Partitioned Spinning Nozzle and High-Loft Nonwoven Fabric

Abstract

A spinneret for melt-spinning polymer fibers is provided that includes a spinneret body having a plurality of spinneret orifices formed across the thickness of the spinneret body. The plurality of spinneret orifices includes (i) a plurality of multicomponent spinneret orifices each having a first multicomponent opening and a separate second multicomponent opening, and (ii) a plurality of single-component spinneret orifices each having a single single-component opening. A nonwoven fabric having regions of single-component and multicomponent fibers is provided along with a method of forming such nonwoven fabrics using a segmented spinneret.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims priority under 35 U.S.C. § 119 to U.S. Patent Application No. 63 / 357,196, filed Jun. 30, 2022, which is hereby incorporated by reference in its entirety.

[0002] Embodiments of the present disclosure generally relate to spinnerets and molds including spinnerets, where the spinneret includes compartments configured to simultaneously melt - spin defined regions of single - component fibers and multi - component fibers. Embodiments of the present disclosure also generally relate to non - woven fabrics and methods of forming such non - woven fabrics.

Background Art

[0003] In non - woven fabrics, the fibers forming the non - woven fabric are generally oriented in the xy - plane of the web. As a result, the resulting non - woven fabric is relatively thin and lacks significant thickness in the loft, i.e., the z - direction. The loft or thickness of non - woven fabrics suitable for use in hygiene - related products (e.g., absorbent products for personal care) promotes comfort (softness) for the user, surge management, and fluid distribution to adjacent components of the product. In this regard, high - loft, low - density non - woven fabrics are used for a variety of end - uses such as sanitary - related products (e.g., sanitary pads and napkins, disposable diapers, incontinence care pads, etc.). High - loft and low - density non - woven fabrics can be used, for example, in products such as towels, industrial wipes, incontinence products, infant care products (e.g., diapers), absorbent feminine care products, and specialized medical goods.

[0004] In order to impart loft or thickness to the nonwoven fabric, it is generally desirable that at least a portion of the fibers forming the web be oriented in the z-direction. Conventionally, such loft nonwoven webs have been produced using crimped staple fibers, or post-forming processes such as creping or pleating of the formed fabric. There are methods for producing high-loft and low-density fabrics, but the fabric generally goes through several steps during the modification that compresses and / or deforms the material. Compression of the fabric can reduce the overall bulk produced, while on the other hand, conveyance of the fabric in the machine direction during various processing steps can induce undesirable elongation in the machine direction and / or necking (e.g., reduction in width in the cross direction) that negatively affects the ability of the processing steps due to overall deformation of the fabric.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, there is still a need in the art for a high-loft nonwoven fabric that has improved resistance to deformation such as elongation in the machine direction and / or reduction in width in the cross direction due to external loads or tensions applied to the nonwoven fabric in the machine direction, and / or resistance to the formation of yarn debris through abrasion. There is also a need in the art for equipment and methods for producing such high-loft nonwoven fabrics.

Means for Solving the Problems

[0006] One or more embodiments of the invention can address one or more of the above problems. One embodiment according to the invention provides a spinneret for melt-spinning polymer fibers, comprising a spinneret body including a plurality of spinneret orifices formed across the thickness of the spinneret body, the plurality of spinneret orifices including (i) a plurality of multicomponent spinneret orifices each having a first multicomponent opening and a second multicomponent opening different therefrom, and (ii) a plurality of single-component spinneret orifices each having a single single-component opening, and the plurality of single-component spinneret orifices optionally including a plurality of polymer composition A (PCA) single-component spinneret orifices and a plurality of polymer composition B (PCB) single-component spinneret orifices.

[0007] In another aspect, the present invention also provides a mold including: (i) a spinneret as described and disclosed herein; (ii) a first polymer distribution path operatively connecting a first inlet to each of the first multi-component openings of a plurality of multi-component spinning orifices of the spinneret; (iii) a second polymer distribution path operatively connecting a second inlet to each of the second multi-component openings of the plurality of multi-component spinning orifices of the spinneret; (iv) a third polymer distribution path operatively connecting a third inlet to at least a first portion of the single-component openings of a plurality of single-component spinning orifices of the spinneret, such as a plurality of PCA single-component spinning orifices; and (v) a fourth polymer distribution path operatively connecting a fourth inlet to at least a second portion of a single single-component opening of a plurality of single-component spinning orifices of the spinneret, such as a PCB single-component spinning orifice.

[0008] In another aspect, the present invention also provides a system including: (i) a mold as described and disclosed herein; (ii) a first polymer source containing a first polymer composition and operatively connected to the first inlet of the mold; (iii) a second polymer source containing a second polymer composition different from the first polymer composition and operatively connected to the second inlet of the mold; and optionally (iv) a third polymer source containing a third polymer composition different from the first and second polymer compositions and operatively connected to the third inlet of the mold.

[0009] In another aspect, the present invention also provides a nonwoven fabric including a plurality of differential fibers containing a plurality of single-component fibers, such as a plurality of different types of single-component fibers including optionally a plurality of single-component fibers of a first type and a plurality of single-component fibers of a second type, and a plurality of crimped multi-component fibers. The nonwoven fabric includes at least one first region including at least a majority (e.g., all) of a first single-component fiber group formed by the plurality of single-component fibers, and at least one second region including at least a majority (e.g., all) of a first multi-component fiber group formed by the plurality of crimped multi-component fibers.

[0010] In another aspect, the present invention also provides a method of manufacturing a nonwoven fabric as described and disclosed herein. The method according to an embodiment of the invention may include the following. (i) Simultaneously melt-spinning a fiber set from a single spinneret as described and disclosed herein, wherein the fiber set optionally contains a plurality of single-component fibers, such as a plurality of different types of single-component fibers including a plurality of first-type single-component fibers and a plurality of second-type single-component fibers, and a plurality of multi-component fibers, and the fiber set forms at least one first region containing at least a majority of a first single-component fiber group of the plurality of single-component fibers and at least one second region containing at least a majority of a first multi-component fiber group of the plurality of multi-component fibers. (ii) Recovering the melt-spun fiber set. (iii) Forming a plurality of crimped multi-component fibers by actively and / or passively forming one or more crimped portions in at least a portion of the plurality of multi-component fibers.

Brief Description of the Drawings

[0011] Now, the invention will be described in more detail below with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. In fact, the present invention can be embodied in many different forms and should not be construed as limited to the embodiments presented herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

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DETAILED DESCRIPTION OF THE INVENTION

[0012] Now, with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown, the invention will be described in more detail below. In fact, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments presented herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. In the specification and in the appended claims, when used, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0013] The invention disclosed herein generally relates to a spinneret having a plurality of "compartments" that can be defined, for example, by spinneret orifices having different shapes, sizes, and / or configurations (e.g., single-component spinneret orifices configured to melt-spin single-component fibers, multi-component spinneret orifices configured to melt-spin one or more types of multi-component fibers, etc.). For example, a group of a plurality of single-component spinneret orifices can define a first compartment, while a plurality of multi-component spinneret orifices can define a second compartment. In this regard, a generally unlimited number of different compartments (e.g., from a single spinner beam) can be included in the spinneret and arranged relative to each other to enable melt spinning of fibers for the production of a nonwoven fabric having a particularly desirable structure that can be defined by the location of corresponding groups of melt-spun fibers present within the nonwoven fabric (e.g., a single-layer nonwoven fabric formed from a single spinner beam equipped with the spinneret according to an embodiment of the invention). According to an embodiment of the invention, the spinneret can be incorporated into a melt spinning die and / or a melt spinning system capable of dispensing and spinning a number of polymer compositions (e.g., 2, 3, 4, 5, 6... different polymer compositions). By way of example, three separate polymer compositions can be melt-spun simultaneously, with the first polymer composition forming the first component of a multi-component fiber, the second polymer composition forming the second component of the multi-component fiber, and the third polymer composition forming a single-component fiber. However, according to an embodiment of the invention, a particular polymer composition may be dispensed in the same die to form both a single-component fiber and one of the components of a multi-component fiber (e.g., a bicomponent fiber).

[0014] According to certain embodiments of the invention, a nonwoven fabric (e.g., a high loft nonwoven fabric formed with a spinneret described and disclosed herein) containing a mixture of single-component fibers and multi-component fibers (e.g., crimped multi-component fibers) according to certain embodiments of the invention may provide beneficial shrinkage in the machine direction (MD) and / or cross direction (CD) compared to similar or identical high loft nonwoven fabrics. Additionally or alternatively, a nonwoven fabric (e.g., a high loft nonwoven fabric formed with a spinneret described and disclosed herein) containing a mixture of both single-component fibers and multi-component fibers (e.g., crimped multi-component fibers) according to certain embodiments of the invention may provide a reduction in "fuzz" or yarn debris during abrasion compared to similar or identical high loft nonwoven fabrics.

[0015] According to certain embodiments of the invention, the total number or weight percentage of single-component fibers present in the nonwoven fabric can be selected to account for, by way of example only, less than about 40% (e.g., less than 33%, less than 30%, less than 25%, less than 20%, less than 15%, or less than about 10%). According to certain embodiments of the invention, the reduction in the amount of single-component fibers provides the advantages of suppressing elongation and / or improving resistance to yarn debris formation due to abrasion, while at the same time maintaining the desired loft / thickness by not removing too many crimped multi-component fibers. According to certain embodiments of the invention, the selection of the location of the single-component fibers (e.g., through the selection of the location of the single-component spinning orifices in the spinneret) can be important in providing improved resistance to yarn debris or "fuzz" formation during abrasion. For example, a small amount of single-component fibers near the outermost surface in contact with the engraved roll (e.g., calendering) can form a "blanket" or "buffer" region of non-crimped fibers that are less likely to be pulled out of the plane during abrasion. However, by utilizing these thin layers of single-component fibers, the nonwoven fabric can retain its loft / thickness through the underlying crimped multi-component fibers. According to certain embodiments of the invention, the level or degree of crimp of the underlying multi-component fibers can improve the loft. By way of example, a small amount of single-component fibers forms a "blanket" or "buffer" region, so the degree of crimp formation can be increased.

[0016] The terms "substantially" or "substantially" may contain a majority (e.g., 95%, 96%, 97%, 98%, 99% of the specified total amount) according to one embodiment of the invention, rather than the total amount specified according to another embodiment of the invention.

[0017] The terms "polymer" or "polymeric", used interchangeably herein, may include homopolymers, copolymers such as block, graft, random, and alternating copolymers, terpolymers, etc., and mixtures and modifications thereof. Further, unless otherwise explicitly limited in other forms, the terms "polymer" or "polymeric" include, without limitation, all possible structural isomers, stereoisomers including geometric isomers, optical isomers or enantiomers, and / or chiral single-molecule configurations of such polymers or polymeric materials. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic configurations of such polymers or polymeric materials. The terms "polymer" or "polymeric" may also include polymers made from various catalyst systems including, without limitation, Ziegler-Natta catalyst systems and metallocene / single-site catalyst systems. The terms "polymer" or "polymeric" shall also include, according to one embodiment of the invention, polymers produced by fermentation processes or from biosources.

[0018] As used herein, the terms "nonwoven fabric" or "nonwoven web" can include a web having a structure of individual fibers, filaments, and / or yarns that are not in a distinguishable repeating pattern such as a knitted or woven fabric. A nonwoven fabric or web according to an embodiment of the invention can be formed by any of the processes conventionally known in the art, such as, for example, a meltblowing process, a spunbond process, needle punching, hydroentangling, air laying, and a bonded carded web process. A "nonwoven web" as used herein can contain a plurality of individual fibers that have not undergone a consolidation process. In some cases, a "nonwoven web" can contain multiple layers, such as one or more spunbond layers and / or one or more meltblown layers. By way of example, a "nonwoven web" can contain a spunbond-meltblown-spunbond structure.

[0019] As used herein, the terms "fabric" or "nonwoven fabric" can include a web of fibers in which the plurality of fibers are mechanically entangled or interconnected, fused, and / or chemically bonded. For example, a nonwoven web of individually laid fibers can be passed through a joining or consolidation process that joins at least a portion of the individual fibers together to form a coherent (e.g., bonded) web of interconnected fibers.

[0020] As used herein, the terms "consolidated by" and "consolidation" may include forming one or more bonding sites that function to increase resistance to external forces (such as abrasion and tensile forces) compared to an unconsolidated web by bringing at least a portion of the fibers of the nonwoven web into contact or interposing them (e.g., by heat fusion, chemical bonding, and / or mechanical entanglement). The one or more bonding sites may include, for example, individual or local regions of the web material that have been softened or melted to cause individual or local deformation in the web material and optionally subsequently or simultaneously compressed. Further, the term "consolidated by" may include the entire nonwoven web that has been treated such that at least a portion of the fibers are brought into contact or interposed (e.g., by heat fusion, chemical bonding, and / or mechanical entanglement) by, as merely a few examples, heat bonding or mechanical entanglement (such as hydroentanglement). Such a web may be considered a "consolidated nonwoven fabric", a "nonwoven fabric", or simply a "fabric" according to certain embodiments of the invention.

[0021] As used herein, the term "spunbond" may include fibers formed by extruding a heat - thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinneret having a diameter of the extruded filaments and then rapidly shrinking them. According to embodiments of the invention, spunbond fibers are generally not sticky when adhered to a collecting surface and may be generally continuous as disclosed and described herein. Spunbond used in certain composites of the invention may include nonwoven fabrics described in the literature as SPINLACE®. Spunbond fibers may include, for example, continuous fibers.

[0022] As used herein, the term "continuous fiber" refers to a fiber that has not been cut from its original length prior to being formed into a nonwoven web or fabric. Continuous fibers can have an average length ranging from greater than about 15 centimeters to greater than 1 meter and extending up to the length of the web or fabric being formed. For example, as used herein, continuous fibers can include fibers where the length of the fiber is at least about 5,000, 10,000, 50,000, or 100,000 times greater than the average diameter of the fiber, such as where the length of the fiber is at least 1,000 times greater than the average diameter of the fiber.

[0023] As used herein, the term "layer" can include a generally recognizable combination of similar material types and / or a function present in the XY plane.

[0024] As used herein, the term "multicomponent fiber" can include fibers formed from at least two different polymer materials or compositions (e.g., two or more) that are extruded from separate extruders but spun together to form a single fiber. As used herein, the term "bicomponent fiber" can include fibers formed from two different polymer materials or compositions that are extruded from separate extruders but spun together to form a single fiber. The polymer materials or polymers are substantially positioned in fixed positions in separate compartments of the cross-section of the multicomponent fiber and extend continuously along the length of the multicomponent fiber. The configuration of the multicomponent fiber can be, for example, a sheath / core configuration where one polymer is surrounded by another polymer, an eccentric sheath / core configuration, a juxtaposed configuration, a pie configuration, or an "island-in-the-sea" configuration, such as each being well known in the art of multicomponent fibers including those having two components.

[0025] As used herein, the term "machine direction" or "MD" includes the direction in which the fabric is manufactured or conveyed. As used herein, the term "cross direction" or "CD" includes the fabric direction that is substantially perpendicular to the MD.

[0026] As used herein, the term "high loft" encompasses materials having a z-direction thickness generally exceeding about 0.3 mm and a relatively low bulk density. The thickness of the "high loft" nonwoven fabric and / or layer is determined using a ProGage thickness tester (Model 89-2009) available from Thwig-Albert Instrument Co., West Berlin, NJ 08091, utilizing a 2" diameter foot to which a 1.45 kPa force is applied during measurement, and can be greater than 0.3 mm (e.g., greater than 0.4 mm, greater than 0.5 mm, or greater than 1 mm). According to certain embodiments of the invention, the thickness of the "high loft" nonwoven fabric and / or layer can be at most any of the following, namely about 3, 2.75, 2.5, 2.25, 2, 1.75, 1.5, 1.25, 1.0, 0.75, 0.5 mm, and / or at least any of the following, namely about 0.3, 0.4, 0.5, 0.75, 1.0, 1.25, 1.5, 1.75, 2.0 mm. The "high loft" nonwoven fabric and / or layer as used herein can additionally have a relatively low density (e.g., bulk density - weight per unit volume) of at most any of the following, namely about 70, 60, 55, 50, 45, 40, 35, 30, 25 kg / m 3 , and / or at least any of the following, namely about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 kg / m 3 such as less than about 70 kg / m 3 and can have a relatively low density (e.g., bulk density - weight per unit volume).

[0027] As used herein, the term "crimp" or "by crimp" encompasses three-dimensional curls or bends such as, for example, folded or compressed portions having an "L" configuration, wavy portions having a "zigzag" configuration, or curled portions having a helical configuration. According to certain embodiments of the invention, the term "crimp" or "by crimp" does not include random two-dimensional waves or irregularities of the fibers, such as those associated with the normal laying of fibers in a melt spinning process.

[0028] As used herein, the term "aspect ratio" encompasses the ratio of the length of the major axis to the length of the minor axis of the cross-section of the fiber in question.

[0029] When melt flow rate (MFR) is referred to in this specification, the value of MFR is always determined in accordance with the standard procedure ASTM D1238 (2.16 kg at 230 °C).

[0030] One embodiment according to the present invention provides a spinneret for melt-spinning polymer fibers including a spinneret body having a plurality of spinneret orifices formed therethrough across the thickness of the spinneret body, the plurality of spinneret orifices including (i) a plurality of multicomponent spinneret orifices each having a first multicomponent opening and a second multicomponent opening different therefrom, and (ii) a plurality of single-component spinneret orifices each having a single single-component opening, the plurality of single-component spinneret orifices optionally including a plurality of polymer composition A (PCA) single-component spinneret orifices and a plurality of polymer composition B (PCB) single-component spinneret orifices. For example, the plurality of PCA single-component spinneret orifices may be arranged to be aligned with a different polymer source than the plurality of PCB single-component spinneret orifices. Additionally or alternatively, the plurality of PCA single-component spinneret orifices may have a different geometric opening area and / or size than the plurality of PCB single-component spinneret orifices. According to one embodiment of the invention, the spinneret body may have a length and a width greater than the length. In this regard, the plurality of spinneret orifices may define a plurality of rows extending independently of each other at least at about 20, 30, 40, 50, 60, 70% of the width, and / or at most at about 100, 95, 90, 80, 70% of the width, etc., of the width, such that the plurality of rows extend independently of each other at least at about 20% of the width.

[0031] According to an embodiment of the invention, a plurality of multi-component spinning orifices may define at least one first section, and a plurality of single-component spinning orifices may define at least one second section. For example, at least one first section may contain a first group of one or more rows including a first outermost row extending along the width direction of the spinneret body. Additionally or alternatively, at least one first section may contain a second group of one or more rows including a second outermost row extending along the width direction of the spinneret body. Additionally or alternatively, at least one second section may contain a third group of one or more rows extending in the width direction of the spinneret body and disposed directly or indirectly between the first group of one or more rows and the second group of one or more rows.

[0032] For example, FIG. 1A illustrates a spinneret 1 including a first section containing one or more rows or a first group of multicomponent spinning orifices 10 including a first outermost row extending along the width direction of the spinneret body, and a second section including a second group of one or more rows of single-component spinning orifices 20 including a second outermost row extending along the width direction of the spinneret body. FIG. 1B shows a spinneret 1 similar to that of FIG. 1A, but according to an embodiment of the invention, the plurality of single-component spinning orifices 20 includes a plurality of polymer composition A (PCA) single-component spinning orifices (i.e., identified as "A" in FIG. 1B) and a plurality of polymer composition B (PCB) single-component spinning orifices (i.e., identified as "B" in FIG. 1B). As described above, the plurality of PCA single-component spinning orifices can be arranged to line up with a different polymer source than the plurality of PCB single-component spinning orifices. Additionally or alternatively, the plurality of PCA single-component spinning orifices can have a different geometric opening area and / or size than the plurality of PCB single-component spinning orifices. In the particular embodiment illustrated in FIG. 1B, the plurality of PCA single-component spinning orifices define the first outermost row of the plurality of spinning orifices, while the plurality of PCB single-component spinning orifices are disposed adjacent thereto between the plurality of PCA single-component spinning orifices and one or more rows of the multicomponent spinning orifices 10. FIG. 1C illustrates another spinneret 1 according to an embodiment of the invention, including a section of the multicomponent spinning orifices 10 and a section of the single-component spinning orifices 20 including an alternating pattern of the plurality of PCA single-component spinning orifices and the plurality of PCB single-component spinning orifices.

[0033] Figure 2A according to an embodiment of the invention illustrates a spinneret 1 including a first section containing a first group of one or more rows of multi-component spinning orifices 10 and a second group of one or more rows of multi-component spinning orifices 15. The spinneret of Figure 2 includes a relatively small second section including a third group of one or more rows of single-component spinning orifices 20 disposed adjacent thereto between the first group of one or more rows of multi-component spinning orifices 10 and the second group of one or more rows of multi-component spinning orifices 15. In this regard, the resulting nonwoven fabric has two outermost surfaces defined by (e.g., crimped) multi-component fibers and an inner portion formed of single-component fibers that can impart strength improvement and / or reduction in elongation to the nonwoven fabric without negatively affecting the loft of the nonwoven fabric. Figure 2B illustrates a spinneret 1 similar to that of Figure 2A, but according to an embodiment of the invention, the section of single-component spinning orifices 20 includes a plurality of PCA single-component spinning orifices and a plurality of PCB single-component spinning orifices disposed adjacent thereto between the two sections of multi-component spinning orifices. The particular embodiment shown in Figure 2B includes an alternating pattern of PCA single-component spinning orifices and PCB single-component spinning orifices along the rows of spinning orifices.

[0034] According to certain embodiments of the invention, the spinneret body may have a total number of rows, and a first group of one or more rows contains at least about 1, 3, 5, 8, 10, 12, 15, 18, 20% of the total number of rows, and / or at most any of the following, i.e., about 45, 40, 38, 35, 32, 30, 28, 25, 22, 20% of the total or number of rows, etc., containing from about 1 to about 45% of the total number of rows. According to certain embodiments of the invention, a given row may be classified into a particular section if at least a majority of the spinneret orifices are of a particular type (e.g., single-component or multi-component). Additionally or alternatively, the spinneret body may have a total number of rows, and a second group of one or more rows contains at least about 1, 3, 5, 8, 10, 12, 15, 18, 20% of the total number of rows, and / or at most any of the following, i.e., about 45, 40, 38, 35, 32, 30, 28, 25, 22, 20% of the total or number of rows, etc., and may contain from about 1 to about 45% of the total number of rows. According to certain embodiments of the invention, a given row may be classified into a particular section if at least a majority of the spinneret orifices are of a particular type (e.g., single-component or multi-component). Additionally or alternatively, the spinneret body may have a total number of rows, and a third group of one or more rows contains at least about 10, 12, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of rows, and / or at most any of the following, i.e., about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total or number of rows, etc., and may contain from about 10 to about 99% of the total number of rows. According to certain embodiments of the invention, a given row may be classified into a particular section if at least a majority of the spinneret orifices are of a particular type (e.g., single-component or multi-component).

[0035] According to an embodiment of the invention, and as illustrated in FIG. 3A, the spinneret 1 may include at least one second section (i.e., single-component spinning orifices) containing a first group of one or more rows of single-component spinning orifices 20 including a first outermost row extending along the width direction of the spinneret body. Additionally, the at least one second section may further contain a second group of one or more rows of single-component spinning orifices 25 including a second outermost row extending along the width direction of the spinneret body. According to an embodiment of the invention, at least one first section (i.e., multi-component spinning orifices) of the spinneret 1 extends along the width direction of the spinneret body and may contain a third group of one or more rows of multi-component spinning orifices 10 disposed directly or indirectly between a first group of one or more rows of single-component spinning orifices 20 and a second group of one or more rows of single-component spinning orifices 25. FIG. 3B illustrates a spinneret 1 similar to that of FIG. 3A, but according to an embodiment of the invention, one of the small sections of the single-component spinning orifices contains a plurality of PCA single-component spinning orifices, and the other small sections of the single-component spinning orifices contain a plurality of PCB single-component spinning orifices.

[0036] According to an embodiment of the invention, the spinneret body may have a total number of rows, and a first group of one or more rows is at least about 1, 3, 5, 8, 10, 12, 15, 18, 20% of the total number of rows, and / or at most any of the following, i.e., about 45, 40, 38, 35, 32, 30, 28, 25, 22, 20% of the total or the rows, etc., containing from about 1 to about 45% of the total number of rows. According to an embodiment of the invention, when at least a majority of the spinneret orifices are of a particular type (e.g., single-component or multi-component), a given row may be classified into a particular section. Additionally or alternatively, the spinneret body may have a total number of rows, and a second group of one or more rows may contain at least about 1, 3, 5, 8, 10, 12, 15, 18, 20% of the total number of rows, and / or at most any of the following, i.e., about 45, 40, 38, 35, 32, 30, 28, 25, 22, 20% of the total or the rows, etc., containing from about 1 to about 45% of the total number of rows. According to an embodiment of the invention, when at least a majority of the spinneret orifices are of a particular type (e.g., single-component or multi-component), a given row may be classified into a particular section. Additionally or alternatively, the spinneret body may have a total number of rows, and a third group of one or more rows contains at least about 10, 12, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of rows, and / or at most any of the following, i.e., about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total or the rows, etc., containing from about 10 to about 99% of the total number of rows. According to an embodiment of the invention, when at least a majority of the spinneret orifices are of a particular type (e.g., single-component or multi-component), a given row may be classified into a particular section.

[0037] According to an embodiment of the invention, and as generally illustrated in FIGS. 3A - 3B, at least one first section may include a plurality of first sections, and at least one second section includes a plurality of second sections. For example, as illustrated in FIG. 4, the plurality of first sections and the plurality of second sections may be arranged in an alternating pattern along the length direction of the spinneret. According to an embodiment of the invention, the plurality of first sections and the plurality of second sections may be arranged in an alternating pattern along the width direction. According to an embodiment of the invention, and as illustrated in FIG. 5, the plurality of first sections (i.e., 10a - 10j) and the plurality of second sections (i.e., 20a - 20j) may be arranged in an alternating pattern along the length direction and the width direction. According to an embodiment of the invention, the examples of the spinnerets in FIGS. 4 and 5 may include a plurality of PCA single - component spinning orifices and a plurality of PCB single - component spinning orifices as described above.

[0038] FIG. 6 illustrates another spinneret 1 according to an embodiment of the invention, including an alternating pattern of multi - component spinning orifices and single - component spinning orifices along the length direction (L) of the spinneret that may be associated with the machine direction (MD) during operation and the length direction (L) of the spinneret that may be associated with the cross - direction (CD) during operation. FIG. 7 illustrates another spinneret 1 according to an embodiment of the invention, including an alternating pattern of multi - component spinning orifices and single - component spinning orifices along the length direction (L) of the spinneret that may be associated with the machine direction (MD) during operation and the length direction (L) of the spinneret that may be associated with the cross - direction (CD) during operation. According to an embodiment of the invention, as described above, the examples of the spinnerets in FIGS. 6 and 7 may include a plurality of PCA single - component spinning orifices and a plurality of PCB single - component spinning orifices.

[0039] According to an embodiment of the invention, at least one first section (i.e., a multi-component spinning orifice) may contain a continuous sheet of a plurality of multi-component spinning orifices, and at least one second section (i.e., a single-component spinning orifice) may contain a plurality of second sections containing islands of single-component spinning orifices dispersed across the continuous sheet of a plurality of multi-component spinning orifices. By way of example, FIG. 8 illustrates a spinneret 1 including at least one first section (i.e., a multi-component spinning orifice) containing a continuous sheet of a plurality of multi-component spinning orifices 10 and at least one second section (i.e., a single-component spinning orifice) containing a plurality of second sections containing islands of single-component spinning orifices 20, 25, 28 dispersed across the continuous sheet of a plurality of multi-component spinning orifices 10. Alternatively, at least one second section may contain a continuous sheet of a plurality of single-component spinning orifices, and at least one first section may contain a plurality of first sections containing islands of multi-component spinning orifices dispersed across the continuous sheet of a plurality of single-component spinning orifices. According to an embodiment of the invention, the example of the spinneret of FIG. 8 may include a plurality of PCA single-component spinning orifices and a plurality of PCB single-component spinning orifices as described above. For example, the island by the single-component spinning orifice 25 may contain a PCA single-component spinning orifice, and the islands by the single-component spinning orifices 20, 28 may contain PCB single-component spinning orifices. Alternatively, each of the islands by the single-component spinning orifices 20, 25, 28 may contain a combination of a plurality of PCA single-component spinning orifices and a plurality of PCB single-component spinning orifices.

[0040] According to an embodiment of the invention, the plurality of multi-component spinning orifices may contain a circular outermost cross-section, a non-circular outermost cross-section, or both. Additionally or alternatively, the plurality of multi-component spinning orifices may contain an average opening area at the discharge surface of the spinneret body of at least any of the following, namely, about 60, 65, 70, 75%, and / or at most any of the following, namely, about 95, 90, 85, 80, 75%, etc., from about 60% to about 95%.

[0041] According to an embodiment of the invention, the plurality of multi-component spinning orifices may contain a circular outermost cross-section having an aspect ratio from 0.8 to 1.2, such as about 0.8, 0.9, 1, and / or at most about 1.2, 1.1, 1, etc. Additionally or alternatively, the plurality of multi-component spinning orifices may contain a non-circular outermost cross-section having an aspect ratio of at least 1.5, such as at least any of the following, i.e., about 1.5, 2, 3, 4, 5, and / or at most any of the following, i.e., about 10, 9, 8, 7, 6, 5, etc.

[0042] According to an embodiment of the invention, the multi-component spinning orifice may define a juxtaposed configuration, a multi-lobed configuration, a sheath-core configuration, an islands-in-the-sheath configuration containing a plurality of such openings where separate second multi-component openings are operatively connected to each other, or a combination thereof, between a first multi-component opening and another second multi-component opening. According to an embodiment of the invention, the sheath-core configuration may include a core opening and a sheath opening, and the core opening may define at least a portion of the outermost periphery of a multi-component spinning orifice having a circular outermost cross-section, or at least a portion of the outermost outer periphery of a multi-component spinning orifice having a non-circular outermost cross-section.

[0043] According to certain embodiments of the invention, the multi-component spinning orifices may contain a combination of multi-component spinning orifices with a circular outermost cross-section and multi-component spinning orifices with a non-circular outermost cross-section. The multi-component spinning orifices with a circular outermost cross-section according to the invention may contain at least any of the following, namely, about 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of multi-component spinning orifices, and / or at most any of the following, namely, about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total number of multi-component spinning orifices, etc., and may contain from 1 to about 99% of the total number of multi-component spinning orifices. Additionally or alternatively, the multi-component spinning orifices with a non-circular outermost cross-section may contain at least any of the following, namely, about 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of multi-component spinning orifices, and / or at most any of the following, namely, about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total number of multi-component spinning orifices, etc., and may contain from 1 to about 99% of the total number of multi-component spinning orifices. According to certain embodiments of the invention, all of the multi-component spinning orifices may be circular or non-circular.

[0044] According to certain embodiments of the invention, the plurality of single-component spinning orifices contain a circular outermost cross-section with an aspect ratio of from 0.8 to 1.2, such as about 0.8, 0.9, 1, and / or at most about 1.2, 1.1, 1, etc. Additionally or alternatively, the plurality of single-component spinning orifices contain a non-circular outermost cross-section with an aspect ratio of at least 1.5, such as at least any of the following, namely, about 1.5, 2, 3, 4, 5, and / or at most any of the following, namely, about 10, 9, 8, 7, 6, 5, etc.

[0045] According to an embodiment of the invention, the single-component spinning orifices may include a combination of a single-component spinning orifice with a circular outermost cross-section and a single-component spinning orifice with a non-circular outermost cross-section. According to an embodiment of the invention, the single-component spinning orifices with a circular outermost cross-section may contain at least any of the following, namely, about 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of single-component spinning orifices, and / or at most any of the following, namely, about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total number of single-component spinning orifices, etc., and may contain from 1 to about 99% of the total number of single-component spinning orifices. Additionally or alternatively, the single-component spinning orifices with a non-circular outermost cross-section may contain at least any of the following, namely, about 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of single-component spinning orifices, and / or at most any of the following, namely, about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total number of single-component spinning orifices, etc., and contain from 1 to about 99% of the total number of single-component spinning orifices. Alternatively, all of the single-component spinning orifices may be circular or non-circular.

[0046] According to an embodiment of the invention, the plurality of spinning orifices of the spinneret may have or define the total number of spinning orifices. According to an embodiment of the invention, at least any of the following, namely, about 1, 2, 3, 5, 10, 12, 15, 18, 20% of the total number of spinning orifices may be single-component spinning orifices, and / or at most any of the following, namely, about 40, 38, 35, 33, 30, 28, 25, 22, 20% of the total number of spinning orifices may be single-component spinning orifices, etc., and about 1 to about 40% of the total number of spinning orifices may be single-component spinning orifices. Additionally or alternatively, at least any of the following, namely, about 60, 62, 65, 67, 70, 72, 75, 78, 80% of the total number of spinning orifices may be multi-component spinning orifices, and / or at most any of the following, namely, about 99, 98, 97, 95, 90, 88, 85, 82, 80% of the total number of spinning orifices may be multi-component spinning orifices, etc., and about 60 to about 99% of the total number of spinning orifices may be multi-component spinning orifices.

[0047] In another aspect, the present invention also provides a die including: (i) a spinneret as described and disclosed herein; (ii) a first polymer distribution path operably connecting a first inlet to each of the first multi-component openings of the plurality of multi-component spinning orifices of the spinneret; (iii) a second polymer distribution path operably connecting a second inlet to each of the second multi-component openings of the plurality of multi-component spinning orifices of the spinneret; (iv) a third polymer distribution path operably connecting a third inlet to at least a first portion of the single-component openings of the plurality of single-component spinning orifices of the spinneret, such as a plurality of PCA single-component spinning orifices; and optionally (v) a fourth polymer distribution path operably connecting a fourth inlet to at least a second portion of a single one of the single-component openings of the plurality of single-component spinning orifices of the spinneret, such as a plurality of PCB single-component spinning orifices. According to an embodiment of the invention, the die is a spunbond die configured for the formation of continuous fibers.

[0048] In another aspect, the present invention also provides a system including: (i) a die as described and disclosed herein; (ii) a first polymer source containing a first polymer composition and operably connected to the first inlet of the die; (iii) a second polymer source containing a second polymer composition different from the first polymer composition and operably connected to the second inlet of the die; and optionally (iv) a third polymer source containing a third polymer composition different from the first and second polymer compositions and operably connected to the third inlet of the die. According to an embodiment of the invention, the first polymer source or the second polymer source may also be operably connected to the third inlet of the die.

[0049] According to an embodiment of the invention, the system further comprises a third polymer source containing a third polymer composition, and the third polymer source is operatively connected to a third inlet. The third polymer composition may be different from, for example, the first polymer composition and the second polymer composition. Alternatively, the third polymer composition may be the same as the first polymer composition or the second polymer composition. Additionally or alternatively, the system may include a fourth polymer source containing a fourth polymer composition, the fourth polymer source is operatively connected to a fourth inlet, the fourth polymer composition is different from the third polymer composition, and the fourth polymer composition may be the same as or different from the first polymer composition and / or the second polymer composition.

[0050] According to an embodiment of the invention, the first polymer source comprises a first hopper, a first extruder, and a first metering pump. The first hopper has a first hopper outlet operatively connected to the first extruder inlet. The first extruder has a first extruder outlet operatively connected to the first metering pump inlet. The first metering pump has a first metering pump outlet operatively connected to a first inlet of the mold. Additionally or alternatively, the second polymer source comprises a second hopper, a second extruder, and a second metering pump. The second hopper has a second hopper outlet operatively connected to the second extruder inlet. The second extruder has a second extruder outlet operatively connected to the second metering pump inlet. The second metering pump has a second metering pump outlet operatively connected to a second inlet of the mold. Additionally or alternatively, the third polymer source comprises a third hopper, a third extruder, and a third metering pump. The third hopper has a third hopper outlet operatively connected to the third extruder inlet. The third extruder has a third extruder outlet operatively connected to the third metering pump inlet. The third metering pump has a third metering pump outlet operatively connected to a third inlet of the mold. Additionally or alternatively, the system may include a fourth polymer source comprising a fourth hopper, a fourth extruder, and a fourth metering pump. The fourth hopper has a fourth hopper outlet operatively connected to the fourth extruder inlet. The fourth extruder has a fourth extruder outlet operatively connected to the fourth metering pump inlet. The fourth metering pump has a fourth metering pump outlet operatively connected to a fourth inlet of the mold.

[0051] In another aspect, the present invention optionally provides a nonwoven fabric comprising a plurality of single-component fibers, such as a plurality of different types of single-component fibers including a plurality of first-type single-component fibers and a plurality of second-type single-component fibers, and a plurality of crimped multi-component fibers. The nonwoven fabric includes at least one first region including at least a majority (e.g., all) of a first single-component fiber group formed by the plurality of single-component fibers, and at least one second region including at least a majority (e.g., all) of a first multi-component fiber group formed by the plurality of crimped multi-component fibers. According to certain embodiments of the invention, different types of single-component fibers can be distinguished from each other as having different polymer compositions, different cross-sections, different average diameters, or combinations thereof. For example, the plurality of first-type single-component fibers can contain or consist of a specific polymer composition (e.g., polymer composition "A"), while the second-type single-component fibers can contain or consist of a different polymer composition (e.g., polymer composition "B").

[0052] According to certain embodiments of the invention, regardless of the specific number and / or relative location of the groups or segments of different types of fibers (e.g., single-component and multi-component fibers), the total weight percentage of all single-component fibers based on the total amount of fibers forming the nonwoven fabric is at least any of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20 wt%, and / or at most any of the following, namely about 40, 38, 35, 33, 30, 28, 26, 25, 24, 22, 20 wt%, etc., and can be from about 1 to about 40%. Additionally or alternatively, the total weight percentage of all multi-component fibers based on the total amount of fibers forming the nonwoven fabric is at least any of the following, namely about 60, 62, 65, 67, 70, 72, 74, 75, 76, 78, 80 wt%, and / or at most any of the following, namely about 99, 98, 97, 95, 94, 92, 90, 88, 86, 85, 82, 80 wt%, etc., and can be from about 60 to about 99 wt%.

[0053] According to an embodiment of the invention, the first single-component fiber group defines the first outermost surface of the nonwoven fabric. Additionally or alternatively, at least one first region further contains a second single-component fiber group of a plurality of single-component fibers, and the second single-component fiber group defines the second outermost surface of the nonwoven fabric. According to an embodiment of the invention, the first multi-component fiber group can be disposed adjacent to the first single-component fiber group, the second single-component fiber group, or both. Additionally or alternatively, the nonwoven fabric can have a total basis weight of from about 10 gsm to about 200 gsm, such as at least any one of the following, namely about 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, 50 gsm, and / or at most any one of the following, namely about 200, 180, 150, 120, 100, 80, 70, 60, 50 gsm. Additionally or alternatively, the first single-component fiber group contains from about 1 to about 30% by weight of the total basis weight, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15% by weight of the total basis weight, and / or at most any one of the following, namely about 30, 28, 26, 25, 24, 22, 20, 18, 16, 15% by weight of the total basis weight. Additionally or alternatively, the second single-component fiber group contains from about 1 to about 30% by weight of the total basis weight, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15% by weight of the total basis weight, and / or at most any one of the following, namely about 30, 28, 26, 25, 24, 22, 20, 18, 16, 15% by weight of the total basis weight. Additionally or alternatively, the first multi-component fiber group contains from about 40 to about 98% by weight of the total basis weight, such as at least any one of the following, namely about 40, 44, 48, 50, 52, 56, 60, 64, 68, 70% by weight of the total basis weight, and / or at most any one of the following, namely about 98, 96, 94, 90, 88, 84, 80, 76, 72, 70% by weight of the total basis weight.According to an embodiment of the invention, the total weight percentage of all single-component fibers based on the total amount of fibers forming the nonwoven fabric is at least any of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20 wt%, and / or at most any of the following, namely about 40, 38, 35, 33, 30, 28, 26, 25, 24, 22, 20 wt%, etc., and can be from about 1 to about 40%. Additionally or alternatively, the total weight percentage of all multi-component fibers based on the total amount of fibers forming the nonwoven fabric is at least any of the following, namely about 60, 62, 65, 67, 70, 72, 74, 75, 76, 78, 80 wt%, and / or at most any of the following, namely about 99, 98, 97, 95, 94, 92, 90, 88, 86, 85, 82, 80 wt%, etc., and can be from about 60 to about 99 wt%.

[0054] According to an embodiment of the invention, a first multi-component fiber group defines a first outermost surface of the nonwoven fabric. Additionally or alternatively, at least one second region further contains a second multi-component fiber group of a plurality of multi-component fibers, and the second multi-component fiber group defines a second outermost surface of the nonwoven fabric. Additionally or alternatively, the first single-component fiber group can be disposed adjacent to the first multi-component fiber group, the second multi-component fiber group, or both. Additionally or alternatively, the nonwoven fabric has a basis weight of from about 10 to about 200 grams per square meter (gsm), such as at least any one of the following, namely about 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, 50 gsm, and / or at most any one of the following, namely about 200, 180, 150, 120, 100, 80, 70, 60, 50 gsm. Additionally or alternatively, the first multi-component fiber group contains from about 1 to about 45% by weight of the basis weight, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25% by weight of the basis weight, and / or at most any one of the following, namely about 45, 42, 40, 38, 35, 32, 30, 28, 26, 25, 24, 22, 20, 18, 16, 15% by weight of the basis weight. Additionally or alternatively, the second multi-component fiber group contains from about 1 to about 45% by weight of the basis weight, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25% by weight of the basis weight, and / or at most any one of the following, namely about 45, 42, 40, 38, 35, 32, 30, 28, 26, 25, 24, 22, 20, 18, 16, 15% by weight of the basis weight. Additionally or alternatively, the first single-component fiber group contains from about 10 to about 98% by weight of the basis weight, such as at least any one of the following, namely about 10, 16, 20, 24, 30, 36, 40, 44, 48, 50, 52, 56, 60, 64, 68, 70% by weight of the basis weight, and / or at most any one of the following, namely about 98, 96, 94, 90, 88, 84, 80, 76, 72, 70, 64, 60, 56, 50% by weight of the basis weight.According to an embodiment of the invention, the total weight percentage of all single-component fibers based on the total amount of fibers forming the nonwoven fabric is at least any of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15 wt%, and / or at most any of the following, namely about 30, 28, 26, 25, 24, 22, 20, 18, 16, 15%, etc., and can be from about 1 to about 30%.

[0055] According to an embodiment of the invention, at least one first region contains a plurality of first regions, and at least one second region contains a plurality of second regions. For example, the plurality of first regions and the plurality of second regions can be arranged in an alternating pattern along the machine direction of the nonwoven fabric, the z direction perpendicular to both the machine direction and the cross direction, or both. Additionally or alternatively, the plurality of first regions and the plurality of second regions can be arranged in an alternating pattern along the cross direction of the nonwoven fabric, the z direction perpendicular to both the cross direction and the machine direction, or both. According to an embodiment of the invention, the plurality of first regions and the plurality of second regions can be arranged in an alternating pattern along the cross direction and the machine direction. According to an embodiment of the invention, the plurality of first regions and the plurality of second regions can be arranged in an alternating pattern in the z direction of the nonwoven fabric, where the z direction is perpendicular to the cross direction and the machine direction. Additionally or alternatively, the nonwoven fabric can have a basis weight of from about 10 to about 200 gsm, such as at least any one of the following, namely about 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, 50 gsm, and / or at most any one of the following, namely about 200, 180, 150, 120, 100, 80, 70, 60, 50 gsm. Additionally or alternatively, the plurality of multi-component fibers can contain from about 1 to about 95% by weight of the basis weight, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, 50% by weight of the basis weight, and / or at most any one of the following, namely about 95, 90, 85, 80, 75, 70, 65, 60, 50% by weight of the basis weight. Additionally or alternatively, the plurality of single-component fibers can contain from about 1 to about 95% by weight of the basis weight, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, 50% by weight of the basis weight, and / or at most any one of the following, namely about 95, 90, 85, 80, 75, 70, 65, 60, 50% by weight of the basis weight.According to an embodiment of the invention, the total weight percentage of all single-component fibers based on the total amount of fibers forming the nonwoven fabric is at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15 wt%, and / or at most any one of the following, namely about 30, 28, 26, 25, 24, 22, 20, 18, 16, 15%, etc., and can be from about 1 to about 30%.

[0056] According to an embodiment of the invention, at least one second region contains a continuous network of a plurality of crimped multi-component fibers, and at least one first region contains a plurality of first regions each containing discrete islands of a plurality of single-component fibers dispersed across the continuous network of the plurality of crimped multi-component fibers. Alternatively, at least one first region contains a continuous network of a plurality of single-component fibers, and at least one second region contains a plurality of second regions each containing discrete islands of crimped multi-component fibers dispersed across the continuous network of the plurality of single-component fibers. According to an embodiment of the invention, the nonwoven fabric may have a total basis weight of from about 10 gsm to about 200 gsm, such as at least any one of the following, namely about 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, 50 gsm, and / or at most any one of the following, namely about 200, 180, 150, 120, 100, 80, 70, 60, 50 gsm. Additionally or alternatively, the plurality of multi-component fibers may contain from about 1 to about 95% by weight of the total basis weight, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, 50% by weight of the total basis weight, and / or at most any one of the following, namely about 95, 90, 85, 80, 75, 70, 65, 60, 50% by weight of the total basis weight. Additionally or alternatively, the plurality of single-component fibers may contain from about 1 to about 95% by weight of the total basis weight, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, 50% by weight of the total basis weight, and / or at most any one of the following, namely about 95, 90, 85, 80, 75, 70, 65, 60, 50% by weight of the total basis weight. According to an embodiment of the invention, the total weight percentage of all the single-component fibers based on the total amount of fibers forming the nonwoven fabric may be from about 1 to about 30%, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 14, 15% and / or at most any one of the following, namely about 30, 28, 26, 25, 24, 22, 20, 18, 16, 15%.

[0057] According to one aspect of the invention, the plurality of crimped multicomponent fibers may contain a circular outermost cross-section, a non-circular outermost cross-section, or both. The plurality of crimped multicomponent fibers may contain various cross-sectional geometries and / or deniers, such as the geometric shape of a circular or non-circular cross-section. According to one embodiment of the invention, the plurality of crimped multicomponent fibers may contain all or substantially all of the same cross-sectional geometry or a mixture of different cross-sectional geometries so as to adjust or control various physical properties.

[0058] Additionally or alternatively, the plurality of crimped multicomponent fibers may contain an average cross-section of from about 8 to about 40 microns (e.g., the longest cross-sectional length is perpendicular to the length of the fiber), such as at least any one of the following, namely about 8, 10, 12, 15, 18, 20 microns, and / or at most any one of the following, namely about 70, 38, 35, 32, 30, 28, 25, 22, 20 microns. According to one embodiment of the invention, the plurality of crimped multicomponent fibers may contain circular crimped multicomponent fibers having any of the above average cross-section values or ranges. Additionally or alternatively, the plurality of crimped multicomponent fibers may contain non-circular crimped multicomponent fibers having an average cross-section of from about 15 to about 40 microns (e.g., the longest cross-sectional length is perpendicular to the length of the fiber), such as at least any one of the following, namely about 15, 18, 20, 22, 25 microns, and / or at most any one of the following, namely about 40, 38, 35, 32, 30, 28, 25 microns. By way of example only, the non-circular fibers may contain trilobal crimped multicomponent fibers having an average cross-section of from about 20 to about 30 microns (e.g., the longest cross-sectional length is perpendicular to the length of the fiber), such as at least any one of the following, namely about 20, 22, 25 microns, and / or at most any one of the following, namely about 30, 28, 25 microns. As another example, the non-circular fibers may contain ribbon-shaped (e.g., rectangular-shaped) crimped multicomponent fibers having an average cross-section of from about 20 to about 30 microns (the longest cross-sectional length is perpendicular to the length of the fiber), such as at least any one of the following, namely about 20, 22, 24, 25 microns, and / or at most any one of the following, namely about 30, 28, 26, 25 microns.

[0059] According to certain embodiments of the invention, the plurality of crimped multicomponent fibers can contain a circular outermost cross-section having an aspect ratio from 0.8 to 1.2, such as about 0.8, 0.9, 1, and / or at most about 1.2, 1.1, 1, etc. Additionally or alternatively, the plurality of crimped multicomponent fibers can contain a non-circular outermost cross-section having an aspect ratio of at least 1.5, such as at least any one of the following, i.e., about 1.5, 2, 3, 4, 5, and / or at most any one of the following, i.e., about 10, 9, 8, 7, 6, 5, etc.

[0060] The crimped multicomponent fibers according to certain embodiments of the invention can include a side-by-side configuration, a multi-lobed configuration, a sheath-core configuration, an island-in-the-sea configuration, or some combination thereof. According to certain embodiments of the invention, the sheath-core configuration includes an eccentric sheath-core configuration, and at least a portion of the outermost periphery of the crimped multicomponent fiber having a circular outermost cross-section, or at least a portion of the outermost outer periphery of the crimped multicomponent fiber having a non-circular outermost cross-section, is defined by the core component. According to certain embodiments of the invention, the plurality of crimped multicomponent fibers includes bicomponent fibers.

[0061] According to certain embodiments of the invention, the plurality of crimped multi-component fibers includes a combination of multi-component fibers having a circular outermost cross-section and multi-component fibers having a non-circular outermost cross-section. For example, the multi-component fibers having a circular outermost cross-section can contain at least any one of the following, namely about 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of multi-component fibers, and / or at most any one of the following, namely about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total number of multi-component fibers, etc., and can contain from 1 to about 99% of the total number of multi-component fibers. Additionally or alternatively, the multi-component fibers having a non-circular outermost cross-section can contain at least any one of the following, namely about 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of multi-component fibers, and / or at most any one of the following, namely about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total number of multi-component fibers, etc., and can contain from 1 to about 99% of the total number of multi-component fibers. According to certain embodiments of the invention, the crimped multi-component fibers can all be multi-component fibers having a circular outermost cross-section or can all be multi-component fibers having a non-circular outermost cross-section.

[0062] Figures 9A - 9H illustrate examples of cross - sectional views of some non - limiting examples of a plurality of crimped multi - component fibers according to an embodiment of the invention. As shown in Figures 9A - 9H, the crimped fiber 50 may contain a first polymer component 52 of a first polymer composition A and a second polymer component 54 of a second polymer composition B. The first and second components 52, 54 may be arranged in substantially distinct compartments in a cross - section of the crimped fiber that extends substantially continuously along the length of the crimped fiber. The first and second components 52, 54 may be arranged in a juxtaposed arrangement in a circular - cross - section fiber as depicted in Figure 9A or in a ribbon - shaped (e.g., non - circular) cross - section fiber as depicted in Figures 9G and 9H. Additionally or alternatively, the first and second components 52, 54 may be arranged in a sheath / core configuration, such as an eccentric sheath / core configuration as depicted in Figures 9B and 9C. In an eccentric sheath / core crimped fiber as shown in Figure 9B, one component fully encapsulates or surrounds the other but is asymmetrically disposed in the crimped fiber so as to allow for the crimping of the fiber (e.g., the first component 52 surrounds the component 54). The eccentric sheath / core configuration as shown in Figure 9C includes a first component 52 (e.g., a sheath component) that surrounds the second component 54 (e.g., a core component) substantially, but not completely such that a portion of the second component is exposed to form part of the outermost surface of the fiber 50. As an additional example, the plurality of crimped multi - component fibers may contain hollow fibers as shown in Figures 9D and 9E or multi - lobed fibers as shown in Figure 9F. However, it should be noted that according to an embodiment of the invention, numerous other cross - sectional configurations and / or fiber shapes may be suitable. In a multi - component fiber according to an embodiment of the invention, the polymer components may exhibit a (volume or mass) ratio of from about 85:15 to about 15:85. According to an embodiment of the invention, a ratio of approximately 50:50 (by volume or mass) is desirable.However, the specific ratios employed can vary as desired, at most being any of the following, namely approximately 85:15, 80:20, 75:25, 70:30, 65:35, 60:40, 55:45, 50:50 by volume or mass, and / or at least any of the following, namely approximately 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80, 15:85 by volume or mass, etc.

[0063] According to an embodiment of the invention, the plurality of crimped multi-component fibers may include self-crimping fibers, and the crimped portions are formed during the laying process. In this regard, the plurality of crimped multi-component fibers may contain (i) a first component containing a first polymer material having an optional first melt flow rate (MFR) of less than 500 g / 10 min, less than 400 g / 10 min, less than 300 g / 10 min, less than 200 g / 10 min, less than 100 g / 10 min, less than 50 g / 10 min, etc., and (ii) a second component containing a second polymer material different from the first component, the second component in which the plurality of crimped multi-component fibers contain one or more three-dimensional crimped portions. Optionally, the second polymer material may contain, for example, an optional second MFR of less than 2000 g / 10 min, 1500 g / 10 min, 1000 g / min, 500 g / 10 min, less than 400 g / 10 min, less than 300 g / 10 min, less than 200 g / 10 min, less than 100 g / 10 min, less than 50 g / 10 min. Additionally or alternatively, the plurality of crimped multi-component fibers may include non-self-crimping fibers that require post-crimping formation operations (such as thermal activation) to provide the desired crimped portions.

[0064] As described above, the plurality of crimped multicomponent fibers contain a first component containing a first polymer composition and a second component containing a second polymer composition, and the first polymer composition is different from the second polymer composition. For example, the first polymer composition may include a first polyolefin composition, and the second polymer composition may include a second polyolefin composition, polyester, or polyamide. According to an embodiment of the invention, the first polyolefin composition may include a first polypropylene or a polypropylene mixture, the second polyolefin composition may include a second polypropylene and / or a second polyethylene, the first polyolefin composition has, for example, a first melt flow rate, the second polymer composition (for example, the second polyolefin composition) has a second melt flow rate, and the first melt flow rate is different from the second melt flow rate. Additionally or alternatively, the first polypropylene or polypropylene mixture may have a lower crystallinity than the second polymer composition (for example, the second polyolefin composition). According to an embodiment of the invention, the second polymer composition may include polyester, polyamide, or a biopolymer (for example, polylactic acid).

[0065] According to an embodiment of the invention, without additional application of heat in the diffuser section immediately after the tension unit but before laying when the tensile force is relaxed, and / or without post-treatment such as after fiber laying and web formation, the first polymer composition and the second polymer composition can be selected such that one or more crimps are developed in a plurality of crimped multi-component fibers. Therefore, the polymer compositions can contain polymers that are different from each other in that they have completely different stress or elastic recovery characteristics, crystallization rates, and / or melt viscosities. According to an embodiment of the invention, as described and disclosed herein, the polymer compositions can be selected such that they self-crimp due to the melt flow rate of the first and second polymer compositions (e.g., no post-crimping operation is required after laying of the fibers from the spinneret). According to an embodiment of the invention, the multi-component fibers can form or have a crimped fiber portion having, for example, a helical crimp in a single continuous direction. For example, one polymer composition can be disposed substantially and continuously inside the helix formed by the crimpability of the fibers. As described above, the plurality of crimped multi-component fibers can include non-self-crimping fibers that require a post-crimping formation operation (e.g., heat activation) to provide a desired crimped portion.

[0066] According to an embodiment of the invention, a plurality of crimped multi-component fibers can include (i) a plurality of first crimped multi-component fibers having a first identifying feature such as a first cross-sectional geometry, a first chemical structure, or a first crimp ratio for a given fiber length, and (ii) a plurality of second crimped multi-component fibers having a second identifying feature such as a second cross-sectional geometry, a second chemical structure, or a second crimp ratio for a given fiber length, wherein the first identifying feature is different from the second identifying feature. The plurality of first crimped multi-component fibers can include, for example, a polyolefin as at least a part thereof (e.g., a component of the multi-component fiber), and the plurality of second crimped multi-component fibers can include, as at least a part thereof, a different polyolefin composition or a non-polyolefin.

[0067] According to an embodiment of the invention, the plurality of crimped multicomponent fibers may include a first component (e.g., a separate phase) containing or consisting of a polymer material containing a polyolefin such as, for example, polypropylene homopolymer, and a second component (e.g., a separate phase) containing or consisting of a different polymer material containing a different polyolefin such as, for example, polypropylene copolymer. The polypropylene copolymer can be, for example, a polypropylene random copolymer or a polypropylene block copolymer. The polypropylene copolymer can include, for example, a minimum weight % of C2 or C4-C8α olefin units distributed across the polypropylene copolymer. For example, the C2 or C4-C8α olefin units can account for from about 1 to about 20 weight % of the polypropylene copolymer, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10 weight % of the propylene copolymer, and / or at most any one of the following, namely about 20, 18, 16, 15, 14, 12, 10 weight % of the propylene copolymer. According to an embodiment of the invention, the first component (e.g., polypropylene homopolymer) can account for from about 20 to 80 weight % of the crimped multicomponent fibers, such as at least any one of the following, namely about 20, 25, 30, 35, 40, 45, 50, 55, 60 weight % of the crimped multicomponent fibers, and / or at most any one of the following, namely about 80, 75, 70, 65, 60 weight % of the crimped multicomponent fibers. Additionally or alternatively, the second component (e.g., polypropylene copolymer) can account for from about 20 to 80 weight % of the crimped multicomponent fibers, such as at least any one of the following, namely about 20, 25, 30, 35, 40, 45, 50, 55, 60 weight % of the crimped multicomponent fibers, and / or at most any one of the following, namely about 80, 75, 70, 65, 60 weight % of the crimped multicomponent fibers.

[0068] According to certain embodiments of the invention, the plurality of single-component fibers may contain a plurality of first-type single-component fibers containing, for example, a third polymer composition different from the first polymer composition and the second polymer composition. Alternatively, the plurality of single-component fibers may contain a plurality of first-type single-component fibers containing, for example, a third polymer composition that is the same as the first polymer composition or the second polymer composition. For example, the third polymer composition may include a third polyolefin composition, a polyester, or a polyamide. According to certain embodiments of the invention, the third polyolefin composition may include a third polypropylene or a mixture of polypropylene and / or a third polyethylene. Additionally or alternatively, the third polymer composition may include a biopolymer (e.g., polylactic acid). According to certain embodiments of the invention, the plurality of single-component fibers may include, for example, a plurality of second-type single-component fibers containing a fourth polymer composition different from the third polymer composition, and the fourth polymer composition may be different from the first polymer composition and the second polymer composition. Alternatively or additionally, the plurality of single-component fibers may include, for example, a plurality of second-type single-component fibers containing a fourth polymer composition different from the third polymer composition, and the fourth polymer composition may be the same as the first polymer composition or the second polymer composition. For example, the fourth polymer composition may contain a fourth polyolefin composition, a polyester, or a polyamide. According to certain embodiments of the invention, the fourth polyolefin composition may contain a fourth polypropylene, or a mixture of polypropylene and / or a fourth polyethylene. Additionally or alternatively, the fourth polymer composition may include a biopolymer (e.g., polylactic acid).

[0069] According to an embodiment of the invention, the plurality of single-component fibers may comprise a polymer material containing or consisting of, for example, a polyolefin (e.g., a polypropylene homopolymer or a polypropylene copolymer). According to an embodiment of the invention, the plurality of single-component fibers may comprise a polymer material that is, for example, completely different from each of those used in the multi-component fibers or the same as one of the polymer materials used in the multi-component fibers. For example, the plurality of multi-component fibers may contain at least one component containing or consisting of a polypropylene copolymer as described above. According to an embodiment of the invention, the plurality of single-component fibers may contain a polymer material having a polymer component containing or consisting of (e.g., the same as or different from that of the multi-component fibers) a polypropylene copolymer. The polypropylene copolymer of the plurality of single-component fibers may be, for example, a polypropylene random copolymer or a polypropylene block copolymer. The polypropylene copolymer may contain, for example, a minimum weight % of C2 or C4-C8 α-olefin units distributed across the polypropylene copolymer. For example, the C2 or C4-C8 α-olefin units may account for from about 1 to about 20 weight % of the propylene copolymer, such as at least any of the following, namely about 1, 2, 3, 5, 6, 8, 10 weight % of the propylene copolymer, and / or at most any of the following, namely about 20, 18, 16, 15, 14, 12, 10 weight % of the propylene copolymer.

[0070] According to an embodiment of the invention, the plurality of single-component fibers may all comprise single-component fibers with a circular outermost cross-section, or may all comprise single-component fibers with a non-circular outermost cross-section. Alternatively, the plurality of single-component fibers may comprise a combination of single-component fibers with a circular outermost cross-section and single-component fibers with a non-circular outermost cross-section. For example, the single-component fibers with a circular outermost cross-section may contain at least any of the following, namely about 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of single-component fibers, and / or at most any of the following, namely about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total number of single-component fibers, etc., and may contain from 1 to about 99% of the total number of single-component fibers. Additionally or alternatively, the single-component fibers with a non-circular outermost cross-section may contain at least any of the following, namely about 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50% of the total number of single-component fibers, and / or at most any of the following, namely about 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50% of the total number of single-component fibers, etc., and contain from 1 to about 99% of the total number of single-component fibers.

[0071] According to an embodiment of the invention, the non-woven fabric may have a density of at most any of the following, namely about 70, 60, 55, 50, 45, 40, 35, 30, 25 kg / m 3 and / or at least any of the following, namely about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 kg / m 3 etc., and may have a density of less than about 70 kg / m 3 Additionally or alternatively, the non-woven fabric may have a thickness in the z-direction perpendicular to the machine direction and the cross-direction of the non-woven fabric, and the thickness may be at most any of the following, namely about 4, 3.8, 3.5, 3.2, 3, 2.75, 2.5, 2.25, 2, 1.75, 1.5, 1.25, 1.0, 0.75, 0.5 mm, and / or at least any of the following, namely about 0.3, 0.4, 0.5, 0.75, 1.0, 1.25, 1.5, 1.75, 2.0 mm, etc., and may contain from about 0.3 mm to about 4 mm.

[0072] According to certain embodiments of the invention, the nonwoven fabric may have a bonding area of from about 1% to about 40%, such as at least any one of the following, namely about 1, 2, 3, 5, 6, 8, 10, 12, 15, 18, 20, 21, 22%, and / or at most any one of the following, namely about 40, 38, 35, 32, 30, 28, 25, 22%. In this regard, the bonding area may be defined by a plurality of separate bonding sites, such as a plurality of thermal bonding points (e.g., via thermal calendering or ultrasonic bonding). Alternatively, the nonwoven fabric is an air-through bond.

[0073] According to certain embodiments of the invention, after 60 rubs, the nonwoven fabric may have a pill grade value difference of from about 0.05 to about 0.35, such as at least any one of the following, namely about 0.05, 0.08, 0.1, 0.15, 0.2, and / or at most any one of the following, namely about 0.35, 0.32, 0.3, 0.25, 0.2 (i.e., the pill grade value after a defined number of rubs via a Martindale abrasion tester minus the pill grade value before abrasion via a Martindale abrasion tester). Additionally or alternatively, after 120 rubs, the nonwoven fabric may have a pill grade value difference of from about 0.05 to about 0.6, such as at least any one of the following, namely about 0.05, 0.08, 0.1, 0.15, 0.2, 0.25, 0.3, and / or at most any one of the following, namely about 0.6, 0.55, 0.5, 0.45, 0.4, 0.35, 0.32, 0.3. Alternatively or additionally, after 180 rubs, the nonwoven fabric may have a pill grade value difference of from about 0.1 to about 0.8, such as at least any one of the following, namely about 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, and / or at most any one of the following, namely about 0.8, 0.75, 0.7, 0.65, 0.6, 0.55, 0.5, 0.45, 0.4.

[0074] In yet another aspect, the present invention also provides a method of manufacturing a nonwoven fabric as described and disclosed herein. The method according to an embodiment of the invention may include the following. (i) Simultaneously melt-spinning a fiber set from a single spinneret, wherein the fiber set contains a plurality of single-component fibers, such as a plurality of different types of single-component fibers including optionally a plurality of first-type single-component fibers and a plurality of second-type single-component fibers, and a plurality of multi-component fibers, and the fiber set forms at least one first region containing at least a majority of a first single-component fiber group by a plurality of single-component fibers and at least one second region containing at least a majority of a first multi-component fiber group by a plurality of multi-component fibers, (ii) recovering the melt-spun fiber set, (iii) forming a plurality of crimped multi-component fibers by actively and / or passively forming one or more crimped portions in at least a portion of the plurality of multi-component fibers.

[0075] According to an embodiment of the invention, the step of forming a plurality of crimped multi-component fibers may include self-crimping the multi-component fibers during a laying process prior to the step of recovering the melt-spun fibers. Additionally or alternatively, the step of forming a plurality of crimped multi-component fibers may include actively exposing the multi-component fibers to an amount of heat sufficient to induce the formation of one or more crimped portions, and the step of actively exposing the multi-component fibers to heat is performed before and / or after the step of recovering the melt-spun fiber set. According to an embodiment of the invention, the method may include a combination of passively self-crimping the multi-component fibers during a laying process prior to recovering the melt-spun fibers and further performing an active crimping formation process on these fibers.

[0076] According to an embodiment of the invention, the method may include a step of consolidating the melt-spun fibers (e.g., consolidating the melt-spun nonwoven web to form a nonwoven fabric). The consolidation method may include a heat bonding operation, such as a thermal calendar operation, an area thermal bonding operation, or an ultrasonic bonding operation. Alternatively, the consolidation method may include an air-jet bonding process.

[0077] Example The present disclosure is further illustrated by the following examples, which should not be construed as limiting in any way. That is, the specific features described in the following examples are merely illustrative and not restrictive.

[0078] With regard to some of the advantages associated with a high-loft spunbond nonwoven fabric formed from a spinneret that includes a combination of a bicomponent spinning orifice and a monocomponent spinning orifice that form a crimped bicomponent spunbond fiber having a juxtaposed configuration (e.g., an improvement in abrasion resistance as demonstrated by pill grade measurements, as discussed later), a variety of high-loft spunbond nonwoven fabrics were produced. Samples 1 and 2 are control samples that use different combinations of polymer materials (e.g., polymers) to form the respective components of the fibers, although all of the fibers are crimped spunbond fibers. Samples 3 - 6 illustrate high-loft spunbond nonwoven fabrics according to certain embodiments of the invention, and a spinneret was used that forms a sample having 70% crimped bicomponent fibers and 30% monocomponent fibers.

[0079] Each of the samples was manufactured from one or more of the following polymers. Polymer 1 was a polypropylene homopolymer (i.e., Exxon PP3155 from Exxon) having an MFR of 36 g / 10 min according to ASTM D1238 (230°C / 2.16 kg) and a melting temperature of 165°C. Polymer 2 was a polypropylene random copolymer having an MFR of 32 g / 10 min according to ASTM D1238 (230°C / 2.16 kg) and a melting temperature of 149°C. Polymer 3 was a different propylene random copolymer having an MFR of 35 g / 10 min according to ASTM D1238 (230°C / 2.16 kg) and a melting temperature of 143°C.

[0080] Sample 1: Sample 1 was the first control, where 100% of the non-woven fabric consisted of crimped bicomponent fibers in which the first component was formed from Polymer 1 and the second component was formed from Polymer 2. Polymer 1 accounted for 60% by weight and Polymer 2 accounted for 40% by weight.

[0081] Sample 2: Sample 2 was the second control, where 100% of the non-woven fabric consisted of crimped bicomponent fibers in which the first component was formed from Polymer 1 and the second component was formed from Polymer 3. Polymer 1 accounted for 60% by weight and Polymer 3 accounted for 40% by weight.

[0082] Sample 3: Sample 3 corresponds to an example of a non-woven fabric according to an embodiment of the invention. This non-woven fabric was formed from 70% by number of crimped bicomponent fibers and 30% by number of monocomponent fibers provided from the same spinneret. The bicomponent fibers were formed from Polymer 1 and Polymer 2, with Polymer 1 accounting for 60% by weight of the bicomponent fibers and Polymer 2 accounting for 40% by weight of the bicomponent fibers. The monocomponent fibers were made of Polymer 1.

[0083] Sample 4: Sample 4 corresponds to another example of a non-woven fabric according to an embodiment of the invention. This non-woven fabric was formed from 70% by number of crimped bicomponent fibers and 30% by number of monocomponent fibers provided from the same spinneret. The bicomponent fibers were formed from Polymer 1 and Polymer 3, with Polymer 1 accounting for 60% by weight of the bicomponent fibers and Polymer 3 accounting for 40% by weight of the bicomponent fibers. The monocomponent fibers were made of Polymer 1.

[0084] Sample 5: Sample 5 corresponds to another example of a non-woven fabric according to an embodiment of the invention. This non-woven fabric was formed from 70% by number of crimped bicomponent fibers and 30% by number of monocomponent fibers provided from the same spinneret. The bicomponent fibers were formed from Polymer 1 and Polymer 2, with Polymer 1 accounting for 60% by weight of the bicomponent fibers and Polymer 2 accounting for 40% by weight of the bicomponent fibers. The monocomponent fibers were made of Polymer 2.

[0085] Sample 6: Sample 6 corresponds to another example of a nonwoven fabric according to an embodiment of the invention. This nonwoven fabric was formed from 70% by number of crimped bicomponent fibers and 30% by number of monocomponent fibers provided from the same spinneret. The bicomponent fibers were formed from Polymer 1 and Polymer 3, with Polymer 1 accounting for 60% by weight of the bicomponent fibers and Polymer 3 accounting for 40% by weight of the bicomponent fibers. The monocomponent fibers were made of Polymer 3.

[0086] Test protocol for abrasion resistance A 1300 Martindale abrasion and fuzzing tester with 9 inspection positions and a PillGrade test unit commercially available from SDL ATLAS were each used to evaluate the abrasion resistance of each sample. Specifically, several parts of each sample were subjected to a Martindale abrasion test according to ASTM D4970 or ISO 12945-2 on the embossed roll side, with Specification Set B (a weight of 9 kPa, 60 rubs, 120 rubs, and 180 rubs were performed at a speed of 47.5 rpm). In this regard, the side of the nonwoven fabric adjacent to the embossed roll was abraded on the opposite side of the nonwoven fabric (e.g., the rubber was removed from the top and the nonwoven fabric was placed directly on the support foam). In this regard, the said part of each sample was subjected to a Martindale abrasion test with 60 rubs, another part of each sample was subjected to a Martindale abrasion test with 120 rubs, and another part of each sample was subjected to a Martindale abrasion test with 180 rubs.

[0087] After each of the sample portions has received that number of frictions per Martindale abrasion test, the untreated sample portions of each sample (e.g., the sample portions that have been pre - abraded) are tested by a pill grade unit according to ASTM D4970 or ISO 12945 - 2 together with each of the said sample portions that have received the Martindale abrasion test. This measures the abrasion impact on the fabric. A value of "5" indicates no abrasion, and lower values or scores represent fabrics where many "pills" or fiber entanglements, or ultimately "balls" of fibers (e.g., increased abrasion) are seen. Put another way, the sample portions of the samples before the abrasion test and after the described cycles (60, 120, 180 frictions via the Martindale abrasion test) are sent to a pill grade test unit for the measurement of "Pillgrade". (For example, a value of "5" represents low to zero friction, while a value close to "0" represents a large amount or high abrasion level).

[0088] In this regard, to explain the improvement in abrasion resistance of non - woven fabrics according to certain embodiments of the invention, a comparison of the numerical grades of "fluffing" among various samples was made. Ultimately, a score or value close to "5", or the difference in values between before abrasion (i.e., before being abraded in the Martindale abrasion test unit) and after abrasion at different cycles, determines the abrasion performance. In this regard, the minimum difference or difference between the value before abrasion (i.e., "0" friction) and multiple abrasions is the best performance data. Table 1 presents a summary of the said pill grade values.

Table 1

[0089] As explained by the data in Table 1, Samples 3 to 6 all showed a significant improvement in wear resistance compared to the control (i.e., Samples 1 and 2), as evidenced by the decrease in the average difference values reported in the rightmost vertical column of Table 1 (e.g., the average difference values for the average loss after 60 rubs, the average loss after 120 rubs, and the average loss after 180 rubs). Each of Samples 5 and 6 explains the unexpected result of forming single-component fibers from a propylene random copolymer. The average difference value reported in the rightmost vertical column of Table 1 for Sample 5 is "0.15", while for Sample 6 it is "0.24", which is 30 - 50% of the values of Samples 3 - 4 and 20 - 35% of the values of Samples 1 - 2.

[0090] The above and other modifications and variations of the invention can be practiced by those skilled in the art without departing from the spirit and scope of the invention more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments can be replaced in whole or in part. Further, those skilled in the art will recognize that the above description is by way of example only and is not intended to limit the invention as further described in such appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary descriptions of the aspects contained herein.

Explanation of Reference Numerals

[0091] 1 Spinneret 10 Multicomponent Spinning Orifice 10a - j First Compartment 15 Multicomponent Spinning Orifice 20 Single - Component Spinning Orifice 20a - j Second Compartment 25 Single - Component Spinning Orifice 28 Single - Component Spinning Orifice 50 Crimped Fiber 52 First Polymer Component 54 Second Polymer Component A First Polymer Composition B Second Polymer Composition

Claims

1. A spinneret for melt-spinning polymer fibers, comprising: a spinneret body including a plurality of spinneret orifices formed across the thickness of the spinneret body; characterized in that the plurality of spinneret orifices include (i) a plurality of multicomponent spinneret orifices each having a first multicomponent opening and a second multicomponent opening different therefrom, and (ii) a plurality of single-component spinneret orifices each having a single single-component opening. Spinneret.

2. The spinneret according to claim 1, wherein the plurality of multicomponent spinneret orifices define at least one first section, and the plurality of single-component spinneret orifices define at least one second section.

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

4. The spinneret according to any one of claims 1 to 3, wherein the plurality of spinneret orifices define the total number of spinneret orifices, the plurality of multicomponent spinneret orifices contain from about 60 to about 99% of the total number of spinneret orifices, and the plurality of single-component spinneret orifices contain from about 1 to about 40% of the total number of spinneret orifices.

5. A nonwoven fabric containing a plurality of insert fibers containing a plurality of single-component fibers and a plurality of crimped multicomponent fibers, comprising: at least one first region containing at least a majority of a first single-component fiber group formed by the plurality of single-component fibers, and at least one second region containing at least a majority of a first multicomponent fiber group formed by the plurality of crimped multicomponent fibers. Nonwoven fabric.

6. The nonwoven fabric according to claim 5, wherein the first single-component fiber group defines the first outermost surface of the nonwoven fabric.

7. The nonwoven fabric according to claim 6, wherein the at least one first region further contains a second single-component fiber group formed by the plurality of single-component fibers, the second single-component fiber group defines the second outermost surface of the nonwoven fabric, and the first multicomponent fiber group is disposed adjacent to the first single-component fiber group, the second single-component fiber group, or both.

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

9. The at least one second region further contains a second multi-component fiber group of the plurality of multi-component fibers, the second multi-component fiber group defines a second outermost surface of the nonwoven fabric, and the first single-component fiber group is disposed adjacent to the first multi-component fiber group, the second multi-component fiber group, or both. The nonwoven fabric according to claim 8.

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

11. The plurality of first regions and the plurality of second regions are arranged in an alternating pattern in the machine direction of the nonwoven fabric, the z direction perpendicular to both the machine direction and the cross direction, or both, or the plurality of first regions and the plurality of second regions are arranged in an alternating pattern in the cross direction of the nonwoven fabric, the z direction perpendicular to both the cross direction and the machine direction, or both. The nonwoven fabric according to claim 10.

12. The plurality of first regions and the plurality of second regions are arranged in an alternating pattern in the cross direction and the machine direction, or the plurality of first regions and the plurality of second regions are also arranged in an alternating pattern in the z direction of the nonwoven fabric, and the z direction is perpendicular to the cross direction and the machine direction. The nonwoven fabric according to claim 10.

13. The at least one second region contains a continuous network of the plurality of crimped multi-component fibers, and the at least one first region includes a plurality of first regions each containing separate islands of the plurality of single-component fibers dispersed across the continuous network of the plurality of crimped multi-component fibers, or the at least one first region contains a continuous network of the plurality of single-component fibers, and the at least one second region contains a plurality of second regions each containing separate islands of crimped multi-component fibers dispersed across the continuous network of the plurality of single-component fibers. The nonwoven fabric according to claim 7.

14. The nonwoven fabric has a total areal weight, the plurality of single-component fibers account for about 1 to about 40% by weight of the total areal weight, and / or the plurality of multi-component fibers account for about 60 to about 99% by weight of the total areal weight. The nonwoven fabric according to claims 5 to 13.

15. A method for manufacturing a nonwoven fabric, (i) simultaneously melt-spinning a fiber set from a single spinneret, wherein the fiber set contains a plurality of single-component fibers and a plurality of multi-component fibers, and the fiber set forms at least one first region containing at least a majority of a first single-component fiber group formed by the plurality of single-component fibers and at least one second region containing at least a majority of a first multi-component fiber group formed by the plurality of multi-component fibers; (ii) recovering the melt-spun fiber set; (iii) forming a plurality of crimped multi-component fibers by actively and / or passively forming one or more crimped portions in at least a part of the plurality of multi-component fibers; A method comprising the above.

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