicomponent fiber.

[0258] A preferred configuration is a side-by-side arrangement in which a first polymer component occupies one side of the fiber and a second polymer component occupies the other side of the fiber.

[0259] Another preferred configuration is a sheath / core arrangement, where a first component, the sheath, substantially surrounds a second component, the core. The resulting sheath / core bicomponent fiber may have a circular or noncircular cross-section. Other structured fiber configurations known in the art can be used, such as segmented pie, island-in-the-sea, and tipped multilobal structures.

[0260] In some embodiments, the fibers are bicomponent, with a first polymer component defining the sheath of the fiber and a second polymer component defining the core of the fiber. In general, the weight percentage of the sheath to the weight percentage of the core in the fiber can vary widely depending on the desired properties of the carded nonwoven fabric. For example, the weight ratio of the sheath to the core can vary from about 5: about 95 to about 95: about 5, such as about 10: about 90 to about 90: about 10, particularly about 20: about 80 to about 80: about 20. In a preferred embodiment, the weight ratio of the sheath to the core is about 25: about 75 to about 35: about 65, with a weight ratio of about 20: about 80 to about 50: about 50 being preferred.

[0261] The nonwoven fabric having the layered woven fabric layer according to the embodiment of the present invention can be used to prepare a variety of different structures. For example, the nonwoven fabric having the layered woven fabric layer may be joined with one or more additional nonwoven or film layers to form a composite sheet material. Examples of additional nonwoven fabrics include spunbond fabrics, airlaid fabrics, meltblown fabrics, carded fabrics, spunlace fabrics, and the like.

[0262] In some embodiments, the nonwoven fabric of the present invention may be combined with one or more additional layers to prepare a composite or laminate. Examples of such composites / laminates include spunbond composites, spunbond-meltblown (SM) composites, spunbond-meltblown-spunbond (SMS) composites, or spunbond-meltblown-meltblown-spunbond (SMMS) composites. In some embodiments, a composite may be prepared that includes a layer of the nonwoven fabric of the present invention and one or more film layers.

[0263] For example, Figures 18A-18D are cross-sectional views of composites according to certain embodiments of the present invention. Figure 18A shows a spunbond-meltblown (SM) composite 800 having a nonwoven fabric 810 with a layered woven fabric layer 410 and a meltblown layer 820 according to an embodiment of the present invention.

[0264] FIG. 18B shows a spunbond-meltblown-spunbond (SMS) composite 850 having two spunbond nonwoven fabric layers 810 according to an embodiment of the present invention and a meltblown layer 820 sandwiched between the spunbond nonwoven fabric layers 810 of the present invention.

[0265] FIG. 18C shows an SMS composite 860 having a spunbond nonwoven fabric layer 810 of the present invention, another spunbond layer 830, and a meltblown layer 820 sandwiched between the two spunbond layers 810,830.

[0266] Finally, Figure 18D shows a spunbond-meltblown-meltblown-spunbond (SMMS) composite 870 having a spunbond nonwoven woven layer 810 of the present invention, a distinct spunbond layer 830, and two meltblown layers 820 sandwiched between the two spunbond layers 810 and 830. Although the SMMS composite 870 is shown as having two distinct spunbond layers 810 and 830, both spunbond layers may be the spunbond nonwoven woven layer 810 of the present invention.

[0267] In these multilayer structures, the basis weight of the spunbond nonwoven fabric layer of the present invention is 3 g / m 2 From the lowest to 80g / m 2 In such multi-layer laminates, both the meltblown and armor regions of the nonwoven fabric of the present invention may contain the same polymer on the surface to ensure optimal adhesion. In some embodiments where the spunbond layer of the present invention is part of a multi-layer structure (e.g., SM, SMS, and SMMS), the amount of meltblown in the structure, as a percentage of the entire structure, may be from about 5 to about 30%, particularly from about 5 to about 15%.

[0268] Another possible composite material may have a meltblown-spunbond-meltblown (MSM) configuration, where the spunbond includes a single woven layer with multiple fiber types.

[0269] Multilayer structures according to embodiments can be prepared in a variety of ways, such as a continuous in-line process where each layer is prepared in successive order on the same line, or the various ways described above including depositing a meltblown layer onto a previously formed spunbond layer. The layers of the multilayer structure can be bonded together to form a multilayer composite sheet material using thermal bonding, mechanical bonding, adhesive bonding, hydroentangling, or a combination thereof. In some embodiments, the layers are thermally point bonded together by passing the multilayer structure through a pair of calendar rolls.

[0270] The nonwoven fabrics prepared according to the embodiments of the present invention can be used in a wide variety of articles and applications. For example, the embodiments of the present invention can be used for personal care applications such as baby care products (diapers, wipes), feminal care products (pads, sanitary towels, tampons), adult care products (incontinence products), or cosmetic applications (pads), agricultural applications such as root wraps, seed bags, crop covers, industrial applications such as workwear coveralls, airline pillows, automobile trunk liners, soundproofing, and household applications such as mattress coil covers and furniture scratch pads.

[0271] Working Example

[0272] The following examples are provided to illustrate one or more embodiments of the invention and are not to be construed as limiting the invention.

[0273] The following materials were used in this example:

[0274] "PP-1" refers to a Ziegler-Natta polypropylene homopolymer having a MFR of 34 g / 10 min as measured by ASTM D1238 and is available from Braskem under the product name CP360H.

[0275] "PP-2" refers to a metallocene-catalyzed polypropylene with a MFR of 24 g / 10 min as measured by ASTM D1238, and is sold by Exxon as an ACHIEVE 登録商標 It is available under the product name 3854.

[0276] Control experiment 1

[0277] In this control experiment, a single layer spunbond fabric was prepared. The spunbond beam included a standard distribution plate configured to produce sheath / core filaments with a sheath / core ratio of 70:30. The sheath included PP-1 and the core included PP-2. After filament formation, the filaments were collected on a collection surface and calendered with a CD rod bond pattern using a calendering unit with a CD rod bond pattern.

[0278] Example 1 of the present invention

[0279] In Inventive Example 1, a single layer spunbond fabric containing multiple fiber types was prepared. The spunbond beam had a zoned distribution plate configured to produce bicomponent filaments having a side-by-side (SBS) configuration and bicomponent filaments having a sheath / core (S / C) configuration. The ratio of SBS filaments to S / C filaments in the zoned distribution plate was 80:20. The SBS filaments were composed of 70% by weight PP-2 and 30% by weight PP-1. The sheath / core filaments were the same as those in Control Example 1 described above. After formation of the filaments, they were collected on a collection surface and calendered using a calendering unit with a CD rod bonding pattern.

[0280] The resulting fabric was evaluated for crimp development using a Keyence VHX-5000 microscope at 50x magnification. The results are provided in Figures 19 and 20 (Control 1 and Inventive Example 1, respectively). The image in Figure 19 is of a single layer spunbond fabric with a single fiber type (i.e., S / C filaments). In the Control 1 fabric, the filaments show little, if any, crimp. In contrast, Figure 20 is an image of a single layer spunbond fabric with two different fiber types, where a significant percentage of the filaments show crimp (SBS filaments) while a small percentage of the filaments (S / C filaments) show little, if any, crimp like the Control 1 filaments. As can be seen in Figure 20, the zoned distribution plate can be used to produce a fabric with a single layer having multiple different fiber types.

[0281] Modifications of the invention described herein will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the invention is not to be limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. A system for preparing a nonwoven fabric having a single woven layer, the single woven layer comprising a plurality of different fiber types, the system comprising: a first polymer source configured to provide a stream of a molten or semi-molten first polymer; a second polymer source configured to supply a stream of a molten or semi-molten second polymer, wherein said first polymer and second polymer are of different types; a spin beam in fluid communication with the first polymer source and the second polymer source, the spin beam comprising a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone constructed and arranged to extrude a plurality of polymer streams into the spinneret that are a different polymer type than the polymer streams extruded by an adjacent zone; a collecting surface disposed below the spinneret on which continuous filaments are deposited to form a single layer containing two or more types of fibers that are different from one another; The system comprising:

2. The system of claim 1, wherein the zoned distribution plate comprises a first distribution zone configured to produce non-crimped or low-crimped filaments and a second distribution zone configured to produce crimped filaments.

3. The system of claim 1 or 2, wherein the zoned distribution plate comprises 2 to 10 zones.

4. 4. The system of claim 1, wherein the zoned distribution plate comprises a first zone configured to produce multicomponent filaments and a second zone configured to produce monocomponent filaments.

5. The system of any one of claims 1 to 4, wherein the first polymer source comprises polypropylene and the second polymer source comprises polypropylene.

6. The system described in claim 2, wherein the first distribution zone is configured to produce non-crimped or low-crimped multicomponent filaments having a sheath / core configuration, and the second distribution zone is configured to produce crimped multicomponent filaments having a side-by-side or eccentric configuration.

7. 6. The system of claim 1, wherein the zoned distribution plate comprises a plurality of zones extending longitudinally in a cross direction of the spin beam or a plurality of zones extending transversely in a machine direction of the spin beam.

8. 8. The system of claim 1, further comprising a third polymer source in fluid communication with the spin beam, wherein the third polymer source is configured to provide a stream of a molten or semi-molten third polymer.

9. 9. The system of any one of claims 1 to 8, wherein the first polymer source comprises a first polymer and the second polymer source comprises a second polymer that is blended with a functional additive that is not blended with the first polymer.

10. 10. The system of claim 9, wherein the functional additive is selected from the group including colorants, UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblock agents, slip agents, optical brighteners, flame retardants, polymer rheology modifiers, and antimicrobial agents.

11. The system described in any one of claims 1 to 10, wherein one or more of the first polymer and the second polymer include a bio-based polymer.

12. The method of claim 1, wherein the single woven fabric layer having a plurality of different fiber types is joined to a film layer.

13. The zoned distribution plate having one of the following zoned distribution configurations: a first zoned distribution configuration, wherein the first zoned distribution configuration includes a first distribution zone and a second distribution zone in fluid communication with the first polymer source, and a third distribution zone distributed between the first distribution zone and the second distribution zone, wherein the first distribution zone and the second distribution zone are configured to produce a multicomponent filament or a monocomponent filament, and the third distribution zone is in fluid communication with both the first polymer source and the second polymer source and is configured to produce a pre-multicomponent filament; a second zoned distribution configuration, wherein the second zoned distribution configuration includes a first distribution zone and a second pumping zone in fluid communication with both the first polymer source and the second polymer source, and a third distribution zone distributed between the first distribution zone and the second distribution zone and in fluid communication with the first polymer source, wherein the third distribution zone is configured to produce monocomponent filaments or multicomponent filaments; A system according to any one of claims 1 to 12.

14. A system for preparing a nonwoven fabric having a single woven fabric layer, the single woven fabric layer comprising a plurality of different fiber types, The system further comprises: a first polymer source configured to provide a stream of a molten or semi-molten first polymer; a second polymer source configured to supply a stream of a molten or semi-molten second polymer, wherein said first polymer and said second polymer are of different types; a spin beam in fluid communication with the first polymer source and the second polymer source, the spin beam comprising a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone constructed and arranged to extrude a plurality of polymer streams to the spinneret, the polymer streams being a different polymer type than the polymer streams extruded by adjacent zones, the zoned distribution plate including a first distribution zone and a second distribution zone in fluid communication with the first polymer source, and a third distribution zone distributed between the first distribution zone and the second distribution zone, the first distribution zone and the second distribution zone configured to produce a first fiber type, and the third distribution zone in fluid communication with the second polymer source and configured to produce a second fiber type different from the first fiber type; and a collecting surface disposed below the spinneret, on which the continuous filaments are deposited to form a single layer including two or more types that are different from each other; The system comprising:

15. 1. A method for preparing a nonwoven fabric having a single woven layer, the single woven layer comprising a plurality of different fiber types, The method further comprising: providing a first polymer source configured to supply a stream of a molten or semi-molten first polymer; providing a second polymer source configured to supply a stream of a molten or semi-molten second polymer, wherein said first polymer and said second polymer are of different types; introducing the first polymer stream and the second polymer stream into a spin beam in fluid communication with the first polymer source and the second polymer source, the spin beam comprising a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone constructed and arranged to extrude a plurality of polymer streams into the spinneret, the polymer streams being a different polymer type than the polymer streams extruded by an adjacent zone; extruding a first stream of said first polymer from said spinneret as first continuous filaments; extruding a second stream of the second polymer from the spinneret as second continuous filaments; and collecting the first continuous filaments and the second continuous filaments on a collection surface disposed below the spinneret to form a single layer including the first continuous filaments and the second continuous filaments of different types. The method comprising:

16. 16. The method of claim 15, wherein the zoned distribution plate comprises a first zone configured to produce multicomponent filaments and a second zone configured to produce monocomponent filaments.

17. The zoned distribution plate having a plurality of distribution zones arranged in one of the following zoned distribution configurations: a first zoned distribution configuration, wherein the first zoned distribution configuration includes a first distribution zone and a second distribution zone in fluid communication with the first polymer source, and a third distribution zone distributed between the first distribution zone and the second distribution zone, wherein the first distribution zone and the second distribution zone are configured to produce a multicomponent filament or a monocomponent filament, and the third distribution zone is in fluid communication with both the first polymer source and the second polymer source and is configured to produce a pre-multicomponent filament; a second zoned distribution configuration, wherein the second zoned distribution configuration includes a first distribution zone and a second pumping zone in fluid communication with both the first polymer source and the second polymer source, and a third distribution zone distributed between the first distribution zone and the second distribution zone and in fluid communication with the first polymer source, wherein the third distribution zone is configured to produce monocomponent filaments or multicomponent filaments; 17. The method of claim 16.

18. The method of claim 15, wherein the zoned distribution plate has 2 to 10 zones.

19. The method of claim 18, wherein the first distribution zone and the second distribution zone of the first zoned distribution configuration are: i. configured to produce non-crimp or low crimp filaments having a sheath / core configuration, where the third distribution zone is configured to produce crimped multicomponent filaments having a side-by-side or eccentric configuration; or ii. configured to produce crimped multicomponent filaments having a side-by-side or eccentric configuration, wherein the third distribution zone of the second zoned distribution configuration is configured to produce non-crimped or low-crimp multicomponent filaments; The method of claim 15.

20. An apparatus for melt spinning polymer fibers, the apparatus comprising a spinneret having a plurality of spinning orifices extending therethrough, the spinneret having a first plurality of spinning orifices configured to produce non-crimped or low crimped filaments and a second plurality of spinning orifices configured to produce crimped filaments.

21. The apparatus of claim 20, wherein the first plurality of spinning orifices configured to produce the non-crimped or low-crimped filaments define one or more first zones of the spinneret, and the second plurality of spinning orifices configured to produce the crimped filaments define one or more second zones of the spinneret.

22. The apparatus of claim 21, wherein the spinneret comprises a plurality of the first zones and a plurality of the second zones.

23. An apparatus as described in claim 21 or 22, wherein the spinneret has a pair of the second zones, and the first zone is positioned between the pair of second zones.

24. The apparatus of claim 22, wherein the plurality of first zones and the plurality of second zones are arranged alternately across the spinneret.

25. The apparatus of claim 20, wherein a spinneret of the second plurality of spinnerets is configured to produce fibers having a side-by-side configuration, an eccentric sheath / core configuration, a D-centric sheath / core configuration, an island-in-the-sea configuration, a ternary configuration, a bisected pie configuration, or a combination thereof.

26. A nonwoven fabric comprising a single layer, the single layer having a plurality of fibers comprising different fiber types, a first fiber type comprising crimped fibers, and the second fiber type comprising non-crinkled or low-crinkled fibers.

27. The nonwoven fabric of claim 26, wherein the first fiber type and the second fiber type are intermingled throughout the entire thickness of the nonwoven fabric.

28. The nonwoven fabric of claim 26, wherein the nonwoven fabric includes a first region primarily comprising crimped fibers and a second region primarily comprising non-crinkled or low-crinkle fibers.

29. The nonwoven fabric of claim 28, wherein the nonwoven fabric comprises a plurality of the first regions and a plurality of the second regions, the plurality of first regions and the plurality of second regions being arranged alternately along the machine direction of the nonwoven fabric, a Z direction perpendicular to the machine direction and transverse direction, or both.

30. The nonwoven fabric described in claim 28, wherein the second region is disposed between a pair of the first regions.

31. The nonwoven fabric of claim 28, wherein the first region defines a first outer surface of the nonwoven fabric, and the second region defines a second outer surface of the nonwoven fabric.

32. A method of using the nonwoven fabric of claim 26 in the manufacture of an absorbent article.

33. A composite sheet material comprising the nonwoven fabric of claim 26, the composite sheet material comprising at least one meltblown fabric layer adhered to a surface of the nonwoven fabric.

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