Then nonwoven fabric

Abstract

A nonwoven fabric comprising multiple fibers, wherein the multiple fibers are bonded to the surface of the nonwoven fabric in an adhesive pattern to form an integrated web, the nonwoven fabric having a vertical axis extending in the machine direction and a horizontal axis extending in the transverse direction, and the adhesive pattern having a plurality of spaced-apart array pairs extending in the machine direction, transverse direction and diagonal direction of the nonwoven fabric, where each array has a plurality of spaced-apart oval-shaped adhesive points, and the nonwoven fabric has an adhesive surface area percentage of less than about 12% and a width of about 6.5 to about 8.0 mm -1 The above nonwoven fabric having an average adhesion point packing value. A thermal calender, a system for preparing the nonwoven fabric, and related methods are also provided.

Description

[Technical Field]

[0001] Cross-reference with related applications This application claims priority to U.S. Provisional Application No. 63 / 454,941, filed on 27 March 2023, the contents of which are incorporated herein by reference.

[0002] The inventions disclosed herein generally relate to nonwoven fabrics, and more particularly to bonded nonwoven fabrics exhibiting improvements in abrasion resistance and flexibility. [Background technology]

[0003] Nonwoven fabrics are used in a wide variety of applications, particularly in clothing, disposable medical supplies, and absorbent materials such as diapers and personal hygiene products. New products developed for these applications have stringent performance requirements, including comfort, body conformity, freedom of movement, excellent flexibility and drape, sufficient tensile strength and durability, and resistance to surface abrasion, pilling, and fuzzing. Therefore, nonwoven fabrics used in these types of products must be designed to meet these performance requirements. [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] Despite considerable effort in the development of nonwoven fabrics, there remains a need for products that exhibit improved abrasion resistance and mechanical properties without sacrificing other beneficial characteristics, such as flexibility. [Means for solving the problem]

[0005] One or more embodiments of the present invention can provide a nonwoven fabric having desirable properties with respect to abrasion resistance and softness while maintaining good mechanical properties, such as tensile strength and elongation.

[0006] One embodiment is a nonwoven fabric comprising a plurality of fibers, the plurality of fibers being bonded to the surface of the nonwoven fabric in an adhesive pattern to form an integrated web, the nonwoven fabric having a vertical axis extending in the machine direction and a horizontal axis extending in the transverse direction. The adhesive pattern has a plurality of spaced-apart array pairs extending in the machine direction, transverse direction and oblique direction of the nonwoven fabric, where each array has a plurality of spaced-apart adhesive points in an oblong shape, the nonwoven fabric having an adhesive surface area percentage of less than about 12% and 3.5 mm -1 Ultra-large, for example, approximately 6.5 to 8.0 mm -1 It has an average bond point packing value.

[0007] In one embodiment of the nonwoven fabric, the bonding point is approximately 0.15 to approximately 0.25 mm 2 It has an average surface area.

[0008] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesion point density of about 50 to about 60 individual adhesion points per square centimeter.

[0009] In one embodiment of the nonwoven fabric, the nonwoven fabric has a Martindale abrasion score of about 1.0 to about 1.5, a lateral handle-o-meter value of about 6.6 to about 7.2 grams, a mechanical handle-o-meter value of about 3.5 to about 3.95 grams, and an average abrasion resistance of 3.2 to 5.5 grams, as measured by the weight of the removed material.

[0010] In one embodiment of the nonwoven fabric, the percentage of the adhesive surface area of ​​the nonwoven fabric is approximately 9.8 to approximately 10%, and the average adhesive point surface area is approximately 0.16 to approximately 0.2 mm². 2 The average packing value at the bonding point is approximately 6.75 to 7.25 mm. -1The nonwoven fabric has an adhesion point density of approximately 52 to 58 individual adhesion points per square centimeter.

[0011] In one embodiment of the nonwoven fabric, the nonwoven fabric exhibits a Martindale abrasion score of 1 to 2, a transverse handle-o-meter value of about 6.7 to about 7.0 grams, a mechanical handle-o-meter value of about 3.6 to about 3.9 grams, and an average abrasion resistance of 3.4 to 3.6 grams, as measured by the weight of the removed material.

[0012] In one embodiment of the nonwoven fabric, the adhesive pattern comprises alternating first and second arrays of individual adhesive points extending transversely across the nonwoven fabric, wherein each individual adhesive point in the first and second arrays has a length and a width, the lengths of the individual adhesive points in the first array are aligned substantially in the same direction and at an angle of about 43 to about 47 degrees with respect to the horizontal axis of the nonwoven fabric, the lengths of the individual adhesive points in the second array are rotated at about 88 to about 92 degrees with respect to the alignment of the individual lengths in the first array, and the individual adhesive points in the second array are laterally offset from adjacent individual adhesive points in the first array.

[0013] In one embodiment of the nonwoven fabric, the number of individual adhesive points per square centimeter is approximately 45 to 60, particularly 50 to 58, and more particularly 54 to 56.

[0014] In one embodiment of the nonwoven fabric, the percentage of the adhesive area of ​​the nonwoven fabric is approximately 9 to 10.5%, particularly approximately 9.8 to 10.2%, and more particularly approximately 9.9 to 10%.

[0015] In one embodiment of the nonwoven fabric, the distance between adjacent bonds in the transverse direction is approximately 1.4 to 1.6 mm, particularly approximately 1.45 to 1.55 mm, and more particularly approximately 1.48 to 1.52 mm.

[0016] In one embodiment of the nonwoven fabric, the distance between adjacent adhesive points within the same array in the diagonal direction of the nonwoven fabric is approximately 0.7 to approximately 0.95 mm, particularly approximately 0.75 to approximately 0.90 mm, and more particularly approximately 0.80 to approximately 0.85 mm.

[0017] In one embodiment of the nonwoven fabric, the bonding point has an oval to elliptical shape, a rectangular shape, a rod shape, or a combination thereof.

[0018] In one embodiment of the nonwoven fabric, the bonding pattern further defines a plurality of alternating third and fourth arrays of repeating individual bonding points extending in the machine direction of the nonwoven fabric, wherein the individual bonding points of the third array are offset in the machine direction from the adjacent individual bonding points of the fourth array.

[0019] In one embodiment of the nonwoven fabric, the bonding pattern further defines a plurality of alternating fifth and sixth arrays of individual bonding points extending obliquely to the machine direction of the nonwoven fabric.

[0020] In one embodiment of the nonwoven fabric, the adjacent bonding points of the fifth array and the sixth array are aligned at an angle of about 88 to about 92 degrees with respect to the alignment direction of the individual adjacent bonding points within the same array.

[0021] In one embodiment of the nonwoven fabric, three adjacent arrays of individual bonds further define a plurality of bond patterns having a quincunx-like bond pattern in both the machine direction and the transverse direction, wherein four individual bond points defining the corners of the quincunx-like bond pattern share substantially the same orientation direction with respect to the transverse or machine direction of the nonwoven fabric, and individual bond points defining the center point of the quincunx-like bond pattern have an orientation direction rotated by about 88 to about 92 degrees with respect to the orientation direction of the individual bond points defining the corners of the quincunx-like bond pattern.

[0022] In one embodiment of the nonwoven fabric, the angle between the array extending diagonally and the array extending transversely is approximately 43 to approximately 47 degrees, particularly approximately 45 degrees.

[0023] In one embodiment of the nonwoven fabric, the nonwoven fabric exhibits a Martindale abrasion score of less than 1.5, particularly 1.2 to 1.5, and more particularly about 1.40 to about 1.45.

[0024] In one embodiment of the nonwoven fabric, the nonwoven fabric has a basis weight of about 20 to about 30 gsm and exhibits flexibility expressed by a transverse handle-meter value of less than 7.0 grams (g), for example, less than 7.9 grams or less than 7.5 grams.

[0025] In one embodiment of the nonwoven fabric, the nonwoven fabric has a reference weight of about 20 to about 30 gsm and exhibits flexibility expressed by a handle-of-meter value in the machine direction of less than 3.9 grams (g), for example less than 3.8 grams or less than 3.78 grams.

[0026] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm thicker than a similarly prepared nonwoven fabric. -1 Except for point bonding with an adhesive pattern having less than 100% adhesive point packing, it exhibits increased tensile strength, elongation, abrasion resistance, and flexibility.

[0027] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 3.5mm adhesive points, it exhibits a tensile strength that is only 10% greater, for example, 3.5mm. -1 The tensile strength of the nonwoven fabric with fewer than 10% to 50%, for example, 12% to 30%, 12% to 25%, 12% to 24%, or 12% to 20%, is greater than that of a similarly prepared nonwoven fabric with fewer than 10% to 30% adhesive point packing.

[0028] In certain embodiments of the nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength that is at least 10% greater compared to a similarly prepared nonwoven fabric having an adhesive surface area of more than 12%.

[0029] In certain embodiments of the nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength that is 10% to 30%, such as 12% to 20%, greater compared to the tensile strength of a similarly prepared nonwoven fabric having an adhesive surface area of more than 12%.

[0030] In certain embodiments of the nonwoven fabric, the nonwoven fabric has an adhesive point packing of less than 3.5mm -1 and exhibits an increase in the tensile strength in the machine direction that is about 10 to about 50% greater compared to a similarly prepared nonwoven fabric having an adhesive point packing of less than 3.5mm.

[0031] In certain embodiments of the nonwoven fabric, the nonwoven fabric has an adhesive point packing of less than 3.5mm -1 and exhibits an increase in the tensile strength in the machine direction of about 10 to about 30%, such as about 12% to about 20%, or about 12 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive point packing of less than 3.5mm.

[0032] In certain embodiments of the nonwoven fabric, the nonwoven fabric has an adhesive point packing of less than 3.5mm -1 and exhibits an increase in the tensile strength in the cross direction that is about 10 to about 50% greater compared to a similarly prepared nonwoven fabric having an adhesive point packing of less than 3.5mm.

[0033] In certain embodiments of the nonwoven fabric, the nonwoven fabric has an adhesive point packing of less than 3.5mm -1 and exhibits an increase in the tensile strength in the cross direction of about 10 to about 30%, such as about 15% to about 25%, about 18% to about 24%, or about 19% to about 21%, compared to a similarly prepared nonwoven fabric having an adhesive point packing of less than 3.5mm.

[0034] In certain embodiments of the nonwoven fabric, the nonwoven fabric exhibits an increase in the tensile strength in the machine direction that is about 10 to about 50% greater compared to a similarly prepared nonwoven fabric having an adhesive surface area of more than 12%.

[0035] In one embodiment of the nonwoven fabric, it exhibits an increase in tensile strength in the mechanical direction of about 10 to about 30%, for example, about 12 to about 20%, or about 12 to about 15%, compared to a similarly prepared nonwoven fabric having a bonding surface area of ​​more than 12%.

[0036] In one embodiment of the nonwoven fabric, it exhibits an increase in transverse tensile strength that is only about 10 to about 50% greater than a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

[0037] In one embodiment of the nonwoven fabric, it exhibits an increase in transverse tensile strength of about 10 to about 30%, for example, about 15 to about 25%, about 18 to about 24%, or about 19 to about 21%, compared to a similarly prepared nonwoven fabric having a bonding surface area of ​​more than 12%.

[0038] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 50% adhesion points, it exhibits an increase in elongation of approximately 4-50%.

[0039] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 50% adhesion point packing, it exhibits an increase in elongation of approximately 4-25%, for example, approximately 5-20%, or approximately 5-15%.

[0040] In one embodiment of the nonwoven fabric, it exhibits an increase in elongation of about 4 to about 50% compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

[0041] In one embodiment of the nonwoven fabric, it exhibits an increase in elongation of about 4 to about 25%, for example, about 5 to about 20%, or about 5 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

[0042] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm-1 Compared to similarly prepared nonwoven fabrics with fewer than 10% adhesive point packing, it shows a 10-30% increase in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score.

[0043] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10-25% increase in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, for example, about 12-24% or about 18-22%.

[0044] In one embodiment of the nonwoven fabric, it exhibits a 10-30% increase in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having a bonding surface area of ​​more than 12%.

[0045] In one embodiment of the nonwoven fabric, it exhibits an increase of about 10 to about 25%, for example, about 12 to about 24%, or about 18 to about 22%, in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having a bonding surface area of ​​more than 12%.

[0046] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 5% adhesive point packing, it shows an average percentage reduction of 5% to 150% in the weight of material removed during abrasion tests (according to test method NWSP 20.5).

[0047] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 9% adhesive point packing, it shows an average percentage reduction of 8% to 120%, e.g., 9% to 95%, in the weight of material removed during abrasion tests (according to test method NWSP 20.5).

[0048] In one embodiment of the nonwoven fabric, it exhibits an average percentage reduction of 5% to 150% in the weight of material removed during an abrasion test (according to test method NWSP 20.5) compared to a similarly prepared nonwoven fabric having a bonding surface area of ​​more than 12%.

[0049] In one embodiment of the nonwoven fabric, it exhibits an average percentage reduction of 8% to 120%, for example 9% to 95%, in the weight of material removed during an abrasion test (according to test method NWSP 20.5) compared to a similarly prepared nonwoven fabric having a bonding surface area of ​​more than 12%.

[0050] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with less than 5% adhesive point packing, it exhibits an increase in flexibility of approximately 5-20%, expressed by the average difference in handle-of-meter values.

[0051] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10% adhesive point packing, it exhibits an increase in flexibility of approximately 6-15%, for example, 8-10%, expressed by the average difference in handle-of-meter values.

[0052] In one embodiment of the nonwoven fabric, it exhibits an increase in flexibility of about 5 to about 20%, expressed by the average difference in handle-of-meter values, compared to a similarly prepared nonwoven fabric having a bonding surface area of ​​more than 12%.

[0053] In one embodiment of the nonwoven fabric, it exhibits an increase in flexibility of about 6 to about 15%, for example 8 to 10%, expressed by the average difference in handle-of-meter values, compared to a similarly prepared nonwoven fabric having a bonding surface area of ​​more than 12%.

[0054] In one embodiment of the nonwoven fabric, the nonwoven fabric is 3.5 mm -1Compared to similarly prepared nonwoven fabrics with less than 5% adhesive point packing, it exhibits an increase in flexibility of approximately 5-20%, expressed by the average difference in handle-of-meter values.

[0055] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.4%, and an area of ​​about 0.15 to about 0.25 mm. 2 The average surface area of ​​each individual bonding point is approximately 6.75 to 7.25 mm². -1 It has an average bond point packing value, a bond point density of approximately 50 to 60 individual bond points per square centimeter, a Martindale wear score of approximately 1.0 to 1.5, a lateral handle-o-meter value of approximately 6.6 to 7.2 grams, a mechanical handle-o-meter value of approximately 3.5 to 3.95 grams, and an average wear resistance of 3.2 to 5.5 grams, measured by the weight of the removed material.

[0056] In one embodiment of the nonwoven fabric, the nonwoven fabric has a bonding area percentage of about 9.8 to about 10%, and a thickness of about 0.15 to about 0.2 mm. 2 The average surface area of ​​each individual bonding point is approximately 7 to 7.2 mm². -1 It has an average bond point packing value, a bond point density of approximately 52 to 58 individual bond points per square centimeter, a Martindale wear score of approximately 1.42 to 1.45, a lateral handle-o-meter value of approximately 6.7 to 7.0 grams, a mechanical handle-o-meter value of approximately 3.6 to 3.9 grams, and an average wear resistance of 3.4 to 3.6 grams, as measured by the weight of the removed material.

[0057] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm. 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 The average bonding point packing value, and 3.5 mm -1Compared to similarly prepared nonwoven fabrics with fewer than 10% greater adhesion point packing, it exhibits an average increase in tensile strength of approximately 10-50%, 12-24%, or 12-22%.

[0058] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm. 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 Compared to similarly prepared nonwoven fabrics having an average bonding point packing value and a bonding surface area greater than 12%, e.g., 18.1%, it has an average increase in tensile strength that is only 10% greater, e.g., about 10-50%, about 12-24%, or about 12-22%.

[0059] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm. 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 The average bonding point packing value, and 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with less than 4% adhesive point packing, it has an average increase in elongation of about 4-50%, for example, about 4-20%, about 4-15%, or about 4-14%.

[0060] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm. 2 The average bonding surface area of ​​each individual is approximately 6.5 to 7.5 mm². -1 Compared to similarly prepared nonwoven fabrics having an average bonding point packing value and a bonding surface area of ​​over 12%, e.g., 18.1%, it has an average increase in elongation of about 4 to about 50%, e.g., about 4 to about 20%, about 4 to about 15%, or about 4 to about 14%.

[0061] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm. 2The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 The average bond point packing value and one or more of the following characteristics: 3.5mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10% adhesion point packing, there is a 10-30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score; 3.5mm -1 Compared to similarly prepared nonwoven fabrics having less than 5-150% of the weight of material removed during abrasion tests (according to test method NWSP 20.5), for example, about 8-120%, or about 9-95%; and 3.5mm -1 Compared to similarly prepared nonwoven fabrics with less than 5% adhesive point packing, this represents an improvement in flexibility of approximately 5-20%, for example, approximately 6-15%, or approximately 8-10%, as indicated by an average improvement in handle-of-meter values.

[0062] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm. 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 The average bond point packing value and one or more of the following characteristics: Compared to similarly prepared nonwoven fabrics with an adhesive surface area of ​​over 12%, e.g., 18.1%, a 10-30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score; Compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, e.g., 18.1%, the average percentage reduction in the weight of material removed during abrasion tests (according to test method NWSP 20.5) is 5-150%, e.g., about 8-120%, or about 9-95%; and Compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​over 12%, e.g., 18.1%, there is an improvement in flexibility of approximately 5 to 20%, e.g., approximately 6 to 15%, or approximately 8 to 10%, as indicated by an average improvement in the handle-of-meter value.

[0063] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm. 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 The average bond point packing value and one or more of the following characteristics: 3.5mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10% adhesive point packing, there is a 10-30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score; 3.5mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 5-150% of the weight of material removed during abrasion testing (according to test method NWSP 20.5), for example, about 8-120% or about 9-95%; 3.5mm -1 Compared to similarly prepared nonwoven fabrics with less than 5% adhesive point packing, there is an improvement in flexibility of approximately 5-20%, for example, approximately 6-15%, or approximately 8-10%, as indicated by an average improvement in the approximately handle-of-meter value; 3.5mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10-50% greater tensile strength in the machine direction (MD), for example, about 10-30%, about 12-20%, or about 12-15% greater; 3.5mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10-50% greater tensile strength in the cross direction (CD), for example, about 10-30%, about 15-25%, about 18-24%, or about 19-21%; and 3.5mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 50% adhesion point packing, this represents an increase in elongation of approximately 4-50%, for example, approximately 5-20%, or approximately 5-15%.

[0064] In one embodiment of the nonwoven fabric, the nonwoven fabric has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm. 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 The average bond point packing value and one or more of the following characteristics: Compared to similarly prepared nonwoven fabrics with an adhesive surface area of ​​over 12%, e.g., 18.1%, a 10-30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score; Compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, e.g., 18.1%, the average percentage reduction in the weight of material removed during abrasion testing (according to test method NWSP 20.5) is 5-150%, e.g., about 8-120%, or about 9-95%; Compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​over 12%, e.g., 18.1%, an improvement in flexibility of 5 to about 20%, e.g., about 6 to about 15%, or about 8 to about 10%, indicated by an average improvement in the approximately handle-of-meter value; Compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​over 12%, for example 18.1%, the increase in tensile strength in the machine direction (MD) is only about 10-50%, for example about 10-30%, for example about 12-20%, or about 12-15% greater; Compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, for example 18.1%, there is an increase in tensile strength in the cross direction (CD) that is only about 10 to about 50%, for example about 10 to about 30%, for example about 15 to about 25%, about 18 to about 24%, or about 19 to about 21%; and Compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​over 12%, e.g., 18.1%, this represents an increase in elongation of approximately 4 to 50%, e.g., approximately 5 to 20%, or approximately 5 to 15%.

[0065] In one embodiment of the nonwoven fabric, the nonwoven fabric includes a spunbond layer.

[0066] The nonwoven fabric comprises a first spunbond layer having few or no crimped filaments, and a second layer containing crimped filaments.

[0067] In one embodiment of the nonwoven fabric, the nonwoven fabric comprises at least two layers, one of which is selected from the group consisting of a meltblown layer, a carded fabric layer, a spunbond layer, a resin-bonded layer, an airlaid fabric layer, and a spunlace layer.

[0068] In one embodiment of the nonwoven fabric, the nonwoven fabric is contained within an absorbent article.

[0069] In one embodiment, the present invention provides an absorbent article comprising the nonwoven fabric. In another embodiment, the present invention relates to the use of the nonwoven fabric, wherein the nonwoven fabric is in an absorbent article.

[0070] In one embodiment, an embodiment of the present invention provides a nonwoven article comprising the nonwoven fabric. In one embodiment of the nonwoven fabric, the nonwoven fabric is an element of a composite sheet material. In one embodiment, an embodiment of the present invention provides a composite sheet material comprising the nonwoven fabric. In some embodiments, the nonwoven fabric comprises a composite sheet material. In some embodiments, the sheet material comprises a meltblown layer comprising the nonwoven fabric according to an embodiment of the present invention. In one embodiment, the meltblown layer is sandwiched between two spunbond layers, at least one of which comprises a nonwoven fabric layer according to the present disclosure.

[0071] An additional perspective is directed to a calendering bond unit comprising an engraved pattern roll configured to impart patterns according to one or more embodiments of the present disclosure.

[0072] In one embodiment, a calendering unit for spot bonding sheet material is provided, the calendering unit comprising a pair of cooperating cylindrical rolls, at least one of which has a recessed pattern thereon, the recessed pattern comprising a plurality of spaced individual bonding points extending radially outward from the surface of the roll, the plurality of bonding points defining a pattern comprising a plurality of spaced arrays extending transversely and radially on the roll, the percentage of the bonding surface area of ​​the nonwoven fabric being less than about 12%, and the average bonding point packing value of the nonwoven fabric being about 6.5 to about 8 mm -1 It is configured and arranged to thermally point-bond the nonwoven fabric.

[0073] In one embodiment, the carving pattern further includes a plurality of spaced arrays extending circumferentially around the roll in a spiral shape on its outer circumference.

[0074] In one embodiment, the bonding point has a continuous side wall and a raised surface, the raised surface being approximately 0.15 to 0.25 mm thick. 2 It has a uniform surface area.

[0075] In one embodiment, the number of adhesive points is approximately 50 to 60 individual adhesive points per square centimeter.

[0076] In one embodiment, the average length of the bonding point is about 0.74 to about 0.78 mm, and the average width of the bonding point is about 0.24 to about 0.36 mm.

[0077] In a further aspect of this disclosure, embodiments are directed toward a system for preparing nonwoven fabrics.

[0078] In one embodiment, a system for preparing nonwoven fabric, The first polymer source and A spin beam communicating with the first polymer supply source, the spin beam being configured and arranged to generate a plurality of polymer fibers, A collection surface located below the spin beam, wherein the collection surface is for depositing the plurality of polymer fibers to form a web, A thermal bonding unit positioned downstream of the spin beam comprises a pair of cylindrical rolls cooperating with each other, at least one of the rolls having a grooved pattern thereon, the grooved pattern having a plurality of spaced individual bonding points extending radially outward from the surface of the roll, the plurality of bonding points configured and arranged to define a pattern including a plurality of spaced arrays extending transversely and radially from the roll and thermally point-bond the web of fibers to form a nonwoven fabric, wherein the percentage of the bonded surface of the nonwoven fabric is less than approximately 12%, and the average bonding point packing value of the nonwoven fabric is approximately 6.5 to approximately 8 mm. -1 The heat bonding unit The above system, which includes the above features, is provided.

[0079] A further aspect of the present invention is also a method for preparing a nonwoven fabric, the method comprising the step of passing a nonwoven web through a heated calender roll, the calender roll comprising a pair of cooperating cylindrical rolls, at least one of the rolls comprising an engraved pattern thereon, the engraved pattern comprising a plurality of spaced individual bonding points extending radially outward from the surface of the roll, the plurality of bonding points comprising a plurality of spaced arrays extending transversely and radially on the roll, and configured and arranged to thermally point-bond the web of fibers to form a nonwoven fabric, wherein the percentage of the bonded surface of the nonwoven fabric is less than about 12%, and the average bonding point packing value of the nonwoven fabric is about 6.5 to about 8 mm -1 Therefore, the above method is being pursued.

[0080] In a certain view, embodiments of the present invention are nonwoven fabrics comprising a plurality of fibers, wherein the plurality of fibers are bonded to the surface of the nonwoven fabric in an adhesive pattern to form an integrated web, the nonwoven fabric having a vertical axis extending in the machine direction and a horizontal axis extending in the transverse direction, the adhesive pattern having a plurality of spaced-apart array pairs extending in the machine direction, transverse direction and diagonal direction of the nonwoven fabric, where each array has a plurality of spaced-apart oval-shaped adhesive points, the nonwoven fabric having a percentage of adhesive surface area of ​​less than about 14%, a collective average adhesive distance of about 1.5 to about 1.7 mm, and about 3.0 to about 5.0 mm -1 This is directed towards the above nonwoven fabric having an average adhesion point packing value of .

[0081] An additional aspect of the present invention is directed toward related methods, systems, and apparatus, wherein the nonwoven fabric has a percentage of adhesive surface area of ​​less than about 14%, a collective average bond distance of about 1.5 to about 1.7 mm, and about 3.0 to about 5.0 mm -1 It has an average bonding point packing value.

[0082] In one embodiment, the fibers of the nonwoven fabric include a blend of polypropylene resin and less than 20% by weight of polypropylene copolymer.

[0083] The present invention has been described in general terms, and the following attached drawings are to be referenced, but these are not necessarily drawn to scale: [Brief explanation of the drawing]

[0084] [Figure 1] Figure 1 shows an adhesive nonwoven fabric having an adhesive pattern according to at least one embodiment of the present invention. [Figure 2A] Figure 2A shows an adhesive point according to one or more embodiments of the present invention. [Figure 2B] Figure 2B shows an adhesive point according to one or more embodiments of the present invention. [Figure 3A]Figure 3A shows various adhesive arrays of adhesive patterns on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 3B] Figure 3B shows various adhesive arrays of adhesive patterns on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 3C] Figure 3C shows various adhesive arrays of adhesive patterns on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 4] Figure 4 shows an adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 5A] Figure 5A shows a secondary adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 5B] Figure 5B shows a secondary adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 6] Figure 6 shows an adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 7A] Figure 7A shows a further adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 7B] Figure 7B shows a further adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 7C] Figure 7C shows a further adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 7D] Figure 7D shows a further adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 8A] Figure 8A shows a further adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 8B] Figure 8B shows a further adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 8C] Figure 8C shows a further adhesion pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention. [Figure 9A]Figure 9A shows a system for preparing an adhesive nonwoven fabric according to at least one embodiment of the present invention. [Figure 9B] Figure 9B shows a system for preparing an adhesive nonwoven fabric according to at least one embodiment of the present invention. [Figure 10] Figure 10 shows a system for preparing an adhesive nonwoven fabric according to at least one embodiment of the present invention. [Figure 11] Figure 11 shows a calendering unit according to at least one embodiment of the present invention. [Figure 12] Figure 12 shows the patterned roll of the calendering unit shown in Figure 11. [Figure 13A] Figure 13A shows various drawings of bonding points according to at least one embodiment of the present invention. [Figure 13B] Figure 13B shows various drawings of bonding points according to at least one embodiment of the present invention. [Figure 13C] Figure 13C shows various drawings of bonding points according to at least one embodiment of the present invention. [Figure 14A] Figure 14A shows a multilayer nonwoven fabric according to at least one embodiment of the present invention. [Figure 14B] Figure 14B shows a multilayer nonwoven fabric according to at least one embodiment of the present invention. [Modes for carrying out the invention]

[0085] The present invention is described more fully below this specification with reference to the accompanying drawings, which show some, but not all, embodiments of the invention. In fact, these inventions may be embodied in many different forms and should not be construed as being limited to the embodiments described herein, but rather these embodiments are provided to satisfy the legal requirements to which this disclosure applies. Similar numbers refer to similar elements throughout. Where used herein and in the accompanying claims, the singular “one” (a or an) and “the” include plural references unless it is clearly evident from the context.

[0086] The words “first” and “second,” as well as “primary,” “exemplary,” and “secondary,” do not indicate order, quantity, or importance, but are used to distinguish one element from another. Furthermore, the words “a” and “an,” and the word “the,” do not indicate a limitation of quantity, but rather indicate that there is “at least one” item being referred to.

[0087] Each embodiment disclosed herein is intended to be applicable to each of the other disclosed embodiments. Any combination and subcombinations of the various elements described herein are within the scope of the present invention.

[0088] If a parameter range is provided, it is understood that all integers within that range, as well as one-tenth and one-hundredth thereof, are also provided by the present invention. For example, "5-10%" includes 5%, 6%, 7%, 8%, 9%, and 10%; 5.0%, 5.1%, 5.2%, ..., 9.8%, 9.9%, and 10.0%; and 5.00%, 5.01%, 5.02%, ..., 9.98%, 9.99%, and 10.00%.

[0089] As used herein, the words “about,” “approximately,” and “substantially” mean, in the context of numbers or ranges, ±10% of the stated or claimed number or range, and in particular, include values ​​within the standard margin of error of measurement (e.g., SEM) of the stated value, or variations of ±0.5%, ±1%, ±5%, or ±10% from the specified value.

[0090] For the purposes of this application, the following terms shall have the meanings set forth below.

[0091] The word "fiber" refers to a fiber with a finite length, or a filament with an infinite length.

[0092] As used herein, the term “monocomponent” means a fiber formed from one polymer, or a fiber formed from a single blend of polymers. Of course, this does not exclude fibers to which additives have been added for purposes such as color, antistatic properties, lubricity, hydrophilicity, or quenchability.

[0093] As used herein, the term “multicomponent” means a fiber formed from at least two polymers (e.g., a two-component fiber) extruded from separate extruders. The at least two polymers may be, independently, identical or different from each other, or may be a blend of polymers. The polymers are arranged within individual zones that are substantially evenly spaced across the cross-section of the fiber. The components may be arranged in any desired configuration, e.g., sheath-core, side-by-side, segmented pie, island-in-the-sea, etc. Various methods for forming multi-component fibers are described in U.S. Patent No. 4,789,592 by Taniguchi et al., U.S. Patent No. 5,336,552 by Strack et al., U.S. Patent No. 5,108,820 by Kaneko et al., U.S. Patent No. 4,795,668 by Kruege et al., U.S. Patent No. 5,382,400 by Pike et al., U.S. Patent No. 5,336,552 by Strack et al., and U.S. Patent No. 6,200,669 by Marmon et al., which are incorporated herein by reference in their entirety. Multi-component fibers having various irregular shapes are also described, for example, in U.S. Patent No. 5,277,976 by Hogle et al., U.S. Patent No. 5,162,074 by Hills, U.S. Patent No. 5,466,410 by Hills, U.S. Patent No. 5,069,970 by Largman et al., and U.S. Patent No. 5,057,368 by Largman et al., the whole of which is incorporated herein by reference.

[0094] As used herein, the terms “nonwoven,” “nonwoven web,” and “nonwoven fabric” mean a structure or web of material formed without using a weaving or knitting process, which is intertwined but not in a recognizable, repeating manner. Nonwoven webs have historically been formed by various conventional processes, such as the meltblown process, the spunbond process, and the staple fiber carding process.

[0095] As used herein, the term “meltblown” refers to a process in which fibers are formed by extruding a molten thermoplastic material through a plurality of thin, usually circular, die capillaries into a high-speed gas (e.g., air) stream, the high-speed gas stream thins the molten thermoplastic material and forms fibers that may be up to the diameter of microfibers. The meltblown fibers are then carried by the gas stream and deposited on a collection surface to form a random web of meltblown fibers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,241 by Buntin et al.

[0096] As used herein, the terms “machine direction” or “MD” refer to the direction of movement of the nonwoven web during manufacturing.

[0097] As used herein, the terms “cross direction” or “CD” refer to the direction perpendicular to the machine direction and extending transversely within the width of the nonwoven web.

[0098] As used herein, the term “diagonal direction” or “DD” means a direction that is positioned at an angle greater than 0 degrees and less than 90 degrees with respect to one or more lateral and mechanical directions.

[0099] As used herein, unless otherwise specified, the term “molecular weight” (or “Mw”) means weight-average molecular weight, which is expressed in grams per mole. This weight-average molecular weight can be measured using common methods such as gel permeation chromatography or “GPC”.

[0100] As used herein, the term “spunbond” refers to the process of extruding a molten thermoplastic material as filaments from a plurality of thin, usually circular, capillaries of a spinneret, then thinning the filaments, and then stretching them mechanically or pneumatically. The filaments are deposited on a collection surface to form a web of substantially continuous filaments arranged randomly, which can then be bonded together to form a single nonwoven fabric. The manufacture of spunbond nonwoven webs is described in patents, for example, U.S. Patent No. 3,338,992; U.S. Patent No. 3,692,613; U.S. Patent No. 3,802,817; U.S. Patent No. 4,405,297; and U.S. Patent No. 5,665,300. Generally, these spunbond processes include extruding the filament from a spinneret, quenching the filament with an airflow to accelerate the solidification of the molten filament, thinning the filament by applying draw tension either by riding the filament in an airflow with air pressure or by winding the filament onto mechanical draw rolls, depositing the drawn filaments onto a foraminous collection surface to form a web, and bonding the web of loose filaments into a nonwoven fabric. The bonding can be any thermal or chemical bonding treatment, typically thermal point bonding.

[0101] As used herein, the term "thermal point bonding" includes passing a material to be bonded, such as one or more webs, between a heated calender roll and an anvil roll. The calender roll is typically engraved such that the fabric is bonded at individual point bonding sites rather than across its surface.

[0102] As used herein, the term "bonding density" refers to the number of individual bond points within a given surface area of the nonwoven fabric.

[0103] As used herein, the term "polymer" generally includes, but is not limited to, homopolymers, copolymers (e.g., block copolymers, graft copolymers, random copolymers, and alternating copolymers), terpolymers, etc., as well as blends and modifications thereof. Moreover, unless otherwise specifically limited, the term "polymer" shall include all possible geometric configurations of the material, such as the above geometric configurations including isotactic, syndiotactic, and random symmetries.

[0104] Nonwoven fabric

[0105] In a first aspect of the present invention, embodiments of the present disclosure are directed to thermally point bonded nonwovens having improved abrasion resistance and flexibility. Generally, an improvement in the abrasion resistance of the surface of a nonwoven can be obtained by increasing the percentage of the bonded area of the nonwoven. That is, the larger the percentage of the area of the fibers that have received thermal point bonding on the surface of the nonwoven, the more the number of fibers that adhere to adjacent fibers increases, so the abrasion resistance of the nonwoven becomes higher. However, such an improvement in abrasion resistance typically results in a decrease in the flexibility of the bonded nonwoven. Therefore, it is generally recognized that there is a trade-off between an improvement in the abrasion resistance and an improvement in the flexibility of the bonded nonwoven.

[0106] Advantageously and surprisingly, the inventors of the present disclosure have discovered that both improved abrasion resistance and flexibility can be obtained by a nonwoven thermally point bonded with an adhesive pattern according to one or more embodiments of the present invention. In particular, an adhesive nonwoven having a first adhesive pattern including a plurality of alternating arrays of individual adhesive points in both the machine direction and the cross direction of the nonwoven, wherein the overall percentage of the adhesive surface area of the nonwoven is less than 12%, the surface area of each individual adhesive point is about 0.10 to 0.60 square millimeters (mm 2 ), the adhesive point packing value is more than about 3.5 mm- 1 super, and the adhesive density is about 20 to 60 individual adhesive points per square centimeter (cm 2 ) has been found to provide a nonwoven having improved flexibility and abrasion resistance compared to similar nonwovens with a larger percentage of the adhesive surface area.

[0107] Referring to Figure 1, an adhesive nonwoven fabric according to one or more embodiments of the present invention is shown and is broadly designated by reference numeral 10. The adhesive nonwoven fabric 10 comprises a surface 12 having a plurality of individual adhesive points 14 thereon. The adhesive points 14 are spaced apart from each other and are configured and arranged to define a first pattern comprising a plurality of arrays extending in the machine direction (MD), transverse direction (CD), and oblique direction (DD) of the nonwoven fabric 10. The nonwoven fabric 10 also has a vertical axis (V) substantially aligned with the machine direction of the nonwoven fabric 10 and a horizontal axis (H) substantially aligned with the transverse direction of the nonwoven fabric 10.

[0108] In the illustrated embodiment, each of the bonding points 14 defines a region of the nonwoven fabric 10 in which the fibers are heat-bonded together to form a unified web.

[0109] An array extending laterally across the nonwoven fabric 10 includes a plurality of individual bonding points 14, the bonding points 14 being spaced apart from each other and extending laterally across the nonwoven fabric. In addition, the laterally extending array has a plurality of array pairs 20, each array pair including a first array A1 defining a first member of the array pair 20 and a second array A2 defining a second member of the array pair. The plurality of array pairs 20 define a pattern in which the first array A1 and the second array A2 are arranged alternately in a repeating pattern in the machine direction of the nonwoven fabric.

[0110] As shown in Figure 1, each of the adhesive points 14 may have a generally oblong shape, such as oval to elliptical, rectangular, or rod / bar shape. In an oblong adhesive point, the adhesive point has a major axis and a minor axis, the length of the major axis being longer than the length of the minor axis (see, for example, reference numerals 30 and 32 in Figures 2A and 2B, respectively). In one embodiment, the major axes of the adhesive points of the same array (e.g., a first array A1) are oriented / aligned in the same direction, while the major axes of the individual adhesive points of the array forming a second member of the array pair (e.g., a second array A2) are oriented / aligned at an angle of about 85 to 95 degrees relative to the alignment of the major axes of the adhesive points 14 of the first array A1. In one embodiment, the individual bonding points of the first array are oriented / aligned with respect to the alignment of the major axes of the bonding points 14 of the second array A2 at an alignment of approximately 86 to 94 degrees, for example, approximately 87 to 93 degrees, 88 to 92 degrees, 86 to 94 degrees, 89 to 91 degrees, or 90 degrees.

[0111] Similarly, an array extending in the machine direction of the nonwoven fabric 10 includes a plurality of individual bonding points 14, which are spaced apart from each other and extend longitudinally in the machine direction of the nonwoven fabric. In addition, the array extending in the machine direction has a plurality of array pairs 22, each array pair including a third array A3 defining a first member of the array pair 22 and a fourth array A4 defining a second member of the array pair 22. The plurality of array pairs 22 define a pattern in which the third array A3 and the fourth array A4 are alternately arranged in a repeating pattern in the transverse direction of the nonwoven fabric.

[0112] With respect to the array pair 22, the major axes of the bonding points 14 of the same array (e.g., the third array A3) are oriented / aligned in the same direction, while the major axes of the individual bonding points of the arrays forming the second member of the array pair (e.g., the fourth array A4) are oriented / aligned at an alignment of about 85 to 95 degrees relative to the alignment of the major axes of the bonding points 14 of the third array A3. In one embodiment, the individual bonding points of the third array A3 are oriented / aligned at an alignment of about 86 to 94 degrees, for example, about 87 to 93 degrees, 88 to 92 degrees, 86 to 94 degrees, 89 to 91 degrees, or 90 degrees relative to the alignment of the major axes of the bonding points 12 of the fourth array A4.

[0113] As previously stated, the nonwoven fabric may also include arrays of individual bonding points 14 extending diagonally across the nonwoven fabric. These diagonal arrays are also arranged in a plurality of array pairs 24 extending across the surface of the nonwoven fabric at angles that are aligned diagonally with respect to the vertical and / or horizontal axes of the nonwoven fabric.

[0114] Each array pair 24 comprises a fifth array A5 and a sixth array A6, and the plurality of array pairs 24 define a pattern in which the fifth array A5 and the sixth array A6 are arranged alternately in a repeating pattern in the diagonal direction of the nonwoven fabric.

[0115] As shown in Figure 1, the major axes of each consecutive adhesive point 14 of the diagonally aligned arrays A5 and A6 are rotated by approximately 85 to 95 degrees relative to the alignment of the major axes of the preceding adhesive point 14 of the same array. In one embodiment, the major axes of each consecutive adhesive point 14 of the diagonally oriented arrays A5 and A6 are rotated by approximately 86 to 94 degrees, for example, approximately 87 to 93 degrees, approximately 88 to 92 degrees, approximately 86 to 94 degrees, approximately 89 to 91 degrees, or 90 degrees relative to the major axis of the preceding adhesive point 14 of the same array.

[0116] In one embodiment, the intersection of the array extending diagonally (DD) and the horizontal axis H of the nonwoven fabric 10 defines an angle a1. The angle a1 is typically about 25 to 55 degrees, more typically about 28 to 48 degrees, and even more typically about 30 to 45 degrees.

[0117] In some cases, the angle a1 is greater than approximately 25 degrees, greater than approximately 26 degrees, greater than approximately 27 degrees, greater than approximately 28 degrees, greater than approximately 29 degrees, greater than approximately 30 degrees, greater than approximately 31 degrees, greater than approximately 32 degrees, greater than approximately 33 degrees, greater than approximately 34 degrees, greater than approximately 35 degrees, greater than approximately 36 degrees, greater than approximately 37 degrees, greater than approximately 38 degrees, greater than approximately 39 degrees, greater than approximately 40 degrees, greater than approximately 41 degrees, greater than approximately 42 degrees, greater than approximately 43 degrees, greater than approximately 44 degrees, greater than approximately 45 degrees, greater than approximately 46 degrees, greater than approximately 47 degrees, greater than approximately 48 degrees, greater than approximately 49 degrees, greater than approximately 50 degrees, greater than approximately 51 degrees, greater than approximately 52 degrees, greater than approximately 53 degrees, and greater than approximately 54 degrees.

[0118] In one embodiment, the angle a1 is less than approximately 55 degrees, less than approximately 54 degrees, less than approximately 53 degrees, less than approximately 52 degrees, less than approximately 51 degrees, less than approximately 50 degrees, less than approximately 49 degrees, less than approximately 48 degrees, less than approximately 47 degrees, less than approximately 46 degrees, less than approximately 45 degrees, less than approximately 44 degrees, less than approximately 43 degrees, less than approximately 42 degrees, less than approximately 41 degrees, less than approximately 40 degrees, less than approximately 39 degrees, less than approximately 38 degrees, less than approximately 37 degrees, less than approximately 36 degrees, less than approximately 35 degrees, less than approximately 34 degrees, less than approximately 33 degrees, less than approximately 32 degrees, less than approximately 31 degrees, less than approximately 30 degrees, less than approximately 29 degrees, less than approximately 28 degrees, less than approximately 27 degrees, and less than approximately 26 degrees.

[0119] In one embodiment, each oval-shaped adhesive point has an average length of approximately 0.65 to 1.25 mm, particularly approximately 0.70 to 1.20 mm, more particularly approximately 1.15 to 0.72 mm, and even more particularly approximately 0.74 to 1.10 mm.

[0120] In a preferred embodiment, the individual oval-shaped bonding points have an average length of about 0.74 to about 0.78 mm, with an average length of about 0.76 mm being slightly more preferred.

[0121] In one embodiment, each of the oval-shaped adhesive points has an average width of about 0.24 to about 0.60 mm, particularly about 0.25 to about 0.55 mm, more particularly about 0.27 to about 0.50 mm, and even more particularly about 0.28 to about 0.48 mm.

[0122] In a preferred embodiment, each of the oval-shaped adhesive points has an average width of about 0.24 to about 0.36 mm, particularly about 0.26 to about 0.32 mm, and more particularly about 0.28 to about 0.31 mm. In a slightly more preferred embodiment, each of the adhesive points has an average width of about 0.30 mm.

[0123] Each of these bonding points has a length-to-width ratio of approximately 1.5 to approximately 8, particularly approximately 1.75 to approximately 4, and more particularly approximately 2 to approximately 2.8.

[0124] In one embodiment, the average cluster bond distance is in the range of approximately 1.10 to approximately 2.25 mm. The average bond distance refers to how densely the contact points are located in a given bonding pattern in the machine direction, transverse direction, and diagonal direction of the nonwoven fabric. The average bond distance can be calculated from the average of the distances between adjacent bonds in the machine direction, the transverse direction, and the diagonal direction of the nonwoven fabric. In some embodiments, the average bond distance is in the range of approximately 1.15 to approximately 2.10 mm, particularly approximately 1.20 to approximately 2.0 mm. Unless otherwise specified, the distance between adjacent bonds is measured by the shortest distance between two adjacent bonds.

[0125] Furthermore, approximately 3.5mm- 1 Adhesive nonwoven fabrics containing adhesive patterns with an average adhesive point packing value exceeding 3.5 mm have a larger percentage of adhesive area and 3.5 mm - 1 It was found that compared to adhesive nonwoven fabrics with an average bonding point packing value of less than a certain value, it provides improvements in flexibility and abrasion resistance, as well as improved mechanical properties.

[0126] The average adhesion point packing value of a given adhesion pattern is calculated by dividing the collective average adhesion point distance by the average surface area of the adhesion points of the adhesion pattern.

[0127] In one embodiment, the adhesive non-woven fabric is about 3.5 to about 10 mm -1 , for example, about 4.5 to about 9 mm -1 , and about 5 to about 7.5 mm -1 , and has an average adhesion point packing value.

[0128] Referring to FIGS. 2A and 2B, the individual adhesion points 14 have a length L1 and a width W1. The length of the adhesion point extends substantially linearly between opposite ends of the adhesion point and defines the major axis 30 of the adhesion point. The width of the adhesion point is the dimension between opposite sides of the adhesion point and defines the minor axis 32 of the adhesion point. The major axis 30 of the individual adhesion points extends through the farthest points of the adhesion point, and the minor axis 32 extends through the closest points of the adhesion point. Generally, the major axis and the minor axis of the individual adhesion points are substantially perpendicular to each other.

[0129] In the illustrated embodiment, the individual adhesion points generally become oval to elliptical in shape. It should be recognized that other shapes, such as ovaloid shapes and their variants, can also be used. For example, the adhesion points can have a rectangular shape, a rod shape, an oval to elliptical shape, or a combination thereof. In one embodiment, the ovaloid-shaped adhesion points can be used in combination with adhesion points of other shapes, such as square shapes, diamond shapes, or circular shapes.

[0130] Exemplary Embodiment A

[0131] Referring to FIGS. 3A - 3C, a preferred embodiment of the adhesive non-woven fabric is shown and is broadly designated by reference numeral 10a. The non-woven fabric 10a includes a plurality of fibers that are point-adhered to each other by a plurality of individual adhesion points 14 for forming an integrated web. The non-woven fabric has a horizontal axis "H" that is aligned substantially in the cross direction "CD" of the non-woven fabric, and a vertical axis "V" that is aligned substantially in the machine direction "MD" of the non-woven fabric.

[0132] In the embodiments shown in Figures 3A to 3C, the overall percentage of the adhesive surface area of ​​the nonwoven fabric is less than approximately 10%, and the surface area of ​​individual adhesive points is approximately 0.1 to approximately 0.30 square millimeters (mm²). 2 The packing value at the bonding point is approximately 6 to 8 mm. -1 The adhesive density is per square centimeter (cm²). 2 There are approximately 45 to 60 individual bonding points per unit.

[0133] The plurality of individual bonding points 14 define a first pattern 34 on the surface 12 of the nonwoven fabric 10a. As shown in Figure 2A, the first pattern 34 includes a series of alternating first and second arrays A1, A2 of individual bonding points 14 extending transversely across the nonwoven fabric 10, the arrays being arranged in array pairs 20. In one embodiment, the individual bonding points 14 defining the second array of the first pattern are laterally offset from adjacent bonding points of the first array. That is, adjacent bonding points of the first and second arrays are not aligned with each other in the machine direction of the nonwoven fabric. This configuration and arrangement is shown in Figure 3A, where the vertical axis V extends only through the bonding points of the second array and not through the bonding points of the first array. In the embodiment shown in Figure 3A, the first array A1 and the second array A2 are substantially aligned with the transverse direction of the nonwoven fabric 10a.

[0134] In a preferred embodiment, the individual bonding points of the first array do not overlap with the individual bonding points of the second array in the machine direction. However, it should be recognized that in some embodiments, the individual bonding points of the first and second arrays may overlap with the bonding points of adjacent arrays in the machine direction.

[0135] In one embodiment, each adhesive point has an average length of about 0.65 to about 0.85 mm, particularly about 0.70 to about 0.80 mm, and more particularly about 0.74 to about 0.78 mm. In a preferred embodiment, each adhesive point has an average length of about 0.76 mm.

[0136] In one embodiment, each adhesive point has an average width of about 0.24 to about 0.36 mm, particularly about 0.26 to about 0.32 mm, and more particularly about 0.28 to about 0.31 mm. In a preferred embodiment, each adhesive point has an average width of about 0.30 mm.

[0137] In one embodiment, each of the bonding points has a length-to-width ratio of about 2 to about 3, particularly about 2.15 to about 2.85, and more particularly about 2.45 to about 2.65.

[0138] Referring again to Figure 3A, the lengths (e.g., major axes) of the individual bonding points of the first array are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the first array and the horizontal axis H of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the horizontal axis H and the major axis of the individual bonding points of the first array A1 is about 43 to about 47 degrees, particularly about 44 to about 46 degrees, and more particularly about 45 degrees.

[0139] In one embodiment, the individual bonding points of the first array have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0140] The lengths of the individual bonding points of the second array are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the second array and the horizontal axis H of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the horizontal axis H and the major axis of the individual bonding points of the second array A2 is about 43 degrees to about 47 degrees, particularly about 44 degrees to about 46 degrees, and more particularly about 45 degrees.

[0141] In one embodiment, the length (e.g., the major axis) of each individual bonding point of the second array is typically rotated by about 88 to 92 degrees, for example, about 89 to 91 degrees, and especially about 90 degrees, relative to the alignment of the lengths (e.g., the major axes) of each individual bonding point of the first array.

[0142] In a preferred embodiment, the intersection of a line segment extending along the major axis of each bonding point of the first array and a line segment extending along the major axis of each bonding point of the second array defines an angle of about 90 degrees.

[0143] In one embodiment, the individual bonding points of the second array have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0144] Referring to Figure 3B, the first pattern 30 of the bonding points further includes a series of alternating third arrays A3 and fourth arrays A4 of individual bonding points 14 extending in the machine direction of the nonwoven fabric 10, the arrays arranged in array pairs 22. In the embodiment shown in Figure 3B, the third array A3 and the fourth array A4 are substantially aligned with the machine direction of the nonwoven fabric 10a. Similar to the first array A1 and the second array A2, the individual bonding points 14 defining the fourth array of the first pattern are offset in the machine direction with respect to adjacent bonding points of the third array. That is, adjacent bonding points of the third array and the fourth array are not aligned with each other in the machine direction of the nonwoven fabric.

[0145] In one embodiment, the lengths of the individual bonding points of the third array A3 are typically aligned at an oblique angle with respect to the vertical axis of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the third array and the vertical axis V of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the vertical axis V and the major axis of the individual bonding points of the third array A3 is about 43 degrees to about 47 degrees, particularly about 44 degrees to about 46 degrees, and more particularly about 45 degrees.

[0146] In one embodiment, the individual bonding points of the third array A3 have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0147] Similarly, the lengths of the individual bonding points of the fourth array are typically aligned at an oblique angle with respect to the vertical axis of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the fourth array and the vertical axis V of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the vertical axis V and the major axis of the individual bonding points of the fourth array A4 is about 43 degrees to about 47 degrees, particularly about 44 degrees to about 46 degrees, and more particularly about 45 degrees.

[0148] In one embodiment, the length (e.g., the long axis) of each individual bonding point of the fourth array is typically rotated by about 88 to 92 degrees, for example, about 89 to 91 degrees, and especially about 90 degrees, relative to the alignment of the lengths (e.g., the long axes) of each individual bonding point of the third array.

[0149] In a preferred embodiment, the intersection of the major axis line segment of each bonding point of the third array and the major axis line segment of each bonding point of the fourth array defines an angle of approximately 90 degrees.

[0150] In one embodiment, the individual bonding points of the fourth array have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0151] Referring next to Figure 3C, the first pattern 34 of the bonding point further includes a series of alternating fifth arrays A5 and sixth arrays A6, the arrays extending obliquely across the surface of the nonwoven fabric with respect to the machine direction of the nonwoven fabric. The fifth array A5 and the sixth array A6 are arranged in array pair 24. As shown in Figure 3C, the intersection of the fifth or sixth array with the horizontal axis H defines an angle a2. Generally, the angle a2 is about 40 to about 50 degrees, particularly about 42 to about 48 degrees, more particularly about 43 to about 47 degrees, and even more particularly about 44 to about 46 degrees. In a preferred embodiment, the angle a2 is about 45 degrees.

[0152] Similarly, the intersections of the fifth and sixth arrays with the vertical axis V define an angle a3. Generally, the angle a3 is about 40 to 50 degrees, particularly about 42 to 48 degrees, more particularly about 43 to 47 degrees, and even more particularly about 44 to 46 degrees. In a preferred embodiment, the angle a3 is about 45 degrees.

[0153] As shown in Figure 3C, each consecutive bond point of the fifth and sixth arrays is rotated by approximately 90 degrees with respect to the preceding bond point of the same array. In this regard, the lengths of bond points 14a and 14c are aligned substantially in the same direction with respect to the horizontal axis H of the nonwoven fabric 10a, and the lengths of bond points 14b and 14d are rotated by approximately 90 degrees with respect to the lengths of bond points 14a and 14c. In this way, the major axis of each consecutive bond point of the same array is substantially perpendicular to the major axis of the preceding or consecutive bond point of the same array.

[0154] Continuing to refer to Figure 3C, the distance d1 between adjacent bonding points within the same array in the lateral direction of the first and second arrays may be in the range of about 1.40 to about 1.60 mm, particularly about 1.45 to about 1.55 mm, and more particularly about 1.48 to about 1.52 mm. In a preferred embodiment, the distance d1 between adjacent bonding points in the lateral direction of the first and second arrays is about 1.51 mm.

[0155] In one embodiment, the distance d2 between adjacent bonding points within the same array of the third and fourth arrays in the machine direction may be in the range of about 1.40 to about 1.60 mm, particularly about 1.45 to about 1.55 mm, and more particularly about 1.48 to about 1.52 mm. In a preferred embodiment, the distance d2 between adjacent bonding points within the same array of the third and fourth arrays in the machine direction is about 1.51 mm.

[0156] In one embodiment, the distance d5 between adjacent bonding points within the same array of the fifth or sixth array may be in the range of about 0.70 to about 0.95 mm, particularly about 0.75 to about 0.90 mm, and more particularly about 0.80 to about 0.85 mm. In a preferred embodiment, the distance d5 between adjacent bonding points within the same array of the fifth and sixth arrays is about 0.82 to about 0.84 mm.

[0157] Similarly, with respect to arrays (not specified by reference number) that are rotated approximately 90 degrees relative to the fifth and sixth arrays and aligned obliquely, the distance d6 between adjacent bonding points within the same array may be in the range of about 0.70 to about 0.95 mm, particularly about 0.75 to about 0.90 mm, and more particularly about 0.80 to about 0.85 mm. In a preferred embodiment, the distance d6 between adjacent bonding points within the same array of the fifth and sixth arrays is about 0.82 to about 0.84 mm.

[0158] In one embodiment, as shown in Figures 3A to 3C, the average cluster bonding point distance may be in the range of approximately 1.15 to approximately 1.45 mm. As previously stated, the average bonding point distance is calculated from the average distance between bonding points in the machine direction, transverse direction, and diagonal direction of the nonwoven fabric. For example, the average cluster bonding point distance can be calculated from the average distances of d1, d2, d5, and d6.

[0159] In certain embodiments, the average set adhesion point distance ranges from about 1.20 to about 1.40 mm, particularly from about 1.25 to about 1.35 mm, more particularly from about 1.26 to about 1.30 mm, and an average distance of 1.27 to 1.29 mm is somewhat more preferred.

[0160] In certain embodiments according to the embodiments of FIGS. 3A - 3C, the adhesive non - woven fabric has an average adhesion point packing value of about 6 to about 10.0 mm -1 e.g., about 6.5 to about 9.5 mm -1 and 7.0 to 8.0 mm -1、 In a preferred embodiment, the adhesive non - woven fabric has an average adhesion point packing value of about 7.0 to about 7.25 mm -1

[0161] More particularly, in certain embodiments according to the embodiments of FIGS. 3A - 3C, the adhesive non - woven fabric is greater than 6.0 mm -1 greater than 6.1 mm -1 greater than 6.2 mm -1 greater than 6.3 mm -1 greater than 6.4 mm -1 greater than 6.5 mm -1 greater than 6.6 mm -1 greater than 6.7 mm -1 greater than 6.8 mm -1 greater than 6.9 mm -1 greater than 7.0 mm -1 greater than 7.1 mm -1 greater than 7.2 mm -1 greater than 7.3 mm -1 greater than 7.4 mm -1 greater than 7.5 mm -1 greater than 7.​​​​​​​​​​​​​​​​​​​​​​​​​​​-1 Super, 9.0mm -1 Super, 9.1mm -1 Super, 9.2mm -1 Super, 9.3mm -1 Super, 9.4mm -1 Super, 9.5mm -1 Super, 9.6mm -1 Super, 9.7mm -1 Super, 9.8mm -1 Super, 9.9mm -1 Ultra, and 10.0 mm -1 It has an average bonding point packing value.

[0162] In one embodiment, according to the embodiments shown in Figures 3A to 3C, the adhesive nonwoven fabric is 10.0 mm -1 Less than 9.9mm -1 Less than 9.8mm -1 Less than 9.7mm -1 Less than 9.6mm -1 Less than 9.5mm -1 Less than 9.4mm -1 Less than 9.3mm -1 Less than 9.2mm -1 Less than 9.1 mm -1 Less than 9.0 mm -1 Less than 8.9mm -1 Less than 8.8mm -1 Less than 8.7mm -1 Less than 8.6mm -1 Less than 8.5mm -1 Less than 8.4mm -1 Less than 8.3mm -1 Less than 8.2mm -1 Less than 8.1 mm -1 Less than 7.0 mm -1 Less than 6.9mm -1 Less than 6.8mm -1 Less than 6.7mm -1 Less than 6.6mm -1 Less than 6.5mm -1 Less than 6.4mm -1 Less than 6.3mm -1 Less than 6.2mm -1 Less than 6.1 mm -1 Less than 6.0 mm -1 Less than 5.9mm -1Less than 5.8mm -1 Less than 5.7mm -1 Less than 5.6mm -1 Less than 5.5mm -1 Less than 5.4mm -1 Less than 5.3mm -1 Less than 5.2mm -1 Less than 5.1 mm -1 Less than and 5.0 mm -1 It has an average adhesion point packing value of less than .

[0163] In one embodiment, the array extending laterally across the nonwoven fabric does not have to be parallel to the horizontal axis H of the nonwoven fabric. In this regard, Figure 4 shows an embodiment in which the first bonding pattern includes an array of individual bonding points, and the array is not aligned with the horizontal axis of the nonwoven fabric 10. As shown in the drawing, array A7 defines an array in which individual bonding points 16 extend laterally across the nonwoven fabric at an angle greater than 0 degrees with respect to the horizontal axis. In particular, the intersection of array A7 with the horizontal axis defines an angle a3 which may be in the range of greater than 0 degrees and less than 6 degrees. In a preferred embodiment, the angle a3 is about 0.5 degrees to about 4 degrees, particularly about 1 degree to about 3 degrees, and an angle of about 2 degrees is preferred.

[0164] In one embodiment, the first pattern defines a plurality of second patterns within the first pattern. In this regard, Figures 5A and 5B show a second pattern 40 having individual adhesive points that collectively define a five-eye-shaped adhesive pattern. As shown in Figures 5A and 5B, three adjacent arrays of individual bonding points (e.g., A1, A2, A1) further define multiple bonding patterns having a fifth-eye pattern in both the machine direction and the transverse direction, and four individual bonding points (40a, 40b, 40c, 40d) defining the corners of the fifth-eye pattern 40 share substantially the same orientation direction with respect to the transverse or machine direction of the nonwoven fabric, where the individual bonding point 44 defining the center point of the fifth-eye pattern has an orientation direction rotated by about 88 to about 92 degrees (e.g., about 89 to about 91 degrees, especially 90 degrees) with respect to the orientation direction of the individual bonding point defining the corners of the fifth-eye pattern.

[0165] Figure 5B shows a partial adhesive pattern 46 of the first adhesive pattern having multiple quintuplet-like adhesive patterns extending in both the machine direction and the transverse direction of the nonwoven fabric. Each quintuplet-like adhesive pattern shares a corner adhesive point with an adjacent quintuplet-like adhesive pattern in both the machine direction and the transverse direction. In this regard, quintuplet-like adhesive pattern 40a shares corner adhesive points 48a, 48b with quintuplet-like adhesive pattern 40b in the transverse direction. Similarly, quintuplet-like adhesive pattern 40a shares corner adhesive points 48c, 48b with an adjacent quintuplet-like adhesive pattern 40c in the machine direction of the nonwoven fabric.

[0166] As described above, the inventors of this disclosure have surprisingly found that abrasion resistance is improved compared to similarly prepared nonwoven fabrics, including oval bonds with a higher percentage of the bonded area of ​​the nonwoven fabric. In particular, embodiments of the present invention provide improved abrasion resistance while having a lower percentage of the bonded area compared to similar nonwoven fabrics.

[0167] The surface area of ​​each individual bonding point 14 according to the embodiments shown in Figures 3A to 3C is typically about 0.10 to 0.40 mm². 2 More typically, about 0.12 to 0.3 mm 2 Furthermore, typically about 0.15 to 0.25 mm 2 In a preferred embodiment, the surface area of ​​each of the individual bonding points is approximately 0.18 mm². 2 That is the case.

[0168] In one embodiment, the average surface area of ​​each individual bonding point 14 according to the embodiment shown in Figures 3A to 3C is greater than 0.1, greater than 0.11, greater than 0.12, greater than 0.13, greater than 0.14, greater than 0.15, greater than 0.16, greater than 0.17, greater than 0.17, greater than 0.18, greater than 0.19, greater than 0.20, greater than 0.21, greater than 0.22, greater than 0.23, greater than 0.24, greater than 0.25, greater than 0.26, greater than 0.27, greater than 0.28, greater than 0.29, and 0.30.

[0169] In one embodiment, the average surface area of ​​each individual bonding point 14 according to the embodiment shown in Figures 3A to 3C is less than 0.30, less than 0.29, less than 0.28, less than 0.27, less than 0.26, less than 0.25, less than 0.25, less than 0.23, less than 0.22, less than 0.21, less than 0.20, less than 0.19, less than 0.18, less than 0.17, less than 0.16, less than 0.15, less than 0.14, less than 0.13, less than 0.12, less than 0.11, and less than 0.10.

[0170] In one embodiment of the present invention, the number of individual adhesive points per square centimeter is about 45 to about 60, more particularly about 50 to about 58, and more particularly about 54 to about 56.

[0171] In some embodiments, the percentage of the adhesive area of ​​the nonwoven fabric is about 9 to about 10.5%, particularly about 9.5 to about 10.4%, and more particularly about 9.8 to about 10.2%. In preferred embodiments, the percentage of the adhesive area of ​​the nonwoven fabric is about 9.9 to about 10%.

[0172] Exemplary Embodiment B

[0173] Referring to Figure 6, an embodiment of the nonwoven fabric is shown and is broadly designated by reference numeral 10b. As in the embodiment shown in Figures 3A–3C, the nonwoven fabric 10b comprises a plurality of fibers point-bonded to one another at a plurality of individual bonding points 14 for forming an integrated web. The nonwoven fabric further comprises a surface 12 thereon which the plurality of individual bonding points 14 are included. The bonding points 14 are spaced apart from one another and are configured and arranged to define a plurality of arrays of the nonwoven fabric 10b extending in the machine direction (MD), transverse direction (CD), and oblique direction (DD). The nonwoven fabric 10b also further comprises a vertical axis (V) substantially aligned with the machine direction of the nonwoven fabric 10 and a horizontal axis (H) substantially aligned with the transverse direction of the nonwoven fabric 10.

[0174] Similar to the embodiments described above, the nonwoven fabric 10b further includes pairs (20) of alternating first arrays (reference number A1) and second arrays (reference number A2) extending laterally in the transverse direction of the nonwoven fabric; pairs (22) of alternating third arrays (reference number A3) and fourth arrays (reference number A4) extending longitudinally in the machine direction of the nonwoven fabric; and pairs (24) of alternating fifth arrays (reference number A5) and sixth arrays (reference number A6) extending obliquely across the surface of the nonwoven fabric with respect to the machine direction of the nonwoven fabric.

[0175] In the embodiment illustrated in Figure 6, the lengths (e.g., major axes) of the individual bonding points of the first array are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the first array and the horizontal axis H of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the horizontal axis H and the major axis of the individual bonding points of the first array is about 43 degrees to about 47 degrees, particularly about 44 degrees to about 46 degrees, and more particularly about 45 degrees.

[0176] In one embodiment, the individual bonding points of the first array have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0177] The lengths (e.g., major axes) of the individual bonding points of the second array are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the second array and the horizontal axis H of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the horizontal axis H and the major axis of the individual bonding points of the second array is about 43 degrees to about 47 degrees, particularly about 44 degrees to about 46 degrees, and more particularly about 45 degrees.

[0178] In one embodiment, the length (e.g., the major axis) of each individual bonding point of the second array is typically rotated by about 88 to 92 degrees, for example, about 89 to 91 degrees, and especially about 90 degrees, relative to the alignment of the lengths (e.g., the major axes) of each individual bonding point of the first array.

[0179] The intersection of the diagonally extending array (e.g., arrays A5, A6) and the horizontal axis H defines an angle a5. Generally, the angle a5 is about 28 to 36 degrees, particularly about 29 to 35 degrees, more particularly about 30 to 34 degrees, and even more particularly about 31 to 33 degrees. In a preferred embodiment, the angle a5 is about 32 degrees.

[0180] In the embodiment shown in Figure 6, the percentage of the adhesive surface area of ​​the nonwoven fabric is less than approximately 12%, and the average surface area of ​​each adhesive point is approximately 0.2 to approximately 0.6 square millimeters (mm²). 2 ) and the adhesive density is 1 square centimeter (cm 2 There are approximately 30 to 30 individual bonding points per unit.

[0181] In one embodiment, the percentage of the adhesive surface area of ​​the nonwoven fabric is approximately 10 to 10.5%, and the average surface area of ​​each adhesive point is approximately 0.35 to 0.45 mm². 2 The packing value at the bonding point is approximately 4.5 to 6.5 mm. -1 The adhesion point density is per square centimeter (cm²). 2 There are approximately 24 to 26 individual bonding points per unit.

[0182] In one embodiment, each bonding point has an average length of about 1.04 to about 1.14 mm, particularly about 1.06 to about 1.12 mm, and more particularly about 1.08 to about 1.10 mm. In a preferred embodiment, each bonding point has an average length of about 1.09 mm.

[0183] In one embodiment, each adhesive point has an average width of about 0.44 to about 0.50 mm, particularly about 0.45 to about 0.49 mm, and more particularly about 0.46 to about 0.48 mm. In a preferred embodiment, each adhesive point has an average width of about 0.47 mm.

[0184] In one embodiment, the average surface area of ​​each bonding point is approximately 0.3 to approximately 0.8 square millimeters (mm²). 2 ), especially about 0.35 to 0.7 mm 2 More specifically, approximately 0.38 to 0.5 mm 2 In some embodiments, the average surface area of ​​each bonding point is approximately 0.4 mm². 2 That is the case.

[0185] In some embodiments, the adhesion density (number of individual adhesion points per square centimeter) is approximately 20 to 30 adhesion points per square centimeter, particularly about 22 to 28, and more particularly 24 to 26.

[0186] The distance d7 between adjacent point bonding points in an array extending laterally within the same array (e.g., arrays A1, A2) is approximately 2.90 to 3.2 mm, particularly approximately 2.95 to 3.15 mm, more particularly approximately 3.0 to 3.12 mm, and even more particularly approximately 3.05 to 3.10 mm. In a preferred embodiment, the distance d7 between adjacent point bonding points in an array extending laterally is approximately 3.08 mm.

[0187] In the same array (e.g., arrays A3, A4), the distance d8 between adjacent point bonding points in the array in the machine direction is typically about 1.65 to about 1.85 mm, particularly about 1.70 to about 1.80 mm, and more typically about 1.72 to about 1.78 mm. In a preferred embodiment, the distance d8 between adjacent point bonding points in an array extending in the machine direction is about 1.75 mm.

[0188] In the diagonal direction within an array (e.g., arrays A5, A6), the distance d9 between adjacent point bonding points within the array is typically about 1.25 to 1.55 mm, particularly about 1.30 to 1.45 mm, and more typically about 1.34 to 1.44 mm. In a preferred embodiment, the distance d9 between adjacent point bonding points within an array extending in the machine direction is about 1.38 to 1.40 mm.

[0189] In one embodiment, the average cluster bonding point distance in the embodiment according to Figure 6 may be in the range of about 1.90 to about 2.25 mm. As previously stated, the average cluster bonding point distance is calculated from the average distance between bonding points in the machine direction, transverse direction, and diagonal direction of the nonwoven fabric. For example, the average cluster bonding point distance can be calculated from the average distances of d7, d8, and d9.

[0190] In one embodiment, the average distance between aggregated bonding points is approximately 1.95 to 2.20 mm, particularly approximately 2.05 to 2.15 mm, and more particularly approximately 2.06 to 2.12 mm, with an average distance of 2.07 to 2.08 mm being slightly more preferable.

[0191] In one embodiment according to the embodiment shown in Figure 6, the adhesive nonwoven fabric is approximately 4 to approximately 6.5 mm -1 For example, approximately 4.5 to 6 mm -1 , and 4.75~5.5mm -1 It has an average bonding point packing value of about 5.0 to about 5.25 mm. In a preferred embodiment, the adhesive nonwoven fabric has an average bonding point packing value of about 5.0 to about 5.25 mm. -1 It has an average bonding point packing value.

[0192] Exemplary Embodiment C

[0193] Additional embodiments of adhesive nonwoven fabrics according to at least one embodiment of the present disclosure are shown and designated by reference no. 10c.

[0194] As shown in the embodiment in Figure 1, the nonwoven fabric 10c comprises a plurality of fibers which are point-bonded to one another at a plurality of individual bonding points 72, 74 to form an integrated web. The nonwoven fabric further comprises a surface 70 thereon which the plurality of individual bonding points 72, 74 are included, collectively defining an adhesive pattern 78 on the surface of the nonwoven fabric 10c. The bonding points 14 are spaced apart from each other and are configured and arranged to define a plurality of arrays extending in the machine direction (MD), transverse direction (CD), and oblique direction (DD) of the nonwoven fabric 10c. The nonwoven fabric 10c also has a vertical axis (V) substantially aligned with the machine direction of the nonwoven fabric 10c and a horizontal axis (H) substantially aligned with the transverse direction of the nonwoven fabric 10c.

[0195] The embodiment in Figure 7B comprises a plurality of first array sets 76, each array of the first array set 76 containing a plurality of individual bonding points extending laterally in the transverse direction of the nonwoven fabric 10c. The first array set 76 includes four arrays (A10, A11, A12, A13), each array extending laterally in the transverse direction of the nonwoven fabric 10c and continuously spaced apart from one another in the machine direction of the nonwoven fabric 10c. That is, if array A10 is the first array of the first array set 76, then the next continuous array in the machine direction of the nonwoven fabric 10c is array A11, the next continuous array following array A11 is array A12, and finally, the next continuous array in the first array set 76 following array A12 is array A13. At this point, the pattern is repeated along the machine direction of the nonwoven fabric 10c.

[0196] In the illustrated embodiment, the array A10 includes a plurality of spaced-apart individual bonding points 72 having a generally oblong shape, e.g., oval to oval-elliptical shape. Additional variations of the oblong bonding points that may be used in embodiments of the present invention have already been described. The lengths (e.g., major axes) of the individual bonding points of the first array A10 are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points 72 of the first array and the horizontal axis H of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the horizontal axis H and the major axis of the individual bonding points of the first array A10 is about 26 to about 34 degrees, particularly about 28 to about 32 degrees, and more particularly 29 to 31 degrees. In a slightly more preferred embodiment, the angle between the horizontal axis H and the major axis of each bonding point of the first array A10 is approximately 30 degrees.

[0197] In one embodiment, the individual bonding points 72 of array A10 have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0198] Following array A10 is array A11. Array A11 includes a plurality of spaced-apart individual bonding points 72, which are generally oblong in shape, e.g., oval to elliptical. Similar to array A10, the lengths (e.g., major axes) of the individual bonding points in array A11 are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. In one embodiment, the angle at the intersection of the horizontal axis H and the major axes of the individual bonding points 74 of array A11 is about 26 to about 34 degrees, particularly about 28 to about 32 degrees, and more particularly 29 to 31 degrees. In a slightly more preferred embodiment, the angle at the intersection of the horizontal axis H and the major axes of the individual bonding points of the first array A11 is about 30 degrees.

[0199] However, in array A11, the alignment of the lengths (e.g., major axes) of the individual adhesive points of array A11 is rotated in the opposite direction to the alignment of array A10 with respect to the vertical axis of the nonwoven fabric. In particular, the lengths (e.g., major axes) of the individual adhesive points 72 of array A11 are typically rotated by about 85 to 95 degrees, for example, about 88 to 92 degrees, and especially about 88 to 92 degrees, with respect to the alignment of the lengths (e.g., major axes) of the individual adhesive points of array A10.

[0200] Array A12 continues from array A11 in the machine direction of the nonwoven fabric 10c. The configuration and arrangement of the bonding points of array A12 are substantially the same as those of array A10. That is, the lengths (e.g., the long axes) of the bonding points 72 of arrays A10 and A12 are substantially aligned in the same direction with respect to the horizontal axis of the nonwoven fabric 10c. Furthermore, adjacent bonding points in arrays A10 and A12 are substantially aligned in the machine direction of the nonwoven fabric 10c.

[0201] Furthermore, it can be seen that the positions of individual bonding points within array A11 are shifted laterally from adjacent bonding points within arrays A10 and A12. In other words, the bonding points of array A11 are not aligned in the mechanical direction with the bonding points of arrays A10 and A12.

[0202] The average distance d10 between adjacent bonding points 74 within the same array A10 may be in the range of 2.2 to 2.6 mm, particularly 2.3 to 2.55 mm, and more particularly about 2.45 to about 2.50 mm. Similarly, the average distance d12 between adjacent bonding points 74 within the same array A12 may be in the range of 2.3 to 2.6 mm, particularly 2.3 to 2.55 mm, and more particularly about 2.45 to about 2.50 mm. The average distance d11 between adjacent bonding points 74 within the same array A11 may be in the range of 2.2 to 2.6 mm, particularly 2.3 to 2.55 mm, and more particularly about 2.45 to about 2.50 mm.

[0203] The array A13 comprises a plurality of circular / square adhesive points 74 extending laterally in the 10c transverse direction of the nonwoven fabric. Typically, the adhesive points 74 have a length-to-width ratio of about 0.9:about 1.1 to about 1:about 1.

[0204] In one embodiment, the individual bonding points 74 of array A13 are substantially aligned in the mechanical direction with adjacent bonding points 74 in array A11.

[0205] The average distance d13 between adjacent bonding points 74 within the same array A13 may be in the range of 2.45 to 2.75 mm, particularly 2.50 to 2.70 mm, and more particularly about 2.55 to about 2.65 mm, with a distance of about 2.58 to about 2.62 mm being slightly more preferred.

[0206] The average distance d14 between adjacent adhesive points in the diagonal direction of the nonwoven fabric may be in the range of about 1.20 to about 1.50 mm, particularly about 1.25 to about 1.45 mm, and more particularly about 1.30 to about 1.40 mm. In a preferred embodiment, the average distance d14 is about 1.32 to about 1.36 mm.

[0207] Referring to Figure 7C, the bonding pattern 78 may further include a second array set 80 having pairs of alternating arrays extending longitudinally in the machine direction of the nonwoven fabric 10c. The second array set 80 has pairs of alternating arrays A14 and A15 that extend in the machine direction of the nonwoven fabric and are spaced apart from each other in the transverse direction. Each array includes a plurality of spaced-apart individual bonding points 72, 74.

[0208] Array A14 includes a plurality of bond points 72 that are generally oval-shaped, such as oval to elliptical bond points. Other variations of oval-shaped bond points have already been described. In some embodiments, and as shown in Figure 7C, the oval-shaped bond points 72 of array A14 are aligned substantially in the same direction with respect to the machine direction of the nonwoven fabric. In some embodiments, the angle between the intersection of the horizontal axis H and the major axis of each bond point of array A14 is about 26 to about 34 degrees, particularly about 28 to about 32 degrees, and more particularly 29 to 31 degrees. In a somewhat more preferred embodiment, the angle between the intersection of the horizontal axis H and the major axis of each bond point of the first array A14 is about 30 degrees.

[0209] Array A15 includes a repeating pattern of multiple oval-shaped bonding points 72, for example, multiple oval to elliptical bonding points, the repeating pattern being preceded and continued by circular / square / rhombic bonding points 74. In this way, all other bonding points in the array are oval-shaped, and all other bonding points are circular / square-shaped.

[0210] Similar to array A14, the lengths (e.g., major axes) of the individual oval-shaped bonding points of array A15 are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. In one embodiment, the angle at the intersection of the horizontal axis H and the major axes of the individual bonding points 74 of array A15 is about 26 to 34 degrees, particularly about 28 to 32 degrees, and more particularly 29 to 31 degrees. In a slightly more preferred embodiment, the angle at the intersection of the horizontal axis H and the major axes of the individual bonding points of the first array A15 is about 30 degrees.

[0211] However, in array A15, the alignment of the lengths (e.g., major axes) of the individual adhesive points of array A15 is rotated in the opposite direction to the alignment of array A14 with respect to the vertical axis of the nonwoven fabric. In particular, the lengths (e.g., major axes) of the individual adhesive points 72 of array A11 are typically rotated by about 85 to 95 degrees, for example, about 88 to 92 degrees, and especially about 88 to 92 degrees, with respect to the alignment of the lengths (e.g., major axes) of the individual adhesive points of array A14.

[0212] The average distance d15 between adjacent bonding points 74, 72 within the same array of array A15 may be in the range of 1.30 to 1.48 mm, particularly 1.34 to 1.44 mm, with the average distance d15 being in the range of approximately 1.36 to approximately 1.40 mm. Similarly, the average distance d16 between adjacent bonding points 74 within the same array of array A14 may be in the range of 1.30 to 1.48 mm, particularly 1.34 to 1.44 mm, with the average distance d16 being in the range of approximately 1.36 to approximately 1.40 mm.

[0213] Referring to Figure 7D, the bonding pattern 78 further has pairs of alternating arrays extending diagonally with respect to the horizontal and vertical axes of the nonwoven fabric 10c. The third array set 82 has pairs of alternating arrays A16 and A17 extending diagonally across the nonwoven fabric and spaced apart from each other in the machine direction. Each array includes a plurality of spaced-apart individual bonding points 72, 74.

[0214] Array A16 has a repeating pattern of three oval-shaped adhesive points 72 and circular / square-shaped adhesive points 74. In particular, array A16 has a first adhesive point 72a whose major axis is aligned in the same direction as the adhesive point 72 of A10. This is followed by a second adhesive point 72b, whose major axis is aligned in the same direction as the adhesive point 72 of array A11. Following array A11 is a third adhesive point 74c with the same alignment as the first adhesive point 72a. Finally, a circular / square-shaped adhesive point 74a follows the third adhesive point 72c.

[0215] The intersection of the diagonally extending array (e.g., arrays A16, A17) and the horizontal axis H defines an angle a6. Generally, the angle a6 is about 26 to 34 degrees, particularly about 27 to 33 degrees, more particularly about 28 to 32 degrees, and even more particularly about 29 to 31 degrees. In a preferred embodiment, the angle a6 is about 30 degrees.

[0216] In one embodiment, the average aggregate bonding point distance in the embodiment according to Figures 7A to 7D may be in the range of approximately 1.65 to approximately 1.85 mm. As previously stated, the average bonding point distance is calculated from the average distance between bonding points in the machine direction, transverse direction, and diagonal direction of the nonwoven fabric. For example, the aggregate average bonding distance can be calculated from the average distance of d10 to d16.

[0217] In some embodiments, the adhesion density (number of individual adhesion points per square centimeter) is approximately 28 to 38 adhesion points per square centimeter, particularly 30 to 36, and more particularly 32 to 34.

[0218] In one embodiment, the average cluster adhesion point distance is in the range of approximately 1.70 to approximately 1.82 mm, particularly approximately 1.72 to approximately 1.80 mm, and more particularly approximately 1.74 to approximately 1.75 mm, with an average distance of 1.75 mm being slightly more preferred.

[0219] In one embodiment according to the embodiments shown in Figures 7A to 7D, the adhesive nonwoven fabric is approximately 4.0 to approximately 6.5 mm thick. -1 For example, approximately 4.5 to 5.75 mm -1 , and approximately 4.75 to 5.5 mm -1 It has an average bonding point packing value of about 5.0 to about 5.25 mm. In a preferred embodiment, the adhesive nonwoven fabric has an average bonding point packing value of about 5.0 to about 5.25 mm. -1 It has an average bonding point packing value.

[0220] In one embodiment, the percentage of the adhesive surface area of ​​the nonwoven fabric according to Figures 7A to 7D is approximately 11 to 12%, and the average surface area of ​​each adhesive point is approximately 0.25 to 0.5 mm². 2The packing value at the bonding point is approximately 4.5 to 5.5 mm. -1 The adhesion point density is per square centimeter (cm²). 2 There are approximately 28 to 38 individual bonding points per unit.

[0221] In one embodiment, the percentage of the adhesive surface area of ​​the nonwoven fabric according to Figures 7A to 7D is approximately 11.4 to 11.6%, and the average surface area of ​​each adhesive point is approximately 0.3 to 0.4 mm². 2 The packing value at the bonding point is approximately 5.05 to 5.15 mm. -1 The adhesion point density is per square centimeter (cm²). 2 There are approximately 32 to 34 individual bonding points per unit.

[0222] Exemplary Embodiment D

[0223] Referring to Figures 8A to 8C, further embodiments of the adhesive nonwoven fabric are shown and are broadly specified by reference numeral 10d. The nonwoven fabric 10d comprises a plurality of fibers point-bonded to one another at a plurality of individual bonding points 14 for forming an integrated web. The nonwoven fabric has a horizontal axis "H" aligned substantially in the transverse direction "CD" of the nonwoven fabric and a vertical axis "V" aligned substantially in the mechanical direction "MD" of the nonwoven fabric.

[0224] With respect to a nonwoven fabric according to a certain embodiment, the inventors of this disclosure have found that improvements in both abrasion resistance and flexibility can be obtained by a nonwoven fabric thermally spot-bonded with an adhesive pattern according to one or more embodiments of the present invention. In particular, an adhesive nonwoven fabric having a first adhesive pattern comprising a plurality of alternating arrays of individual adhesive points in both the mechanical and transverse directions of the nonwoven fabric, wherein the overall percentage of the adhesive surface area of ​​the nonwoven fabric is less than 14%, and the surface area of ​​the individual adhesive points is about 0.10 to 0.60 square millimeters (mm²). 2 ) and the packing value at the bonding point is approximately 2.0 m- 1 It is extremely large, for example, 3-5 mm -1 , and adhesive density per square centimeter (cm 2It has been found that a nonwoven fabric with approximately 20 to 60 individual bonding points per surface area provides a nonwoven fabric that has improved flexibility and abrasion resistance compared to similar nonwoven fabrics with a larger percentage of bonding surface area.

[0225] In the embodiments shown in Figures 8A to 8C, the overall percentage of the adhesive surface area of ​​the nonwoven fabric is less than approximately 14%, and the surface area of ​​individual adhesive points is approximately 0.2 to approximately 0.60 square millimeters (mm²). 2 The packing value at the bonding point is approximately 2 to 6 mm. -1 The adhesive density is per square centimeter (cm²). 2 There are approximately 28 to 40 individual bonding points per unit.

[0226] The plurality of individual bonding points 14 define a first pattern 90 on the surface 12 of the nonwoven fabric 10d. As shown in Figure 8A, the first pattern 90 includes a series of alternating first arrays A18 and second arrays A19 of individual bonding points 14 extending transversely across the nonwoven fabric 10d, the arrays arranged in array pairs 92a. In one embodiment, the individual bonding points 14 defining the second array of the first pattern are laterally offset from adjacent bonding points of the first array. That is, adjacent bonding points of the first and second arrays are not aligned with each other in the machine direction of the nonwoven fabric. This configuration and arrangement is shown in Figure 8A, where the vertical axis V extends only through the bonding points of the second array and not through the bonding points of the first array. In the embodiment shown in Figure 8A, the first array A18 and the second array A19 are substantially aligned with the transverse direction of the nonwoven fabric 10d.

[0227] In a preferred embodiment, the individual bonding points of the first array do not overlap with the individual bonding points of the second array in the machine direction. However, it should be recognized that in some embodiments, the individual bonding points of the first and second arrays may overlap with the bonding points of adjacent arrays in the machine direction.

[0228] In one embodiment, the percentage of the adhesive surface area of ​​the nonwoven fabric is approximately 13-14%, and the average surface area of ​​each adhesive point is approximately 0.44-0.50 mm². 2 The packing value at the bonding point is approximately 3 to 5 mm. -1 The adhesion point density is per square centimeter (cm²). 2 There are approximately 30 to 35 individual bonding points per unit.

[0229] In one embodiment, each bonding point has an average length of about 1.04 to about 1.14 mm, particularly about 1.06 to about 1.12 mm, and more particularly about 1.08 to about 1.10 mm. In a preferred embodiment, each bonding point has an average length of about 1.09 mm.

[0230] In one embodiment, each adhesive point has an average width of about 0.44 to about 0.50 mm, particularly about 0.45 to about 0.49 mm, and more particularly about 0.46 to about 0.48 mm. In a preferred embodiment, each adhesive point has an average width of about 0.47 mm.

[0231] In one embodiment, the average surface area of ​​each bonding point is approximately 0.3 to approximately 0.8 square millimeters (mm²). 2 ), especially about 0.35 to 0.7 mm 2 More specifically, approximately 0.38 to 0.5 mm 2 In some embodiments, the average surface area of ​​each bonding point is approximately 0.4 mm². 2 That is the case.

[0232] Referring again to Figure 8A, the lengths (e.g., major axes) of the individual bonding points of the first array are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. That is, the intersection of the major axes of the individual bonding points of the first array (see reference no. 30 in Figure 2A) and the vertical axis V of the nonwoven fabric defines an angle a8 greater than 45 degrees and less than 55 degrees. In one embodiment, the angle between the intersection of the vertical axis V and the major axes of the individual bonding points of array A18 is about 48 to about 53 degrees, particularly about 49 to about 51 degrees, and more particularly about 50 degrees.

[0233] In one embodiment, the individual bonding points of the first array have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0234] The lengths of the individual bonding points of the second array are typically aligned at an oblique angle with respect to the machine direction of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the second array and the horizontal axis H of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the horizontal axis H and the major axis of the individual bonding points of the second array A19 is about 43 degrees to about 47 degrees, particularly about 44 degrees to about 46 degrees, and more particularly about 45 degrees.

[0235] In one embodiment, the length (e.g., the major axis) of each individual bonding point of the second array is typically rotated by about 88 to 92 degrees, for example, about 89 to 91 degrees, and especially about 90 degrees, relative to the alignment of the lengths (e.g., the major axes) of each individual bonding point of the first array.

[0236] In a preferred embodiment, the intersection of a line segment extending along the major axis of each bonding point of the first array and a line segment extending along the major axis of each bonding point of the second array defines an angle of about 90 degrees.

[0237] In one embodiment, the individual bonding points of the second array have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0238] Referring to Figure 8B, the first pattern 90 of the bonding points further includes a series of alternating third and fourth arrays A20, A21 of individual bonding points 14 extending in the machine direction of the nonwoven fabric 10, the arrays arranged in array pair 92b. In the embodiment shown in Figure 8B, the third array A20 and the fourth array A21 are substantially aligned with the machine direction of the nonwoven fabric 10d. Similar to the first array A18 and the second array A19, the individual bonding points 14 defining the fourth array of the first pattern are offset in the machine direction with respect to adjacent bonding points of the third array. That is, adjacent bonding points of the third array and the fourth array are not aligned with each other in the machine direction of the nonwoven fabric.

[0239] In one embodiment, the lengths of the individual bonding points of the third array A20 are typically aligned at an oblique angle with respect to the vertical axis of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the third array and the vertical axis V of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the horizontal axis V and the major axis of the individual bonding points of the third array A20 is about 43 to about 47 degrees, particularly about 44 to about 46 degrees, and more particularly about 45 degrees.

[0240] In one embodiment, the individual bonding points of the third array A3 have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0241] Similarly, the lengths of the individual bonding points of the fourth array A21 are typically aligned at an oblique angle with respect to the vertical axis of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the fourth array and the vertical axis V of the nonwoven fabric defines an angle greater than 0 degrees and less than 90 degrees. In one embodiment, the angle between the intersection of the vertical axis V and the major axis of the individual bonding points of the fourth array A21 is about 43 degrees to about 47 degrees, particularly about 44 degrees to about 46 degrees, and more particularly about 45 degrees.

[0242] In one embodiment, the length (e.g., the major axis) of each of the fourth arrays is typically rotated by about 88 to 92 degrees, for example, about 89 to 91 degrees, and especially about 90 degrees, relative to the alignment of the lengths (e.g., the major axes) of each of the third arrays.

[0243] In a preferred embodiment, the intersection of the major axis line segment of each bonding point of the third array and the major axis line segment of each bonding point of the fourth array defines an angle of approximately 90 degrees.

[0244] In one embodiment, the individual bonding points of the fourth array have lengths (e.g., major axes) that are aligned with each other in substantially the same direction.

[0245] Referring next to Figure 8C, the first pattern 90 of the bonding points further includes a series of alternating fifth arrays A22 and sixth arrays A23, the arrays extending obliquely across the surface of the nonwoven fabric with respect to the machine direction of the nonwoven fabric. The fifth array A5 and the sixth array A6 are arranged in array pair 92c. As shown in Figure 3C, the intersection of the fifth array or the sixth array with the horizontal axis H defines an angle a9. Generally, the angle a9 is about 25 to about 35 degrees, particularly about 27 to about 33 degrees, more particularly about 28 to about 32 degrees, and even more particularly about 29 to about 31 degrees. In a preferred embodiment, the angle a9 is about 30 degrees.

[0246] Similarly, the intersections of the fifth and sixth arrays with the vertical axis V define an angle a10. Generally, the angle a10 is about 55 to 65 degrees, particularly about 56 to 34 degrees, more particularly about 58 to 62 degrees, and even more particularly about 59 to 61 degrees. In a preferred embodiment, the angle a10 is about 60 degrees.

[0247] As shown in Figure 8C, each consecutive bond point of the fifth and sixth arrays is rotated by approximately 90 degrees with respect to the preceding bond point of the same array. In this regard, the lengths of bond points 14a and 14c are aligned substantially in the same direction with respect to the horizontal axis H of the nonwoven fabric 10a, and the lengths of bond points 14b and 14d are rotated by approximately 90 degrees with respect to the lengths of bond points 14a and 14c. In this way, the major axis of each consecutive bond point of the same array is substantially perpendicular to the major axis of the preceding or consecutive bond point of the same array.

[0248] Continuing to refer to Figure 8C, the distance d16 between adjacent bonding points within the same array in the lateral direction of the first and second arrays may be in the range of about 2.3 to about 2.7 mm, particularly about 2.4 to about 2.6 mm, and more particularly about 2.48 to about 2.52 mm. In a preferred embodiment, the distance d16 between adjacent bonding points in the lateral direction of the first and second arrays is about 2.5 mm.

[0249] In one embodiment, the distance d17 between adjacent bonding points within the same array of the third and fourth arrays in the machine direction may be in the range of about 1.20 to about 1.40 mm, particularly about 1.25 to about 1.35 mm, and more particularly about 1.28 to about 1.32 mm. In a preferred embodiment, the distance d17 between adjacent bonding points within the same array of the third and fourth arrays in the machine direction is about 1.3 mm.

[0250] In one embodiment, the average distance d18 between adjacent bonding points within the same array of the fifth array and the sixth array (diagonal array) may be in the range of about 0.80 to about 1.2 mm, particularly about 0.9 to about 1.1 mm, and more particularly about 0.95 to about 1.05 mm. In a preferred embodiment, the distance d18 between adjacent bonding points within the same array of the fifth array and the sixth array is about 0.98 to about 1.02 mm.

[0251] Similarly, with respect to arrays (not specified by reference number) that are rotated approximately 90 degrees relative to the fifth and sixth arrays and aligned obliquely, the distance d18 between adjacent bonding points within the same array may be in the range of about 0.80 to about 1.2 mm, particularly about 0.9 to about 1.1 mm, and more particularly about 0.95 to about 1.05 mm. In a preferred embodiment, the distance d18 between adjacent bonding points within the same array of the fifth and sixth arrays is about 0.98 to about 1.02 mm.

[0252] In one embodiment, the average joint adhesion distance in the embodiment according to Figures 8A to 8C may be in the range of approximately 1.4 to approximately 1.8 mm. As previously stated, the average joint adhesion distance is calculated from the average distance between adhesion points in the machine direction, transverse direction, and diagonal direction of the nonwoven fabric. For example, the average joint adhesion distance can be calculated from the average distances of d16, d17, and d18.

[0253] In one embodiment, the average cluster adhesion point distance is approximately 1.45 to 1.75 mm, particularly approximately 1.5 to 1.7 mm, and more particularly approximately 1.55 to 1.65 mm, with an average distance of 1.58 to 1.62 mm being slightly more preferable.

[0254] In one embodiment according to the embodiments shown in Figures 8A to 8C, the adhesive nonwoven fabric is approximately 2 to approximately 6 mm thick. -1 For example, approximately 2.5 to 5.5 mm -1 , and approximately 3.0 to 5.0 mm -1 It has an average bonding point packing value of about 3.75 to about 4.25 mm. In a preferred embodiment, the adhesive nonwoven fabric has an average bonding point packing value of about 3.75 to about 4.25 mm. -1 It has an average bonding point packing value.

[0255] More specifically, in one embodiment according to the embodiments shown in Figures 8A to 8C, the adhesive nonwoven fabric is 2.0 mm -1 Super, 2.1mm -1 Super, 2.2mm -1 Super, 2.3mm -1 Super, 2.4mm -1 Super, 2.5mm -1 Super, 2.6mm -1Super, 2.7mm -1 Super, 2.8mm -1 Super, 2.9mm -1 Super, 3.0mm -1 Super, 3.1mm -1 Super, 3.2mm -1 Super, 3.3mm -1 Super, 3.4mm -1 Super, 3.5mm -1 Super, 3.6mm -1 Super, 3.7mm -1 Super, 3.8mm -1 Super, 3.9mm -1 Super, 4.0mm -1 Super, 4.1mm -1 Super, 4.2mm -1 Super, 4.3mm -1 Super, 4.4mm -1 Super, 4.5mm -1 Super, 4.6mm -1 Super, 4.7mm -1 Super, 4.8mm -1 Super, 4.9mm -1 Super, 5.0mm -1 Super, 5.1mm -1 Super, 5.2mm -1 Super, 5.3mm -1 Super, 5.4mm -1 Super, 5.5mm -1 Super, 5.6mm -1 Super, 5.7mm -1 Super, 5.8mm -1 Super, 5.9mm -1 Ultra, and 6.0mm -1 It has an average adhesion point packing value exceeding that of the above.

[0256] In one embodiment, according to the embodiments shown in Figures 8A to 8C, the adhesive nonwoven fabric is 6.0 mm -1 Less than 5.9mm -1 Less than 5.8mm -1 Less than 5.7mm -1 Less than 5.6mm -1 Less than 5.5mm -1 Less than 5.4mm -1 Less than 5.3mm -1 Less than 5.2mm -1 Less than 5.1 mm -1 Less than 5.0 mm-1 Less than 4.9mm -1 Less than 4.8mm -1 Less than 4.7mm -1 Less than 4.6mm -1 Less than 4.5mm -1 Less than 4.4mm -1 Less than 4.3mm -1 Less than 4.2mm -1 Less than 4.1 mm -1 Less than 4.0 mm -1 Less than 3.9mm -1 Less than 3.8mm -1 Less than 3.7mm -1 Less than 3.6mm -1 Less than 3.5mm -1 Less than 3.4mm -1 Less than 3.3mm -1 Less than 3.2mm -1 Less than 3.1 mm -1 Less than 3.0 mm -1 Less than 2.9mm -1 Less than 2.8mm -1 Less than 2.7mm -1 Less than 2.6mm -1 Less than 2.5mm -1 Less than 2.4mm -1 Less than 2.3mm -1 Less than 2.2mm -1 Less than 2.1 mm -1 Less than and 2.0 mm -1 It has an average bonding point packing value.

[0257] In one embodiment, the array extending laterally from the nonwoven fabric 10d does not have to be parallel to the horizontal axis H of the nonwoven fabric. As previously stated with reference to Figure 4, the array of individual bonding points in the later direction does not have to be aligned with the horizontal axis of the nonwoven fabric. As shown in Figure 4, array A7 defines an array in which the individual bonding points 14 extend laterally from the nonwoven fabric at an angle greater than 0 degrees with respect to the horizontal axis. In particular, the intersection of the array (A7 in Figure 4) and the horizontal axis defines an angle a3 which may be greater than 0 degrees and less than 6 degrees. In a preferred embodiment, the angle a3 is about 0.5 degrees to about 4 degrees, particularly about 1 degree to about 3 degrees, and an angle of about 2 degrees is preferred.

[0258] As shown in the embodiments in Figures 3A to 3C, the first pattern defines a plurality of second patterns within the first pattern. Referring again to Figures 5A and 5B, the nonwoven fabric 10d may have a second pattern 40 which includes individual bonding points that collectively define a five-eye-shaped bonding pattern. As shown in Figures 5A and 5B, three adjacent arrays of individual bonding points (e.g., A18, A19, A18) further define multiple bonding patterns having a fifth-eye pattern in both the machine direction and the transverse direction, where four individual bonding points (40a, 40b, 40c, 40d) defining the corners of the fifth-eye pattern 40 share substantially the same orientation direction with respect to the transverse or machine direction of the nonwoven fabric, where the individual bonding point 44 defining the center point of the fifth-eye pattern has an orientation direction rotated by about 88 to about 92 degrees (e.g., about 88 to about 91 degrees, especially 90 degrees) with respect to the orientation direction of the individual bonding point defining the corners of the fifth-eye pattern. Details of the fifth-eye pattern have already been described.

[0259] As described above, the inventors of this disclosure have surprisingly found that the nonwoven fabric exhibits improved abrasion resistance compared to similarly prepared nonwoven fabrics, with a higher percentage of oval bond in the bonding area. In particular, embodiments of the present invention provide improved abrasion resistance while having a lower percentage of bonding area compared to similar nonwoven fabrics.

[0260] The surface area of ​​each individual bonding point 14 according to the embodiments shown in Figures 8A to 8C is typically about 0.2 to about 0.60 mm². 2 More typically, about 0.3 to 0.5 mm 2 Furthermore, typically about 0.35 to 0.45 mm 2 In a preferred embodiment, the surface area of ​​each of the individual bonding points is approximately 0.4 mm². 2 That is the case.

[0261] In one embodiment, the average surface area of ​​each individual bonding point 14 according to the embodiment shown in Figures 8A to 8C is 0.2 mm². 2 Super, 0.21mm 2 Super, 0.22mm 2 Super, 0.23mm 2 Super, 0.24mm 2 Super, 0.25mm 2 Super, 0.26mm 2 Super, 0.27mm 2 Super, 0.28mm 2 Super, 0.29mm 2 Super, 0.30mm 2 Super, 0.31mm 2 Super, 0.32mm 2 Super, 0.33mm 2 Super, 0.34mm 2 Super, 0.35mm 2 Super, 0.36mm 2 Super, 0.37mm 2 Super, 0.38mm 2 Super, 0.39mm 2 Super, 0.40mm 2 Super, 0.41mm 2 Ultra, 0.42mm 2 Super, 0.43mm 2 Super, 0.44mm 2 Ultra, 0.45mm 2 Super, 0.46mm 2 Super, 0.47mm 2 Super, 0.48mm 2 Ultra-thin, 0.49mm 2 Super, 0.50mm 2 Super, 0.51mm 2 Super, 0.52mm 2 Super, 0.53mm 2 Super, 0.54mm 2 Super, 0.55mm 2 Super, 0.56mm 2 Super, 0.57mm 2 Super, 0.58mm 2 Super, 0.59mm 2 Ultra, and 0.60mm 2 That is the case.

[0262] In one embodiment, the average surface area of ​​each of the individual bonding points 14 according to the embodiment shown in Figures 8A to 8C is 0.60 mm². 2 Less than 0.59 mm 2 Less than 0.58 mm 2 Less than 0.57 mm 2 Less than 0.56 mm 2 Less than 0.55 mm 2 Less than 0.54 mm 2 Less than 0.53 mm 2 Less than 0.52 mm 2 Less than 0.51 mm 2 Less than 0.50 mm 2 Less than 0.49 mm 2 Less than 0.48 mm 2 Less than 0.47 mm 2 Less than 0.46 mm 2 Less than 0.45 mm 2 Less than 0.44 mm 2 Less than 0.43mm 2 Less than 0.42 mm 2 Less than 0.41 mm 2 Less than 0.40 mm 2 Less than 0.39 mm 2 Less than 0.38 mm 2 Less than 0.37 mm 2 Less than 0.36 mm 2 Less than 0.35 mm 2 Less than 0.34 mm 2 Less than 0.33mm 2 Less than 0.32 mm 2 Less than 0.31 mm 2 Less than 0.30 mm 2 Less than 0.29 mm 2 Less than 0.28 mm 2 Less than 0.27 mm 2 Less than 0.26 mm 2 Less than 0.25 mm 2 Less than 0.24 mm 2 Less than 0.23mm 2 Less than 0.22 mm 2 Less than 0.21 mm 2 Less than and 0.20 mm 2 That is the case.

[0263] In one embodiment of the present invention, the number of individual adhesive points per square centimeter is about 30 to about 36, more particularly about 32.5 to 34.5, and more particularly 33 to 34.

[0264] In some embodiments, the percentage of adhesive surface area of ​​the nonwoven fabric 10d is about 13 to about 14%, particularly about 13.1 to about 13.9%, and more particularly about 13.2 to about 13.8%. In a preferred embodiment, the percentage of adhesive surface area of ​​the nonwoven fabric is about 13.3 to about 13.5%.

[0265] The bonding patterns described herein may be used to heat-bond a wide variety of different nonwoven fabric structures.

[0266] In one embodiment, the disclosure provides a spunbond nonwoven fabric comprising a plurality of fibers heat-bonded to each other to form an integrated web.

[0267] On the other hand, while the present invention generally describes spunbond fabrics prepared from continuous filaments, it should be recognized that other nonwoven fabrics and fibers, such as meltblown fibers and meltblown fabrics, stapled fibers and carded fabrics, wet-laid fabrics, resin-bonded fabrics, and air-laid fabrics, as well as combinations thereof, can also be prepared according to embodiments of the present invention.

[0268] In one embodiment, the fibers of the nonwoven fabric may include single-component fibers, multi-component fibers, or a combination thereof.

[0269] In one embodiment, the fibers of the nonwoven fabric include multi-component fibers that may contain at least two polymer components arranged in structural domains across the cross-section of the fiber. As is generally known to those skilled in the art, the polymer domains or components are located in zones substantially continuously positioned across the cross-section of the multi-component fiber and extend continuously along the length of the multi-component fiber. A multi-component fiber may contain two or more components.

[0270] A preferred configuration is a parallel arrangement, where a first polymer component defines a first continuous, distinct zone extending along the length of the fiber, and a second polymer component defines a second continuous, distinct zone extending along the length of the fiber. Both the first and second polymer components define at least a portion of the outer surface of the continuous fiber. In some embodiments, the first and second distinct zones of the parallel continuous fiber exist in a ratio ranging from 10:90 to 90:10, particularly about 40:60 to 60:40, and more particularly about 50:50. The parallel configuration is particularly useful for the preparation of crimped fibers. Other configurations that may be useful for the preparation of crimped fibers include eccentric sheath / core and D-eccentric sheath / core configurations.

[0271] Another preferred configuration is a sheath / core arrangement, where the first component, the sheath, substantially surrounds the second component, the core. The resulting two-component fiber sheath / core configuration may have a circular or non-circular cross-section. Other structured fiber configurations known in the art, including segmented pie, island-in-the-sea, and tipped multilobal, can also be used.

[0272] In one embodiment, the fiber is two-component, with a first polymer component defining the sheath of the fiber and a second polymer component defining the core of the fiber. Generally, the weight percentage of the sheath to the weight percentage of the core in the fiber can vary considerably depending on the desired properties of the nonwoven fabric. For example, the weight ratio of the sheath to the core can vary from about 5:95 to about 95:5, for example, about 10:about 90 to about 90:about 10, and especially about 20:about 80 to about 80:about 20. In a preferred embodiment, the weight ratio of the sheath to the core is about 25:about 75 to about 35:about 65, with a preferred weight ratio of about 30:about 70 to about 50:about 50.

[0273] A preferred sheath / core two-component fiber used in the fabric production of the present invention may have a higher melting point component as the core and a lower melting point component as the sheath. For example, an aliphatic polyester component may be used as the sheath, and the core may be a high-melting-point polymer component including polyolefin, such as polypropylene. Such a structure with an aliphatic polyester on the surface can lower the calender oil bonding temperature, and therefore save energy during the preparation of the nonwoven web.

[0274] A wide variety of polymers can be used in the preparation of nonwoven fabrics according to embodiments of this disclosure.

[0275] Nonwoven fabrics according to embodiments of the present invention can be prepared from a wide variety of different polymers and polymer blends. Examples of suitable polymers for preparing the fibers include, for example, polypropylene and polyethylene and their copolymers, polyesters such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and polybutylene terephthalate (PBT), nylon, polystyrene, polyurethane, copolymers, and blends thereof, as well as other synthetic polymers that may be used in the preparation of the fibers. In some embodiments, the polymers can be selected from the group consisting of: polyolefins, polyesters, polyethylene terephthalate, polybutylene terephthalate, polycyclohexylene dimethylene terephthalate, polytrimethylene terephthalate, polymethyl methacrylate, polyamides, nylons, polyacrylics, polystyrenes, polyvinyls, polytetrafluoroethylenes, ultra-high molecular weight polyethylenes, very high molecular weight polyethylenes, high molecular weight polyethylenes, polyether ether ketones, non-fibrous plasticized celluloses, polyethylenes, polypropylenes, polybutylenes, polymethylpentenes, low-density polyethylenes, linear low-density polyethylenes, high-density polyethylenes, polystyrenes, acrylonitrile-butadiene-styrenes, styrene-acrylonitriles, styrene triblock and styrene tetrablock copolymers, styrene-butadienes, styrene-maleic anhydride, ethylene vinyl acetate, ethylene vinyl alcohol, polyvinyl chlorides, cellulose acetate, cellulose butyrate, plasticized cellulose derivatives, cellulose propionate, ethylcellulose, natural fibers, their derivatives, their polymer blends, their copolymers, or combinations thereof.

[0276] In one embodiment, the polymer used for the fiber preferably includes polyolefins, such as polypropylene, polyethylene, blends of polypropylene and polyethylene, and combinations thereof.

[0277] A wide variety of polypropylenes may be used in embodiments of the present invention, typically having a molecular weight greater than about 120,000 g / mol, and more typically in the range of about 150,000 to about 300,000 g / mol. In one embodiment, the polypropylene has a molecular weight in the range of about 160,000 to about 250,000 g / mol, particularly in the range of about 160,000 to about 180,000 g / mol.

[0278] In one embodiment for preparing spunbond fibers, the polypropylene that may be used typically has an MFR of about 10 to about 100 g / 10 min, particularly about 20 to about 40 g / 10 min, with an MFR of about 22 to about 38 g / 10 min being somewhat more typical. Unless otherwise specified, the MFR is measured according to ASTM D-1238.

[0279] An example of such polypropylene is available from ExxonMobil, for example, PP3155 (36 MFR g / 10 min, density 0.90 g / cm³). 3 , and Mw 172 kg / mol); PP3155E5 (36 MFR g / 10 min, density 0.90 g / cm³) 3 , and Mw 172 kg / mol); and ACHIEVE 商標 3854 (24 MFR g / 10 min, density 0.90g / cm 3 ) may be included. SABIC 登録商標 Polypropylene available from, for example, SABIC PP 511A (25 MFR g / 10 min, 0.905 g / cm³). 3 Polypropylene available from Borealis, e.g., HG475FB (27 MFR g / 10 min), and polypropylene available from Braskem, e.g., CP360H (34 MFR g / 10 min), may also be used.

[0280] In one embodiment for preparing meltblown fibers, the polypropylene that can be used typically has an MFR greater than about 500 g / 10 min. For example, the polypropylene may have an MFR of about 500 to about 2500 g / 10 min, particularly about 1000 to about 1500 g / 10 min, with an MFR of about 1200 to about 1400 g / 10 min being somewhat more typical. An example of such polypropylene is available from Braskem, for example, H155 (MFR of 1284 g / 10 min).

[0281] In one embodiment, the fiber may include a multi-component fiber, for example, a binary fiber having a first polymer component and a second polymer component, wherein the second polymer component includes a blend of polyolefins, the blend having a first polyolefin in the blend having a low MFR, for example less than 100 g / 10 min, and the second polyolefin having a higher MFR than the first polyolefin, for example greater than 500 g / 10 min, particularly greater than 1,000 g / 10 min. Typically, the MFR of the blend is less than 50 g / 10 min, and the MFR ratio of the low-MFR polyolefin to the high-MFR polyolefin is 1:100, particularly 1:20 to 1:50. Typically, the amount of high-MFR in the blend is about 0.5 to 12% by weight, particularly about 2 to 8% by weight, based on the total weight of the blend, and more particularly about 3 to 6% by weight, based on the total weight of the blend.

[0282] In one such embodiment, the first polymer component comprises a polypropylene polymer having an MFR of about 20 to about 40 g / 10 min, and the second polymer component comprises a blend of low-MFR polypropylene having an MFR of about 20 to about 40 g / 10 min and high-MFR polypropylene having an MFR of about 1,100 to about 1,400 g / 10 min, wherein the amount of high-MFR polypropylene in the blend, based on the total weight of the blend, is about 3 to about 6% by weight. The polypropylene in the first polymer component may be the same as or different from the low-MFR polypropylene in the second polymer component. When such fibers are prepared in a parallel, eccentric, or D-center configuration, they can be used to prepare nonwoven fabrics containing crimped fibers.

[0283] In some embodiments, the polyolefin may include a polyethylene polymer. A wide variety of polyethylene polymers can be used in the fibers of the present invention. For example, high-density polyethylene, branched (e.g., non-linear) low-density polyethylene, or linear low-density polyethylene (LLDPE) can also be used. The polyethylene can be produced using any of the well-known processes, including metallocene catalysts or Ziegler-Natta catalyst systems. Generally, polyethylene polymers conventionally used in the production of spunbond fabrics may be suitable for use in the present invention.

[0284] In one embodiment of the present invention, the polyethylene component is approximately 0.90 to approximately 0.97 g / cm³ 3 It contains polyethylene having a density of (ASTM D-792). In particular, preferred polyethylene is 0.93 to 0.965 g / cm³. 3 More specifically, approximately 0.94 to 0.965 g / cm³ 3 It has a density value range of ,. A suitable example of polyethylene is one available from Dow Chemical Company, e.g., ASPUN 商標 6834 (Melt flow index of 17g / 10 min (ISO 1133) and 0.95g / cm³) 3Polyethylene polymer resin having a density (ASTM D-792), as well as HD 6908.19 (provided by ExxonMobil), with a melt flow index range of 7.5-9 g / 10 min (ISO 1133) and 0.9610-0.9680 g / cm³. 3 It contains a resin having a density (ASTM D-792).

[0285] LLDPE can also be used in several embodiments of the present invention. LLDPE is typically produced by a catalytic solution method or a fluidized bed method under conditions established in the art. The resulting polymer is characterized by an essentially linear skeleton. The density is controlled by the level of comonomers incorporated into the linear polymer skeleton. Various alpha-olefins are typically copolymerized with ethylene when producing LLDPE. Preferably, alpha-olefins having 4 to 8 carbon atoms are present in the polymer in amounts of up to about 10%. The most typical comonomers are butene, hexene, 4-methyl-1-pentene, and octene. Generally, LLDPE can be produced to obtain a variety of densities and melt index properties, making the polymer suitable for melt spinning with polypropylene. Preferably, the LLDPE has a melt index greater than 10, and more preferably 15 or greater in the case of spunbond filaments. Particularly preferred is 0.90 to 0.97 g / cm³. 3 This is an LLDPE polymer having a density and a melt flow index greater than 25. Examples of commercially available and suitable linear low-density polyethylene polymers include those available from Dow Chemical Company, e.g., ASPUN 商標 Type 6811 (MFR 27g / 10min, density 0.923g / cm 3 ), ASPUN 商標 Type 6834 (MFR 17g / 10min, density 0.95g / cm 3 ), ASPUN 商標 Type 6000 (MFR 30g / 10min, density 0.955g / cm 3 ), ASPUN 商標Type 6850 (MFR 30g / 10min, density 0.955g / cm 3 ), Dow LLDPE 2500 (MFR 55g / 10min, density 0.923g / cm 3 ), Dow LLDPE Type 6808A (MFR 36g / 10min, density 0.940g / cm 3 ), as well as linear low-density polyethylene polymers from Exxon Chemical Company's Exact series, such as Exact2003 (MFR 31 g / 10 min, density 0.921 g / cm³). 3 ), includes.

[0286] In some embodiments, the polymer may be stretchable and / or elastic.

[0287] In one embodiment, the nonwoven fabric comprises a blend of an olefin polymer and an elastomeric olefin copolymer.

[0288] For applications intended for the preparation of spunbond fabrics, the olefin polymer typically has an MFR of about 5 to about 150 g / 10 min, with an MFR of about 15 to about 50 g / 10 min, and more particularly about 20 to about 40 g / 10 min being somewhat preferred. The amount of the olefin polymer in the fiber is typically 75 to 95% by weight, and more particularly about 80 to about 95% by weight, based on the total weight of the fiber.

[0289] In addition, polypropylene, which can be used as the first polypropylene, may have an MFR of about 10 to about 100 g / 10 min, particularly about 20 to about 40 g / 10 min, with an MFR of about 22 to about 38 g / 10 min being somewhat more typical. Unless otherwise specified, the MFR is measured according to ASTM D-1238.

[0290] An example of such polypropylene is available from ExxonMobil, for example, PP3155 (36 MFR g / 10 min, density 0.90 g / cm³). 3, and Mw 172 kg / mol); PP3155E5 (36 MFR g / 10 min, density 0.90 g / cm³) 3 , and Mw 172 kg / mol); and ACHIEVE 商標 3854 (24 MFR g / 10 min, density 0.90g / cm 3 ) may include. SABIC 登録商標 Polypropylene available from, for example, SABIC PP 511A (25 MFR g / 10 min, density 0.905 g / cm³). 3 ), as well as polypropylene available from Borealis, such as HG475FB (27 MFR g / 10 min), may also be used.

[0291] In a preferred embodiment, the olefin polymer includes polypropylene. A wide variety of polypropylenes can be used as the olefin polymer in the fiber. Suitable polypropylenes can be produced using any of the well-known processes, including metallocene catalysts and Ziegler-Natta catalyst systems.

[0292] In one embodiment, the olefin copolymer comprises a propylene copolymer having at least two different types of monomer units, one of which is propylene. Preferred examples of monomer units include, for example, ethylene and higher α-olefins in the C4-C20 range, such as 1-butene, 4-methyl-1-pentene, 1-hexene, or 1-octene, and 1-decene, or mixtures thereof. Preferably, ethylene is copolymerized with propylene, and as a result, the propylene copolymer has propylene units (polymer chain units derived from propylene monomer) and ethylene units (polymer chain units derived from ethylene monomer).

[0293] The olefin copolymer is present as a trace component in the polypropylene blend. The amount of the olefin copolymer in the blend is typically 5 to 25% by weight, based on the total weight of the fibers, and particularly about 6 to 20% by weight, based on the total weight of the fibers. More particularly, the amount of the olefin copolymer in the blend is about 1 to about 25% by weight, based on the total weight of the blend. In particular, the amount of the olefin copolymer is about 2 to about 20% by weight, for example about 4 to about 16%, about 5 to about 15%, and about 6 to about 14% by weight, based on the total weight of the blend.

[0294] Typically, the units or comonomers of the propylene copolymer are derived from ethylene, or at least one of C4-10 alpha-olefins is present in an amount of 1%-35% or 5%-about 35% of the weight of the propylene-alpha-olefin copolymer. It may be present in an amount of % by weight, or 7-32% by weight, or 8-about 25% by weight, or 8-20% by weight, or even 8-18% by weight. In this way, the comonomer content is such that the propylene-α-olefin copolymer has an isothermal heat of fusion (DSC) of preferably 75,000 Gy (75 J / g) or less, a melting point of 100°C or less, and a crystallinity of 2%-about 65%. It has tactic polypropylene and can preferably be adjusted so that the melt flow rate is 0.5-90 dg / min.

[0295] In some embodiments, the propylene-α-olefin copolymer may consist of ethylene-derived units. The propylene-α-olefin copolymer may be 5% to 35%, or 5% to 20%, or 10% to 12%, or 15% to 20% of the weight of the propylene-α-olefin copolymer. It may have ethylene-derived units expressed in weight percent. In some embodiments, the propylene-α-olefin copolymer essentially consists of units derived from propylene and ethylene, i.e., the propylene-α-olefin copolymer is the ethylene and / or propylene used in polymerization.

[0296] In one embodiment, the propylene-α-olefin copolymer may have a triad tacticity (measured by 13C-NMR) of at least 75%, at least 80%, at least 82%, at least 85%, or at least 90% of three propylene units. The “triad tacticity” is quantified as follows: The tacticity ratio (denoted herein as “m / r”) is measured by 13C nuclear magnetic resonance (“NMR”). The tacticity ratio is m / rN. It is calculated by Cheng as defined in 17 MACROMOLECULES 1950 (1984) (incorporated herein by reference). The notation “m” or “r” represents the stereochemistry of adjacent propylene group pairs, where “m” represents meso and “r” represents racemic. A m / r ratio of 1.0 generally represents a syndiotactic polymer, while an m / r ratio of 2.0 generally represents an atactic material. Theoretically, isotactic materials have an m / r ratio approaching infinity, and many by-product atactic polymers have a sufficient isotactic content to produce m / r ratios exceeding 50.

[0297] A suitable example of a propylene-α-olefin copolymer is VISTAMAXX 登録商標 (ExxonMobil Chemical Company, Houston, Tex., USA), VERSIFY 登録商標 (The Dow Chemical Company,Midland,Mich.,USA),Grades of TAFMER 登録商標 XM or NOTIO 登録商標 (Mitsui Company, Japan), and grades of SOFTEL 登録商標 This may include (Basell Polyfins, the Netherlands).

[0298] In one embodiment, the nonwoven fabric may include fibers comprising a blend of a first polypropylene polymer and an olefin copolymer, wherein the olefin copolymer comprises low-isotactic polypropylene (e.g., polypropylene having an isotacticity of 30-70 mol% [mmmm]).

[0299] Accordingly, in one embodiment, the low isotactic polypropylene may be present in amounts of about 1 to about 25% by weight, about 2 to about 24% by weight, about 3 to about 22% by weight, about 4 to about 21% by weight, about 5 to about 20% by weight, about 6 to about 19% by weight, about 7 to about 18% by weight, about 8 to about 17% by weight, about 9 to about 16% by weight, and about 10 to about 15% by weight, based on the total weight of the first polypropylene component.

[0300] The low-isotactic polypropylene is generally characterized by one or more of the following properties: Iso-tacticity: Mesopentad fraction of 20-70 mol% [mmmm]; Number-average molecular weight (Mw) between 10,000 and 200,000; Melting temperature of approximately 60 to 120°C; Melt flow rate (MFR) exceeding 40g / 10 minutes.

[0301] In addition to the above characteristics, low isotactic polypropylene may have a B viscosity of approximately 7,000 to 400,000 mPa and a tensile modulus of approximately 80 to 120 MPa.

[0302] A suitable low-isotactic polypropylene polymer generally has an isotacticity of about 20 to about 70 [mmmm] (mol%), particularly 30 to 60 mol% [mmmm], and more particularly 35 to 55 mol% [mmmm]. In one embodiment, the low-isotactic polypropylene has an isotacticity of about 40 to about 50 mol% [mmmm].

[0303] The low-isotactic polypropylene has stereochemistry (e.g., stereoregularity index (mm), mesopentad fraction [mmmm], racemic pentad fraction [rrrr], racemic-meso-racemic-mesopentad fraction [rmrm], and triad fractions [mm], [rr], and [mr]) according to the peak assignments proposed by A. Zambelli et al., "Macromolecules, No. 8, p. 687 (1975)". 13 It can be measured by 13C-NMR spectroscopy. (Manufactured by JEOL Corporation) 13 13C-NMR (model JNM-EX400) can be used to obtain spectra according to the following parameters: Method: A method for complete proton decoupling; Concentration: 220mg / mL; Solvent: Mixed solvent of 1,2,4-trichlorobenzene and deuterated benzene (90 / 10 volume ratio) Temperature: 130℃; Pulse width: 45 degrees; Pulse repetition time: 4 seconds; Accumulation: 10,000 times; M = m / s × 10 R = γ / S × 10 S=Pββ+Pαβ+Pαγ <calculation formula> S=Pββ:19.8~22.5PPm Pαβ: 18.0~17.5 ppm Pαγ: 17.5~17.1 ppm γ: Racemic pentad chain: 20.7~20.3 PPm m: Mesopentad chain: 21.7~22.5 ppm.

[0304] In one embodiment, the low isotactic polypropylene has isotacticity [mmmm] (mol%) greater than about 30, greater than about 31, greater than about 32, greater than about 33, greater than about 34, greater than about 35, greater than about 36, greater than about 37, greater than about 38, greater than about 39, greater than about 40, greater than about 41, greater than about 42, greater than about 43, greater than about 44, greater than about 45, greater than about 46, greater than about 47, greater than about 48, greater than about 49, greater than about 50, greater than about 51, greater than about 52, greater than about 53, greater than about 54, greater than about 55, greater than about 56, greater than about 57, greater than about 58, greater than 59, and about 60.

[0305] In one embodiment, the low isotactic polypropylene has isotacticity [mmmm] (mol%) of about 60, about 59, about 58, about 57, about 56, about 55, about 54, about 53, about 52, about 51, about 50, about 49, about 48, about 47, about 46, about 45, about 44, about 43, about 42, about 41, about 40, about 39, about 38, about 37, about 36, about 35, about 34, about 33, about 32, and about 31.

[0306] In some embodiments, the low isotactic polypropylene may have a crystallinity of about 30 to about 60%, for example, 35 to 55%, 40 to 50%, preferably 42 to 48%. In one embodiment, the low isotactic polypropylene may have a crystallinity of about 44 to about 46%. The crystallinity of the low isotactic polypropylene may be measured according to ASTM D-3418-15.

[0307] In one embodiment, the low isotactic polypropylene typically has an MFR greater than 40 g / 10 min and a molecular weight less than 140,000 g / mol, particularly an MFR greater than 45 g / 10 min and a molecular weight less than 135,000 g / mol. In a preferred embodiment, the low isotactic polypropylene has a molecular weight of 125,000 g / mol to 135,000 g / mol and an MFR of about 45 to about 55 g / 10 min. Unless otherwise specified, the MFR is measured according to ASTM D-1238.

[0308] In one embodiment, the low-isotactic polypropylene has a melting temperature greater than about 60°C, particularly about 60 to about 120°C, and more particularly about 60 to about 100°C. In one embodiment, the low-isotactic polypropylene has a melting temperature of about 65 to about 85°C, particularly about 70 to about 80°C. The melting temperature of the low-isotactic polypropylene can be measured according to ISO 306 Method A 50.

[0309] In one embodiment, the low-tacticity polypropylene has a molecular weight in the range of about 30,000 to about 150,000 g / mol, particularly about 45,000 to about 140,000 g / mol, and more particularly about 70,000 to about 135,000 g / mol. In a preferred embodiment, the low-isotactic polypropylene has a molecular weight of about 128,000 to about 132,000 g / mol.

[0310] In one embodiment, the low isotactic polypropylene may have the following molecular weights: less than about 150,000 g / mol, less than about 145,000 g / mol, less than about 140,000 g / mol, less than about 138,000 g / mol, less than about 136,000 g / mol, less than about 134,000 g / mol, less than about 132,000 g / mol, less than about 130,000 g / mol, less than about 128,000 g / mol, less than about 126,000 g / mol, less than about 124,000 g / mol, less than about 122,000 g / mol, less than about 120,000 g / mol, less than about 118,000 g / mol, less than about 116,000 g / mol, less than about 114,000 g / mol, less than about 112,000 g / mol. , less than approximately 110,000 g / mol, less than approximately 108,000 g / mol, less than approximately 106,000 g / mol, less than approximately 104,000 g / mol, less than approximately 102,000 g / mol, less than approximately 100,000 g / mol, less than approximately 98,000 g / mol, less than approximately 96,000 g / mol, less than approximately 94,000 g / mol, less than approximately 92,000 g / mol, about 90 Less than 1,000 g / mol, less than approximately 88,000 g / mol, less than approximately 86,000 g / mol, less than approximately 84,000 g / mol, less than approximately 82,000 g / mol, less than approximately 80,000 g / mol, less than approximately 78,000 g / mol, less than approximately 76,000 g / mol, less than approximately 74,000 g / mol, less than approximately 72,000 g / mol, or approximately 70,000 g / mol.

[0311] In some embodiments, the low-isotactic polypropylene has a lower molecular weight than the first polypropylene into which it is blended. For example, in one embodiment of the present invention, the percentage difference in molecular weight between the first polypropylene and the isotactic polypropylene is 5 to 150%. In one embodiment, the percentage difference may be 7 to 120%. In a preferred embodiment, the percentage difference in molecular weight between the first polypropylene and the isotactic polypropylene is about 20 to about 35%, more preferably about 25 to about 30%.

[0312] In this invention, the percentage difference is calculated as follows: Percentage difference

number

[0313] In one embodiment, the first polypropylene has a molecular weight of 172,000 g / mol, and the low isotactic polypropylene has a molecular weight of approximately 130,000 g / mol, with a percentage difference of approximately 27.8%. In another embodiment, the first polypropylene may have a molecular weight of approximately 140,000 g / mol, and the low isotactic polypropylene may have a molecular weight of 130,000 g / mol, resulting in a percentage difference of approximately 7%. In a further embodiment, the first polypropylene may have a molecular weight of approximately 172,000 g / mol, and the low isotactic polypropylene may have a molecular weight of 45,000 g / mol, resulting in a percentage difference of approximately 117%.

[0314] A suitable example of low-isotactic polypropylene is the trade name L-MODU. 商標 It is available from Idemitsu under the following conditions. For example, S400 (approximately 2,600 MFR g / 10 min, density 0.87 g / cm³) 3 , and Mw 45 kg / mol); S600 (390 MFR g / 10 min, density 0.87 g / cm³) 3 , and Mw 75 kg / mol); and S901 (50 MFR g / 10 min, density 0.87 g / cm³) 3 This includes, and Mw 130 kg / mol), etc.

[0315] In other embodiments, the low-isotactic polypropylene may have ethylene copolymers and propylene units.

[0316] As described above, the low-isotactic polypropylene is blended with the first polypropylene. Typically, the blending is carried out in an extruder under heating and pressure to produce a homogeneous blend before being fed into a spin beam as a molten or semi-molten polymer stream.

[0317] The amount of the low-isotactic polypropylene in the blend is typically about 0.1 to about 40% by weight, and more particularly about 5 to about 25% by weight, based on the total weight of the polypropylene components. In one embodiment, the amount of the low-isotactic polypropylene in the blend is typically about 5 to about 20% by weight, more typically about 8 to about 16% by weight, and even more typically about 10 to about 15% by weight, based on the total weight of the propylene components.

[0318] In some embodiments, the polypropylene component may contain additives, such as pigments, antimicrobial agents, processing aids, fillers (e.g., Ca2O3), hydrophilic agents, antistatic agents, hydrophobic additives, plant-derived components (e.g., aloe vera, vitamin E), flame retardants, biodegradability enhancers, slip agents, etc.

[0319] In some embodiments, the polymer may include polymers derived from mechanically or chemically recycled raw materials. For example, up to 100% of the polymers constituting the nonwoven fabric may be derived from recycled polymers.

[0320] In further embodiments, nonwoven fabrics according to one or more embodiments of the present invention may be prepared from bio-based materials, particularly bio-based polymers. In contrast to polymers derived from petroleum sources, bio-based polymers are generally derived from bio-based materials. In some embodiments, bio-based polymers are also considered biodegradable. A special class of biodegradable products made from bio-based materials are considered compostable if they are capable of being decomposed in a combined environment. The European standard EN 13432, "Proof of Compostability of Plastic Products," may be used to determine whether a fabric or film composed of sustainable contents can be classified as compostable.

[0321] In one such embodiment, the nonwoven fabric comprises fibers containing a bio-based polymer. In another embodiment, the fibers are substantially free of synthetic materials, such as petroleum-based materials and polymers. For example, the fibers comprising the nonwoven fabric may have less than 25% by weight of non-bio-based material, more preferably less than 20% by weight, less than 15% by weight, less than 10% by weight, and even more preferably less than 5% by weight of non-bio-based material, based on the total weight of the nonwoven fabric.

[0322] In one embodiment, the nonwoven fabric may include fibers comprising a bio-based polymer and a petroleum-derived polymer.

[0323] In one embodiment, the bio-based polymers used may include aliphatic polyester-based polymers, such as polylactic acid, and bio-derived polyethylene.

[0324] Aliphatic polyesters useful in the present invention include homopolymers and copolymers of poly(hydroxyalkanoates), and homopolymers and copolymers of such aliphatic polyesters derived from reaction products of one or more polyols and one or more polycarboxylic acids, which typically include homopolymers and copolymers of the above aliphatic polyesters formed from reaction products of one or more alkanediols and one or more alkanedicarboxylic acids (or acyl derivatives). Polyesters can further be derived from polyfunctional polyols, such as glycerin, sorbitol, pentaerythritol, and combinations thereof, to form branched, star-shaped, and graft homopolymers and copolymers. Polyhydroxyalkanoates are generally formed from hydroxy acid monomer units or derivatives thereof. These include, for example, polylactic acid, polyhydroxybutyrate, polyhydroxyvalerate, polycaprolactone, etc. Miscible and immiscible blends of aliphatic polyesters with one or more additional semicrystalline or amorphous polymers may also be used.

[0325] One useful class of aliphatic polyesters is poly(hydroxyalkanoates) or derivatives thereof, obtained by condensation polymerization or ring-opening polymerization of hydroxy acids. A suitable poly(hydroxyalkanoate) may be represented by the following formula: H(O--R--C(O)--)nOH, where R is a linear or branched alkylene moiety having 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms which may be substituted by catenary oxygen atoms (bonded to carbon atoms in the carbon chain); and n is a number such that the ester is polymerizable, preferably such that the molecular weight of the aliphatic polyester is at least 10,000 daltons, preferably at least 30,000 daltons, and most preferably at least 50,000 daltons. In one embodiment, the molecular weight of the aliphatic polyester is typically less than 1,000,000 daltons, preferably less than 500,000 daltons, and most preferably less than 300,000 daltons. R may further contain one or more catenary (i.e., in-chain) ether oxygen atoms. Generally, the R group of a hydroxy acid has a pendant hydroxyl group that is either a primary or secondary hydroxyl group.

[0326] Useful poly(hydroxyalkanoates) include, for example, homopolymers and copolymers of poly(3-hydroxybutyrate), poly(4-hydroxybutyrate), poly(3-hydroxyvalerate), poly(lactic acid) (also known as polylactide), poly(3-hydroxypropanoate), poly(4-hydropentanoate), poly(3-hydroxypentanoate), poly(3-hydroxyhexanoate), poly(3-hydroxyheptanoate), poly(3-hydroxyoctanoate), polydioxanone, polycaprolactone, and polyglycolic acid (i.e., polyglycolides). Two or more copolymers of the above hydroxy acids, for example, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), poly(lactate-co-3-hydroxypropanoate), poly(glycolides-co-p-dioxanone), and poly(lactic acid-co-glycolic acid), may also be used. Blends of two or more of the poly(hydroxyalkanoates) may also be used, as may blends with one or more semicrystalline or amorphous polymers and / or copolymers.

[0327] The aliphatic polyester may be a block copolymer of poly(lactic acid-coglycolic acid). Aliphatic polyesters useful in the compositions of the present invention may include homopolymers, random copolymers, block copolymers, star-branched random copolymers, star-branched block copolymers, dendritic copolymers, hyperbranched copolymers, graft copolymers, and combinations thereof.

[0328] Other useful classes of aliphatic polyesters include those derived from reaction products of one or more alkanediols and one or more alkanedicarboxylic acids (or acyl derivatives). Such polyesters have the following general formula: [ka] Here, R' and R'' each represent an alkylene moiety which may be linear or branched having 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms, and m is the number for which the ester is polymerizable, preferably a number such that the molecular weight of the aliphatic polyester is at least 10,000 daltons, preferably at least 30,000 daltons, most preferably at least 50,000 daltons, but less than 1,000,000 daltons, preferably less than 500,000 daltons, most preferably less than 300,000 daltons. Each n is independently 0 or 1. R' and R'' may further contain one or more catenary (i.e., chain-like) ether oxygen atoms.

[0329] Examples of aliphatic polyesters include (a) one or more of the following diacides (or their derivatives): succinic acid; adipic acid; 1,12-dicarboxydodecane; fumaric acid; glutaric acid; diglycolic acid; and maleic acid; and (b) one or more of the following diols: ethylene glycol; polyethylene glycol; 1,2-propanediol; 1,3-propanediol; 1,2-propanediol; 1,2-butanediol; 1,3-butanediol; 1,4-butanediol; 2,3-butanediol; 1,6-hexanediol; 1,2-alkanediols having 5 to 12 carbon atoms; diethylene glycol; 300 The materials include polyethylene glycol having a molecular weight of ~10,000 daltons, preferably 400 to 8,000 daltons; propylene glycol having a molecular weight of 300 to 4,000 daltons; block or random copolymers derived from ethylene oxide, propylene oxide or butylene oxide; dipropylene glycol; and polypropylene glycol, as well as (c) optionally, small amounts, i.e., 0.5 to 7.0 mole percent, of polyols having more than 2 functionalities, such as glycerol, neopentyl glycol and pentaerythritol, and homopolymers and copolymers derived from them.

[0330] Such polymers may include polybutylene succinate homopolymers, polybutylene adipate homopolymers, polybutylene adipate-succinate copolymers, polyethylene succinate-adipate copolymers, polyethylene glycol succinate homopolymers, and polyethylene adipate homopolymers.

[0331] Commercially available aliphatic polyesters include poly(lactide), poly(glycolide), poly(lactide-co-glycolide), poly(L-lactide-co-trimethylenecarbonate), poly(dioxanone), poly(butylene succinate), and poly(butylene adipate).

[0332] The term "aliphatic polyester" includes not only polyesters made solely from aliphatic and / or cycloaliphatic components, but also polyesters that contain aromatic units in addition to aliphatic and / or cycloaliphatic units, insofar as the polyester has a substantially sustainable content.

[0333] In addition to PLA-based resins, nonwoven fabrics according to embodiments of the present invention may include other polymers derived from aliphatic components having one carboxylic acid group and one hydroxyl group, which are alternatively called polyhydroxyalkanoates (PHA). Examples include polyhydroxybutyrate (PHB), poly-(hydroxybutyrate-co-hydroxyvaleterate) (PHBV), poly-(hydroxybutyrate-co-polyhydroxyhexanoate) (PHBH), polyglycolic acid (PGA), and poly-(epsilon-caprolactone) (PCL), preferably polylactic acid (PLA).

[0334] Examples of polymers that may be used in embodiments of the present invention include polymers derived from a combination of an aliphatic component having two carboxylic acid groups and an aliphatic component having two hydroxyl groups, as well as polyesters derived from aliphatic diols and aliphatic dicarboxylic acids, such as polybutylene succinate (PBSU), polyethylene succinate (PESU), polybutylene adipate (PBA), polyethylene adipate (PEA), and polytetramethylene adipate / terephthalate (PTMAT).

[0335] Useful aliphatic polyesters include those derived from semicrystalline polylactic acid. Poly(lactic acid) or polylactide (PLA) has lactic acid as its main degradation product, is commonly found in nature, is non-toxic, and is widely used in the food, pharmaceutical, and medical industries. The polymer can be prepared by ring-opening polymerization of lactide, which is a dimer of lactic acid. Lactic acid is optically active, and the dimer appears in four different forms: L,L-lactide, D,D-lactide, D,L-lactide (mesolactide), and a racemic mixture of L,L- and D,D-. By polymerizing these lactides as pure compounds or blends, poly(lactide) polymers with different stereochemical properties and different physical properties, including the aforementioned physical properties such as crystallinity, can be obtained. L,L- or D,D-lactide yields semi-crystalline poly(lactide), while poly(lactide) obtained from D,L-lactide is amorphous.

[0336] Generally, polylactic acid-based polymers are prepared from dextrose, a sugar source obtained from field corn. In North America, corn is used because it is the most economical source of plant starch to be ultimately converted into sugar. However, it should be recognized that dextrose can also be obtained from sources other than corn. The sugar is converted to lactic acid or lactic acid derivatives through fermentation using microorganisms. The lactic acid can then polymerize to form PLA. In addition to corn, other agricultural sugar sources may be used, including rice, sugar beets, sugarcane, wheat, and cellulosic materials, such as xylose recovered from wood pulping.

[0337] The polylactide preferably has a high enantiomer ratio to maximize the intrinsic crystallinity of the polymer. The crystallinity of poly(lactic acid) is based on the regularity of the polymer backbone and its ability to crystallize with other polymer chains. When a relatively small amount of one enantiomer (e.g., D-) copolymerizes with the opposite enantiomer (e.g., L-), the polymer chain becomes irregular in shape and crystallinity decreases. For these reasons, when crystallinity is preferred, polylactic acid is desirable in which at least 85% isomer, at least 90% isomer, or at least 95% isomer to maximize the crystallinity.

[0338] In some embodiments, approximately equimolar blends of D-polylactide and L-polylactide are also useful. In some embodiments, this blend forms a unique crystalline structure with a higher melting point than either D-poly(lactide) or L-(polylactide) alone, and exhibits improved thermal stability.

[0339] Copolymers including block and random copolymers of poly(lactic acid) and other aliphatic polyesters may also be used. Useful comonomers include glycolides, beta-propiolactone tetramethylglycolide, beta-butyrolactone, gamma-butyrolactone, pivalolactone, 2-hydroxybutyric acid, alpha-hydroxyisobutyric acid, alpha-hydroxyvaleric acid, alpha-hydroxyisovaleric acid, alpha-hydroxycaproic acid, alpha-hydroxyethylbutyric acid, alpha-hydroxyisocaproic acid, alpha-hydroxy-beta-methylvaleric acid, alpha-hydroxyoctanoic acid, alpha-hydroxydecanoic acid, alpha-hydroxymyristic acid, and alpha-hydroxystearic acid.

[0340] Blends of poly(lactic acid) with one or more other aliphatic polyesters or one or more other polymers may also be used. Examples of useful blends include poly(lactic acid) with polyvinyl alcohol, polyethylene glycol / polysuccinate, polyethylene oxide, polycaprolactone, and polyglycolide.

[0341] In one preferred embodiment, the aliphatic polyester component comprises a PLA-based resin. A wide variety of different PLA resins can be used to prepare nonwoven fabrics according to embodiments of the present invention. The PLA resin should have molecular properties suitable for spinning in a spunbond process. Preferred examples include PLA resins supplied by Nature Works LLC (Minnetonka, Minn. 55345), such as Grade 6752D, Grade 6100D, and Grade 6202D, which are believed to be produced in general accordance with the teachings of U.S. Patent No. 5,525,706 and U.S. Patent No. 6,807,973 by Gruber et al. Other examples of preferred PLA resins include L130, L175, and LX175, all of which are available from Corbion of Arkelsedijk 46, 4206 AC Gorinchem, the Netherlands.

[0342] In some embodiments, the nonwoven fabric of the present invention may contain a bio-based polymer component of a biodegradable product derived from an aliphatic component having one carboxylic acid group (or a polyester-forming derivative thereof, e.g., an ester group) and one hydroxyl group (or a polyester-forming derivative thereof, e.g., an ether group), or it may be derived from a combination of an aliphatic component having two carboxylic acid groups (or a polyester-forming derivative thereof, e.g., an ester group) and an aliphatic component having two hydroxyl groups (or a polyester-forming derivative thereof, e.g., an ether group).

[0343] Additional non-limiting examples of bio-based polymers include polymers directly derived from organisms, such as polyhydroxyalkanoates (e.g., poly(beta-hydroxyalkanoate), poly(3-hydroxybutyrate-co-3-hydroxyvalerate, NODAX) 商標 This includes polymers extracted from plants and biomass, such as polysaccharides and their derivatives (e.g., gum, cellulose, cellulose esters, chitin, chitosan, starch, chemically modified starch), proteins (e.g., zein, whey, gluten, collagen), lipids, lignin, and natural rubber; as well as modern polymers obtained from naturally derived monomers and their derivatives, such as biopolyethylene, biopolypropylene, polytrimethylene terephthalate, polylactic acid, nylon 11, alkyd resins, succinic acid-based polyesters, and biopolyethylene terephthalate.

[0344] In some embodiments, the non-cellulose staple fibers may include bio-based polymers, including bio-based polyethylene derived from biological sources. For example, bio-based polyethylene can be prepared from sugars, where sugars are fermented to produce ethanol, which is then dehydrated to provide ethylene. A suitable example of sugarcane-derived polyethylene is available from Braskem SA under product name PE SHA7260.

[0345] Optional ingredients

[0346] In some embodiments, the fiber may contain one or more additives that are blended with one or more polymers during the melt extrusion step. Examples of suitable additives include one or more molecular filters and / or substrate filters, e.g., zeolites, ion exchange particles, activated carbon, etc.; colorants, e.g., pigments (e.g., TiO2); UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblocking agents, slip agents, surfactants, fluorescent whitening agents, flame retardants, antimicrobial agents, e.g., copper oxide and zinc oxide, etc.

[0347] In some embodiments, it may be useful to optionally treat the nonwoven fabric with a finishing agent that includes additives or other chemicals, such as antimicrobial agents, flame retardants, catalysts, lubricants, softeners, light stabilizers, antioxidants, colorants, such as dyes and / or pigments, antistatic agents, fillers, odor control agents, fragrances, aromatics, and combinations thereof. The compositions described herein may contain other optional components.

[0348] Fabric properties

[0349] In one embodiment, for example, the fabric may have a maximum mechanical direction (MD) tensile strength of about 20 to about 75 N / 5 cm. In another embodiment, for example, the fabric may have a maximum MD tensile strength of about 22 N / 5 to about 65 N / 5 cm. In a further embodiment, for example, the fabric may have a maximum MD tensile strength of about 50 N / 5 to about 65 N / 5 cm. Accordingly, in one embodiment, the fabric may have at least one maximum MD tensile strength from the following: 20, 25, 26, 27, 28, 29, 30, 50, 60, 70, and 80 N / 5cm, and / or up to approximately 100, approximately 75, approximately 70, approximately 65, approximately 60, approximately 55, approximately 50, and approximately 45 N / 5cm (e.g., approximately 25 to approximately 100 N / 5cm, approximately 30 to approximately 75 N / 5cm, approximately 45 to approximately 65 N / 5cm, etc.). In general, it should be recognized that the MD tensile strength and CD tensile strength may vary depending on the basis weight of the fabric. In particular, nonwoven fabrics according to embodiments of the present invention may exhibit higher MD tensile strength and CD tensile strength than those shown above when the base weight exceeds 30 gsm.

[0350] In one embodiment, for example, the fabric may have a transverse (CD) tensile strength of up to about 5 N / 5 to about 85 N / 5 cm. In another embodiment, for example, the fabric may have a CD tensile strength of up to about 6 N / 5 to about 75 N / 5 cm. In some embodiments, for example, the fabric may have a CD tensile strength of up to about 7 to about 25 N / 5 cm. Therefore, in one embodiment, the fabric may have at least one maximum CD tensile strength from the following: 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, and 30 N / 5cm and / or maximum approximately 85, approximately 80, approximately 75, approximately 70, approximately 65, approximately 60, approximately 55, approximately 50, approximately 45, approximately 40, approximately 35, approximately 30, approximately 29, approximately 28, approximately 27, approximately 26, and approximately 25 N / 5cm (e.g., approximately 15 to approximately 85 N / 5cm, approximately 15 to approximately 30 N / 5cm, etc.).

[0351] In one embodiment, for example, the nonwoven fabric may have a standard weight of about 5 grams (gsm) to about 150 gsm per square meter. In another embodiment, for example, the fabric may have a standard weight of about 8 to about 70 gsm. In one embodiment, for example, the fabric may have a standard weight of about 10 to about 50 gsm. In a further embodiment, for example, the fabric may have a standard weight of about 11 gsm to about 30 gsm. In one embodiment, the fabric may have a standard weight of about 15 gsm to about 25 gsm. Thus, in one embodiment, the fabric may have at least one upper gsm weight from the following: 5, 6, 7, 8, 9, 10, and 11 gsm and / or up to about 150, about 100, about 70, about 60, about 50, about 40, and about 30 gsm (e.g., about 9 to about 60 gsm, about 11 to about 40 gsm, etc.).

[0352] In one embodiment, for example, the fiber may have a linear mass density of about 0.05 to about 12 dtex. In another embodiment, for example, the fiber may have a linear mass density of about 1 dtex to about 10 dtex. In a further embodiment, for example, the fiber may have a linear mass density of about 1.2 dtex to about 6 dtex. Thus, in one embodiment, the fiber has at least one linear mass density from the following: 0.6, 0.7, 0.8, 0.9, 1.0, 1, 1.1, 1.2, 1.3, 1.4, 1.5, and 1.6 dtex and / or up to about 2.5, about 2.4, about 2.3, about 2.2, about 2.1, about 2.0, about 1.9, about 1.8, and about 1.7 dtex (e.g., about 1 to about 2.5 dtex, about 1.1 to about 1.8 dtex, etc.).

[0353] With respect to meltblown fibers, the fibers may have a linear mass density of approximately 0.05 to approximately 2.0 dtex.

[0354] In one embodiment, an adhesive nonwoven fabric according to an embodiment of the present invention exhibits improved abrasion resistance. Abrasion resistance is often measured by a friction test. In this test, the surface of the fabric is rubbed in a very controlled manner, and the loosened fibers are removed and weighed. Compared with a nonwoven fabric with low abrasion resistance, a fabric with improved abrasion resistance shows a reduction in the weight of the removed fibers. In some embodiments, the nonwoven fabric showed an average weight of material removed during a full abrasion test of less than 5 mg, and in particular less than 4 mg, when measured according to test method NWSP 20.5. The abrasion test method NWSP 20.5 is described in detail in the following Examples section.

[0355] In one embodiment, a nonwoven fabric according to the present invention may exhibit a Martindale abrasion score of less than 2, particularly less than 1.5. In one embodiment, a nonwoven fabric according to the present invention may exhibit a Martindale abrasion score of about 1.0 to about 2.0, particularly 1.0 to about 1.6, and more particularly about 1.1 to about 1.5. In one embodiment, a nonwoven fabric according to the present invention may exhibit a Martindale abrasion score of about 1.40 to about 1.45. A test method for evaluating the Martindale abrasion score is described in detail in the following Examples section.

[0356] In one embodiment, a nonwoven fabric according to the present invention may exhibit Martindale abrasion scores greater than 1.0, greater than 1.05, greater than 1.10, greater than 1.15, greater than 1.20, greater than 1.25, greater than 1.30, greater than 1.35, greater than 1.40, greater than 1.45, greater than 1.50, greater than 1.55, greater than 1.60, greater than 1.65, greater than 1.70, greater than 1.75, greater than 1.80, greater than 1.85, greater than 1.90, greater than 1.95, and greater than 1.99.

[0357] In one embodiment, a nonwoven fabric according to the present invention may exhibit Martindale abrasion scores of less than 2.0, less than 1.95, less than 1.90, less than 1.85, less than 1.80, less than 1.75, less than 1.70, less than 1.65, less than 1.60, less than 1.55, greater than 1.50, less than 1.45, less than 1.40, less than 1.35, less than 1.30, less than 1.25, less than 1.20, less than 1.15, less than 1.10, less than 1.05, and less than 1.01.

[0358] In one embodiment, an adhesive nonwoven fabric according to an embodiment of the present invention exhibits an improvement in flexibility, expressed by a transverse handle-of-meter value of less than 7.0 grams (g), e.g., less than 7.9 g or less than 7.5 g, for a nonwoven fabric having a basis weight of 20 to 30 gsm. The handle-of-meter value is measured according to NWSP 90.3, which is described in detail in the following Examples section.

[0359] In one embodiment, an adhesive nonwoven fabric according to an embodiment of the present invention exhibits an improvement in flexibility, expressed by a transverse handle-of-meter value of less than 3.9 grams (g), for example, less than 3.8 grams or less than 3.78 grams, for a nonwoven fabric having a basis weight of 20 to 30 gsm.

[0360] In one embodiment, a nonwoven fabric according to an embodiment of the present invention is compared to a similarly prepared nonwoven fabric, where the similarly prepared nonwoven fabric is 3.5 mm thick. -1 Less than, for example, 4.0 mm -1 Except for being spot-bonded with an adhesive pattern having an adhesive point packing of less than 3.5 mm, it exhibits an improvement of one or more of the following: tensile strength, elongations, abrasion resistance, and softness. In one embodiment, the similarly prepared nonwoven fabric is spot-bonded with a pattern in which the percentage of the adhesive surface area of ​​the nonwoven fabric is 18.1%. That is, in the similarly manufactured nonwoven fabric, the overall adhesive point pattern is the same, except that the surface area of ​​the individual adhesive points is larger so that the percentage of the overall adhesive surface area of ​​the nonwoven fabric is larger, and as a result the packing value of the adhesive points is also reduced. In one embodiment, the similarly prepared fabric is similar to the adhesive pattern in the comparative fabric which is 3.5 mm -1 Less than, for example, 4.0 mm -1The fabric is substantially identical to that of the present invention, except that it has a packing of fewer than 100 bond points (e.g., polymer chemistry, fiber structure, and extrusion conditions). The process conditions used for the similarly prepared nonwoven fabric may have some variations, such as slight variations in calender temperatures and pressure.

[0361] In one embodiment, the nonwoven fabric according to an embodiment of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with adhesive point packing of less than 3.5 mm, it may exhibit tensile strength 10% greater. In some embodiments, 3.5 mm -1 Less than, for example, 4.0 mm -1 It may show an increase in tensile strength of only 10-50%, for example, 12-30%, 12-25%, 12-24%, or 12-20%, compared to a similarly prepared nonwoven fabric with less than 10-50% adhesive point packing.

[0362] In one embodiment, a nonwoven fabric according to an embodiment of the present invention may exhibit a tensile strength that is 10% greater than a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%. In some embodiments, the nonwoven fabric may exhibit an increase in tensile strength that is 10% to 30%, for example, 12% to 20%, greater than the tensile strength of a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0363] In particular, the nonwoven fabric according to the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics having less than 3.5 mm of adhesive point packing, it may exhibit an increase in mechanical direction (MD) tensile strength that is only 10% to 50% greater. In some embodiments, the nonwoven fabric of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1Compared to similarly prepared nonwoven fabrics with fewer than 10-30% adhesive point packing, it may show an increase in mechanical direction (MD) tensile strength that is only about 10-30%, for example, about 12-20%, or about 12-15% greater.

[0364] In addition, the nonwoven fabric according to the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics having less than 3.5 mm of adhesive point packing, the nonwoven fabric of the present invention may exhibit an increase in transverse (CD) tensile strength that is only about 10% to about 50% greater. In some embodiments, the nonwoven fabric of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10-30% adhesive point packing, it may show an increase in CD tensile strength of only about 10-30%, for example, about 15-25%, 18-24%, or 19-21%.

[0365] In some embodiments, a nonwoven fabric according to the present invention may exhibit an increase in tensile strength in the mechanical direction (MD) of about 10 to about 50% greater than a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%. In some embodiments, a nonwoven fabric according to the present invention may exhibit an increase in tensile strength in the MD of about 10 to about 30%, for example, about 12 to about 20%, or about 12 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0366] In one embodiment, a nonwoven fabric according to the present invention may exhibit an increase in transverse (CD) tensile strength of about 10 to about 50% greater than a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%. In some embodiments, a nonwoven fabric according to the present invention may exhibit an increase in CD tensile strength of about 10 to about 30%, for example, about 15 to about 25%, about 18 to about 24%, or about 19 to about 21%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0367] In some embodiments, the nonwoven fabric according to the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics having adhesive point packing of less than 3.5 mm, it may exhibit an increase in elongation of about 4 to about 50%. In some embodiments, the nonwoven fabric of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 50% adhesive point packing, it may show an increase in elongation of about 4-25%, for example, about 5-20%, or about 5-15%.

[0368] In some embodiments, nonwoven fabrics according to the present invention may exhibit an increase in elongation of about 4 to about 50% compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, for example, 18.1%. In some embodiments, nonwoven fabrics according to the present invention may exhibit an increase in elongation of about 4 to about 25%, for example, about 5 to about 20%, or about 5 to about 15%, compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0369] In one embodiment, the nonwoven fabric according to the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics having fewer than 3.5 mm adhesive point packings, the present invention may exhibit a 10-30% increase in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score. In some embodiments, the nonwoven fabric of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics having fewer than 10 bond point packings, it may show an increase of about 10–25%, for example, about 12–24%, or about 18–22%, in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score.

[0370] In one embodiment, a nonwoven fabric according to the present invention may show a 10-30% increase in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%. In some embodiments, a nonwoven fabric according to the present invention may show an increase of about 10-25%, for example, about 12-24%, or about 18-22%, in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0371] In some embodiments, the nonwoven fabric according to the present invention is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with less than 3.5 mm of adhesive point packing, the nonwoven fabric showed an average percentage reduction of 5-150% in the weight of material removed during abrasion tests (according to test method NWSP 20.5). In one embodiment, the nonwoven fabric of the present invention is 3.5 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 120% adhesive point packing, it may show an average percentage reduction of 8-120%, e.g., 9-95%, in the weight of material removed during abrasion testing (according to test method NWSP 20.5).

[0372] In some embodiments, nonwoven fabrics according to embodiments of the present invention showed an average percentage reduction of 5 to 150% in the weight of material removed during abrasion tests (according to test method NWSP 20.5) compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, for example, 18.1%. In some embodiments, nonwoven fabrics according to the present invention may show an average percentage reduction of 8 to 120%, for example, 9 to 95%, in the weight of material removed during abrasion tests (according to test method NWSP 20.5) compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0373] In some embodiments, the nonwoven fabric according to the embodiment of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1Compared to similarly prepared nonwoven fabrics having adhesive point packing of less than 3.5 mm, the nonwoven fabric showed an improvement in flexibility of about 5 to about 20%, indicated by an average improvement in handle-of-meter value. In one embodiment, the nonwoven fabric of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 50% adhesive point packing, it may show an improvement in flexibility of about 6-15%, for example, 8-10%, indicated by an average improvement in handle-of-meter value.

[0374] In some embodiments, nonwoven fabrics according to embodiments of the present invention showed an improvement in flexibility, indicated by an average improvement of about 5 to about 20% in handle-of-meter value compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, for example, 18.1%. In some embodiments, nonwoven fabrics of the present invention may show an improvement in flexibility, indicated by an average improvement of about 6 to about 15%, for example, 8 to about 10% in handle-of-meter value, compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0375] In one embodiment, the nonwoven fabric according to an embodiment of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics having less than 3.5 mm of adhesive point packing, it showed an improvement in flexibility of about 5 to about 20% (measured with a handle-o-meter). In one embodiment, the nonwoven fabric of the present invention is 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 15% adhesive point packing, it may show an improvement in flexibility of about 6-15%, for example, 8-10%.

[0376] In one embodiment, a nonwoven fabric according to an embodiment of the present invention showed an improvement in flexibility of about 5 to about 20% (measured with a handle-o-meter) compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%. In another embodiment, a nonwoven fabric of the present invention may show an improvement in flexibility of about 6 to about 15%, for example, 8 to 10%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0377] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.6 to about 10.4%, and a thickness of about 0.15 to about 2.0 mm. 2 The average surface area of ​​each individual bonding point is approximately 6.75 to 7.25 mm². -1 It can be characterized by having an average bond point packing value, a bond point density of about 50 to about 60 individual bond points per square centimeter, a Martindale abrasion score of about 1.0 to about 1.5 (e.g., 1.4 to 1.5), a transverse handle-o-meter value of about 6.6 to about 7.2 grams (for nonwoven fabrics having a basis weight of 20 to 30 gsm), a mechanical handle-o-meter value of about 3.5 to about 3.95 grams, and an average abrasion resistance of 3.2 to 5.5 grams, measured by the weight of the removed material.

[0378] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.8 to about 10%, and about 0.16 to about 0.19 mm 2 The average surface area of ​​each individual bonding point is approximately 7.0 to 7.3 mm². -1 It can be characterized by having an average bond point packing value, a bond point density of approximately 52 to 58 individual bond points per square centimeter, a Martindale abrasion score of approximately 1.42 to 1.45, a transverse handle-o-meter value of approximately 6.7 to 7.0 grams (for nonwoven fabrics with a basis weight of 20 to 30 gsm), a mechanical handle-o-meter value of approximately 3.6 to 3.9 grams, and an average abrasion resistance of 3.4 to 3.6 grams, measured by the weight of the removed material.

[0379] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 The average bonding point packing value, and 3.5 mm -1 Less than, for example, 4.0 mm -1 It can be characterized by having an average increase in tensile strength that is only 10% greater, for example, about 10% to about 50%, about 12% to about 24%, or about 12% to about 22%, compared to a similarly prepared nonwoven fabric having the same adhesion point packing value.

[0380] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of approximately 9.6 to approximately 10.2%, and an area of ​​approximately 0.15 to approximately 0.25 mm. 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 It can be characterized by having an average increase in tensile strength of only 10% greater, for example, about 10% to about 50%, about 12% to about 24%, or about 12% to about 22%, compared to a similarly prepared nonwoven fabric having an average bonding point packing value and a bonding surface area of ​​more than 12%, for example, 18.1%.

[0381] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 The average bonding point packing value, and 3.5 mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics having less than 50% adhesive point packing, it may be characterized by having an average increase in elongation of about 4 to about 50%, for example, about 4 to about 20%, about 4 to about 15%, or about 4 to about 14%.

[0382] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm 2The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 It can be characterized by having an average increase in elongation of about 4 to about 50%, for example, about 4 to about 20%, about 4 to about 15%, or about 4 to about 14%, compared to a similarly prepared nonwoven fabric having an average bonding point packing value and a bonding surface area of ​​more than 12%, for example, 18.1%.

[0383] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 It can be characterized by having an average bonding point packing value and one or more of the following characteristics: i) 1mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10% adhesive point packing, there is a 10-30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score; ii) 1mm -1 Compared to similarly prepared nonwoven fabrics having less than 5-150% average percentage reduction in the weight of material removed during abrasion tests (according to test method NWSP 20.5), for example, about 8-120% or 9-95%; and iii) 1mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 5% adhesive point packing, this improvement in flexibility is indicated by an average improvement of approximately 5-20%, for example, approximately 6-15%, or 8-10%, in the handle-of-meter value.

[0384] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 It can be characterized by having an average bonding point packing value and one or more of the following characteristics: i) A 10% to 30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, e.g., 18.1%; ii) an average percentage reduction of 5-150%, for example about 8-120%, or 9-95%, in the weight of material removed during abrasion tests (according to test method NWSP 20.5) compared to similarly prepared nonwoven fabrics having an adhesive surface area of ​​more than 12%, for example 18.1%; and iii) Improvement in flexibility, indicated by an average improvement of about 5 to about 20%, for example, about 6 to about 15% or 8 to 10%, in the handle-of-meter value compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0385] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.10 to about 0.25 mm 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 It can be characterized by having an average bonding point packing value and one or more of the following characteristics: i) 1mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 10% adhesion point packing, there is a 10-30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score; ii) 3.5mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 5-150% average percentage reduction in the weight of material removed during abrasion tests (according to test method NWSP 20.5), for example, about 8-120% or 9-95%; iii) 3.5mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 5% adhesive point packing, the improvement in flexibility is indicated by an average improvement of approximately 5-20%, for example, approximately 6-15% or 8-10% in the handle-of-meter value; iv) 3.5mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with fewer than 50% adhesive point packing, the increase in mechanical direction (MD) tensile strength is only about 10-50%, 10-30%, 12-20%, or 12-15%, for example; v) 3.5mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics having less than 50% adhesive point packing, the increase in transverse (CD) tensile strength is only about 10-50%, for example, about 10-30%, for example, about 15-25%, about 18-24%, or about 19-21%; and vi) 3.5mm -1 Less than, for example, 4.0 mm -1 Compared to similarly prepared nonwoven fabrics with less than 50% adhesive point packing, this represents an increase in elongation of approximately 4-50%, for example, approximately 5-20%, or approximately 5-15%.

[0386] In one embodiment, the nonwoven fabric according to the embodiment of the present invention has an adhesive area percentage of about 9.6 to about 10.2%, and an area of ​​about 0.15 to about 0.25 mm 2 The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². -1 It can be characterized by having an average bonding point packing value and one or more of the following characteristics: i) A 10% to 30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, e.g., 18.1%; ii) An average percentage reduction of 5-150%, for example, about 8-120% or 9-95% in the weight of material removed during abrasion testing (according to test method NWSP 20.5), compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, e.g., 18.1%; iii) Improvement in flexibility, indicated by an average improvement of approximately 5 to approximately 20%, for example, approximately 6 to approximately 15% or 8 to 10%, in the handle-of-meter value compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%; iv) An increase in mechanical direction (MD) tensile strength that is only about 10 to about 50%, for example about 10 to about 30%, for example about 12 to about 20%, or about 12 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example 18.1%; v) An increase in transverse (CD) tensile strength that is only about 10-30%, for example, about 15-25%, about 18-24%, or about 19-21%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%; and vi) An increase in elongation of about 4 to about 50%, for example, about 5 to about 20%, or about 5 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

[0387] System and method for preparing nonwoven fabrics

[0388] A certain aspect of the present invention provides a system and method for preparing an adhesive nonwoven fabric according to the embodiments described above.

[0389] Referring to Figure 8, for example, a schematic diagram of a spunbond nonwoven fabric preparation system according to one embodiment of the present invention, and broadly designated by reference no. 100a, is shown. As shown in Figure 8, a first polymer source (i.e., hopper) 102 is in fluid communication with a spin beam 104 via an extruder 106.

[0390] In one embodiment, the first polymer source may provide a flow of molten or semi-molten polymer resin. After extrusion, the extruded polymer flow is fed into a spin beam 104, at which point the flow enters a plurality of spinnerets (not shown) and is spun into filaments. After spinning, the spun filaments may then be stretched (i.e., thinned) by a stretching unit (not shown) and randomized in a diffusion device. The spin beam 104 generates a curtain of filaments 108 which is deposited on a collection surface 110 to form a web of filaments 112. At this stage, the filaments may comprise a web of filaments 112 which may not be adhered to each other or may be slightly adhered to each other.

[0391] A calender bonding unit 116, including a calender, is located downstream of the collection surface 110 and is configured and designed to thermally point-bond adjacent filaments to each other and to impart a bonding pattern to the surface according to embodiments of the present invention as described above. As detailed below, the calender comprises a pair of cooperating rolls, the first roll 116a having a grooved patterned roll from which a plurality of bonding points extend from its surface, and the second roll 116b having a smooth or anvil surface. During bonding, the web 112 of the filaments passes between the pair of cooperating rolls, which are heated to a temperature sufficient to soften at least one of the polymer components constituting the filaments of the web 112, thereby producing a bonded nonwoven fabric 124. In one embodiment, the bonded nonwoven fabric 124 is moved to a winder 118, where the fabric is then wound onto a roll.

[0392] In some embodiments, a pair of cooperating rolls 120 (also referred to herein as “press rolls”) stabilize the web of the filament by compressing it before it is fed to the calender 116 for bonding. In some embodiments, for example, the press rolls may further include a ceramic coating deposited on their surface. In some embodiments, for example, one of the pair of cooperating rolls 120 may be located above the collection surface 110, and the other of the pair of cooperating rolls 120 may be located below the collection surface 110. In some embodiments, the system may further include a hot knife (not shown) that exposes the web 112 to a flow of heated gas, such as air, to lightly bond and stabilize the web.

[0393] In some embodiments, the system 100a may further include a vacuum source 128 positioned below the collection surface 110. The vacuum source 128 provides a vacuum that helps to pull and tug the filament curtain 108 onto the collection surface 110.

[0394] Referring to Figure 9, further aspects of a system and method for preparing a nonwoven fabric according to at least one embodiment of the present invention are shown and are broadly specified by reference no. 100b. In this embodiment, the system 100b may be configured and designed to produce multi-component filaments, such as two-component filaments.

[0395] The system 100b includes a first polymer source (i.e., a hopper) 130a which is in fluid communication with the spin beam 134 via the extruder 136a. A second polymer source (i.e., a hopper) 130b is further in fluid communication with the spin beam 134 via the extruder 136b. When preparing a multi-component fabric, the first polymer source may provide a flow of a first polymer resin, and the second polymer source may provide a flow of a second polymer resin. In melt-spinning applications, the polymer flow is typically molten or semi-molten. The first and second polymer resins may be different polymers or the same polymer, depending on the desired application and desired properties of the nonwoven fabric.

[0396] After extrusion, the extruded polymer flow is fed into the spin beam 134, at which point the flow enters several spinnerets (not shown) and is spun into filaments. After spinning, the spun filaments may then be stretched (i.e., thinned) by a stretching unit (not shown) and randomized in a diffusion device. The spin beam 134 generates a curtain of filaments 138, which is deposited on the collection surface 110 to form a web of filaments 140. At this stage, the web 140 may consist of multicomponents filaments that are not or only slightly adhered to one another.

[0397] A calender bonding unit 116, including a calender, is positioned downstream of the collection surface 110 and is configured and designed to thermally point-bond adjacent filaments to each other and to impart a bonding pattern to the surface according to embodiments of the present invention as described above. As detailed below, the calender comprises a pair of cooperating rolls, the first roll 116a having a grooved patterned roll from which multiple bonding points extend from its surface, and the second roll 116b having a smooth or anvil surface. During bonding, the web 140 of the filaments passes between the pair of cooperating rolls, which are heated to a temperature sufficient to soften at least one polymer component constituting the filaments of the web 140, the softened polymer component fusing and bonding to adjacent filaments in the web to form a bonded nonwoven fabric 142. In one embodiment, the bonded nonwoven fabric 142 moves to a winder 118, where the fabric is then wound onto a roll.

[0398] Similar to the embodiments described above, system 100b may include an optional pair of cooperating rolls 120, an optional hot knife, and a vacuum source 128.

[0399] Embodiments of the present invention may further include multilayer nonwoven fabrics having 2 to 10 layers, for example, 2 to 5 layers, and especially 2 to 3 layers.

[0400] The various layers of the nonwoven fabric may include one or more spunbond layers, one or more carded layers, one or more airlaid layers, one or more meltblown layers, and so on.

[0401] In one embodiment, the adhesive nonwoven fabric may include a layer having single-component filaments and a layer having multi-component filaments, for example, two-component filaments.

[0402] In embodiments in which the adhesive nonwoven fabric comprises multiple layers, the system may optionally include additional fiber forming apparatus. For example, a system according to an embodiment of the present invention may include one or more meltblown beams, apparatus for preparing one or more carded fabric layers, apparatus for preparing one or more airlaid fabric layers, etc. These additional apparatus may be located on the same production line as the other fiber forming apparatus to provide a continuous system. Alternatively, one or more additional layers may be supplied from a feed roll on which a pre-prepared nonwoven fabric has been wound.

[0403] In one embodiment, the adhesive nonwoven fabric may include at least one spunbond layer with little to no crimping, and at least one layer having crimped filaments.

[0404] Referring to Figure 10, further aspects of a system and method for preparing a nonwoven fabric according to at least one embodiment of the present invention are shown and are broadly specified by reference no. 100c. In system 100c, the system is configured and designed to have at least two spin beams and to produce an adhesive nonwoven fabric having at least two layers.

[0405] As shown in the figure, system 100c includes an extruder 152 and a first spin beam 150 which is in fluid communication with a first polymer supply source (hopper 154). After extrusion, the extruded polymer flow is fed into the spin beam 150, at which point the flow enters several spinnerets (not shown) and is spun into filaments. After spinning, the spun filaments may then be stretched (i.e., thinned) by a stretching unit (not shown) and randomized in a diffusion device. The spin beam 150 generates a curtain of filaments 156 which deposits on a collection surface 110 to form a web of filaments. At this stage, the filaments may comprise a web of filaments 158 which may not be adhered to each other or may be slightly adhered to each other.

[0406] The second spin beam 160 is located downstream of the first spin beam 150. The second spin beam is in fluid communication with the second extruder 162a (which is in communication with the second polymer supply source (hopper 164a)) and the third extruder 162b (which is in communication with the third polymer supply source (hopper 164b)).

[0407] After extrusion, the polymer streams extruded from the extruders 162a and 162b are fed into the spin beam 160, at which point the streams enter multiple spinnerets (not shown) and are spun into multi-component filaments. After spinning, the spun filaments may then be stretched (i.e., thinned) by a stretching unit (not shown) and randomized in a diffusion device. The spin beam 160 generates a curtain 166 of multi-component filaments, which are layered and deposited on the web 158 to create a composite web 168 containing at least two layers. At this stage, the filaments of the web 158 may not be bonded to each other, or may be slightly bonded.

[0408] As in the embodiments described above, a calender bonding unit 116 including a calender is positioned downstream of the collection surface 110 and is configured and designed to thermally point-bond adjacent filaments to each other and to impart a bonding pattern to the surface according to embodiments of the invention as described above. During bonding, the web 168 of the filaments passes between a pair of cooperative rolls, which are heated to a temperature sufficient to soften at least one of the polymer components constituting the filaments of the web 168, thereby producing a bonded nonwoven fabric 170. In one embodiment, the bonded nonwoven fabric 170 is moved to a winder 118, where the fabric is then wound onto a roll.

[0409] Similar to the embodiments described above, system 100c may include an optional pair of cooperating rolls 120 and a vacuum source 128.

[0410] In one embodiment, the nonwoven fabric may be air-through bonded via the calender bonding unit before heat spot bonding.

[0411] According to one embodiment, for example, bonding the web to form an adhesive nonwoven fabric involves heat-spot bonding the web with heat and pressure via a calender having a pair of cooperating rolls having patterned rolls. The patterned rolls impart a three-dimensional geometric bonding pattern to the nonwoven fabric.

[0412] Figure 11 shows a calendering unit 16 according to at least one embodiment of the present disclosure. In one embodiment, the calendering unit comprises a pair of cylindrical rolls 116a, 116b positioned opposite each other and cooperating to receive a nonwoven fabric between them. In the illustrated embodiment, the patterned roll 116a comprises a plurality of individual raised adhesive points 200 extending radially outward from the surface 202 of the patterned roll 116a, and arranged to define one or more patterns on the surface 202 of the patterned roll 116a.

[0413] The roll 116b (also called an anvil roll) generally has a smooth surface 204. However, in some embodiments, both the rolls 116a and 116b can be patterned by having a plurality of individual raised adhesive points 200 extending radially outward from the surfaces 202 and 204.

[0414] Both rolls 116a and 116b have central axes 210 and 212, respectively, that extend laterally in the CD direction. The central axes 210 and 212 of rolls 116a and 116b are substantially perpendicular to the MD direction of the system for producing the nonwoven fabric of the present invention (see systems 106a to 106c in Figures 8 to 10). Rolls 116a and 116b also include radial axes r1 and r2 that extend radially outward from the central axes 210 and 212.

[0415] The bonding points are collectively arranged and dispersed across the surface of the pattern roll, defining a first pattern that is imparted to the nonwoven sheet when it is heat-bonded by passing between the rolls 116a and 116b of the calender bonding unit 116.

[0416] In one embodiment, the patterned roll 116a comprises a plurality of arrays, each array comprising a plurality of spaced-apart individual bonding points extending across the surface of the patterned roll 116a. The arrays of bonding points on the surface of the patterned roll 116a are configured and designed to impart a plurality of arrays of thermal bonding points to the nonwoven fabric in the mechanical, transverse, and oblique directions via the calender bonding unit 116.

[0417] Referring here to Figure 12, in order to provide the nonwoven fabric with an array of bonding points extending in the machine direction, the patterned roll 116a has a plurality of pairs of annular arrays AA1, AA2, where each annular array AA1, AA2 of the pair 214 has a plurality of spaced bonding points 200 located radially around the outer surface of the patterned roll 116a. Typically, the individual bonding points of each annular array are located in the same plane defined by the radial axis r1. The annular array has a plurality of array pairs 214, each array pair including a first annular array AA1 defining a first member of the annular array pair 214 and a second annular array AA2 defining a second member of the array pair 214. The plurality of annular array pairs 214 define a pattern in which the first annular array AA1 and the second annular array AA2 are alternately arranged in a repeating pattern across the surface of the patterned roll 116a in the direction lateral to the roll.

[0418] In one embodiment, the individual bonding points 200 of the second annular array AA2 are radially offset from adjacent bonding points of the first annular array AA1. That is, adjacent bonding points of the first and second annular arrays are not aligned with each other in the lateral direction of the patterned roll on the surface of the roll, while the bonding points of all other annular arrays are substantially aligned in the lateral direction of the roll. For example, in Figure 12, the bonding points 200a and 200c in a separate annular array AA2 are aligned with each other in the lateral direction, while the bonding points 200b and 200d in the first annular array AA1 are not aligned with the bonding points 200a and 200c in the lateral direction of the patterned roll 116a.

[0419] In one embodiment, the patterned roll 116a also includes an array of individual, spaced-out bonding points 200 extending laterally from the patterned roll. In addition, the laterally extending array of the patterned roll 116a has a plurality of lateral array pairs 216, each array pair comprising a first lateral array CDA1 defining a first member of the lateral array pair 216 and a second lateral array CDA2 defining a second member of the array pair. The plurality of lateral array pairs 216 define a pattern in which the first lateral array CDA1 and the second lateral array CDA2 are arranged in a radially alternating repeating pattern along the circumference of the patterned roll. In one embodiment, the first lateral array CDA1 and the second lateral array CDA2 extend across the surface 202 of the roll in a direction substantially parallel to the central axis 210 of the roll.

[0420] In one embodiment, each of the adhesive points 200 of the first transverse array CDA1 is laterally offset from the adjacent adhesive points of the second annular array CDA2. That is, adjacent adhesive points of the first and second transverse arrays are not radially aligned with each other on the surface of the patterned roll, while adhesive points of all other transverse arrays are substantially radially aligned on the surface of the roll. For example, in Figure 12, adhesive points 200a and 200e in a separate transverse array CDA2 are radially aligned with each other, while adhesive points 200b and 200f in the first transverse array CDA1 are not radially aligned with adhesive points 200a and 200e on the patterned roll 116a.

[0421] In one embodiment, the patterned roll 116a further comprises a plurality of helical arrays having a plurality of bonding points, which are configured and designed to form a helical pattern extending circumferentially around the outer surface of the patterned roll 116a. In this regard, Figure 12 shows a helical array pair 218 having a first helical array SPA1 and a second helical array SPA2, where the plurality of helical array pairs are spaced apart across the surface of the patterned roll 116a. The helical arrays impart a pattern to the nonwoven sheet having a plurality of arrays extending obliquely across the surface of the bonded nonwoven (see, for example, arrays A5 and A6 in Figure 1).

[0422] Referring to Figure 13A, the bonding point 200 is generally oval in shape, such as elliptical, rectangular, or rod-shaped. In some embodiments, the patterned roll 116a may include combinations of oval bonding points and circular / square / rhombic bonding points, such as a grooved roll used to form the bonding patterns shown in Figures 7A to 7D.

[0423] In an oval-shaped adhesive point, the adhesive point 200 has a major axis 230 and a minor axis 232, and the length of the major axis of the adhesive point is longer than the length of the minor axis of the adhesive point.

[0424] In one embodiment, the major axes of the bonding points of the same array (e.g., a first annular array AA1) are oriented / aligned in the same direction, while the major axes of the individual bonding points of the array forming a second member of the array pair (e.g., a second annular array AA2) are oriented / aligned at an alignment of about 85 to 95 degrees relative to the alignment of the major axes of the bonding points 200 of the first annular array AA1. In one embodiment, the individual bonding points of the first annular array are oriented / aligned at an alignment of about 86 to 94 degrees, for example, about 87 to 93 degrees, about 88 to 92 degrees, about 86 to 94 degrees, about 89 to 91 degrees, or about 90 degrees relative to the alignment of the major axes of the bonding points 200 of the second annular array AA2.

[0425] In one embodiment, the adhesion point density (the number of individual adhesion points per square centimeter on the surface of the patterned roll) is approximately 50 to approximately 65 cm². 2 That is the case.

[0426] Referring again to Figure 13A, a perspective view of a raised adhesive point 200 according to at least one embodiment of the present invention is shown. As illustrated, the raised adhesive point 200 includes a base portion 220, a raised surface 222, and a continuous side wall 224 extending between the base portion 220 and the raised surface 222. The raised surface is configured and designed to engage with individual areas on the surface of the nonwoven fabric, and to soften and fuse the fibers engaged at the adhesive point by applying sufficient pressure and heat to form individual adhesive points on the surface of the nonwoven fabric.

[0427] In one embodiment, the average length of the major axis 230 of the bonding point is approximately 0.65 to approximately 1.25 mm, particularly approximately 0.70 to approximately 1.20 mm, more particularly approximately 0.72 to approximately 1.15 mm, and even more particularly approximately 0.74 to approximately 1.10 mm.

[0428] In a preferred embodiment, the average length of the long axis 230 of the bonding point is about 0.74 to about 0.78 mm, with an average length of about 0.76 mm being slightly more preferred.

[0429] In one embodiment, the average length of the long axis 230 of the bonding point is less than 1.25 mm, less than 1.24 mm, less than 1.23 mm, less than 1.22 mm, less than 1.21 mm, less than 1.20 mm, less than 1.19 mm, less than 1.18 mm, less than 1.17 mm, less than 1.16 mm, less than 1.15 mm, less than 1.14 mm, less than 1.13 mm, less than 1.12 mm, less than 1.11 mm, less than 1.10 mm, less than 1.09 mm, less than 1.08 mm, less than 1.07 mm, less than 1.06 mm, less than 1.05 mm, less than 1.04 mm, less than 1.03 mm, less than 1.02 mm, less than 1.01 mm, less than 1.00 mm, less than 0.99 mm, less than 0.98 mm, less than 0.97 mm , less than 0.96 mm, less than 0.95 mm, less than 0.94 mm, less than 0.93 mm, less than 0.92 mm, less than 0.91 mm, less than 0.90 mm, less than 0.89 mm, less than 0.88 mm, less than 0.87 mm, less than 0.86 mm, less than 0.85 mm, less than 0.84 mm, less than 0.83 mm, less than 0.82 mm, less than 0.81 mm, less than 0.80 mm, less than 0.79 mm, less than 0.78 mm, less than 0.77 mm, less than 0.76 mm, less than 0.75 mm, less than 0.74 mm, less than 0.73 mm, less than 0.72 mm, less than 0.71 mm, less than 0.70 mm, less than 0.69 mm, less than 0.68 mm, less than 0.67 mm, or less than 0.66 mm.

[0430] In some embodiments, the average length of the long axis 230 of the bond points is greater than 0.65 mm, greater than 0.66 mm, greater than 0.67 mm, greater than 0.68 mm, greater than 0.69 mm, greater than 0.70 mm, greater than 0.71 mm, greater than 0.72 mm, greater than 0.73 mm, greater than 0.74 mm, greater than 0.75 mm, greater than 0.76 mm, greater than 0.7 mm. >7mm, >0.78mm, >0.79mm, >0.80mm, >0.81mm, >0.82mm, >0.83mm, >0.84mm, >0.85mm, >0.86mm, >0.87mm, >0.88mm, >0.89mm, >0.90mm, >0.91mm, >0.92mm, 0.9 >3mm, >0.94mm, >0.95mm, >0.96mm, >0.97mm, >0.98mm, >0.99mm, >1.0mm, >1.01mm, >1.02mm, >1.03mm, >1.04mm, >1.05mm, >1.06mm, >1.07mm, >1.08mm, 1.09 More than mm, more than 1.1 mm, more than 1.11 mm, more than 1.12 mm, more than 1.13 mm, more than 1.14 mm, more than 1.15 mm, more than 1.16 mm, more than 1.17 mm, more than 1.18 mm, more than 1.19 mm, more than 1.20 mm, more than 1.21 mm, more than 1.22 mm, more than 1.23 mm, and more than 1.24 mm.

[0431] In one embodiment, the average width of the short axis 232 of the bonding point is approximately 0.24 to approximately 0.60 mm, particularly approximately 0.25 to approximately 0.55 mm, more particularly approximately 0.27 to approximately 0.50 mm, and even more particularly approximately 0.28 to approximately 0.48 mm.

[0432] In a preferred embodiment, the average width of the minor axis 232 of the bonding point is about 0.24 to about 0.36 mm, particularly about 0.26 to about 0.32 mm, and more particularly about 0.28 to about 0.31 mm. In a slightly more preferred embodiment, each of the bonding points has an average width of about 0.30 mm.

[0433] In one embodiment, the average width of the short axis 232 of the bonding point is less than 0.6 mm, less than 0.59 mm, less than 0.58 mm, less than 0.57 mm, less than 0.56 mm, less than 0.55 mm, less than 0.54 mm, less than 0.53 mm, less than 0.52 mm, less than 0.51 mm, less than 0.50 mm, less than 0.49 mm, less than 0.48 mm, less than 0.47 mm, less than 0.46 mm, less than 0.45 mm, less than 0.44 mm. The size is full, less than 0.43 mm, less than 0.42 mm, less than 0.41 mm, less than 0.40 mm, less than 0.39 mm, less than 0.38 mm, less than 0.37 mm, less than 0.36 mm, less than 0.35 mm, less than 0.34 mm, less than 0.33 mm, less than 0.32 mm, less than 0.31 mm, less than 0.30 mm, less than 0.29 mm, less than 0.28 mm, less than 0.27 mm, less than 0.26 mm, or less than 0.25 mm.

[0434] In some embodiments, the average width of the short axis 232 of the bond points is greater than 0.24 mm, greater than 0.25 mm, greater than 0.26 mm, greater than 0.27 mm, greater than 0.28 mm, greater than 0.29 mm, or 0.30 m. More than m, more than 0.31mm, more than 0.32mm, more than 0.33mm, more than 0.34mm, more than 0.35mm, more than 0.36mm, more than 0.37mm, more than 0.38mm, more than 0.39mm, 0.40m The dimensions are greater than m, greater than 0.41 mm, greater than 0.42 mm, greater than 0.43 mm, greater than 0.44 mm, greater than 0.45 mm, greater than 0.46 mm, greater than 0.47 mm, greater than 0.48 mm, greater than 0.49 mm, greater than 0.50 mm, greater than 0.51 mm, greater than 0.52 mm, greater than 0.53 mm, greater than 0.54 mm, greater than 0.55 mm, greater than 0.56 mm, greater than 0.57 mm, greater than 0.58 mm, or greater than 0.59 mm.

[0435] In the preparation of the nonwoven fabrics shown in Figures 8A to 8C, the long axis 230 of the bonding point is approximately 1.0 to 1.2 mm, particularly approximately 1.2 to 1.18 mm, and more particularly approximately 1.12 to 1.06 mm. In a somewhat preferred embodiment for preparing the nonwoven fabrics shown in Figures 8A to 8C, the individual bonding points have an average length of approximately 1.09 mm.

[0436] In the preparation of the nonwoven fabrics shown in Figures 8A to 8C, the short axis 232 of the bonding point is approximately 0.35 to 0.6 mm, particularly approximately 0.4 to 0.5 mm, and more particularly approximately 0.42 to 0.52 mm. In a somewhat preferred embodiment for preparing the nonwoven fabrics shown in Figures 8A to 8C, the individual bonding points have an average width of approximately 0.47 mm.

[0437] In one embodiment, the surface area of ​​the raised surface 222 is approximately 0.15 to approximately 0.75 mm². 2 Especially approximately 0.18 to 0.55 mm 2 More specifically, about 0.20 to 0.35 mm 2 In a preferred embodiment, the surface area of ​​the raised surface 222 is approximately 0.20 to approximately 0.30 mm². 2 More preferably about 0.21 to 0.25 mm 2 , that is.

[0438] In the preparation of the nonwoven fabric shown in Figures 8A to 8C, the surface area of ​​the raised surface 222 is approximately 0.25 to 0.55 mm². 2 Especially approximately 0.30 to 0.50 mm 2 More specifically, about 0.35 to 0.45 mm 2 In a preferred embodiment, the surface area of ​​the raised surface 222 is approximately 0.38 to approximately 0.42 mm². 2 , more preferably about 0.4 mm 2 , that is.

[0439] Figures 13B and 13C are side views of the adhesive point 200 as seen along the major axis 230 and minor axis 232 of the adhesive point, respectively. In one embodiment, the adhesive point 200 may have an average height h (distance between the base 220 and the raised surface 222) of about 0.5 to about 1.25 mm, particularly about 0.85 to about 1.15 mm, and more particularly about 0.9 to about 1.1 mm, with a height of about 0.95 to about 1.05 mm being somewhat preferable, and a height of about 1.0 mm being even more preferable.

[0440] In one embodiment, the average height 200 of the bonding point is less than 1.20 mm, less than 1.19 mm, less than 1.18 mm, less than 1.17 mm, less than 1.16 mm, less than 1.15 mm, less than 1.14 mm, less than 1.13 mm, less than 1.12 mm, less than 1.11 mm, less than 1.10 mm, less than 1.09 mm, less than 1.08 mm, less than 1.07 mm, less than 1.06 mm, and 1.05 mm. Less than m, less than 1.04 mm, less than 1.03 mm, less than 1.02 mm, less than 1.01 mm, less than 1.00 mm, less than 0.99 mm, less than 0.98 mm, less than 0.97 mm, less than 0.96 mm, less than 0.95 mm, less than 0.94 mm, less than 0.93 mm, less than 0.92 mm, less than 0.91 mm, less than 0.90 mm, less than 0.89 mm, less than 0.88 mm, less than 0.87 mm , less than 0.86mm, less than 0.85mm, less than 0.84mm, less than 0.83mm, less than 0.82mm, less than 0.81mm, less than 0.80mm, less than 0.79mm, less than 0.78mm, less than 0.77mm, less than 0.76mm, less than 0.75mm, less than 0.74mm, less than 0.73mm, less than 0.72mm, less than 0.71mm, less than 0.70mm, less than 0.69mm, 0. It is less than 68mm, less than 0.67mm, less than 0.66mm, less than 0.65mm, less than 0.64mm, less than 0.63mm, less than 0.62mm, less than 0.61mm, less than 0.60mm, less than 0.59mm, less than 0.58mm, less than 0.57mm, less than 0.56mm, less than 0.55mm, less than 0.54mm, less than 0.53mm, less than 0.52mm, or less than 0.51mm.

[0441] In one embodiment, the average height 200 of the bonding point is greater than 0.5 mm, greater than 0.51 mm, greater than 0.52 mm, greater than 0.53 mm, greater than 0.54 mm, greater than 0.55 mm, greater than 0.56 mm, greater than 0.57 mm, greater than 0.58 mm, greater than 0.59 mm, greater than 0.60 mm, greater than 0.61 mm, greater than 0.62 mm, greater than 0.63 mm, greater than 0.64 mm, and 0.65 mm. >mm, >0.66mm, >0.67mm, >0.68mm, >0.69mm, >0.70mm, >0.71mm, >0.72mm, >0.73mm, 0.74mm Super, More than 0.75mm, More than 0.76mm, More than 0.77mm, More than 0.78mm, More than 0.79mm, More than 0.80mm, More than 0.81mm, More than 0.82mm, More than 0.83mm, 0 More than .84mm, More than 0.85mm, More than 0.86mm, More than 0.87mm, More than 0.88mm, More than 0.89mm, More than 0.90mm, More than 0.91mm, More than 0.92mm, 0.9 More than 3mm, more than 0.94mm, more than 0.95mm, more than 0.96mm, more than 0.97mm, more than 0.98mm, more than 0.99mm, more than 1.0mm, more than 1.01mm, more than 1.02mm , greater than 1.03 mm, greater than 1.04 mm, greater than 1.05 mm, greater than 1.06 mm, greater than 1.07 mm, greater than 1.08 mm, greater than 1.09 mm, greater than 1.1 mm, greater than 1.11 mm, greater than 1.12 mm, greater than 1.13 mm, greater than 1.14 mm, greater than 1.15 mm, greater than 1.16 mm, greater than 1.17 mm, greater than 1.18 mm, greater than 1.19 mm, or greater than 1.20 mm.

[0442] In one embodiment for preparing the nonwoven fabrics shown in Figures 8A to 8C, the bonding point 200 may have an average height h (distance between the base 220 and the raised surface 222) of about 0.5 to about 0.85 mm, particularly about 0.55 to about 0.8 mm, and more particularly about 0.6 to about 0.75 mm, with a height of about 0.65 to about 0.75 mm being somewhat more preferred, a height of about 0.65 to about 0.7 mm being somewhat more preferred, and a height of about 0.68 mm being even more preferred.

[0443] In one embodiment, the continuous sidewall 224 of the bonding point 200 may be perpendicular to the surface 202 of the patterned roll. In another embodiment, the continuous sidewall 224 of the bonding point 200 may be inclined with respect to the surface of the patterned roll. As shown in Figures 13B and 13C, the angle a7 between the surface 202 and the continuous sidewall 224 is about 90 to about 120 degrees, and is particularly about 105 to about 115 degrees.

[0444] In another embodiment, the lateral arrays (e.g., CDA1, CDA2) extending along the CD of the patterned roll 116a may be inclined with respect to the central axis 210. That is, rather than being parallel to the central axis, the lateral arrays may extend at an angle of inclination greater than 0 degrees and less than 6 degrees with respect to a horizontal line drawn laterally across the surface of the patterned roll (a horizontal line parallel to the central axis 210). In particular, the angle of inclination ranges from greater than 0 to less than 6 degrees. In a preferred embodiment, the angle a3 is about 0.5 degrees to about 4 degrees, particularly about 1 degree to about 3 degrees, with an angle of about 2 degrees being preferred.

[0445] Nonwoven fabrics according to embodiments of the present invention can be used in a wide variety of applications, including absorbent and personal hygiene applications, medical applications, such as clothing, gowns, face masks, and wound dressings. Other applications include industrial applications such as housing construction, filtration, and furniture. Other possible applications include agricultural applications such as ground coverings, root wraps, plant covers, and protective bags. In one embodiment, the nonwoven fabric can be combined with one or more additional layers to form a laminate. In particular, laminates containing the nonwoven fabric of the present invention can be adapted for use in disposable absorbent articles such as diapers, pants, adult incontinence products, and sanitary napkins, or any other articles that may benefit from the desirable properties provided by the nonwoven fabric according to embodiments of the present invention.

[0446] Nonwoven fabrics according to embodiments of the present invention can be used to prepare a wide variety of different structures. For example, in some embodiments, the adhesive nonwoven fabric of the present invention may consist of about 1 to about 10 layers, particularly 2 to 8 layers, for example 3 to 6 layers.

[0447] In this regard, Figure 14A is a cross-sectional side view of a single-layer adhesive nonwoven fabric 300 according to at least one embodiment of the present invention. The nonwoven fabric 300 includes a plurality of fibers bonded at a plurality of spaced-out individual bonding points to form an integrated web. The nonwoven fabric 300 comprises a first surface 302 and a second surface 304, at least one of which includes an adhesive pattern according to one or more of the aforementioned bonding patterns. In one embodiment, the first surface 302 has an adhesive pattern according to at least one embodiment of the present invention, and the second surface does not have an adhesive pattern thereon. That is, during bonding, only the surface 302 is in contact with the patterned roll having a plurality of individual bonding points.

[0448] Referring to Figure 14B, a cross-sectional side view of a two-layer composite nonwoven fabric according to at least one embodiment of the present invention, and broadly designated by reference numeral 320, is shown. The composite nonwoven fabric 320 has a first layer 322 and a second layer 324 bonded to each other at an interface 326. The first layer 322 has a surface 328 having an adhesive pattern 330 disposed thereon, as described above, according to at least one embodiment of the present disclosure. The second nonwoven fabric 324 has an outer surface 332. In one embodiment, the outer surface 332 of the second nonwoven fabric layer 324 may have a substantially smooth surface that has not been spot-bonded by a calender roll. In another embodiment, the outer surface 332 may include an applied adhesive pattern according to at least one embodiment of the present disclosure, as described above.

[0449] The second nonwoven layer may include the same type of nonwoven fabric as the first nonwoven layer. In one embodiment, the second nonwoven layer may include the same type of nonwoven fabric as the first nonwoven layer. For example, the second nonwoven fabric may be a meltblown fabric, a spunbond fabric, a carded fabric, an airlaid fabric, a resin-bonded fabric, and a spunlace fabric, etc.

[0450] In some embodiments, both the first nonwoven fabric and the second nonwoven fabric may each include a spunbond nonwoven fabric.

[0451] In one embodiment, the adhesive nonwoven fabric may be combined with one or more additional layers to prepare a composite material or laminated material.

[0452] Examples of these composite materials / laminations may include spunbond composite materials, such as spunbond-meltblown (SM) composite materials, spunbond-meltblown-spunbond (SMS) composite materials, or spunbond-meltblown-meltblown-spunbond (SMMS) composite materials. In some embodiments, a composite material comprising one layer of the adhesive nonwoven fabric and one or more film layers may be prepared. It should be recognized that other configurations are also within the scope of the present invention.

[0453] In these multilayer structures, the basis weight of the spunbond nonwoven fabric layer may range from a minimum of 5 gsm to a maximum of 150 gsm. In certain embodiments having a multilayer structure (e.g., SM, SMS, and SMMS), the amount of meltblown in the composite structure may range from about 5 to 30% by weight of the structure, particularly about 5 to 15% by weight, as a weight percentage of the entire structure.

[0454] The multilayer structures according to the embodiments can be prepared in various ways, including a continuous in-line process in which each layer is prepared sequentially on the same line, or by depositing a second nonwoven fabric layer on a previously formed spunbond layer. Each layer of the multilayer structure can be thermally spot-bonded to form a multilayer composite sheet material, providing a composite sheet material having the bonding pattern described herein. In addition, composite sheet materials according to certain embodiments of the present invention may be subjected to other bonding techniques, such as thermal bonding by air drying, mechanical bonding, adhesive bonding, water entanglement, or a combination thereof. In one embodiment, each layer is thermally bonded to the others by passing the multilayer structure through a bonding unit comprising a pair of calender rolls, on which the patterned rolls of the calender have a patterned surface including the bonding pattern of the present invention.

[0455] As described above, fabrics prepared according to embodiments of the present invention can be used in a wide variety of articles and applications. For example, embodiments of the present invention can be used in personal care applications, such as baby care products (diapers, wipes), feminine care products (pads, sanitary napkins, tampons), adult care products (incontinence products), or cosmetic applications (pads), agricultural applications, such as root wrappers, seed bags, crop covers, industrial applications, such as workwear coveralls, aircraft pillows, automobile trunk liners, soundproofing materials, and household products, such as mattress coil covers, furniture scratch pads.

[0456] The following embodiments are provided to illustrate one or more embodiments of the present invention and should not be construed as limiting the invention.

[0457] Examples

[0458] The spunbond nonwovens in the following examples were prepared using the Reicofil 4S spunbond spinning line manufactured by Reifenhaeuser. Unless otherwise specified, all percentages are weight percentages. The materials and test methods used in each example are described below.

[0459] Test method:

[0460] Standard weights were measured according to NWSP 130.1.

[0461] MD and CD tensile strengths were measured according to NWSP 110.4B (modified: gauge length was 100 mm, sample width was 50 mm, and speed was 100 mm / min).

[0462] MD and CD elongation rates were measured according to NWSP 110.4B (modified: gauge length was 100 mm, sample width was 50 mm, and speed was 100 mm / min).

[0463] The caliper was measured according to NWSP 120.6.

[0464] Air permeability was measured according to ASTM 90.3.

[0465] Hydrohead values ​​were measured according to WSP 80.6.

[0466] The Handle-O-Meter value was measured according to NWSP 90.3.

[0467] Softness bending was measured according to WSP 90.1.

[0468] Abrasion resistance was measured according to NWSP 20.5: the surface of each test sample of the nonwoven fabric was rubbed 32 times against white rubber at a pressure of 9 kPa. The weight of the test sample was measured before rubbing. After rubbing, the test sample was scraped off and weighed again.

[0469] The Martindale Abrasion Test Method Grading Scale (Martindale Abrasion Scoring) is used. In this method, the surface of each test sample of the nonwoven fabric is rubbed 32 times against white rubber at a pressure of 9 kPa. Next, the surface of each sample is evaluated under a microscope for the appearance of defects and then graded on a scale of 1 to 5, where scores of 1 to 2 are considered consumer-acceptable, and scores of 3 to 5 are considered unacceptable. A lower score indicates better abrasion resistance of the fabric. The score is determined based on the following criteria: Score of 1-2: The sample has few or no visible defects (the sample may contain some fuzz (short fibers lifted from the fabric) or tiny pilling (less than 2mm in diameter)); Score of 2-3: The sample contains pilling (ball-shaped fibers less than 2mm in diameter) and thin strings (less than 2mm in width), and the pilling and strings are not connected to the network of individual fibers; Score of 3 or higher: Samples show rope (long fibers twisted to form braided rope), loft, spiderweb (interconnected rope and lint network that increases the loft of the fabric, and cut spiderweb, holes on the fabric surface, and increased loft).

[0470] material:

[0471] "PP-1" refers to homopolymer polypropylene with an MFR of 34 g / 10 min, available from Braskem under product number CP360H.

[0472] "PP-2" refers to homopolymer polypropylene with an MFR of 1284 g / 10 min, available from Basell under product number H155.

[0473] "PP-3" refers to a metallocene-catalyzed polypropylene with an MFR of 35 g / 10 min, available from Basell under product number HM562S.

[0474] "PP-4" refers to homopolymer polypropylene with an MFR of 35 g / 10 min, available from IRPC under product code 1105SC.

[0475] "CoPP" is from ExxonMobil to VISTAMAXX 商標 This refers to a polypropylene copolymer with an MFR of 48 g / 10 min, available under the trademark 7050FL.

[0476] "L-MODU" is L-MODU from Idemitsu 商標 This refers to a low-isotactic polypropylene copolymer available under the product name [product name].

[0477] "TiO2" refers to Remafin White PPF2K002G titanium dioxide, available from Clariant / Avient under product code PP0N420701.

[0478] "SA" is from Evonik Industries to ACCURES. 登録商標 This refers to a slip agent available under the trademark SF617.

[0479] Comparative Example 1:

[0480] In Comparative Example 1, a two-layer spunbond nonwoven fabric was prepared. The first layer had non-crimped filaments made of PP-1, and the second layer had two-component filaments arranged in a side-by-side (70:30) configuration, with one side containing PP-1 and the other side containing a blend of PP-1 and PP-2. The amount of PP-1 in the blend was 98.65% by weight based on the total weight of the blend, and the amount of PP-2 was 1.35% by weight.

[0481] The resulting two layers of spunbond fabric were thermally spot-bonded using a calendering unit comprising a smooth anvil roll and a grooved pattern roll having an adhesive pattern similar to that shown in Figure 1, except for the size of the individual bonding points, the density of the bonding points, and the percentage of the overall bonded surface area of ​​the bonded nonwoven fabric. The patterned roll was heated to a temperature of approximately 152°C. In Comparative Example 1, the percentage of the bonded nonwoven fabric surface was 18.1%, and the adhesive density was 49.9 bonding points per square centimeter.

[0482] Example 1 of the present invention was identical to the nonwoven fabric of Comparative Example 1, except that the nonwoven fabric sample was thermally spot-bonded using a calendering unit having a roll patterned with an adhesive pattern according to the pattern shown in Figure 1. In addition, the patterned roll had a transverse inclination of approximately 2 degrees. The calendering unit was operated at a temperature of approximately 155°C. The surface percentage of the bonded nonwoven fabric in Example 1 of the present invention was 9.92%, and the adhesive density was 55.2 bonded points per square centimeter.

[0483] The dimensions and physical characteristics of the engraving rolls used in Comparative Example 1 and Example 1 of the present invention are summarized in Tables 1 and 2 below.

[0484] [Table 1]

[0485] [Table 2]

[0486] Ten samples were prepared and evaluated for Comparative Example 1 and Example 1 of the present invention. The average results are shown in Tables 3 to 5 below.

[0487] [Table 3]

[0488] [Table 4]

[0489] Table 4 shows that the nonwoven fabric of the present invention showed an increase in both tensile strength and elongation compared to Comparative Example 1. The increase in tensile strength was particularly surprising, as an increase in the percentage of adhesive area is typically expected to increase the tensile strength of the nonwoven fabric compared to nonwoven fabrics with a lower percentage of adhesive area.

[0490] In particular, the nonwoven fabric of Example 1 of the present invention showed an increase in tensile strength in the mechanical direction of more than 10%, and especially more than 12%, compared to the nonwoven fabric of Comparative Example 1. In addition, the nonwoven fabric of Example 1 of the present invention showed an increase in tensile strength in the transverse direction of more than 15%, and especially more than 20%, compared to the nonwoven fabric of Comparative Example 1.

[0491] In the nonwoven fabric of Example 1 of the present invention, the elongation in both the machine direction and the transverse direction was improved compared to the nonwoven fabric of Comparative Example 1. For example, the nonwoven fabric of Example 1 of the present invention showed increases of 4.6% and 13.9% in the elongation in the machine direction and transverse direction, respectively, compared to the nonwoven fabric of Comparative Example 1.

[0492] The breathability of the fabrics in Comparative Example 1 and Example 1 of the present invention was equivalent, with Example 1 showing only a slight decrease of less than 2%.

[0493] [Table 5]

[0494] Surprisingly, the nonwoven fabric of the present invention also showed improvements in abrasion resistance and flexibility compared to Comparative Example 1. In particular, a fabric with a higher percentage of adhesive area is expected to have reduced abrasion resistance compared to the nonwoven fabric of Example 1 of the present invention, which had approximately half the percentage of adhesive area of ​​the nonwoven fabric of Comparative Example 1. The smooth surface of Example 1 of the present invention (the surface in contact with the surface of the smooth anvil roll) showed an approximately 74% reduction in material removed during the abrasion test compared to the nonwoven fabric of Comparative Example 1. The surface of the nonwoven fabric of Example 1 of the present invention in contact with the pattern roll showed a slight percentage increase (approximately 9.7%) in material removed during the abrasion test compared to the nonwoven fabric of Comparative Example 1; however, the average abrasion resistance of both sides of the nonwoven fabric showed an approximately 63% reduction in material removed during the abrasion test compared to the nonwoven fabric of Comparative Example 1. Thus, these results indicate that the fabric of the present invention has a percentage reduction in adhesive area and shows improvement in abrasion resistance compared to the comparative nonwoven fabric (which has a higher percentage of adhesive area).

[0495] Evaluation using the Martindale scoring method also showed that the fabric of the present invention demonstrated improved abrasion resistance compared to the nonwoven fabric of Comparative Example 1. In particular, Example 1 of the present invention showed an 18.2% decrease in the percentage of the Martindale score, which reflects an improvement of almost 20% in abrasion resistance. This is also remarkable because the amount of surface area bonded in Example 1 of the present invention is almost half that of Comparative Example 1.

[0496] In addition, the fabric of the present invention also showed improvement in softness compared to the nonwoven fabric of Comparative Example 1, as evidenced by the decrease in the Handle-O-Meter (HOM) value.

[0497] From the above results, it is clear that the nonwoven fabric of the present invention exhibits higher mechanical properties, coupled with increased abrasion resistance and increased flexibility. Since the percentage of the adhesive area of ​​the nonwoven fabric decreases compared to Comparative Example 1, both tensile strength and abrasion resistance are expected to decrease, and therefore such improvements are not expected in combination.

[0498] Examples 2 and 3 of the present invention

[0499] In Examples 2 and 3 of the present invention, a three-layer spunbond nonwoven fabric was prepared, with each layer containing the same polymer blend. The nonwoven fabric was thermally spot-bonded by operating a calendering unit at a temperature of approximately 150°C. The calendering unit had the same engraving pattern as in Example 1 of the present invention. In Examples 2 and 3 of the present invention, the bonded surface percentage of the nonwoven fabric was 9.92%, and the bonding density was 55.2 bond points per square centimeter. The nonwoven fabric in Example 2 of the present invention was prepared with a polymer throughput of 180 kg / m / hour and a cabin pressure of 5100 Pa. The nonwoven fabric in Example 3 of the present invention was prepared with a polymer throughput of 160 kg / m / hour and a cabin pressure of 5300 Pa.

[0500] The fibers of Examples 2 and 3 of the present invention consist of a blend of 92.2% PP-3, 7.0% CoPP, and 0.8% TiO2 and SA.

[0501] Example 4 of the present invention

[0502] In the following Example 4 of the present invention, a three-ply spunbond nonwoven fabric was prepared using a calendering unit comprising a smooth anvil roll and an engraved patterned roll having an adhesive pattern configured to produce an adhesive pattern similar to that shown in Figure 8A. The die cabin pressure was operated at a pressure exceeding 5,100 Pa with a polymer throughput of 200 kg / m / hour.

[0503] The fibers in Example 4 of the present invention contained a blend of 81.4% PP-4, 18.0% L-MODU, and 0.8% TiO2 and SA. The calendering unit was operated at a temperature of approximately 150°C. The percentage of the surface of the nonwoven fabric bonded in Example 4 of the present invention was 13.4%, and the bonding density was 33.4 bonding points per square centimeter.

[0504] The individual bonding points on the mortising roll had an average height of 68 mm, an average width of 0.47 mm, and an average length of 1.09 mm. The average surface area of ​​the bonding points was 0.4 mm. 2 The aggregate average bonding distance is 1.6 mm, and the bonding packing density is 4 mm -1 That was the case.

[0505] The properties of the nonwoven fabrics in Examples 2 to 4 of the present invention are provided in Table 6 below.

[0506] [Table 6]

[0507] [Table 7]

[0508] Interestingly, as can be seen from the comparison between Example 2 and Example 3 of the present invention, it was observed that thinner fibers were obtained due to the decrease in throughput and increase in cabin pressure. In particular, the fibers of Example 2 of the present invention showed an average filament size of 1.26 Dtex, while the fibers of Example 3 of the present invention showed an average filament size of 0.9 Dtex. This represents a 28.6% decrease in fiber thinness.

Claims

1. A nonwoven fabric comprising multiple fibers, wherein the multiple fibers are bonded to the surface of the nonwoven fabric in an adhesive pattern to form an integrated web, the nonwoven fabric having a vertical axis extending in the machine direction and a horizontal axis extending in the transverse direction, and the adhesive pattern having a plurality of spaced-apart array pairs extending in the machine direction, transverse direction and diagonal direction of the nonwoven fabric, where each array has a plurality of spaced-apart oval-shaped adhesive points, and the nonwoven fabric has an adhesive surface area percentage of less than about 12% and about 6.5 to about 8.0 mm －１ The nonwoven fabric having an average adhesion point packing value.

2. In the aforementioned nonwoven fabric, the adhesive point is approximately 0.15 to approximately 0.25 mm ２ The nonwoven fabric according to claim 1, having an average surface area.

3. The nonwoven fabric according to any one of claims 1 to 2, wherein the nonwoven fabric has an adhesion point density of about 50 to about 60 individual adhesion points per square centimeter.

4. The nonwoven fabric according to any one of claims 1 to 3, wherein the nonwoven fabric has a Martindale abrasion score of about 1.0 to about 1.5, a transverse handle-o-meter value of about 6.6 to about 7.2 grams, a mechanical handle-o-meter value of about 3.5 to about 3.95 grams, and an average abrasion resistance of 3.2 to 5.5 grams as measured by the weight of the removed material.

5. The percentage of the adhesive surface area of ​​the nonwoven fabric is approximately 9.8% to 10%, and the average adhesive point surface area is approximately 0.16% to 0.2mm². ２ The average packing value at the bonding point is approximately 6.75 to 7.25 mm. －１ The nonwoven fabric according to any one of claims 1 to 4, wherein the adhesion point density of the nonwoven fabric is about 52 to about 58 individual adhesion points per square centimeter.

6. The nonwoven fabric according to any one of claims 1 to 5, wherein the nonwoven fabric exhibits an average abrasion resistance of 3.4 to 3.6 grams, as measured by a Martindale abrasion score of 1 to 2, a transverse handle-o-meter value of about 6.7 to about 7.0 grams, a mechanical handle-o-meter value of about 3.6 to about 3.9 grams, and the weight of the removed material.

7. The nonwoven fabric according to any one of claims 1 to 6, wherein the bonding pattern comprises alternating first and second arrays of individual bonding points extending transversely to the nonwoven fabric, wherein each individual bonding point of the first and second arrays has a length and a width, the lengths of the individual bonding points of the first array are aligned substantially in the same direction and at an angle of about 43 to about 47 degrees with respect to the horizontal axis of the nonwoven fabric, the lengths of the individual bonding points of the second array are rotated by about 88 to about 92 degrees with respect to the alignment of the individual lengths of the first array, and the individual bonding points of the second array are laterally offset from adjacent individual bonding points of the first array.

8. The nonwoven fabric according to any one of claims 1 to 7, wherein the number of individual adhesive points per square centimeter is approximately 45 to approximately 60, more particularly approximately 50 to approximately 58, and more particularly approximately 54 to approximately 56.

9. The nonwoven fabric according to any one of claims 1 to 8, wherein the percentage of the adhesive area of ​​the nonwoven fabric is about 9 to about 10.5%, more particularly about 9.8 to about 10.2%, and more particularly about 9.9 to about 10%.

10. The nonwoven fabric according to any one of claims 1 to 9, wherein the distance between adjacent adhesives in the transverse direction is approximately 1.4 to approximately 1.6 mm, particularly approximately 1.45 to approximately 1.55 mm, and more particularly approximately 1.48 to approximately 1.52 mm.

11. The nonwoven fabric according to any one of claims 1 to 10, wherein the distance between adjacent adhesive points within the same array in the diagonal transverse direction of the nonwoven fabric is about 0.7 to about 0.95 mm, particularly about 0.75 to about 0.90 mm, and more particularly about 0.80 to about 0.85 mm.

12. The nonwoven fabric according to any one of claims 1 to 11, wherein the adhesive point has an oval, elliptical, rectangular, rod-shaped, or a combination thereof.

13. The nonwoven fabric according to claim 7, wherein the bonding pattern further defines a plurality of alternating third and fourth arrays of repeating individual bonding points extending in the machine direction of the nonwoven fabric, wherein the individual bonding points of the third array are offset in the machine direction from the adjacent individual bonding points of the fourth array.

14. The nonwoven fabric according to claim 13, wherein the bonding pattern further defines a plurality of alternating fifth and sixth arrays of individual bonding points extending obliquely to the machine direction of the nonwoven fabric.

15. The nonwoven fabric according to claim 14, wherein the adjacent bonding points of the fifth array and the sixth array are aligned at an angle of about 88 to about 92 degrees with respect to the alignment direction of the individual adjacent bonding points within the same array.

16. The nonwoven fabric according to any one of claims 1 to 15, wherein three adjacent arrays of individual bonding points further define a plurality of bonding patterns having a fifth-eye pattern in both the machine direction and the transverse direction, wherein four individual bonding points defining the corners of the fifth-eye pattern share substantially the same orientation direction with respect to the transverse or machine direction of the nonwoven fabric, and individual bonding points defining the center point of the fifth-eye pattern have an orientation direction rotated by about 88 to about 92 degrees with respect to the orientation direction of the individual bonding points defining the corners of the fifth-eye pattern.

17. The nonwoven fabric according to any one of claims 1 to 16, wherein the angle between the array extending diagonally and the array extending laterally is about 43 degrees to about 47 degrees, particularly about 45 degrees.

18. The nonwoven fabric according to any one of claims 1 to 17, wherein the nonwoven fabric exhibits a Martindale abrasion score of less than 1.5, particularly 1.2 to 1.5, and more particularly about 1.40 to about 1.

45.

19. The nonwoven fabric according to any one of claims 1 to 18, wherein the nonwoven fabric has a standard weight of about 20 to about 30 gsm and exhibits flexibility expressed by a transverse handle-of-meter value of less than 7.0 grams (g), for example less than 7.9 grams or less than 7.5 grams.

20. The nonwoven fabric according to any one of claims 1 to 19, wherein the nonwoven fabric has a reference weight of about 20 to about 30 gsm and exhibits flexibility expressed by a handle-o-meter value in the machine direction of less than 3.9 grams (g), for example less than 3.8 grams or less than 3.78 grams.

21. The aforementioned nonwoven fabric differs from a similarly prepared nonwoven fabric by 3.5 mm. －１ A nonwoven fabric according to any one of claims 1 to 20, exhibiting increased tensile strength, elongation, abrasion resistance, and flexibility, except that it is spot-bonded with an adhesive pattern having fewer than 100 adhesive-point packings.

22. The aforementioned nonwoven fabric is 3.5 mm －１ Compared to similarly prepared nonwoven fabrics with fewer than 3.5 mm of adhesive point packing, it exhibits a tensile strength that is 10% or more greater, for example, 3.5 mm. －１ A nonwoven fabric according to any one of claims 1 to 21, exhibiting an increase in tensile strength of only 10% to 50%, for example, 12% to 30%, 12% to 25%, 12% to 24%, or 12% to 20%, compared to a similarly prepared nonwoven fabric having less than 10% to 50% tensile strength of 12% to 30%, 12% to 25%, 12% to 24%, or 12% to 20% tensile strength of

23. The nonwoven fabric according to any one of claims 1 to 22, wherein the nonwoven fabric exhibits an increase in tensile strength that is at least 10% greater than that of a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

24. The nonwoven fabric according to any one of claims 1 to 23, wherein the nonwoven fabric exhibits an increase in tensile strength that is 10% to 30%, for example, 12% to 20%, greater than the tensile strength of a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

25. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 24, exhibiting an increase in tensile strength in the mechanical direction that is only about 10 to about 50% greater than a similarly prepared nonwoven fabric having less than 10-50% adhesive point packing.

26. The non-woven fabric is 3.5 mm －１ The non-woven fabric according to any one of claims 1 to 25, showing an increase in tensile strength in the machine direction of about 10% to about 30%, such as about 12% to about 20%, or about 12 to about 15%, compared to a similarly prepared non-woven fabric having less than the adhesion point packing.

27. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 26, exhibiting an increase in transverse tensile strength that is only about 10 to about 50% greater than a similarly prepared nonwoven fabric having less than 10-50% adhesive point packing.

28. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 27, exhibiting an increase in transverse tensile strength of about 10 to about 30%, for example, about 15 to about 25%, about 18% to about 24%, or about 19% to about 21%, compared to a similarly prepared nonwoven fabric having less than 10% adhesive point packing.

29. The nonwoven fabric according to any one of claims 1 to 28, wherein the nonwoven fabric exhibits an increase in mechanical tensile strength that is only about 10 to about 50% greater than a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

30. The nonwoven fabric according to any one of claims 1 to 29, wherein the nonwoven fabric exhibits an increase in tensile strength in the mechanical direction of about 10 to about 30%, for example, about 12 to about 20%, or about 12 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

31. The nonwoven fabric according to any one of claims 1 to 30, wherein the nonwoven fabric exhibits an increase in transverse tensile strength that is only about 10 to about 50% greater than that of a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

32. The nonwoven fabric according to any one of claims 1 to 31, wherein the nonwoven fabric exhibits an increase in transverse tensile strength of about 10 to about 30%, for example, about 15 to about 25%, about 18 to about 24%, or about 19 to about 21%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

33. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 32, exhibiting an increase in elongation of about 4 to about 50% compared to a similarly prepared nonwoven fabric having less than 50% adhesive point packing.

34. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 33, exhibiting an increase in elongation of about 4 to about 25%, for example, about 5 to about 20%, or about 5 to about 15%, compared to a similarly prepared nonwoven fabric having less than 40% adhesive point packing.

35. The nonwoven fabric according to any one of claims 1 to 34, wherein the nonwoven fabric exhibits an increase in elongation of about 4 to about 50% compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

36. The nonwoven fabric according to any one of claims 1 to 35, wherein the nonwoven fabric exhibits an increase in elongation of about 4 to about 25%, for example, about 5 to about 20%, or about 5 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

37. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 36, exhibiting a 10% to 30% increase in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having less than 10% adhesive point packing.

38. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 37, exhibiting an increase of about 10 to about 25%, for example, about 12 to about 24%, or about 18 to about 22%, in abrasion resistance, expressed by a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having less than 10% abrasion point packing.

39. The nonwoven fabric according to any one of claims 1 to 38, wherein the nonwoven fabric exhibits a 10 to 30% increase in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

40. The nonwoven fabric according to any one of claims 1 to 39, wherein the nonwoven fabric exhibits an increase of about 10 to about 25%, for example, about 12 to about 24%, or about 18 to about 22%, in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

41. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 40, exhibiting an average percentage reduction of 5% to 150% in the weight of material removed during an abrasion test (according to test method NWSP 20.5) compared to a similarly prepared nonwoven fabric having less than 5% adhesive point packing.

42. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 41, exhibiting an average percentage reduction of 8% to 120%, for example 9% to 95%, in the weight of material removed during an abrasion test (according to test method NWSP 20.5), compared to a similarly prepared nonwoven fabric having less than 90% adhesive point packing.

43. The nonwoven fabric according to any one of claims 1 to 42, wherein the nonwoven fabric exhibits an average percentage reduction of 5% to 150% in the weight of material removed during an abrasion test (according to test method NWSP 20.5) compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

44. The nonwoven fabric according to any one of claims 1 to 43, wherein the nonwoven fabric exhibits an average percentage reduction of 8% to 120%, for example 9% to 95%, in the weight of material removed during an abrasion test (according to test method NWSP 20.5) compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

45. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 44, exhibiting an increase in flexibility of about 5 to about 20%, expressed by the average difference in handle-to-meter values, compared to a similarly prepared nonwoven fabric having less than 50% adhesive point packing.

46. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 45, exhibiting an increase in flexibility of about 6 to about 15%, for example 8% to about 10%, as expressed by the average difference in handle-of-meter values, compared to a similarly prepared nonwoven fabric having less than 10% adhesive point packing.

47. The nonwoven fabric according to any one of claims 1 to 46, wherein the nonwoven fabric exhibits an increase in flexibility of about 5 to about 20%, expressed by the average difference in handle-to-meter values, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

48. The nonwoven fabric according to any one of claims 1 to 47, wherein the nonwoven fabric exhibits an increase in flexibility of about 6 to about 15%, for example 8 to 10%, as expressed by the average difference in handle-of-meter values, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%.

49. The aforementioned nonwoven fabric is 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 48, exhibiting an increase in flexibility of about 5 to about 20%, expressed by the average difference in handle-to-meter values, compared to a similarly prepared nonwoven fabric having less than 50% adhesive point packing.

50. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.4%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average surface area of ​​each bonding point is approximately 6.75 to 7.25 mm². －１ A nonwoven fabric according to any one of claims 1 to 49, having an average bond point packing value, a bond point density of about 50 to about 60 individual bond points per square centimeter, a Martindale abrasion score of about 1.0 to about 1.5, a transverse handle-o-meter value of about 6.6 to about 7.2 grams, a mechanical handle-o-meter value of about 3.5 to about 3.95 grams, and an average abrasion resistance of 3.2 to 5.5 grams, as measured by the weight of the removed material.

51. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.8 to 10%, and an area of ​​approximately 0.15 to 0.2 mm. ２ The average surface area of ​​each bonding point is approximately 7 to 7.2 mm². －１ A nonwoven fabric according to any one of claims 1 to 50, having an average bond point packing value, a bond point density of about 52 to about 58 individual bond points per square centimeter, a Martindale abrasion score of about 1.42 to about 1.45, a transverse handle-o-meter value of about 6.7 to about 7.0 grams, a mechanical handle-o-meter value of about 3.6 to about 3.9 grams, and an average abrasion resistance of 3.4 to 3.6 grams, as measured by the weight of the removed material.

52. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.2%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². －１ The average bond point packing value, and 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 51, having an average increase in tensile strength of only 10% greater than a similarly prepared nonwoven fabric having less than 10% of the adhesive point packing, for example, about 10% to about 50%, about 12% to about 24%, or about 12% to about 22%.

53. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.2%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². －１ A nonwoven fabric according to any one of claims 1 to 52, having an average increase in tensile strength of only 10% greater, for example, about 10 to about 50%, about 12 to about 24%, or about 12 to about 22%, compared to a similarly prepared nonwoven fabric having an average bonding point packing value and a bonding surface area of ​​more than 12%, for example, 18.1%.

54. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.2%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². －１ The average bond point packing value, and 3.5 mm －１ A nonwoven fabric according to any one of claims 1 to 53, having an average increase in elongation of about 4 to about 50%, for example, about 4 to about 20%, about 4 to about 15%, or about 4 to about 14%, compared to a similarly prepared nonwoven fabric having less than 40% adhesive point packing.

55. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.2%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average bonding surface area of ​​each individual is approximately 6.5 to 7.5 mm². －１ A nonwoven fabric according to any one of claims 1 to 54, having an average increase in elongation of about 4 to about 50%, for example, about 4 to about 20%, about 4 to about 15%, or about 4 to about 14%, compared to a similarly prepared nonwoven fabric having an average bonding point packing value and a bonding surface area of ​​more than 12%, for example, 18.1%.

56. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.2%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². －１ The nonwoven fabric according to any one of claims 1 to 55, having an average adhesion point packing value and one or more of the following characteristics: iv) 3.5 mm －１ Compared to similarly prepared nonwoven fabrics with fewer than 10% adhesive point packing, there is a 10% to 30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score; v) 3.5 mm －１ Compared to similarly prepared nonwoven fabrics having less than 5% to 150%, for example about 8% to about 120%, or about 9% to about 95%, in the weight of material removed during abrasion tests (according to test method NWSP 20.5), average percentage reduction; and vi) 3.5 mm －１ Compared to similarly prepared nonwoven fabrics with less than 5% adhesive point packing, this represents an improvement in flexibility of approximately 5-20%, for example, approximately 6-15%, or approximately 8-10%, as indicated by an average improvement in handle-to-meter values.

57. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.2%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². －１ The nonwoven fabric according to any one of claims 1 to 56, having an average adhesion point packing value and one or more of the following characteristics: iv) A 10% to 30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, e.g., 18.1%; v) an average percentage reduction of 5% to 150%, for example about 8% to about 120%, or about 9% to about 95%, in the weight of material removed during abrasion testing (according to test method NWSP 20.5), compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example 18.1%; and vi) An improvement in flexibility of about 5 to about 20%, for example, about 6 to about 15%, or about 8 to about 10%, as indicated by an average improvement in the handle-of-meter value, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

58. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.2%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². －１ The nonwoven fabric according to any one of claims 1 to 57, having an average adhesion point packing value and one or more of the following characteristics: vii) 3.5 mm －１ Compared to similarly prepared nonwoven fabrics with fewer than 10% adhesive point packing, there is a 10% to 30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score; viii) 3.5mm －１ Compared to similarly prepared nonwoven fabrics having less than 5% adhesive point packing, the average percentage reduction in the weight of material removed during abrasion testing (according to test method NWSP 20.5) is 5% to 150%, for example, about 8% to about 120%, or about 9% to about 95%; ix) 3.5 mm －１ Compared to similarly prepared nonwoven fabrics with less than 5% adhesive point packing, there is an improvement in flexibility of about 5-20%, for example, about 6-15%, or about 8-10%, as indicated by an average improvement in handle-of-meter values; x) 3.5 mm －１ Compared to similarly prepared nonwoven fabrics with fewer than 10-50% greater tensile strength in the mechanical direction (MD), for example, about 10-30%, 12-20%, or 12-15% greater; xi) 3.5 mm －１ Compared to similarly prepared nonwoven fabrics having less than 10-50% greater tensile strength in the transverse direction (CD), for example, about 10-30%, about 15-25%, about 18-24%, or about 19-21%; and xii) 3.5mm －１ Compared to similarly prepared nonwoven fabrics with less than 50% adhesion point packing, this represents an increase in elongation of approximately 4 to 50%, for example, approximately 5 to 20%, or approximately 5 to 15%.

59. The aforementioned nonwoven fabric has an adhesive area percentage of approximately 9.6 to 10.2%, and an area of ​​approximately 0.15 to 0.25 mm. ２ The average bonding surface area of ​​each individual is approximately 6.75 to 7.25 mm². －１ A nonwoven fabric according to any one of claims 1 to 58, having an average adhesion point packing value and one or more of the following characteristics: vii) A 10% to 30% improvement in abrasion resistance, expressed as a percentage difference in the Martindale abrasion score, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, e.g., 18.1%; viiii) An average percentage reduction of 5% to 150%, for example about 8% to 120%, or about 9% to 95%, in the weight of material removed during an abrasion test (according to test method NWSP 20.5), compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, e.g., 18.1%; Compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, e.g., 18.1%, an improvement in flexibility of about 5 to about 20%, e.g., about 6 to about 15%, or about 8 to about 10%, as indicated by an average improvement in the handle-of-meter value; x) An increase in tensile strength in the mechanical direction (MD) that is only about 10 to about 50%, for example about 10 to about 30%, for example about 12 to about 20%, or about 12 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example 18.1%; xi) An increase in transverse (CD) tensile strength that is only about 10 to about 50%, for example about 10 to about 30%, for example about 15 to about 25%, about 18 to about 24%, or about 19 to about 21%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example 18.1%; and xi) An increase in elongation of about 4 to about 50%, for example, about 5 to about 20%, or about 5 to about 15%, compared to a similarly prepared nonwoven fabric having an adhesive surface area of ​​more than 12%, for example, 18.1%.

60. The nonwoven fabric according to any one of claims 1 to 59, wherein the nonwoven fabric includes a spunbond layer.

61. The nonwoven fabric according to any one of claims 1 to 60, wherein the nonwoven fabric comprises a first spunbond layer having few or no crimped filaments, and a second layer containing crimped filaments.

62. The nonwoven fabric according to any one of claims 1 to 61, wherein the nonwoven fabric comprises at least two layers, one of which is selected from the group consisting of a meltblown layer; a carded fabric layer; a spunbond layer; a resin adhesive layer; an airlaid fabric layer; and a spunlace layer.

63. The use of the nonwoven fabric according to any one of claims 1 to 62, wherein the nonwoven fabric is contained within an absorbent article.

64. A nonwoven article comprising the nonwoven fabric described in any one of claims 1 to 63.

65. A composite sheet material comprising a nonwoven fabric according to any one of claims 1 to 64.

66. The composite sheet material according to claim 65, wherein the sheet material includes a meltblown layer.

67. The composite sheet material according to claim 26, wherein the meltblown layer is sandwiched between two spunbond layers, where at least one of the spunbond layers conforms to a nonwoven fabric layer according to any one of claims 1 to 61.

68. An absorbent article comprising a nonwoven fabric as described in any one of claims 1 to 62.

69. A calendering unit for spot bonding sheet material, the calendering unit comprising a pair of cooperating cylindrical rolls, at least one of the pair of cylindrical rolls having a recessed pattern thereon, the recessed pattern comprising a plurality of spaced individual bonding points extending radially from the surface of the roll, the plurality of bonding points being configured and arranged to define a pattern comprising a plurality of spaced arrays extending lateral and radially from the roll and thermally spot-bond the nonwoven fabric, wherein the percentage of the bonding surface area of ​​the nonwoven fabric is less than approximately 12%, and the average bonding point packing value of the nonwoven fabric is approximately 6.5 to approximately 8 mm. －１ The calendar adhesive unit.

70. The calendering unit according to claim 69, wherein the engraved pattern further comprises a plurality of spaced arrays extending circumferentially around the roll in a spiral shape on its outer circumference.

71. The aforementioned bonding point has a continuous side wall and a raised surface, the raised surface being approximately 0.15 to approximately 0.25 mm ２ A calendar adhesive unit according to claim 69 or 70, having an average surface area.

72. The calendar adhesive unit according to any one of claims 69 to 71, wherein the number of adhesive points is about 50 to about 60 individual adhesive points per square centimeter.

73. A calendar adhesive unit according to any one of claims 69 to 72, wherein the average length of the adhesive points is about 0.74 to about 0.78 mm, and the average width of the adhesive points is about 0.24 to about 0.36 mm.

74. A system for preparing nonwoven fabrics, The first polymer source and A spin beam communicating with the first polymer supply source, wherein the spin beam is configured and arranged to generate a plurality of polymer fibers, A collection surface located below the spin beam, wherein the collection surface is for depositing the plurality of polymer fibers to form a web, A thermal bonding unit positioned downstream of the spin beam, the thermal bonding unit comprises a pair of cooperating cylindrical rolls, at least one of the pair of cylindrical rolls having a recessed pattern thereon, the recessed pattern having a plurality of spaced-apart individual bonding points extending radially outward from the surface of the roll, the plurality of bonding points being configured and arranged to define a pattern including a plurality of spaced-apart arrays extending transversely and radially from the roll and thermally point-bond the web of fibers to form a nonwoven fabric, wherein the percentage of the bonded surface of the nonwoven fabric is less than about 12%, and the average bonded point packing value of the nonwoven fabric is about 6.5 to about 8 mm －１ The heat bonding unit and The system comprising the above-mentioned features.

75. A method for preparing an adhesive nonwoven fabric, Prepare a nonwoven web containing multiple fibers. The introduction of the nonwoven web into a heat bonding unit having a pair of cooperating cylindrical rolls, wherein at least one of the pair of cylindrical rolls has a recessed pattern thereon, the recessed pattern has a plurality of spaced-apart individual bonding points extending radially outward from the surface of the roll, and the plurality of bonding points define a pattern including a plurality of spaced-apart arrays extending lateral and radially to the roll, and The method involves thermally spot-bonding the fiber web to form a nonwoven fabric, wherein the percentage of the adhesive surface area of ​​the nonwoven fabric is less than approximately 12%, and the average adhesive point packing value of the nonwoven fabric is approximately 6.5 to approximately 8 mm. １ Therefore, to form The method, including the method described above.

76. A nonwoven fabric comprising multiple fibers, wherein the multiple fibers are bonded to the surface of the nonwoven fabric in an adhesive pattern to form an integrated web, the nonwoven fabric having a vertical axis extending in the machine direction and a horizontal axis extending in the transverse direction, and the adhesive pattern having a plurality of spaced-apart array pairs extending in the machine direction, transverse direction and diagonal direction of the nonwoven fabric, where each array has a plurality of spaced-apart oval-shaped adhesive points, the nonwoven fabric having a percentage of adhesive surface area of ​​less than about 14%, a collective average adhesive distance of about 1.5 to about 1.7 mm, and about 3.0 to about 5.0 mm －１ The nonwoven fabric having an average adhesion point packing value.

77. The nonwoven fabric according to claim 76, wherein the fibers comprise a blend of polypropylene resin and less than 20% by weight of polypropylene copolymer.

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