Small-sized calcium carbonate particles in nonwoven fabrics and films

Abstract

Nonwoven fabrics, films, and composites thereof are provided, in which at least the nonwoven fabric or film comprises a plurality of small-sized calcium carbonate (CaCO3) particles having a generally narrow distribution.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority under 35 U.S.C. § 119 to U.S. patent application Ser. No. 63 / 399,861, filed Aug. 22, 2022, which is expressly incorporated by reference herein in its entirety.

[0002] Inventive embodiments of the present disclosure generally relate to providing nonwoven fabrics, films, and composites thereof having a plurality of small-sized calcium carbonate (CaCO) particles generally having a narrow distribution. [Background technology]

[0003] Various films and nonwoven fabrics can be used alone or in combination for use in a diverse range of applications, such as breathable and / or barrier applications or products. For example, films and nonwoven fabrics are routinely used in the construction of hygiene products (e.g., diapers, femcare products, personal wipes, etc.), medical applications (e.g., medical gowns and drapes), and industrial applications (e.g., house wraps, roof linings, etc.). The use of films and nonwoven fabrics can be particularly desirable in applications requiring cost-effective materials for moisture control (e.g., water vapor breathability) and / or barrier properties (e.g., alcohol repellency and / or blood resistance). In some cases, the manufacture of these materials may employ the incorporation of filler materials (e.g., particles) that reduce the total amount of polymeric material required to make the final product and / or play a key role in creating breathability, such as in the case of breathable microporous films.

[0004] However, the use of calcium carbonate as a filler in films and nonwovens may be undesirable due to extra material costs, increased manufacturing complexity, and / or quality control issues associated with excessive loading, diffusion, and / or agglomeration of calcium carbonate within the material being manufactured. For example, the use of calcium carbonate in microporous films may compromise the balance between strength and breathability due to agglomeration of some of the calcium carbonate particles or when the particle size distribution includes too many large and / or fine particles, resulting in a final film lacking adequate uniformity in properties and / or composition. For example, the current industry standard average particle size for calcium carbonate when used as a filler is between about 1.2 and about 1.6 microns (e.g., a D50 of 1.2 to 1.6), but also includes a significant portion of particles greater than 5 microns. For example, a conventional calcium carbonate particle size distribution may have a D98 value of 5 to 10 microns. The presence of such large particles not only hinders manufacturing but can also lead to the formation of defects in the final product (eg, film and / or nonwoven fabric). Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made to solve the problems in the prior art described above. [Means for solving the problem]

[0006] One or more embodiments of the present invention may address one or more of the aforementioned problems. Some embodiments according to the present invention provide a nonwoven fabric including a plurality of fibers comprising: (i) a polymer-based component; and (ii) an additive component including a plurality of calcium carbonate particles dispersed within the polymer-based component. The calcium carbonate particles have a particle size distribution having a mean and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns.

[0007] In another aspect, the present invention provides a film that includes (i) a polymer-based component and (ii) an additive component including a plurality of calcium carbonate particles dispersed within the polymer-based component, wherein the plurality of calcium carbonate particles have a particle size distribution having a mean and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns.

[0008] In another aspect, the present invention provides a composite including a first nonwoven layer bonded directly or indirectly to a first film, wherein at least one of the first nonwoven layer and the first film includes a respective additive component including a plurality of calcium carbonate particles dispersed within a respective polymer-based component, the plurality of calcium carbonate particles having a particle size distribution having a mean and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns.

[0009] In another aspect, the present invention provides a method of forming a nonwoven fabric, such as those described and disclosed herein, comprising the steps of: (i) forming a polymer melt including a polymer-based component and an additive component including a plurality of calcium carbonate particles dispersed within the polymer-based component; (ii) forming a plurality of fibers from the polymer melt; and (iii) consolidating the plurality of fibers to form the nonwoven fabric.

[0010] In another aspect, the present invention provides a method of forming a film, such as those described and disclosed herein, comprising: (i) forming a polymer melt including a polymer-based component and an additive component including a plurality of calcium carbonate particles dispersed within the polymer-based component; and (ii) extruding the polymer melt into a film.

[0011] In yet another aspect, the present invention provides a method of forming a composite, such as those described and disclosed herein, comprising directly or indirectly bonding a first nonwoven layer to a first film, wherein at least one of the first nonwoven layer or the first film comprises a plurality of calcium carbonate particles having a particle size distribution having an average and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns. DETAILED DESCRIPTION OF THE INVENTION

[0012] The present invention will now be described in more detail below. Indeed, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0013] The disclosed invention generally relates to the use of particulate minerals, including alkaline earth metal carbonates, such as calcium carbonate, having a significantly smaller average particle size compared to conventional fillers (e.g., average particle size of 1.2 to 1.6 microns) in the formation of nonwoven fabrics, films, and composites. The use of small-sized calcium carbonate particles, according to certain embodiments of the invention, can provide products (e.g., nonwoven fabrics, films, and composites) with improved uniformity and / or physical properties, such as machine direction (MD) and cross direction (CD) tensile strength per basis weight, relative to similarly constructed comparable products (e.g., nonwoven fabrics, films, and composites) that differ only in the average size of the filler used therein.

[0014] The terms "substantial" or "substantially" may encompass a given total amount according to certain embodiments of the present invention, or a majority but not the given total amount (e.g., 95%, 96%, 97%, 98%, or 99% of the given total amount) according to other embodiments of the present invention.

[0015] The terms "polymer" or "polymer system," used interchangeably herein, can include homopolymers, copolymers, such as block, graft, random, and alternating copolymers, terpolymers, and the like, as well as blends and modifications thereof. Furthermore, unless otherwise specifically limited, the terms "polymer" or "polymer system" include all possible structural isomers, stereoisomers, including without limitation, geometric isomers, optical isomers, or enantiomers, and / or any chiral molecular configurations of such polymer or polymeric material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic configurations of such polymer or polymeric material. The terms "polymer" or "polymer system" also include polymers made from various catalyst systems, including, without limitation, Ziegler-Natta catalyst systems and metallocene / single-site catalyst systems. According to certain embodiments of the present invention, the terms "polymer" or "polymer system" also include polymers produced by fermentation processes or that are biosourced.

[0016] As used herein, the terms "nonwoven" and "nonwoven web" may include webs having a structure of individual fibers, filaments, and / or threads that are layered together rather than in an identifiable, repeating manner, such as a knitted or woven fabric. Nonwoven fabrics or webs, according to certain embodiments of the present invention, may be formed by any process conventionally known in the art, such as meltblowing, spunbonding, needlepunching, hydroentangling, airlaid, and bonded-carded web processes. As used herein, a "nonwoven web" may include a plurality of individual fibers that have not been subjected to a consolidation process.

[0017] As used herein, the terms "fabric" and "nonwoven fabric" may include a web of fibers in which a plurality of fibers are mechanically entangled or interconnected, fused together, and / or chemically bonded together. For example, a nonwoven web of individually layered fibers may be subjected to a bonding or consolidation process to bond at least some of the individual fibers together to form a coherent (e.g., consolidated) web of interconnected fibers.

[0018] As used herein, the terms "consolidated" and "consolidation" can include bringing at least some portions of the fibers of a nonwoven web closer together or attaching them (e.g., heat-sealing together, chemically bonding together, and / or mechanically entangling together) to form bond sites, which function to increase resistance to external forces (e.g., abrasion and tensile forces) compared to a non-consolidated web. Bond sites can include, for example, discrete or localized regions of web material that have been softened or melted, optionally subsequently or simultaneously compressed to form discrete or localized deformations of the web material. Additionally, the term "consolidated" can include an entire nonwoven web that has been processed such that at least some of the fibers are brought into closer proximity or attachment therebetween (e.g., heat-sealed together, chemically bonded together, and / or mechanically entangled together), for example, by thermal bonding or mechanical entanglement (e.g., hydroentanglement), just to name a few. Such a web, according to certain embodiments of the present invention, can be considered a "consolidated nonwoven," a "nonwoven fabric," or simply a "fabric."

[0019] As used herein, the term "staple fibers" may include fibers cut from a filament. According to certain embodiments, any type of filament material may be used to form the staple fibers. For example, the staple fibers may be formed from polymeric and / or elastomeric fibers. Non-limiting examples of materials may include polyolefins (e.g., polypropylene or polypropylene-containing copolymers), polyethylene terephthalate, and polyamides. The average length of the staple fibers may include, by way of example only, from about 2 centimeters to about 15 centimeters.

[0020] As used herein, the term "spunbond" may include fibers formed by extruding a molten thermoplastic material as filaments from multiple thin, usually circular, capillaries of a spinneret. The diameter of the extruded filaments then rapidly decreases. In accordance with one embodiment of the present invention, as described and disclosed herein, spunbond fibers are generally not tacky and may be generally continuous when they are deposited on a collecting surface. It is noted that spunbonds used in certain composites of the present invention may include nonwoven fabrics described in the literature as SPINLACE®. Spunbond fibers may include, for example, continuous fibers.

[0021] As used herein, the term "continuous fibers" refers to fibers that are not cut from their 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, up to the length of the web or fabric to be formed. For example, continuous fibers as used herein can include fibers whose fiber length is at least 1,000 times greater than their average fiber diameter, e.g., at least about 5,000, 10,000, 50,000, or 100,000 times greater than their average fiber diameter.

[0022] As used herein, the term "meltblown" may include fibers formed by extruding molten thermoplastic material as molten threads or filaments through multiple narrow die capillaries into a converging, high-velocity, usually high-temperature gas (e.g., air) stream that attenuates the filaments and reduces their diameter, which may be up to microfiber diameter according to certain embodiments of the present invention. According to one embodiment of the present invention, the die capillaries may be circular. The meltblown fibers are then carried by the high-velocity gas stream and deposited on a collecting surface to form a web of randomly distributed meltblown fibers. Meltblown fibers may include microfibers, which may be continuous or discontinuous, and are generally tacky when deposited on a collecting surface. However, meltblown fibers are shorter in length than spunbond fibers.

[0023] As used herein, the term "cellulosic fiber" may include, for example, fibers derived from hardwood trees, softwood trees, or a combination of hardwood and softwood trees, prepared for use in papermaking stock and / or fluff pulp stock by any known suitable cooking, refining, and bleaching process. Cellulosic fibers may include recycled fibers and / or virgin fibers. Recycled fibers differ from virgin fibers in that the fibers have been subjected to a drying process at least once. In some embodiments, at least a portion of the cellulosic fibers may be provided from non-woody herbaceous plants, including, but not limited to, kenaf, cotton, hemp, jute, flax, sisal, or abaca. In some embodiments of the present invention, cellulosic fibers may include either bleached or unbleached pulp fibers, such as high-yield pulp and / or mechanical pulp, e.g., thermomechanical pulp (TMP), chemi-mechanical pulp (CMP), and bleached chemi-thermomechanical pulp (BCTMP). In this regard, the term "pulp" as used herein may include cellulose that has been subjected to processing, e.g., thermal, chemical, and / or mechanical treatment. In some embodiments of the present invention, cellulosic fibers may include one or more regenerated cellulose fibers (e.g., viscose, rayon, lyocell fibers, etc.). In some embodiments of the present invention, cellulosic fibers may include one or more pulp materials.

[0024] The term "melt fibrillation," as used herein, may constitute a general class of fiber manufacturing and is defined in that one or more polymers are melted and extruded into many possible configurations (e.g., coextruded, homogeneous, or bicomponent films or filaments), which may then be fibrillated or fiberized into a plurality of individual filaments to form melt fibrillated fibers. Non-limiting examples of melt fibrillation methods may include meltblowing, melt burst fiber, and melt film fibrillation. The term "melt film fibrillation," as used herein, may include methods in which a melt film is produced from a melt and then a fluid is used to form fibers (e.g., melt film fibrillated fibers) from the melt film. Examples include U.S. Patent Nos. 6,315,806, 5,183,670, 4,536,361, 6,382,526, 6,520,425, and 6,695,992, the contents of each of which are incorporated herein by reference to the extent such disclosures are consistent with this disclosure. Additional examples include U.S. Patent Nos. 7,628,941, 7,722,347, 7,666,343, 7,931,457, 8,512,626, and 8,962,501. These describe the Arium™ melt film fibrillation process for producing melt film fibrillated fibers (eg, having submicron fibers).

[0025] As used herein, the term "monolithic" film may include any film that is continuous and free or substantially free of pores (e.g., completely free of pores). In certain alternative embodiments of the present invention, a "monolithic" film may contain fewer pore structures than would otherwise be found in a microporous film. According to certain non-limiting example embodiments of the present invention, a monolithic film may act as a barrier to liquids and particulate matter while allowing moisture vapor to pass through. Additionally, without intending to be bound by theory, moisture vapor movement through the laminate may help reduce and / or limit discomfort resulting from excess moisture trapped against the skin, thereby achieving and maintaining high breathability and thereby providing a molded article that is more comfortable to wear. A "monolithic" film may, for example, comprise a highly breathable polymer.

[0026] As used herein, the term "highly breathable polymer" may include any polymer or elastomer that is selectively permeable to water vapor but substantially impermeable to liquid water and capable of forming a breathable film. For example, in this case, the polymer can absorb and desorb water vapor, providing a barrier to aqueous fluids (e.g., water, blood, etc.). For example, a highly breathable polymer may absorb water vapor from one side of the film and release it to another side of the film, thereby allowing water vapor to transport through the film. Because a highly breathable polymer can impart breathability to a film, a film formed from such a polymer need not contain pores (e.g., a monolithic film). According to certain embodiments of the present invention, a "highly breathable polymer" when formed into a film, may have a density of at least 500 g / m2. 2 The polymer may include any thermoplastic polymer or elastomer having a moisture vapor transmission rate (MVTR) of at least 750 g / m² when formed into a film, such as a film having a thickness of about 25 microns or less. 2 / day or at least 1000g / m2 The highly breathable polymer may include any thermoplastic polymer or elastomer having an MVTR of 100 / day. According to certain embodiments of the present invention, the highly breathable polymer may include, for example, any one or combination of polyether block amide copolymers (e.g., PEBAX® from Arkema Group), polyester block amide copolymers, copolyester thermoplastic elastomers (e.g., ARNITEL® from DSM Engineering Plastics, HYTREL® from EI DuPont de Nemours and Company), or thermoplastic urethane elastomers (TPU).

[0027] As used herein, the term "microporous" film can include a polymeric film layer containing a plurality of micropores dispersed throughout the film body. Microporous films can be manufactured, for example, by dispersing finely divided particles of a non-hygroscopic filler material, typically an inorganic salt (e.g., calcium carbonate), in a suitable polymer, forming a film of the filled polymer, and stretching the film to provide good porosity and water vapor absorption or transmission. For example, the breathability of a microporous film can depend on the formation of intricate pore paths within the film by stretching the filler-impregnated film to impart the desired porosity (e.g., pore formation). Furthermore, the barrier properties of such microporous films are affected by the surface tension of the liquid to which they are exposed (e.g., they are more easily permeated by isopropyl alcohol than by water), and they are more easily permeated by odors than solid films (e.g., monolithic films).

[0028] As used herein, the term "layer" may include any generally recognizable combination of similar material type and / or function that exists in the XY plane.

[0029] All integer endpoints disclosed herein that can create smaller ranges within a given range disclosed herein are within the scope of certain embodiments of the invention. For example, a disclosure of about 10 to about 15 encompasses disclosure of intermediate ranges, such as about 10 to about 11, about 10 to about 12, about 13 to about 15, about 14 to about 15, etc. Furthermore, all single decimal endpoints (e.g., numbers reported to one decimal place after rounding) that can create smaller ranges within a given range disclosed herein are within the scope of certain embodiments of the invention. For example, a disclosure of about 1.5 to about 2.0 encompasses disclosure of intermediate ranges, such as about 1.5 to about 1.6, about 1.5 to about 1.7, about 1.7 to about 1.8, etc.

[0030] Some embodiments according to the present invention provide a nonwoven fabric including a plurality of fibers comprising (i) a polymer-based component and (ii) an additive component including a plurality of calcium carbonate particles dispersed within the polymer-based component, wherein the plurality of calcium carbonate particles have a particle size distribution having a mean and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns.

[0031] According to certain embodiments of the present invention, the particle size distribution may have a D98 value of 3 microns or less, e.g., 3, 2.5, 2, 1.8, 1.5, 1.2, and 1 micron or less. Additionally or alternatively, the particle size distribution may have a D10 value of 0.05 to 0.25 microns, e.g., at least about 0.05, 0.08, 0.1, and 0.12 microns and / or at most about 0.25, 0.22, 0.2, 0.18, 0.16, 0.15, 0.14, and 0.12 microns. Additionally or alternatively, the particle size distribution may have a standard deviation of about 0.05 to about 0.3 microns, e.g., at least about 0.05, 0.075, and 0.1 microns and / or at most about 0.3, 0.25, 0.2, 0.15, and 0.1 microns.

[0032] According to certain embodiments of the present invention, the calcium carbonate particles may include a coating thereon. For example, the coating may include a fatty acid, such as stearic acid or acrylonitrile styrene acrylate. The coating may facilitate, for example, a more uniform distribution of the calcium carbonate particles within a polymeric component. This may facilitate the formation of a product (e.g., a nonwoven fabric) with more uniformity (e.g., appearance and / or physical properties). The coating may comprise, for example, about 0.1 to about 3% by weight of the calcium carbonate particles, e.g., at least about any of 0.1, 0.3, 0.05, 0.8, 1, 1.2, 1.4, and 1.5% by weight, and / or at most about any of 3, 2.8, 2.5, 2.2, 2, 1.8, 1.6, and 1.5% by weight.

[0033] According to certain embodiments of the present invention, the plurality of calcium carbonate particles may comprise from about 3 to about 40% by weight of the plurality of fibers, e.g., at least about any of 3, 5, 6, 8, 10, 12, 15, 18, and 20% by weight of the plurality of fibers, and / or up to about any of 40, 38, 35, 32, 30, 28, 25, 22, and 20% by weight of the plurality of fibers.

[0034] According to certain embodiments of the present invention, the plurality of fibers may comprise spunbond fibers, meltblown fibers, or staple fibers. According to certain embodiments of the present invention, the plurality of fibers comprises spunbond fibers having an average diameter of about 10 to about 30 microns, e.g., at least about any of 10, 12, 15, 18, and 20 microns, and / or at most about any of 30, 28, 25, 22, and 20 microns. According to certain embodiments of the present invention, the plurality of fibers comprises meltblown fibers having an average diameter of about 5 to about 12 microns, e.g., at least about any of 5, 6, 7, and 8 microns, and / or at most about any of 12, 11, 10, 9, and 8 microns.

[0035] The nonwoven fabric, according to certain embodiments of the present invention, may further comprise a plurality of cellulosic fibers, such as natural cellulosic fibers and / or regenerated cellulosic fibers (e.g., viscose, rayon, lyocell fibers, etc.). For example, the nonwoven fabric may comprise a plurality of fibers intermingled with one another and a coform comprising a plurality of cellulosic fibers. Alternatively, the nonwoven fabric may be a mechanically consolidated (e.g., hydroentangled, needlepunched, etc.) layer of one or more layers of a plurality of fibers (e.g., containing a plurality of calcium carbonate particles) and one or more layers of cellulosic fibers. According to certain embodiments of the present invention, the plurality of cellulosic fibers can comprise from about 10 to about 90 weight percent of the nonwoven fabric, e.g., at least about any of 10, 15, 20, 25, 30, 35, 40, and 45 weight percent of the total fiber content of the nonwoven fabric, and / or up to about any of 90, 85, 80, 75, 70, 65, 60, 55, 50, and 45 weight percent of the total fiber content of the nonwoven fabric. Additionally or alternatively, the plurality of fibers can comprise from about 10 to about 90 weight percent of the nonwoven fabric, e.g., at least about any of 10, 15, 20, 25, 30, 35, 40, and 45 weight percent of the total fiber content of the nonwoven fabric, and / or up to about any of 90, 85, 80, 75, 70, 65, 60, 55, 50, and 45 weight percent of the total fiber content of the nonwoven fabric.

[0036] According to certain embodiments of the present invention, a nonwoven fabric includes a first nonwoven layer including a plurality of fibers, the fibers including a plurality of calcium carbonate particles, a second layer including a plurality of cellulosic fibers, and a third layer including the second nonwoven layer, wherein the second layer is positioned between the first and second layers, and the first, second, and third layers are mechanically consolidated together or thermally consolidated together.

[0037] According to certain embodiments of the present invention, the nonwoven fabric has the following structure: (Structure 1)S1 a -M b , (Structure 2) S1 a -Mb -S2 c , (Structure 3)S1 a -N d , (Structure 4)S1 a -N d -S2 c , (Structure 5)S1 a -M b -N d -S2 c , (Structure 6)S1 a -N d -S3 e -N f -S2 c , (Structure 7)S1 a -N d -M b -N f -S2 c , (Structure 8)S1 a -M b -S3 e -M g -S2 c , (Structure 9)S1 a -M b -N d -M g -S2 c or any combination thereof, and Here, "M" includes a meltblown layer, "N" includes a melt fibrillated fiber-containing layer; "S1" includes the first spunbond layer; "S2" includes the second spunbond layer; "S3" includes the third spunbond layer; "a" represents the number of layers and is independently selected from 1, 2, 3, 4, and 5; "b" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; "c" represents the number of layers and is independently selected from 1, 2, 3, 4, and 5; "d" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; "e" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; "f" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; "g" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; Here, one or more individual layers may contain a plurality of calcium carbonate particles.

[0038] According to certain embodiments of the present invention, the polymer-based component includes a synthetic polymer, such as a polyolefin, polyester, polyamide, or any combination thereof. Additionally or alternatively, the polymer component can include one or more bio-sourced polymers, such as one or more polylactic acids. The polymer-based component can include about 0-100% by weight of one or more synthetic polymers, such as at least about any of 1, 5, 10, 15, 2, 25, 30, 35, 40, 45, and 50% by weight, and / or up to about any of 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% by weight. Additionally or alternatively, the polymeric component can include about 0-100% by weight of one or more bio-sourced polymers, e.g., at least about any of 1, 5, 10, 15, 2, 25, 30, 35, 40, 45, and 50% by weight, and / or up to about any of 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% by weight.

[0039] The nonwoven fabric, according to certain embodiments of the present invention, has a basis weight of from about 3 to about 500 gsm, for example, at least about any of 3, 5, 8, 10, 15, 20, 30, 50, 80, 100, 150, 200, and 250 gsm, and / or at most about any of 500, 450, 400, 350, 300, 250, and 200 gsm.

[0040] According to certain embodiments of the present invention, the nonwoven fabric comprises a bonded area of ​​about 3 to about 50%, e.g., at least about any of 3, 5, 8, 10, 12, 15, 18, 20, 22, and 25%, and / or at most about any of 50, 45, 40, 35, 30, 28, and 25%. Alternatively, the nonwoven fabric is face bonded and has a 100% bonded area. Additionally or alternatively, the nonwoven fabric can be mechanically consolidated.

[0041] According to certain embodiments of the present invention, a nonwoven fabric has a three-dimensional (3D) image applied to a first side and / or a second side of the nonwoven fabric. According to certain embodiments of the present invention, the 3D image comprises a 3D pattern on at least the first side of the nonwoven fabric (typically on both outer sides of the nonwoven fabric) and includes a plurality of recessed portions in the z-direction relative to an imaginary central plane extending through the nonwoven fabric in an xy-plane perpendicular to the z-direction. Additionally or alternatively, the 3D image comprises a 3D pattern on the first side of the nonwoven fabric (typically on both outer sides of the nonwoven fabric) and includes a plurality of raised portions in the z-direction relative to an imaginary central plane extending through the nonwoven fabric in an xy-plane perpendicular to the z-direction.

[0042] According to certain embodiments of the present invention, the nonwoven fabric may include a plurality of holes extending therethrough. The plurality of holes may define an open area of ​​from about 3 to about 40%, e.g., at least about any of 3, 5, 8, 10, 12, 15, 18, and 20%, and / or at most about any of 40, 38, 35, 32, 30, 28, 25, 22, and 20%. Additionally or alternatively, the plurality of holes may define an open area of ​​at least about 0.008 mm. 2 ~about 7mm 2 average individual opening area, e.g., at least about 0.008, 0.01, 0.15, 0.2, 0.3, 0.5, 0.8, 1, 1.5, 2, 2.5, and 3 mm 2 and / or up to about 7, 6.5, 6, 5.5, 5, 4.5, 4, 3.5, and 3 mm 2According to certain embodiments of the present invention, the plurality of holes may be located within a recessed portion of the nonwoven fabric.

[0043] In another aspect, the present invention provides a method for forming a nonwoven fabric, such as those described and disclosed herein, comprising: (i) forming a polymer melt including a polymer-based component and an additive component including a plurality of calcium carbonate particles dispersed within the polymer-based component; (ii) forming a plurality of fibers from the polymer melt; and (iii) consolidating the plurality of fibers to form the nonwoven fabric. According to certain embodiments of the present invention, the step of forming the plurality of fibers may include processing the polymer melt via a spunbonding process, a meltblowing process, or a melt fibrillation process. The plurality of fibers may be deposited directly or indirectly onto a moving belt to form a nonwoven web, which may then be consolidated to form the nonwoven fabric, for example, via one or more of the consolidation steps noted herein.

[0044] In another aspect, the present invention provides a film including (i) a polymer-based component and (ii) an additive component including a plurality of calcium carbonate particles dispersed within the polymer-based component. The plurality of calcium carbonate particles have a particle size distribution having a mean and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns. Additionally or alternatively, the particle size distribution has a D98 value of 3 microns or less, e.g., at most any of 3, 2.5, 2, 1.8, 1.5, 1.2, and 1 micron. Additionally or alternatively, the particle size distribution has a D10 value of 0.05 to 0.25 microns, e.g., at least about any of 0.05, 0.08, 0.1, and 0.12 microns, and / or at most about any of 0.25, 0.22, 0.2, 0.18, 0.16, 0.15, 0.14, and 0.12 microns. Additionally or alternatively, the particle size distribution has a standard deviation of about 0.05 to about 0.3 microns, e.g., at least about any of 0.05, 0.075, and 0.1 microns, and / or at most about any of 0.3, 0.25, 0.2, 0.15, and 0.1 microns.

[0045] According to certain embodiments of the present invention, the calcium carbonate particles may include a coating thereon. For example, the coating may include a fatty acid, such as stearic acid or acrylonitrile styrene acrylate. The coating may facilitate, for example, a more uniform distribution of the calcium carbonate particles within a polymeric component. This may facilitate the formation of a product (e.g., a film) with a more uniform (e.g., appearance and / or physical properties). The coating may comprise, for example, about 0.1 to about 3% by weight of the calcium carbonate particles, e.g., at least about any of 0.1, 0.3, 0.05, 0.8, 1, 1.2, 1.4, and 1.5% by weight, and / or at most about any of 3, 2.8, 2.5, 2.2, 2, 1.8, 1.6, and 1.5% by weight.

[0046] According to certain embodiments of the present invention, the plurality of calcium carbonate particles can comprise from about 3 to about 40% by weight of the film, e.g., at least about any of 3, 5, 6, 8, 10, 12, 15, 18, and 20% by weight of the film, and / or up to about any of 40, 38, 35, 32, 30, 28, 25, 22, and 20% by weight of the film. Additionally or alternatively, the film comprises a thickness of from about 3 to about 200 microns, e.g., at least about any of 3, 4, 5, 6, 7, 8, 9, 10, 20, 30, 40, 50, 60, 80, and 100 microns, and / or up to about any of 200, 180, 160, 150, 140, 120, and 100 microns. And alternatively, the film comprises a basis weight of from about 5 to about 100 gsm, for example, at least about any of 5, 8, 10, 15, 20, 25, 30, 35, 40, 45, and 50 gsm, and / or at most about any of 100, 90, 80, 70, 60, and 50 gsm.

[0047] According to certain embodiments of the present invention, the film comprises a monolayer film. According to certain embodiments of the present invention, the film may comprise a monolayer film, which is a monolithic film comprising at least one highly breathable polymer. According to certain embodiments of the present invention, the highly breathable polymer may comprise at least one of a thermoplastic urethane (TPU), a polyether block amide copolymer (e.g., PEBAX® from Arkema Group or Vetsamid® E from Evonik), or a copolyester thermoplastic elastomer (e.g., ARNITEL® from DSM Engineering Plastics or HYTREL® from EI DuPont de Nemours and Company). According to certain embodiments of the present invention, the film may comprise a polyether block ester copolymer comprising (i) a soft block comprising polyethylene glycol and (ii) a hard block comprising polybutyl terephthalate. According to certain embodiments of the present invention, the film may comprise a copolymer of isotactic polypropylene microcrystalline regions and random amorphous regions. Alternatively, or in addition, the film may comprise a monolayer film that is a microporous film. Microporous films can generally be produced by dispersing finely divided particles of a non-hygroscopic filler material, such as an inorganic salt (e.g., calcium carbonate), in a suitable polymer, then forming a film of the filled polymer and stretching the film to provide good porosity and water vapor absorption or transmission. According to certain embodiments of the present invention, the film may comprise a polyolefin, such as polyethylene or polypropylene, or a copolymer comprising a first polyolefin, such as a first polyethylene, and a second polyolefin, such as a second polypropylene.

[0048] According to certain embodiments of the present invention, the film may comprise a multilayer film. The multilayer film may include, for example, from 2 to about 10 individual film layers, for example, at least about 2, 3, 4, and 5 individual film layers, and / or at most about 10, 9, 8, 7, 6, and 5 individual film layers. The multilayer film may include, for example, at least a first skin layer and a core layer, wherein the first skin layer has a first thickness and the core layer has a second thickness, wherein the first thickness is less than the second thickness. According to certain embodiments of the present invention, the multilayer film may include a second skin layer, wherein the core layer is located between the first skin layer and the second skin layer. According to certain embodiments of the present invention, at least one of the first skin layer and the core layer may comprise a microporous film layer. Additionally or alternatively, the core layer may include a monolithic film layer sandwiched between two skin layers, which may be microporous film layers or monolithic film layers.

[0049] According to certain embodiments of the present invention, at least one of the first skin layer, the second skin layer, and the core layer comprises a microporous film layer containing a plurality of calcium carbonate particles. For example, at least one of the first skin layer and the second skin layer can comprise a plurality of calcium carbonate particles, and the core layer comprises a second plurality of calcium carbonate particles having a second particle size distribution having an average and / or median (D50) diameter of 1 to about 3 microns, e.g., at least about any of 1, 1.2, 1.4, 1.6, 1.8, and 2.0 microns, and / or at most about any of 3, 2.8, 2.6, 2.4, 2.2, and 2 microns. According to certain embodiments of the present invention, the core layer comprises a monolithic film layer.

[0050] According to certain embodiments of the present invention, the film has a tensile strength of at least about 400 g / m2 as determined according to ASTM test method E-96D. 2 / 24 hours, e.g., at least about 400, 600, 800, 1000, 2000, 3000, 4000, 4500, 5000, 5500, 6000, 6500, 7000, 7500, and 8000 g / m, as determined according to ASTM test method E-96D. 2 / 24 hours, and / or up to about 12000, 11000, 10000, 9000, and 8000 g / m2 as determined in accordance with ASTM Test Method E-96D. 2 / 24 hours.

[0051] In another aspect, the present invention provides a method of forming a film, such as those described and disclosed herein, comprising: (i) forming a polymer melt including a polymer-based component, such as those described herein, and an additive component including a plurality of calcium carbonate particles dispersed within the polymer-based component; and (ii) extruding the polymer melt into a film (e.g., a monolayer or multilayer film). According to certain embodiments of the present invention, a multilayer film can be formed by extruding a plurality of individual polymer melts, wherein one or more (e.g., all) of the individual polymer melts include the small-sized calcium carbonate particles described herein.

[0052] In another aspect, the present invention provides a composite including a first nonwoven layer directly or indirectly bonded to a first film, wherein at least one of the first nonwoven layer and the first film includes a respective additive component including a plurality of calcium carbonate particles dispersed within a respective polymer-based component. The plurality of calcium carbonate particles have a particle size distribution having an average and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns. According to certain embodiments of the present invention, the first nonwoven layer can include a nonwoven fabric, such as those described and disclosed herein. And / or the first film can include a film, such as those described and disclosed herein.

[0053] According to certain embodiments of the present invention, the first film can be thermally bonded directly to the first nonwoven layer. According to certain embodiments of the present invention, the first film can be melt extruded directly onto the first nonwoven layer. Alternatively, the composite can further include an adhesive layer positioned between the first nonwoven layer and the first film. The adhesive layer can have a basis weight of about 0.2 to about 5 gsm, e.g., at least about any of 0.2, 0.4, 0.5, 0.6, 0.8, 1, 1.2, 1.4, 1.5, 1.6, 1.8, 2, 2.2, 2.4, and 2.5 gsm, and / or at most about any of 5, 4.5, 4, 3.5, 3, and 2.5 gsm.

[0054] According to certain embodiments of the present invention, the composite has a hydrostatic pressure resistance of at least about 500 cm according to AATCC 127-1995, e.g., at least about any of 500, 550, 600, 650, 700, 750, and 800 cm, and / or at most about any of 1500, 1400, 1300, 1200, 1100, 1000, 900, and 800 cm. Additionally or alternatively, the composite has a hydrostatic pressure resistance of at least about 400 g / m as determined according to ASTM test method E-96D. 2 / 24 hour moisture vapor transmission rate (MVTR), e.g., at least about 400, 600, 800, 1000, 2000, 3000, 4000, 4500, 5000, 5500, 6000, 6500, 7000, 7500, and 8000 g / m, as determined according to ASTM test method E-96D 2 / 24 hours, and / or up to about 12000, 11000, 10000, 9000, and 8000 g / m2 as determined in accordance with ASTM Test Method E-96D. 2 / 24 hours.

[0055] According to certain embodiments of the present invention, the composite may have a basis weight of from about 10 to about 400 gsm, e.g., at least about any of 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, and 150 gsm, and / or at most about any of 450, 420, 400, 380, 350, 320, 300, 280, 250, 220, 200, 180, 160, and 150 gsm. Additionally or alternatively, the composite may have a thickness of from about 5 to about 50 mils, e.g., at least about any of 5, 6, 8, 10, 12, 15, 18, and 20 mils, and / or at most about any of 50, 45, 40, 35, 30, 25, and 20 mils.

[0056] According to certain embodiments of the present invention, the composite may have a machine direction trapezoid tear resistance of about 20 to about 50 lbs, e.g., at least about any of 20, 22, 25, 26, 28, and 30 lbs, and / or at most about any of 50, 48, 45, 42, 40, 38, 36, 35, 34, 32, and 30 lbs, per ASTM D 5733. Additionally or alternatively, the composite may have a cross direction trapezoid tear resistance of about 20 to about 50 lbs, e.g., at least about any of 20, 22, 25, 26, 28, and 30 lbs, and / or at most about any of 50, 48, 45, 42, 40, 38, 36, 35, 34, 32, and 30 lbs, per ASTM D 5733.

[0057] According to certain embodiments of the present invention, the composites may have a machine direction puncture strength of about 50 to about 100 lbs, e.g., at least about any of 50, 52, 55, 58, 60, 62, 65, and 70 lbs, and / or at most about any of 100, 95, 90, 85, 80, 78, 75, 72, and 70 lbs, according to ASTM D5034. Additionally or alternatively, the composites may have a cross direction puncture strength of about 50 to about 100 lbs, e.g., at least about any of 50, 52, 55, 58, 60, 62, 65, and 70 lbs, and / or at most about any of 100, 95, 90, 85, 80, 78, 75, 72, and 70 lbs, according to ASTM D5034.

[0058] According to certain embodiments of the present invention, the total weight of the film can comprise from about 5 to about 95 weight percent of the composite, e.g., at least about any of 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50 weight percent of the composite, and / or up to about any of 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50 weight percent of the composite. Additionally or alternatively, the total weight of the nonwoven fabric can comprise from about 5 to about 95 weight percent of the composite, e.g., at least about any of 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50 weight percent of the composite, and / or up to about any of 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50 weight percent of the composite.

[0059] In yet another aspect, the present invention provides a method of forming a composite, such as those described and disclosed herein, comprising directly or indirectly bonding a first nonwoven layer to a first film, wherein at least one of the first nonwoven layer or the first film comprises a plurality of calcium carbonate particles having a particle size distribution having an average and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns. According to certain embodiments of the present invention, the composite can be activated by subjecting the composite to gradual stretching in the CD and / or MD.

[0060] According to certain embodiments of the present invention, the first film may be melt extruded directly onto the first nonwoven layer. Alternatively, the first film and the first nonwoven layer may be formed separately and then bonded together, for example, thermally or adhesively bonded together.

[0061] According to certain embodiments of the present invention, the nonwoven fabrics, films, and / or composites described and disclosed herein can be utilized in or incorporated into a wide variety of end products for a wide variety of functional applications. By way of example only, the nonwoven fabrics, films, and / or composites described and disclosed herein can be utilized in or incorporated into (i) hygiene products, such as diaper topsheets, absorbent / distribution layers (ADLs), barrier leg cuffs (BLCs), backsheet nonwovens, core wraps, dusting layers, and ear panels; (ii) healthcare products, such as surgical gowns, surgical drapes, curtains, and face masks; and (iii) various specialty segments, such as crop covers, house wraps, packaging materials (e.g., serializable packaging materials), liquid and / or air filtration media, wipes, and tablecloths.

[0062] These and other modifications and variations of the present invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the present invention, which is more particularly defined in the appended claims. Additionally, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those skilled in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the invention as further described in such appended claims. Accordingly, the spirit and scope of the appended claims should not be limited to the illustrative descriptions of variations contained herein.

Claims

1. 1. A nonwoven fabric comprising: a plurality of fibers, the plurality of fibers comprising: (i) a polymer-based component; and (ii) an additive component comprising a plurality of calcium carbonate particles dispersed within the polymer-based component, wherein the plurality of calcium carbonate particles have a particle size distribution having an average and / or median (D50) diameter of 0.3 to about 0.8 microns, for example, at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns.

2. 10. The nonwoven fabric of claim 1, wherein the particle size distribution has (i) a D98 value of 3 microns or less, e.g., any of 3, 2.5, 2, 1.8, 1.5, 1.2, and 1 microns or less; (ii) a D10 value of 0.05 to 0.25 microns, e.g., at least any of about 0.05, 0.08, 0.1, and 0.12 microns, and / or at most any of about 0.25, 0.22, 0.2, 0.18, 0.16, 0.15, 0.14, and 0.12 microns; or (iii) both (i) and (ii).

3. 3. The nonwoven fabric of claim 1 or 2, wherein the plurality of calcium carbonate particles comprises a coating thereon, wherein the coating comprises a fatty acid, such as stearic acid or acrylonitrile styrene acrylate, and wherein the coating comprises from about 0.1 to about 3% by weight of the plurality of calcium carbonate particles, e.g., at least about any of 0.1, 0.3, 0.05, 0.8, 1, 1.2, 1.4, and 1.5% by weight, and / or at most about any of 3, 2.8, 2.5, 2.2, 2, 1.8, 1.6, and 1.5% by weight.

4. 4. The nonwoven fabric of claims 1-3, wherein the plurality of calcium carbonate particles comprises from about 3 to about 40% by weight of the plurality of fibers, e.g., at least about any of 3, 5, 6, 8, 10, 12, 15, 18, and 20% by weight of the plurality of fibers, and / or at most about any of 40, 38, 35, 32, 30, 28, 25, 22, and 20% by weight of the plurality of fibers.

5. The nonwoven fabric of claims 1-4, wherein the plurality of fibers comprises spunbond fibers, meltblown fibers, or staple fibers.

6. The nonwoven fabric has the following structure: (Structure 1) S1 ａ -M ｂ 、 (Structure 2) S1 ａ -M ｂ -S2 ｃ 、 (Structure 3) S1 ａ -N ｄ 、 (Structure 4) S1 ａ -N ｄ -S2 ｃ 、 (Structure 5) S1 ａ -M ｂ -N ｄ -S2 ｃ 、 (Structure 6) S1 ａ -N ｄ -S3 ｅ -N ｆ -S2 ｃ 、 (Structure 7) S1 ａ -N ｄ -M ｂ -N ｆ -S2 ｃ 、 (Structure 8) S1 ａ -M ｂ -S3 ｅ -M ｇ -S2 ｃ 、 (Structure 9) S1 ａ -M ｂ -N ｄ -M ｇ -S2 ｃ or any combination thereof, and Here, "M" includes a meltblown layer; "N" includes a melt fibrillated fiber-containing layer; "S1" comprises the first spunbond layer; "S2" comprises the second spunbond layer; "S3" includes the third spunbond layer; "a" represents the number of layers and is independently selected from 1, 2, 3, 4, and 5; "b" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; "c" represents the number of layers and is independently selected from 1, 2, 3, 4, and 5; "d" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; "e" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; "f" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; "g" represents the number of layers and is independently selected from 0, 1, 2, 3, 4, and 5; wherein one or more individual layers may comprise the plurality of calcium carbonate particles; The nonwoven fabric according to any one of claims 1 to 4.

7. 1. A film comprising: (i) a polymer-based component; and (ii) an additive component comprising a plurality of calcium carbonate particles dispersed within the polymer-based component, wherein the plurality of calcium carbonate particles have a particle size distribution having an average and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns.

8. 8. The film of claim 7, wherein the particle size distribution has (i) a D98 value of 3 microns or less, e.g., any of 3, 2.5, 2, 1.8, 1.5, 1.2, and 1 microns or less, (ii) a D10 value of 0.05 to 0.25 microns, e.g., at least any of about 0.05, 0.08, 0.1, and 0.12 microns, and / or at most any of about 0.25, 0.22, 0.2, 0.18, 0.16, 0.15, 0.14, and 0.12 microns, or (iii) both (i) and (ii).

9. 9. The film of claim 7 or 8, wherein the plurality of calcium carbonate particles comprises a coating thereon, wherein the coating comprises a fatty acid, such as stearic acid or acrylonitrile styrene acrylate, and wherein the coating comprises from about 0.1 to about 3% by weight of the plurality of calcium carbonate particles, e.g., at least about any of 0.1, 0.3, 0.05, 0.8, 1, 1.2, 1.4, and 1.5% by weight, and / or at most about any of 3, 2.8, 2.5, 2.2, 2, 1.8, 1.6, and 1.5% by weight.

10. (i) the plurality of calcium carbonate particles constitutes about 3 to about 40% by weight of the film, e.g., at least about any of 3, 5, 6, 8, 10, 12, 15, 18, and 20% by weight of the film, and / or at most about any of 40, 38, 35, 32, 30, 28, 25, 22, and 20% by weight of the film; or (ii) the film has a thickness of about 3 to about 200 microns, e.g., at least about any of 3, 4, 5, 6, 7, 8, 9, 10, 20, 30, 40, 50, 60, 80, and 100 microns.

10. The film of claims 7-9, wherein (i) the film has a basis weight of from about 5 to about 100 gsm, e.g., at least about 5, 8, 10, 15, 20, 25, 30, 35, 40, 45, and 50 gsm, and / or at most about 100, 90, 80, 70, 60, and 50 gsm, or (iv) any combination of (i), (ii), and (iii).

11. The film of claims 7 to 10, wherein the film comprises a single layer film, wherein the single layer film is a monolithic film or a microporous film.

12. The film of claims 7-10, wherein the film comprises a multilayer film.

13. 13. The film of claim 12, wherein the multilayer film comprises at least a first skin layer and a core layer, wherein the first skin layer has a first thickness and the core layer has a second thickness, the first thickness being less than the second thickness, and wherein the first skin layer comprises the plurality of calcium carbonate particles and the core layer comprises a second plurality of calcium carbonate particles having a second particle size distribution having an average and / or median (D50) diameter of 1 to about 3 microns, e.g., at least about any of 1, 1.2, 1.4, 1.6, 1.8, and 2.0 microns, and / or at most about any of 3, 2.8, 2.6, 2.4, 2.2, and 2 microns.

14. 1. A composite comprising: a first nonwoven layer bonded directly or indirectly to a first film, wherein at least one of the first nonwoven layer and the first film includes a respective additive component comprising a plurality of calcium carbonate particles dispersed within a respective polymer-based component, wherein the plurality of calcium carbonate particles have a particle size distribution having an average and / or median (D50) diameter of 0.3 to about 0.8 microns, e.g., at least about any of 0.3, 0.35, 0.4, 0.45, and 0.5 microns, and / or at most about any of 0.9, 0.85, 0.8, 0.75, 0.7, 0.65, and 0.6 microns.

15. 15. The composite of claim 14, wherein the first film is thermally bonded directly to the first nonwoven layer, melt extruded directly onto the first nonwoven layer, or adhesively bonded to the first nonwoven layer.

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