Nonwoven fabric having a single layer with multiple different fiber types, and apparatus, system, and method for manufacturing the same.

Abstract

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

Description

Technical Field

[0001] Cross - reference to related applications This application claims the benefit of U.S. Provisional Application No. 63 / 136,122, filed on January 11, 2021, the content of which is incorporated herein by reference in its entirety.

[0002] The presently disclosed invention generally relates to non - woven fabrics, and more particularly to non - woven fabrics having a laminated woven fabric layer with two or more regions of a desired function.

Background Art

[0003] Non - woven fabrics are used in a variety of applications, such as, among other things, clothing, disposable medical products, and absorbent articles (e.g., diapers and personal hygiene products). New products developed for these applications have strict performance requirements, such as comfort, body conformity, freedom of body movement, good softness and drape, adequate tensile strength and durability, and resistance to surface abrasion, linting or fuzzing, including the above - mentioned strict performance requirements. Therefore, non - woven fabrics used in these kinds of products must be designed to meet these performance requirements.

[0004] In some situations, it may be desirable for the non - woven fabric to also exhibit different properties or combinations of properties within the non - woven fabric. To achieve this goal, typically, it is necessary to combine multiple layers of non - woven fabric to form a composite structure. This typically involves the use of multiple spin beams for preparing multiple non - woven fabric layers, and the individual layers impart the desired properties to the resulting composite non - woven fabric.

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

[0006] The use of multiple spin beams inevitably increases the complexity and cost associated with manufacturing nonwovens that exhibit different properties in different regions of the nonwoven fabric. [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] While considerable effort has been put into the development of nonwoven fabrics, there is still a need for products that exhibit multiple properties and functionalities. [Means for solving the problem]

[0008] One or more embodiments of the present invention provide a nonwoven fabric comprising a single layer containing multiple different fibers, each of which has a desired functionality.

[0009] In one embodiment, aspects of the present invention are directed to a system for preparing a nonwoven fabric having a single woven layer comprising a plurality of different fiber types, the system comprising: a first polymer source configured to supply a stream of a first molten or semi-molten polymer; a second polymer source configured to supply a stream of a second molten or semi-molten polymer, wherein the first polymer and the second polymer are of different types; a spin beam in fluid communication with the first and second polymer sources, wherein the spin beam comprises a zoned distribution plate located upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone configured and arranged to extrude a plurality of polymer streams into the spinneret, wherein the polymer streams are of a different type from the polymer streams extruded by adjacent zones; and a collection surface located below the spinneret, wherein continuous filaments are deposited on the collection surface to form a single layer comprising two or more types of fibers that are of different types from each other.

[0010] In some embodiments, the zoned distribution plate comprises 2 to 10 zones, for example, 2 to 4 zones, or 2 to 3 zones.

[0011] In some embodiments, the zoned distribution plate comprises a first zone configured for producing multi-component filaments and a second zone configured for producing single-component filaments. In some embodiments, the first polymer source comprises polypropylene, and the second polymer source comprises a different polypropylene.

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

[0013] In one embodiment, the zoned distribution plate comprises a plurality of zones extending longitudinally in the intersecting direction of the spin beam. In some embodiments, the zoned distribution plate comprises a plurality of zones extending transversely in the mechanical direction of the spin beam.

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

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

[0016] In one embodiment, the first distribution zone is configured to extrude a polymer stream containing a single-component filament, and the second distribution zone is configured to extrude a polymer stream having a sheath / core structure containing the first polypropylene polymer and the second polypropylene polymer.

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

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

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

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

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

[0022] In one embodiment, the system is configured to produce a laminated woven fabric layer having two or more regions of different fiber types. In these embodiments, the laminated woven fabric layer is extruded from the spin beam as a single layer.

[0023] In one embodiment, the system may be configured to produce a non-woven fabric layer having a plurality of fiber types, where the plurality of fiber types are mixed throughout the thickness of the woven fabric layer.

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

[0025] Embodiments of the present invention are also directed to the use of the system of the present invention and the zone-zoned distribution plate in the production of non-woven fabrics.

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

[0027] Embodiments of the present invention are also directed to the zoned distribution plate for use in a spunbond system for preparing a spunbond nonwoven fabric having a plurality of different fiber types within a single woven fabric layer.

[0028] In certain embodiments, the present invention is directed to a system for preparing a nonwoven fabric having a laminated woven fabric layer, the system comprising: a first polymer source configured to supply a stream of a first polymer in a molten or semi-molten state; a second polymer source configured to supply a stream of a second polymer in a molten or semi-molten state, wherein the first polymer and the second polymer are of different types; a spin beam in fluid communication with the first polymer source and the second polymer source, the spin beam comprising a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings disposed in a plurality of zones, each zone being configured and arranged to extrude a plurality of polymer streams of different polymer types than the polymer stream extruded by an adjacent zone to the spinneret; and a collection surface disposed below the spinneret, the collection surface having continuous filaments deposited thereon to form a stratified nonwoven fabric, wherein the stratified nonwoven fabric comprises a single layer having two or more regions where adjacent regions are of different types of fibers.

[0029] In one embodiment of a system for preparing layered woven fabrics, the zoned distribution plate includes a first zone configured for producing multi-component filaments and a second zone configured for producing single-component filaments. In some embodiments, the zoned distribution plate comprises 2 to 10 zones.

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

[0031] In one embodiment of the system for preparing a layered woven fabric, the system further comprises a third polymer source or a fourth polymer source in fluid communication with the spin beam, wherein the third polymer source and / or the fourth polymer source is configured to supply a stream of molten or semi-molten third and / or fourth polymer.

[0032] A part of the present invention is also directed toward a method for preparing a nonwoven fabric having a single woven layer, wherein the single woven layer comprises several different types of fibers, the method comprising: providing a first polymer source configured to supply a stream of a first polymer in a molten or semi-molten state; providing a second polymer source configured to supply a stream of a second polymer in a molten or semi-molten state, wherein the first polymer and the second polymer are of different types; introducing the first polymer stream and the second polymer stream into a spin beam in fluid communication with the first polymer source and the second polymer source, wherein the spin beam comprises zoned distribution plates (or a stack of distribution plates) located upstream of a spinneret. The zoned distribution plate comprises a plurality of distribution openings arranged in a plurality of zones, each zone configured and arranged to extrude a plurality of polymer streams, which are of a different polymer type from the polymer streams extruded by adjacent zones, into the spinneret; extruding a first stream of the first polymer from the spinneret as a first continuous filament; extruding a second stream of the second polymer from the spinneret as a second continuous filament; and collecting the first and second continuous filaments on a collection surface located below the spinneret to form a single layer comprising the first and second continuous filaments of different types.

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

[0034] In one embodiment of the method, the zoned distribution plate comprises a first zone configured for producing a multi-component filament and a second zone configured for producing a single-component filament. In one embodiment, the first polymer source comprises polypropylene, and the second polymer source comprises polypropylene. The polypropylene of the first polymer source and the polypropylene of the second polymer source may be different or the same.

[0035] In one embodiment of the method, the zoned distribution plate comprises a first zone configured for producing a single-component filament and a second zone configured for producing a single-component filament in which the polymer may be the same or different in each polymer stream.

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

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

[0038] In some embodiments of the present invention, the zoned distribution plate comprises a plurality of zones that extend longitudinally in the direction of intersection of the spin beams.

[0039] In one embodiment of the method, the zoned distribution plate comprises a plurality of zones extending laterally in the mechanical direction of the spin beam.

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

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

[0042] In one embodiment, the first distribution zone is configured to extrude a polymer stream containing a single-component filament, and the second distribution zone is configured to extrude a polymer stream having a sheath / core structure containing the first polypropylene polymer and the second polypropylene polymer.

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

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

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

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

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

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

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

[0050] In one embodiment of the present invention, the spin beam is configured to produce a nonwoven fabric layer having a plurality of fiber types, wherein the plurality of fiber types are mixed throughout the entire thickness of the woven fabric layer.

[0051] In one embodiment, the method includes the step of bonding the fibers of the fabric together, for example, by heat bonding, mechanical bonding, or chemical bonding, to form a cohesive fabric.

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

[0053] In a further view, a spunbond nonwoven fabric is provided having a single woven layer comprising a plurality of continuous filaments that adhere to each other to form a cohesive web, wherein the plurality of continuous filaments comprises a first fiber type and a second fiber type different from the first fiber type.

[0054] In one embodiment, multiple fiber types are mixed throughout the entire thickness of a single woven layer. In some embodiments, the single woven layer is a layered woven layer, where the first fiber type is mainly located in a first region of the layered woven layer, and the second fiber type is mainly located in a second region of the layered woven layer.

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

[0056] In one embodiment, the first fiber type includes a multi-component filament, and the second fiber type includes a single-component filament. In one embodiment, the first fiber type includes polypropylene, and the second fiber type includes polypropylene. In one such embodiment, the first fiber type includes a crimped filament, and the second fiber type includes a non-crimped filament or a low-crimped filament.

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

[0058] In one embodiment, the first fiber type includes a multi-component filament having a sheath / core structure comprising the first polypropylene polymer and the second polypropylene polymer, and the second fiber type includes a single-component filament comprising the first polypropylene polymer. In some embodiments, the multi-component filament includes a two-component fiber having a side-by-side, eccentric, or D-centric sheath / core structure.

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

[0060] In a further view, embodiments of the present invention are directed to a multilayered composite sheet material, wherein the sheet material comprises at least one spunbond layer according to embodiments of the present invention. That is, a spunbond fabric having a single layer having multiple different fiber types.

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

[0062] In another embodiment, the composite sheet material includes at least one meltblown layer sandwiched between two spunbond layers, each of which includes at least one spunbond layer comprising a single woven fabric layer comprising a first fiber type and a second fiber type different from the first fiber type.

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

[0064] Having described the present invention in general terms, we will now refer to the attached drawings, however, these drawings are not necessarily drawn to scale. [Brief explanation of the drawing]

[0065] [Figure 1] Figure 1 shows a nonwoven fabric having a single layer according to at least one embodiment of the present invention. [Figure 2] Figure 2 shows a nonwoven fabric having a layered woven fabric layer according to at least one embodiment of the present invention. [Figure 3] Figure 3 shows a system for preparing a nonwoven fabric having a layered woven fabric layer according to an embodiment of the present invention. [Figure 4] Figure 4 shows the spin pack for use in the system shown in Figure 3. [Figure 5] Figure 5 shows various zoned distribution plates according to embodiments of the present invention. [Figure 6] Figure 6 shows various zoned distribution plates according to embodiments of the present invention. [Figure 7] Figure 7 shows various zoned distribution plates according to embodiments of the present invention. [Figure 8] Figure 8 shows various zoned distribution plates according to embodiments of the present invention. [Figure 9] Figure 9 shows various zoned distribution plates according to embodiments of the present invention. [Figure 10] Figure 10 shows various zoned distribution plates according to embodiments of the present invention. [Figure 11] Figure 11 shows various zoned distribution plates according to embodiments of the present invention. [Figure 12] Figure 12 is a cross-sectional view of a nonwoven fabric having layered woven fabric layers in each fabric, according to at least one embodiment of the present invention. [Figure 13] Figure 13 is a cross-sectional view of a nonwoven fabric having layered woven fabric layers, according to at least one embodiment of the present invention. [Figure 14] Figure 14 is a cross-sectional view of a nonwoven fabric having layered woven fabric layers, according to at least one embodiment of the present invention. [Figure 15] Figure 15 is a cross-sectional view of a nonwoven fabric having layered woven fabric layers, according to at least one embodiment of the present invention. [Figure 16] Figure 16 is a cross-sectional view of a nonwoven fabric having layered woven fabric layers in each fabric, according to at least one embodiment of the present invention. [Figure 16a] Figure 16a is a cross-sectional view of a multi-component fiber according to one embodiment of the present invention. [Figure 17] Figure 17 is a cross-sectional view of a nonwoven fabric having layered woven fabric layers in each fabric, according to at least one embodiment of the present invention. [Figure 18A] Figure 18A shows various composite fabric structures according to one or more embodiments of the present invention. [Figure 18B] Figure 18B shows various composite fabric structures according to one or more embodiments of the present invention. [Figure 18C] Figure 18C shows various composite fabric structures according to one or more embodiments of the present invention. [Figure 18D] Figure 18D shows various composite fabric structures according to one or more embodiments of the present invention. [Figure 19]Figure 19 is a magnified image of the surface of a spunbond nonwoven fabric having a single fiber type. [Figure 20] Figure 20 is a magnified view of the surface of a spunbond nonwoven fabric having two different types of fiber. [Modes for carrying out the invention]

[0066] The present invention will be described in more detail below with reference to the accompanying drawings, which show only some, and not all, embodiments of the invention. In fact, the invention may be embodied in many different forms and should not be construed as being limited to the embodiments described herein. Rather, these embodiments are provided to satisfy the legal requirements to which this disclosure applies. Similar numbers refer to similar elements throughout.

[0067] Words such as "first," "second," "primary," "exemplary," and "secondary" do not indicate any order, quantity, or importance, but rather are used to distinguish one element from another. Furthermore, the words "a," "an," and "the" do not indicate a limit on quantity, but rather indicate the existence of "at least one" of the items being referred to.

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

[0069] If a parameter range is provided, it should be 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%, 10%, 5.0%, 5.1%, 5.2%...9.8%, 9.9%, and 10.0%; as well as 5.00%, 5.01%, 5.02%...9.98%, 9.99%, and 10.00%.

[0070] As used herein, the words “about,” “approximately,” and “substantially” in the context of numerical values ​​or ranges mean ±10% of the stated or requested numerical value or range, and in particular include values ​​within the range of the standard measurement error (e.g., SEM) of the stated value, or variations of ±0.5%, ±1%, ±5%, or ±10% from the specified value.

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

[0072] The word "fiber" can refer to a fiber of finite length or a filament of infinite length.

[0073] As used herein, the term "single component" refers to 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 coloring, antistatic properties, lubricity, hydrophilicity, or hydrophilicity.

[0074] As used herein, the term “multicomponent” refers to 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 the same as or different from each other, or they may be a blend of polymers. The polymers are arranged in separate zones that are substantially evenly spaced across the cross-section of the fiber. The components may be arranged in any desired configuration, such as sheath-core, side-by-side, pie, island-in-the-sea, etc. Various methods for forming multi-component fibers are described in U.S. Patent No. 4,789,592 for Taniguchi et al., U.S. Patent No. 5,336,552 for Strack et al., U.S. Patent No. 5,108,820 for Kaneko et al., U.S. Patent No. 4,795,668 for Kruege et al., U.S. Patent No. 5,382,400 for Pike et al., U.S. Patent No. 5,336,552 for Strack et al., and U.S. Patent No. 6,200,669 for Marmon et al., which are incorporated herein by reference in their entirety. Multi-component fibers having various irregular shapes are also described in U.S. Patent No. 5,277,969 for Hogle et al., U.S. Patent No. 5,162,074 for Hills, U.S. Patent No. 5,466,410 for Hills, U.S. Patent No. 5,069,970 for Largman et al., and U.S. Patent No. 5,057,368 for Largman et al., which are incorporated herein by reference in their entirety.

[0075] As used herein, the terms “nonwoven,” “nonwoven web,” and “nonwoven fabric” refer to a structure or web of material formed without the use of weaving or knitting processes, which produces a structure of intertwined individual fibers or threads, but not in an identifiable repeating manner. Nonwoven webs have historically been formed by various conventional processes, such as meltblown processes, spunbond processes, and staple fiber carding processes.

[0076] As used herein, the term “meltblown” refers to a process by which fibers are formed by extruding a molten thermoplastic material through a plurality of fine, typically circular, die-capillaries into a high-speed gas (e.g., air) stream that elongates the molten thermoplastic material, thereby forming fibers that can be made into 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. 3,849,244 to Buntin.

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

[0078] As used herein, the term “machine direction,” or “MD,” refers to the direction of movement of the nonwoven web during manufacturing.

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

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

[0081] As used herein, the term “spunbond” refers to the process of extruding molten thermoplastic material as filaments from a plurality of fine, usually circular, spinnerets, and then thinning and drawing the filaments mechanically or pneumatically. The filaments are deposited on a collection surface to form a web of substantially continuous, randomly arranged filaments, which can then be bonded together to form a cohesive nonwoven fabric. The manufacture of spunbond nonwoven webs is described in patent specifications, e.g., 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, etc. 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 by winding it with an air stream or by winding it onto a mechanical draw roll, depositing the drawn filament on a foraminous collection surface to form a web, and bonding the web of loose filaments to a nonwoven fabric. The bonding can be any thermal bonding treatment or chemical bonding treatment, with thermal point bonding being typical.

[0082] As used herein, “thermal point bonding” includes passing the material to be bonded, for example, one or more fiber webs to be bonded, between a heated calender roll and an anvil roll. The calender roll is typically patterned so that the fabric is bonded at individual point bonding sites rather than across its entire surface.

[0083] As used herein, the terms “through air bonded” or “through air bonding” refer to a type of thermal bonding in which the materials to be bonded, such as a fiber web, are subjected to the application of a heated gas, such as air, where the temperature of the heated gas is higher than the softening or melting temperature of at least one polymer component of the materials to be bonded. The heated gas softens the at least one polymer component, and in some cases becomes semi-molten, causing the polymers of adjacent fibers to fuse and form a thermal bond. Air thermal bonding also includes passing the material through a heated oven.

[0084] As used herein, the term “polymer” generally includes, but is not limited to, homopolymers, copolymers, such as block copolymers, graft copolymers, random copolymers and alternating copolymers, terpolymers, etc., as well as blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” includes all possible geometric configurations of the material, such as isotactic symmetry, syndiotactic symmetry and random symmetry.

[0085] I. Nonwoven fabric layer having multiple different types of fibers

[0086] One embodiment of the present invention is directed to a spunbond nonwoven fabric comprising at least two different fiber types arranged in a single woven layer. "Different fiber types" or "different fiber types" means, for example, that one of the fibers in a single woven layer differs from, for example, other types of fibers in a single woven layer in one or more of the following: 1) structure or cross-section (e.g., single-component or two-component), 2) differences in composition, e.g., differences in composition having different polymers, chemicals, or functional additives, and 3) differences in properties, e.g., differences in properties of thickness, average fiber diameter, porosity, density, loft, denier, hydrophilic / hydrophobicity, and color. For example, in some embodiments, the single woven layer may comprise a first fiber type comprising multi-component fibers and a second fiber type comprising mainly single-component fibers.

[0087] In some embodiments, the different fiber types in the single woven layer may be mixed homogeneously or non-homogeneously to form the woven layer. For example, in some embodiments, the single woven layer includes at least two different fiber types that are mixed together such that the different fiber types are substantially mixed throughout the entire thickness of the single woven layer. In this regard, Figure 1 shows a cross-section of a nonwoven fabric 2 having a single woven layer 4 containing a first fiber 6 and a second fiber 8, where the first fiber 6 and the second fiber 8 are mixed together throughout the entire thickness of the single woven layer. In the illustrated embodiment shown in Figure 1, the first fiber 6 comprises a single-component filament of a first fiber type, and the second fiber 8 comprises a crimped two-component fiber of a different fiber type from the first fiber. As will be described in detail later, the crimped fiber typically has a side-by-side configuration, an eccentric sheath / core configuration, or a D-centric sheath / core configuration.

[0088] Despite having multiple different fiber types (e.g., two or more) where two different fiber types (first fiber 6 and second fiber 8) are different from each other, the first fiber 6 and second fiber 8 of a single woven fabric layer 12 are extruded and deposited from a single molten spin beam so that the multiple fibers are formed as a single layer. The nonwoven fabric also comprises a first outer surface 9a and a second outer surface 9b.

[0089] In the embodiment shown in Figure 1, the first fiber 6 and the second fiber 8 are shown substantially intermingled throughout the entire thickness "T" of the single woven layer 4. However, it should be recognized that there may be one or more regions in which one of the multiple fiber types is the dominant fiber. For example, in some embodiments, one fiber type may be more abundant near one of the multiple surfaces of the single woven layer 4. In some embodiments, the gradient may have a gradient in which one of the multiple fiber types is more abundant near one surface and less abundant near the opposite surface of the single woven layer 4.

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

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

[0092] In one embodiment, each different type of fiber may be primarily arranged within discrete regions of the single woven layer. Thus, the nonwoven fabric has at least one single fabric layer, which comprises two or more regions in which the fibers of at least one region are of a different type than the fibers of another region of the layered woven layer.

[0093] One embodiment of the present invention is directed to a spunbond nonwoven fabric having at least one layered woven layer, wherein the layered woven layer comprises two or more regions in which the fibers in at least one region are of a different type than the fibers in another region of the layered woven layer. In the layered woven layer, the different types of fibers are not substantially mixed such that a region of the single woven layer mainly comprises a single type of fiber, while different regions of the single woven layer contain a different type of fiber than one or more other regions of the single woven layer. For example, in some embodiments, the layered woven layer may comprise a first region mainly comprising multi-component fibers and a second region mainly comprising mono-component fibers.

[0094] Referring to Figure 2, an example of a nonwoven fabric having a layered woven layer is illustrated and broadly designated by reference letter 10. The nonwoven fabric 10 comprises a layered woven layer 12 having a first region 14 and a second region 16 in which the fibers of the first region 14 and the second region 16 are of different types. The fibers of the layered woven layer 12 are extruded from a single molten spin beam and deposited so that the fibers of the layered woven layer 12 are formed as a single layer, even though there are multiple regions (e.g., two or more) in which the multiple fibers of the multiple regions are of different types. In the embodiment shown in Figure 2, the second region 16 overlaps the first region 14 at an interface 18. The nonwoven fabric 10 comprises a first outer surface 20 and a second outer surface 22.

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

[0096] Figure 2 illustrates a layered woven fabric having two regions of different types of fibers, but it should be recognized that the layered woven fabric may include multiple regions of different types of fibers. For example, the layered woven fabric may include 2 to 10 regions in which adjacent regions contain different types of fibers. In a preferred embodiment, the layered woven fabric may include 2 to 4 regions, particularly 2 to 3 regions, of different fiber types.

[0097] In some embodiments, the multiple regions of different fiber types may extend in the intersecting direction of the nonwoven fabric. In other embodiments, the multiple regions of different fiber types may extend in the machine direction of the nonwoven fabric.

[0098] As described in more detail below, the single woven layer is formed as a single layer from which fibers of at least two different fiber types are extruded from the same molten spin beam. Nonwovens having two different fiber types in a single woven layer can offer several advantages. In particular, a single spin beam can be used to prepare a single woven layer having multiple functionalities. In comparison, to achieve similar results with conventional spunbond systems typically requires multiple spin beams, where each spin beam produces a single woven layer having the desired properties. These individually produced woven layers are then laminated together to form a composite (multilayer) nonwoven. Using multiple spin beams to achieve the desired functionality typically increases the complexity and cost associated with preparing the nonwoven.

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

[0100] Examples of suitable additives include one or more colorants (e.g., pigments (e.g., TiO2)), UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblocking agents, slip agents, fluorescent whitening agents, flame retardants, antimicrobial agents (e.g., silver, copper oxide, and zinc oxide), polymer rheology modifiers, etc. In one embodiment, one or more polymer streams include polypropylene having low isotacticity, such as polypropylene rheology modifiers, e.g., L-MODU available from Idemitsu. 商標 , can encompass.

[0101] II. Systems, apparatus, and methods for preparing woven fabric layers of multiple fiber types

[0102] One embodiment of the present invention is also directed toward an apparatus and method for producing a nonwoven fabric comprising multiple different fiber types in a single layer. In particular, an embodiment of the present invention also provides a distribution plate for use in a spunbond spin beam for producing a nonwoven fabric having the woven layer of the present invention. Additional embodiments of the present invention are also directed toward articles comprising the woven layer of the present invention and the use of the woven layer of the present invention in the manufacture of absorbent articles.

[0103] As described in more detail below, a nonwoven fabric having a single woven layer containing multiple fiber types may be prepared using a spunbond spinning system, wherein the spin pack comprises a zoned dispensing plate having multiple dispensing zones configured and arranged to supply polymer streams to a spinneret, and the polymer stream in one dispensing zone is of a different type from the polymer streams in one or more other dispensing zones of the zoned dispensing plate. With respect to polymer streams, the terms “different types” or “different polymer types” mean, for example, that the polymer stream in one dispensing zone differs in one or more of the following: 1) structure or cross-section (e.g., single-component or multi-component), 2) differences in composition, e.g., differences in composition having different polymers, chemicals, or functional additives, and 3) differences in properties that differ from, for example, the polymer streams in a second and / or third dispensing zone of the zoned dispensing plate, e.g., hydrophilic / hydrophobic, differences in color.

[0104] Referring to Figure 3, for example, a system for preparing a spunbond nonwoven fabric containing a single woven layer having multiple different fiber types is schematically shown and is specified by reference letter 30.

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

[0106] If present, the spin beam assembly 44 comprises multiple meters and pumps for supplying two or more polymer streams to the spin pack. In some embodiments, the spin beam assembly may also comprise one or more heating elements for maintaining the molten polymer streams at a desired temperature. An example of a spin beam assembly that may be used in some embodiments of the present invention is described in U.S. Patent No. 7,7740,777, the contents of which are incorporated herein by reference.

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

[0108] In one embodiment, the nonwoven web may be passed through a bonding station 54 where the filaments are bonded together to form a cohesive web. According to the present invention, a wide variety of bonding methods may be used, including thermal bonding (e.g., by air bonding or calendering), mechanical bonding (e.g., by hydroentanglement or needle punching), and chemical bonding (e.g., by the use of adhesive resins). In one embodiment, the bonding station comprises a thermal bonding unit having a pair of opposing calender rolls.

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

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

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

[0112] In some embodiments, the system may also include a pair of cooperating rolls (not shown) (also referred to herein as “press rolls”) located downstream from the outlet of the spin beam. In this regard, the press rolls may be configured to stabilize the web of filaments by compressing the web before delivering the web of fibers from the outlet of the spin beam toward the bonding unit. In some embodiments, for example, the press rolls may have a ceramic coating deposited on their surface. In one embodiment, for example, one roll of the pair of cooperating rolls may be located above the collection surface 52, and the second roll of the pair of cooperating rolls may be located below the collection surface 52.

[0113] In some embodiments and as shown in Figure 3, the system may include a vacuum source 58 located below the collection surface 52 to draw a plurality of continuous filaments from the outlet of the spin beam onto the collection surface 52 before they are delivered to the bonding unit.

[0114] Finally, the bonded spunbond nonwoven fabric is moved to a winding machine 56, where it is wound onto a roll.

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

[0116] In some embodiments, the system may include additional devices for further modifying or treating the nonwoven fabric. For example, the system may include a kiss roller or similar device for applying a topical treatment, such as a surfactant, to the surface of the nonwoven fabric. In some embodiments, the system may also include one or more devices for stepwise stretching the nonwoven fabric. An example of such a device is a ring roller, which comprises a plurality of interlocking rings for stretching a selected area of ​​the nonwoven fabric.

[0117] The system illustrated in Figure 3 may be configured to produce a single woven layer in which multiple different types of fibers are mixed homogeneously or non-uniformly. In some embodiments of the preparation of a layered woven layer, for example, the layered woven layer illustrated in Figure 2, the collection surface may be operated at a higher speed to help facilitate the distribution of different types of fibers to discrete regions within the single woven layer. Alternatively or in combination, a stream of continuous filaments extruded by the spin beam may be deposited on a rotating cylinder. In some embodiments, the surface of the rotating cylinder may be equipped with a screen which may be equipped with a vacuum source.

[0118] Figure 4 is a schematic diagram of a spin pack 46 according to at least one embodiment of the present invention. The spin pack 46 typically comprises a plurality of plates sandwiched together in the order of a top plate 60, a polymer melt screen 62, a zoned distribution plate 64, and a spinneret 66. The spin pack essentially adjusts the flow of the molten polymer stream to 1) form a desired type of fiber (e.g., monocomponent fiber or multicomponent fiber, where the fiber has a specific cross-sectional geometric configuration, etc.), 2) form a desired number of fibers to be continuously extruded by the system, and 3) distribute the molten polymer to desired distribution zones based on the type of polymer.

[0119] The polymer melting screen 62 is equipped with a filter for filtering the polymer stream before introducing it into the zoned distribution plate 64.

[0120] The spinneret is located downstream of the polymer melting screen 62 and the zoned distribution plate 64. The spinneret comprises a plurality of spinnerets arranged in an array extending in the direction of the intersecting spin beam. For example, the spinneret may be arranged in a substantially horizontal rectangular array, typically with 1,000 to 6,000 orifices per meter of length of the spinneret. As used herein, the term “spinneret” refers to the bottom of the spin pack that feeds and passes the molten polymer through orifices for extruding it into the quenching station. The spinneret can be implemented by drilling or etching holes in a plate or other structure that can supply the required fiber stream.

[0121] Additionally, the spinneret may have a variety of different shapes (e.g., circular, square, elliptical, keyhole, multi-lobed (e.g., trefoil), etc.), resulting in a variety of fiber cross-sectional shapes. An exemplary spin pack for use with System 30 is described in U.S. Patent No. 5,162,040 to Hills, the disclosure of which is incorporated herein by reference in its entirety. However, it should be noted that any conventional or other spin pack for spinning fibers may be used with System 30.

[0122] The zoned distribution plate 64 comprises an upper surface 70 and a lower surface 72. The upper surface 70 is located opposite the polymer melting screen 62 and comprises a plurality of etched channels, which are arranged and configured to receive two or more polymer melting streams and then distribute the polymer streams to desired distribution zones. In addition, the zoned distribution plate 64 may comprise a plurality of channels arranged and configured to combine two or more different polymer melting streams into desired configurations (e.g., two-component (side-by-side, core / sheath, eccentric core / sheath, D-centric core / sheath, segmented pie, island-in-the-sea, etc.), three-component, etc.).

[0123] The lower surface 72 of the zoned distribution plate is positioned opposite the spinneret and has a plurality of distribution openings from which the distributed polymer stream is introduced into the corresponding spinning orifice of the spinneret and subsequently extruded as a molten or semi-molten filament.

[0124] In one embodiment of the present invention, the zoned distribution plate is configured to distribute, combine, and extrude multiple polymer streams of different kinds, particularly two to four polymer streams of different kinds. For example, the zoned distribution plate may be configured to extrude a polymer stream containing four different polymers (e.g., polymers A, B, C, and D). Polymers A, B, C, and D may be distributed and extruded as single-component filaments, or they may be combined to form a multi-component filament containing two or more combinations of polymers A, B, C, and D, where the polymers are arranged as separate polymer components in the cross-section of the polymer stream and thus in the resulting multi-component fiber.

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

[0126] In the embodiment shown in Figure 3, only a single zoned distribution plate is shown. It should be noted that the zoned distribution plate 64 may comprise two or more distribution plates stacked on top of each other and configured to cooperate in supplying multiple molten polymer streams to the distribution opening. As described in more detail below, the distribution opening is located across the underside of the distribution plate within multiple distribution zones, where each distribution zone is configured to extrude a polymer stream of a different type than the polymer streams of adjacent zones.

[0127] III. Zoned Representative Distribution Plates

[0128] Figures 5 to 11 show partial views of the underside of a zoned distribution plate according to various embodiments of the present invention. Considering the number of distribution openings typically present on a distribution plate, the number of rows and columns illustrated in Figures 5 to 11 have been reduced for simplification and do not imply any limitation on the actual number of distribution openings.

[0129] Similar to the spinneret, the distribution openings 82 shown in Figures 5–11 are arranged in a rectangular array having multiple rows (designated by the reference letter "R") that extend longitudinally in the direction of intersection of the spin beam between the proximal end 78a and the distal end 78b of the zoned distribution plate. In some embodiments, the distribution openings are also arranged as multiple columns (designated by the reference letter "C") that extend transversely in the mechanical direction of the spin beam. The zoned distribution plate is not limited to a specific number of distribution openings, but typically has about 1,000 to about 6,000 distribution openings per meter.

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

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

[0132] In addition, the first distribution zone has fewer than 80 rows of distribution openings, fewer than 79 rows, fewer than 78 rows, fewer than 77 rows, fewer than 76 rows, fewer than 75 rows, fewer than 74 rows, fewer than 73 rows, fewer than 72 rows, fewer than 71 rows, fewer than 70 rows, fewer than 69 rows, fewer than 68 rows, fewer than 67 rows, fewer than 66 rows, fewer than 65 rows, fewer than 64 rows, fewer than 63 rows, fewer than 62 rows, fewer than 61 rows, fewer than 60 rows, fewer than 59 rows, fewer than 58 rows, fewer than 57 rows, fewer than 56 rows, fewer than 55 rows, fewer than 54 rows, fewer than 53 rows, fewer than 52 rows, fewer than 51 rows, fewer than 50 rows, fewer than 49 rows, fewer than 48 rows, fewer than 47 rows, fewer than 46 rows, fewer than 45 rows, fewer than 44 rows, fewer than 43 rows, and 42 rows. The system may include rows with less than 1, less than 41, less than 40, less than 39, less than 38, less than 37, less than 36, less than 35, less than 34, less than 33, less than 32, less than 31, less than 30, less than 29, less than 28, less than 27, less than 26, less than 25, less than 24, less than 23, less than 22, less than 21, less than 20, less than 19, less than 18, less than 17, less than 16, less than 15, less than 14, less than 13, less than 12, less than 11, less than 10, less than 9, less than 8, less than 7, less than 6, less than 5, less than 4, less than 3, and less than 2.

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

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

[0135] In addition, the second distribution zone has 80 rows of distribution openings, fewer than 79 rows, fewer than 78 rows, fewer than 77 rows, fewer than 76 rows, fewer than 75 rows, fewer than 74 rows, fewer than 73 rows, fewer than 72 rows, fewer than 71 rows, fewer than 70 rows, fewer than 69 rows, fewer than 68 rows, fewer than 67 rows, fewer than 66 rows, fewer than 65 rows, fewer than 64 rows, fewer than 63 rows, fewer than 62 rows, fewer than 61 rows, fewer than 60 rows, fewer than 59 rows, fewer than 58 rows, fewer than 57 rows, fewer than 56 rows, fewer than 55 rows, fewer than 54 rows, fewer than 53 rows, fewer than 52 rows, fewer than 51 rows, fewer than 50 rows, fewer than 49 rows, fewer than 48 rows, fewer than 47 rows, fewer than 46 rows, fewer than 45 rows, fewer than 44 rows, fewer than 43 rows, and 42 rows. The table may include rows with a full number of elements, rows with fewer than 41 elements, rows with fewer than 40 elements, rows with fewer than 39 elements, rows with fewer than 38 elements, rows with fewer than 37 elements, rows with fewer than 36 elements, rows with fewer than 35 elements, rows with fewer than 34 elements, rows with fewer than 33 elements, rows with fewer than 32 elements, rows with fewer than 31 elements, rows with fewer than 30 elements, rows with fewer than 29 elements, rows with fewer than 28 elements, rows with fewer than 27 elements, rows with fewer than 26 elements, rows with fewer than 25 elements, rows with fewer than 24 elements, rows with fewer than 23 elements, rows with fewer than 22 elements, rows with fewer than 21 elements, rows with fewer than 20 elements, rows with fewer than 19 elements, rows with fewer than 18 elements, rows with fewer than 17 elements, rows with fewer than 16 elements, rows with fewer than 15 elements, rows with fewer than 14 elements, rows with fewer than 13 elements, rows with fewer than 12 elements, rows with fewer than 11 elements, rows with fewer than 10 elements, rows with fewer than 9 elements, rows with fewer than 8 elements, rows with fewer than 7 elements, rows with fewer than 6 elements, rows with fewer than 5 elements, rows with fewer than 4 elements, rows with fewer than 3 elements, and rows with fewer than 2 elements.

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

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

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

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

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

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

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

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

[0144] A typical example of a nonwoven fabric layer having a layered woven fabric layer that can be prepared using the zoned distribution plate, as shown in Figure 5, is described in more detail below.

[0145] Figure 7 shows a further example of a zoned distribution plate 90 that can be used according to an embodiment of the present invention. In this embodiment, the zoned distribution plate 90 comprises a first distribution zone 92 configured to extrude a two-component filament having a side-by-side configuration, and a second distribution zone 94 configured to extrude a two-component filament having an eccentric sheath / core configuration or a D-centric sheath / core configuration. Advantageously, each of the first distribution zone 92 and the second distribution zone 94 may be configured to produce crimped filaments of different types. For example, one zone may produce a helical crimp, and the other zone may produce a sinusoidal crimp.

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

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

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

[0149] A typical example of a nonwoven fabric layer having a layered woven fabric layer, which can be prepared using the zoned distribution plate shown in Figure 7, is described in more detail below.

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

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

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

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

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

[0155] A typical example of a nonwoven fabric layer having a layered woven fabric layer, which can be prepared using the zoned distribution plate shown in Figure 8, is described in more detail below.

[0156] Figure 9 shows another example of a zoned distribution plate 110 that can be used according to an embodiment of the present invention. In this embodiment, the zoned distribution plate 110 comprises a first distribution zone 112, a second distribution zone 114, and a third distribution zone 116 sandwiched between the first and second distribution zones 112 and 114. In one embodiment, the first and second distribution zones 112 and 114 may be configured to form an outer region of the layered nonwoven fabric, and the third distribution zone 116 may be configured to form an inner region of the layered nonwoven fabric.

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

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

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

[0160] A typical example of a nonwoven fabric layer having a layered woven fabric layer, which can be prepared using the zoned distribution plate shown in Figure 9, is described in more detail below.

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

[0162] In the embodiment shown in Figure 10, a total of four distribution zones are illustrated, but it should be recognized that the zoned distribution plate may have any number of alternating distribution zones, for example, about 2 to about 40, about 5 to about 30, or about 10 to about 20.

[0163] The alternating distribution zone may be configured to extrude single-component filaments or multi-component filaments.

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

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

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

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

[0168] IV. Representative examples of layered woven fabrics

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

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

[0171] Crimped fibers tend to improve the loft and softness of nonwoven fabrics, making them particularly useful in sanitary applications. However, crimped fibers typically have the disadvantage of low mechanical strength and dimensional stability. As a result, crimped nonwoven fabrics tend to have significant neck-in, which essentially results in fabric shrinkage in the intersecting direction under MD stress. To address this problem, U.S. Patent Publication No. 2016 / 0221300 (hereinafter referred to as "Publication 300") describes a composite laminate in which a crimped spunbond fabric is deposited on top of a non-crimped spunbond fabric. The non-crimped spunbond fabric provides dimensional stability to the crimped spunbond fabric. However, the system and method described in Publication 300 have drawbacks. In particular, it requires at least two separate spunbond fabric layers, which require two separate spin beams and devices associated with each spin beam. This increases the complexity and cost of preparing the composite laminate described in Publication No. 300.

[0172] Advantageously, the inventors have discovered that by using a single woven fabric layer having two different fiber types, a crimped fabric with improved dimensional stability can be provided without requiring multiple spunbond spin beams.

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

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

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

[0176] The first fiber 6 is a non-crimped or low-crimped filament and typically includes a single-component or multi-component fiber that does not unfold a helical crimp, e.g., a centric sheath / core configuration. The first fiber provides strength to the nonwoven fabric and improves its dimensional stability.

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

[0178] Further embodiments provide a nonwoven fabric having a layered woven layer containing crimped filaments. In this regard, Figure 12 shows an embodiment of a nonwoven fabric 200 having a layered woven layer 210 having a first region 220 containing crimped continuous filaments and a second region 230 of non-crimped or low-crimped filaments. In one embodiment, the layered woven layer shown in Figure 12 can be prepared using the zoned distribution plate shown in Figure 5 or Figure 6, which has been described earlier. As shown, the first region 220 and the second region 230 extend in the intersecting direction of the nonwoven fabric such that one region overlaps the other. Low-crimped or non-crimped fibers typically have fewer than 2 loops per centimeter of fiber length.

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

[0180] In one embodiment, the first region 220 comprising a crimped continuous filament comprises a binary fiber in which one polymer component differs from the other polymer component (e.g., differences in crystallinity, molecular weight, melting temperature, polydispersity index, flexural modulus, heat of fusion, melt flow rate (MFR), and crimp-inducing polymer additives (e.g., a blend with meltblown resin and / or polymers having low isotacticity)), and thus the binary fiber favorably develops or has natural crimp. In one embodiment, the crimped continuous filament has a binary configuration selected from the group including side-by-side, eccentric sheath / core, D-centric sheath / core, or other configurations that can develop or retain crimp. The crimped continuous filament of the first region 220 provides improved loft and softness.

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

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

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

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

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

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

[0187] In one embodiment, the second region 230 of non-crimped or low-crimped filaments typically includes single-component or multi-component fibers that do not unfold helical crimp, e.g., a centric sheath / core configuration. The filaments of the second region 230 provide strength to the nonwoven fabric and improve its dimensional stability.

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

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

[0190] The ratio of the first region 220 to the second region 230 (based on the number of rows of distribution openings) is approximately 40:60 to approximately 90:10, with a ratio of approximately 30:70 being more preferable.

[0191] Referring now to Figure 13, a further embodiment of a nonwoven fabric having a layered woven layer, which can be manufactured according to an embodiment of the present invention, is illustrated. As shown, the nonwoven fabric 300 comprises a layered woven layer 310 having a first region 320 and a second region 330, where the fibers in the two regions are of different types. As previously described, the layered woven layer 310 is extruded from a spin beam as a single layer. In one embodiment, the layered woven layer illustrated in Figure 13 can be prepared using the zoned distribution plate shown in Figures 5, 6, or 7, as previously described.

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

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

[0194] In one embodiment, the nonwoven fabric 300 may have a basis weight of about 8 to 65 grams / square meter (gsm), particularly about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 300 has a basis weight of about 15 to about 30 gsm.

[0195] Referring here to Figure 14, another embodiment of the nonwoven fabric 400 having a layered woven layer 410 is shown. The nonwoven fabric 400 comprises a layered woven layer 410 having a first region 420 and a second region 430, where the fibers of the two regions are of different types. The nonwoven fabric 400 of Figure 14 can be prepared using the zoned distribution plate according to the embodiment shown in Figure 7 and particularly described above.

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

[0197] The first region 420 of the layered woven fabric layer 410 may have the same material, structure and composition as the first region 220 of the nonwoven fabric 200 described earlier. In a preferred embodiment, the crimped continuous filament of the first region 420 comprises a two-component filament having a side-by-side configuration, wherein the first polymer component of the two-component fiber comprises metallocene-catalyzed polypropylene having an MFR of 19 to 40 g / min, and the other second polymer component comprises Ziegler-Natta-catalyzed polypropylene having an MFR of about 20 to 35 g / 10 min.

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

[0199] In one embodiment, the ratio of the sheath to the core in the two-component filament of the second region 430 may be about 90:about 10 to about 10:about 90, with a preferred ratio of 30:70.

[0200] In a further embodiment of the layered woven fabric layer 410, the second region 430 may include a continuous filament having a sheath / core structure, wherein the sheath comprises a polyethylene polymer and the core comprises a polypropylene polymer, for example, one of the metallocenes or Ziegler-Natta-catalyzed polypropylenes described above. The second region 430, comprising a two-component filament having a polyethylene sheath, can provide a region of nonwoven fabric having improved softness and drape, while also improving the flexibility of the nonwoven fabric 400.

[0201] In one embodiment, the nonwoven fabric 400 may have a basis weight of about 8 to about 65 grams / square meter (gsm), particularly about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 400 has a basis weight of about 15 to about 30 gsm.

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

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

[0204] In one embodiment of the nonwoven fabric 500, a third region 540 includes crimped continuous filaments, as previously described in relation to the embodiment shown in Figure 12. Similar to the previous embodiment, the crimped continuous filaments help to improve the loft and softness of the nonwoven fabric 500.

[0205] Advantageously, the first region 520 and the second region 530 may comprise non-crimped filaments or low-crimped filaments, which sandwich a third region 540 of crimped continuous filaments between the non-crimped filaments and the low-crimped filaments. In this way, the first region 520 and the second region 530 help to improve the strength, abrasion resistance and dimensional stability of the nonwoven fabric.

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

[0207] In one embodiment, the first and second regions may be identical to each other (i.e., both are of the same polymer type), while the third region 540 defines the interior of the layered woven fabric layer. In a preferred embodiment, the third region 540 may be composed of crimped continuous filaments as described above, while the first and second regions may be composed of un-crimped or low-crimped filaments. Advantageously, in this embodiment, outer surfaces are provided on both sides of the crimped continuous filaments, thus improving the overall strength and dimensional stability of the layered woven fabric layer.

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

[0209] In one embodiment, the nonwoven fabric 500 may have a basis weight of about 8 to about 65 grams / square meter (gsm), particularly about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 500 has a basis weight of about 15 to about 30 gsm.

[0210] Referring to Figure 16, a nonwoven fabric 600 is shown having three regions of different fiber types, where each region extends in the intersecting direction of the nonwoven fabric. In one embodiment, the nonwoven fabric 600 may be prepared using the zoned distribution plate illustrated in Figure 9, which was described earlier.

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

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

[0213] Similar to the embodiments described earlier, each of the first, second, and third regions of the layered woven fabric may have a variety of different structures (e.g., single-component or multi-component), different compositions (e.g., polymers, chemicals, or functional additives), and different properties (e.g., loft, density, basis weight, hydrophilic / hydrophobic, etc.).

[0214] In one embodiment, the first region 620 and the second region 630 may be identical to each other (i.e., both are of the same polymer type), while the third region 640 defines the interior of the layered woven fabric layer. In a preferred embodiment, the third region 640 may be composed of crimped continuous filaments as described above, while the first and second regions are composed of un-crimped or low-crimped filaments. Advantageously, in this embodiment, the crimped continuous filaments have outer surfaces on both sides, and therefore the overall strength, abrasion resistance, and dimensional stability of the layered woven fabric layer can be improved.

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

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

[0217] This embodiment, having a pair of opposing segments, offers the advantage of being able to form filaments from immiscible polymers. For example, in one embodiment, the first pair of segments comprises a polypropylene polymer, and the second pair of segments comprises a polyethylene polymer.

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

[0219] In one embodiment, the nonwoven fabric 600 may have a basis weight of about 8 to about 65 grams / square meter (gsm), particularly about 10 to about 40 gsm. In a preferred embodiment, the nonwoven fabric 600 has a basis weight of about 15 to about 30 gsm.

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

[0221] Referring to Figure 17, the nonwoven fabric 700 is illustrated to have multiple regions of different fiber types extending in the machine direction of the nonwoven fabric. In one embodiment, the nonwoven fabric 700 may be prepared using the zoned distribution plate illustrated in Figure 11, which was described earlier.

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

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

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

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

[0226] Advantageously, the nonwoven fabric 700 may help improve the dimensional stability of the fabric in the intersecting direction through non-crimped or low-crimped filaments that resist strain in a second series of multiple alternating regions (e.g., 730a, 730b, 730c...).

[0227] Nonwoven fabric 700 may be useful in preparing nonwoven fabrics having zoned regions for hydrophilic / hydrophobic properties and other functional enhancements.

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

[0229] The above examples are provided to illustrate various embodiments within the scope of the present invention and should not be construed as limiting the invention to any particular embodiment disclosed. It should be recognized that various different nonwoven fabrics having the layered woven fabric layer 410 can be prepared according to embodiments of the present invention.

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

[0231] In embodiments including crimped filaments, polypropylene, polypropylene blends, and copolymers thereof may be advantageously employed. In some embodiments, the propylene polymer is a crystalline propylene polymer based on propylene, where examples include propylene homopolymers, and propylene / α-olefin random copolymers of propylene and one or more α-olefin ethylenes (e.g., ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 3-methyl-1-butene, 3-methyl-1-pentene, 3-ethyl-1-pentene, 4-methyl-1-pentene, and 4-methyl-1-hexene), such as propylene / ethylene random copolymers and propylene / ethylene / 1-butene random copolymers.

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

[0233] In one such embodiment, the nonwoven fabric having a layered woven fabric includes fibers containing sustainable polymers. In one embodiment, the fibers are substantially free of synthetic materials, such as petroleum-based materials and polymers. For example, the fibers constituting the nonwoven fabric may have less than 25% by weight of 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 bio-based material, based on the total weight of the nonwoven fabric.

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

[0235] Aliphatic polyesters useful in the present invention include homopolymers and copolymers of poly(hydroxyalkanoates), and homopolymers and copolymers of aliphatic polyesters derived from reaction products of one or more polyols and one or more polycarboxylic acids, which are typically formed from reaction products of one or more alkanediols and one or more alkanedicarboxylic acids (or acyl derivatives). Polyesters can also be derived from polyfunctional polyols, such as glycerin, sorbitol, pentaerythritol, and combinations thereof, to form branched, star-shaped, and grafted 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 semicrystalline or amorphous polymers may also be used.

[0236] 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 20 carbon atoms optionally substituted by catenary oxygen atoms (bonded to carbon atoms in the carbon chain), preferably 1 to 12 carbon atoms; n is a number such that the ester is polymerizable, preferably such that the molecular weight of the aliphatic polyester is at least 10,000 daltons, preferably at least 30,000 daltons, and most preferably at least 50,000 daltons. In some embodiments, the molecular weight of the aliphatic polyester is typically less than 1,000,000, preferably less than 500,000, and most preferably less than 300,000 daltons. R may further contain one or more catenary (i.e., chain-like) ether oxygen atoms. Generally, the R group of a hydroxy acid is such that the pendant hydroxyl group is a primary or secondary hydroxyl group.

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

[0238] Aliphatic polyesters may also be block copolymers of poly(lactic acid-coglycolic acid). Aliphatic polyesters useful in the compositions of the present invention include homopolymers, random copolymers, block copolymers, star-branched random copolymers, star-branched block copolymers, dendritic copolymers, hyperbranched copolymers, graft copolymers, and combinations thereof.

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

[0240] Here, R' and R'' each represent an alkylene moiety that may be linear or branched, having 1 to 20 carbon atoms, preferably 1 to 12 carbon atoms; and m is a number such that the ester is polymerizable, preferably such that the molecular weight of the aliphatic polyester is at least 10,000, preferably at least 30,000, most preferably at least 50,000 daltons, but less than 1,000,000, preferably less than 500,000, 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.

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

[0242] 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.

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

[0244] 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, provided that the polyester has a substantially sustainable content.

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

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

[0247] Useful aliphatic polyesters include those derived from semicrystalline polylactic acid. Polylactic acid, or polylactide (PLA), is derived primarily from lactic acid, 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 crystallinity) can be obtained. L,L- or D,D-lactide yields semicrystalline poly(lactide), while poly(lactide) obtained from D,L-lactide is non-crystalline.

[0248] 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 be obtained from sources other than corn. The sugar is converted to lactic acid or lactic acid derivatives by fermentation using microorganisms. The lactic acid then polymerizes to form PLA. Other agricultural sugar sources can be used, such as rice, sugar beets, sugarcane, wheat, cellulosic materials, and other agricultural sugar sources mentioned above, such as xylose recovered from wood pulping.

[0249] To maximize the intrinsic crystallinity of the polymer, polylactic acid preferably has a high enantiomer ratio. The crystallinity of polylactic acid is based on the regularity of the polymer backbone and its ability to crystallize with other polymer chains. When a relatively small amount of one enantiomer (e.g., D-) 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, it is desirable to have polylactic acid with at least 85% of one isomer, at least 90% of one isomer, or at least 95% of one isomer to maximize crystallinity.

[0250] In some embodiments, nearly equimolar blends of D-polylactide and L-polylactide are also useful. This blend forms a unique crystalline structure with a higher melting point (approximately 210°C) than D-poly(lactide) and L-poly(polylactide) alone (approximately 190°C), and exhibits improved thermal stability.

[0251] Copolymers, such as block and random copolymers of polylactic 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.

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

[0253] In one preferred embodiment, the aliphatic polyester component includes 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 suitable molecular properties for spinning in a spunbond process. Examples of suitable resins include PLA resins supplied by NatureWorks LLC at Minnetonka, Minn. 55345, e.g., grades 6752D, 6100D, and 6202D, which are believed to be commonly manufactured in accordance with the disclosures of U.S. Patent Nos. 5,525,706 and 6,807,973 to Gruber et al. Other examples of suitable PLA resins may include L130, L175, and LX175 from Corbion, Arkelsedijk 46, 4206 AC Gorinchem, Netherlands.

[0254] In some embodiments, the nonwoven fabric of the present invention may contain a sustainable 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 aliphatic components having two hydroxyl groups (or a polyester-forming derivative thereof, e.g., an ester group) and two carboxylic acid groups (or a polyester-forming derivative thereof, e.g., an ester group).

[0255] Additional non-limiting examples of bio-based polymers include polymers produced directly from living organisms, such as polyhydroxyalkanoates (e.g., poly(beta-hydroxyalkanoate), poly(3-hydroxybutyrate-co-3-hydroxyvalerate), NODAX 商標 This includes, for example, 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, natural rubber; and current polymers derived from naturally occurring monomers and derivatives, such as biopolyethylene, biopolypropylene, polytrimethylene terephthalate, polylactic acid, nylon (NYLON) 11, alkyd resins, succinic acid-based polyesters, and biopolyethylene terephthalate.

[0256] In some embodiments, the bio-based polymer may include bio-based polyethylene derived from biological sources. For example, bio-based polyethylene can be prepared from sugars that are fermented to produce ethanol, which is then dehydrated to yield ethylene. A suitable example of sugarcane-derived polyethylene is available from Braskem SA under the product name PE SHA7260.

[0257] As previously stated, embodiments of the nonwoven fabric may include one or more regions in the layered woven fabric layer 410 in which the fibers are multi-component. In one embodiment, the fibers include multi-component fibers having at least two polymer components arranged in structured domains across the cross-section of the fiber. As is generally known to those skilled in the art, the polymer domains or components are arranged in zones substantially continuously arranged across the cross-section of the multi-component fiber and extend continuously along the length of the multi-component fiber. Three or more components may be present in the multi-component fiber.

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

[0259] 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 sheath / core fiber may have a circular or non-circular cross-section. Other structured fiber configurations known in the art, such as segmented pie structures, island-in-the-sea structures, and tipped multilobal structures, can be used.

[0260] In one embodiment, the fiber is two-component, with a first polymer component defining the fiber sheath and a second polymer component defining the fiber core. Generally, the weight percentage of sheath to core in the fiber can vary considerably depending on the desired properties of the carded nonwoven fabric. For example, the weight ratio of the sheath to the core can vary from about 5:95 to about 95:5, for example, about 10:90 to about 90:10, and especially about 20:80 to about 80:20. In a preferred embodiment, the weight ratio of the sheath to the core is about 25:75 to about 35:65, with a preferred weight ratio of about 20:80 to about 50:50.

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

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

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

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

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

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

[0267] In these multilayer structures, the basis weight of the spunbond nonwoven fabric layer of the present invention is 3 g / m². 2 From the lowest to 80g / m 2 This may be the case. In such a multilayer laminate, both the meltblown region and the outer layer region of the nonwoven fabric of the present invention may contain the same polymer on the surface to ensure optimal adhesion. In some embodiments in which the spunbond layer of the present invention is part of a multilayer structure (e.g., SM, SMS, and SMMS), the amount of meltblown in the structure may be about 5 to about 30%, particularly about 5 to about 15%, as a percentage of the entire structure.

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

[0269] Multilayer structures according to the embodiments can be prepared in various ways, for example, a continuous in-line process in which each layer is prepared in a continuous sequence on the same line, or in various ways including depositing a meltblown layer on a previously formed spunbond layer. The layers of the multilayer structure can be bonded together to form a multilayer composite sheet material using thermal bonding, mechanical bonding, adhesive bonding, hydroentungling, or a combination thereof. In one embodiment, the layers are thermally spot-bonded to each other by passing the multilayer structure through a pair of calender rolls.

[0270] Nonwoven 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 for personal care applications, such as baby care products (diapers, wipes), fem care products (pads, sanitary towels, 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, airline pillows, car trunk liners, soundproofing materials, and household products, such as mattress coil covers and furniture scratch pads.

[0271] Example

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

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

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

[0275] "PP-2" refers to a metallocene-catalyzed polypropylene with a melt flow rate (MFR) of 24 g / 10 min measured by ASTM D1238 and is available under the product name ACHIEVE 登録商標 3854 from Exxon.

[0276] Control Experiment 1

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

[0278] Example 1 of the Present Invention

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

[0280] The resulting fabrics were evaluated for crimp development at 50x magnification using a Keyence VHX-5000 microscope. The results are provided in Figures 19 and 20 (Control Experiment 1 and Example 1 of the present invention, respectively). The image in Figure 19 is of a single-layer spunbond fabric having a single fiber type (i.e., S / C filament). In the fabric of Control Experiment 1, the filament shows little to no crimp, if present. In contrast, Figure 20 is an image of a single-layer spunbond fabric having two different fiber types, where a significant proportion of the filaments (SBS filament) show crimp, while a small proportion of the filaments (S / C filament) show little to no crimp, similar to the filament in Control Experiment 1. As seen in Figure 20, the zoned distribution plate can be used to produce fabrics having single layers with multiple different fiber types.

[0281] Modifications of the invention described herein will occur to those of ordinary skill in the art having the benefit of the teachings presented in the foregoing description and the associated drawings. Accordingly, the invention is not to be limited to the specific embodiments disclosed, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Exemplary embodiments of the present invention are as follows. [Section 1] A system for preparing a nonwoven fabric having a single woven layer, wherein the single woven layer comprises a plurality of different fiber types, and the system A first polymer source configured to supply a stream of a first polymer in a molten or semi-molten state; A second polymer source configured to supply a stream of a second polymer in a molten or semi-molten state, wherein the second polymer is of a different type than the first polymer; A spin beam in fluid communication with the first polymer source and the second polymer source, wherein the spin beam comprises a zoned distribution plate located upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone configured and arranged to extrude a plurality of polymer streams into the spinneret, each of which is of a different polymer type than the polymer streams extruded by adjacent zones; The collection surface located below the spinneret, wherein continuous filaments are deposited to form a single layer containing two or more types of fibers that are different from each other. The system comprising the above-mentioned features. [Section 2] The system according to item 1, wherein the zoned distribution plate comprises 2 to 10 zones. [Section 3] The system according to claim 1 or 2, wherein the zoned distribution plate comprises a first zone configured for producing multi-component filaments and a second zone configured for producing single-component filaments. [Section 4] The system according to any one of claims 1 to 3, wherein the first polymer source comprises polypropylene and the second polymer source comprises polypropylene. [Section 5] The system according to any one of claims 1 to 4, wherein the zoned distribution plate comprises a first zone configured for producing crimped filaments and a second zone configured for producing non-crimped or low-crimped filaments. [Section 6] The system according to any one of claims 1 to 5, wherein the zoned distribution plate comprises a plurality of zones extending longitudinally in the direction of intersection of the spin beams. [Section 7] The system according to any one of claims 1 to 6, wherein the zoned distribution plate comprises a plurality of zones extending laterally in the mechanical direction of the spin beam. [Section 8] The system according to any one of claims 1 to 7, further comprising a third polymer source in fluid communication with the spin beam, wherein the third polymer source is configured to supply a stream of molten or semi-molten third polymer. [Section 9] The system according to any one of claims 1 to 8, wherein the first polymer source comprises a first polypropylene polymer, and the second polymer source comprises a second polypropylene polymer different from the first polypropylene polymer. [Section 10] The system according to claim 9, wherein the second distribution zone is configured to extrude a polymer stream comprising a single-component filament, and the first distribution zone is configured to extrude a polymer stream having a sheath / core configuration comprising the first polypropylene polymer and the second polypropylene polymer. [Section 11] The system according to any one of claims 1 to 10, wherein the first polymer source comprises a first polymer, and the second polymer source comprises a second polymer which is blended with a functional additive not blended with the first polymer. [Section 12] The system according to claim 11, wherein the functional additive is selected from the group comprising colorants, UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblocking agents, slip agents, fluorescent whitening agents, flame retardants, polymer rheology modifiers, and antimicrobial agents. [Section 13] The system according to any one of claims 1 to 12, wherein the first distribution zone has about 10 to about 50 distribution openings arranged in the intersecting direction of the spin beam, and the second distribution zone has about 10 to about 50 distribution openings arranged in the intersecting direction of the spin beam. [Section 14] The system according to any one of items 1 to 13, wherein the ratio of the number of rows of distribution openings in the first distribution zone to the number of rows of distribution openings in the second distribution zone is 10:90 to 90:10, in particular about 50:about 50. [Section 15] The system according to any one of claims 1 to 14, wherein the zoned distribution plate comprises a third distribution zone, and the second distribution zone is sandwiched between the first distribution zone and the third distribution zone. [Section 16] The system according to item 15, wherein the first distribution zone and the third distribution zone are in fluid communication with the first polymer source. [Section 17] The system according to claim 16, wherein the first distribution zone and the second distribution zone are configured to produce low-crepe filaments or non-crepe filaments, and the second distribution zone is configured to produce crimped filaments. [Section 18] The system according to any one of claims 1 to 17, wherein the system is configured to produce a layered woven fabric having two or more regions of different fiber types. [Section 19] The system according to any one of claims 1 to 17, wherein the system is configured to produce a nonwoven fabric layer having a plurality of fiber types, wherein the plurality of fiber types are mixed throughout the entire thickness of the woven fabric layer. [Section 20] The system according to any one of claims 1 to 19, further comprising an adhesive unit for bonding the aforementioned fibers together to form a cohesive fabric. [Section 21] Use of any one of the systems described in items 1 to 20 in the manufacture of nonwoven fabrics. [Section 22] Use of the nonwoven fabric as described in item 21 in the manufacture of absorbent articles. [Section 23] A system for preparing a nonwoven fabric having a layered woven fabric layer, A first polymer source configured to supply a stream of a first polymer in a molten or semi-molten state; A second polymer source configured to supply a stream of a second polymer in a molten or semi-molten state, wherein the second polymer is of a different type than the first polymer; A spin beam in fluid communication with the first polymer source and the second polymer source, wherein the spin beam comprises a zoned distribution plate located upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone configured and arranged to extrude a plurality of polymer streams into the spinneret, each of which is of a different polymer type than the polymer streams extruded by adjacent zones; and, A collection surface located below the spinneret, wherein continuous filaments are deposited thereon to form a layered nonwoven fabric, wherein the layered fabric includes a single layer having two or more adjacent regions of different types of fibers. The system including the above. [Section 24] The system according to paragraph 23, wherein the zoned distribution plate comprises a first zone configured for producing multi-component filaments and a second zone configured for producing single-component filaments. [Section 25] The system according to paragraph 23, wherein the zoned distribution plate comprises 2 to 10 zones. [Section 26] The system according to any one of claims 23 to 25, wherein the zoned distribution plate comprises a first zone configured for producing crimped filaments and a second zone configured for producing non-crimped or low-crimped filaments. [Section 27] The system according to any one of claims 23 to 26, wherein the zoned distribution plate comprises a plurality of zones extending longitudinally in the direction of intersection of the spin beams. [Section 28] The system according to any one of claims 23 to 26, wherein the zoned distribution plate includes a plurality of zones extending laterally in the mechanical direction of the spin beam. [Section 29] The system according to any one of claims 23 to 28, further comprising a third polymer source in fluid communication with the spin beam, wherein the third polymer source is configured to supply a stream of molten or semi-molten third polymer. [Section 30] A method for preparing a nonwoven fabric having a single woven layer, wherein the single woven layer comprises a plurality of different fiber types, and the method Prepare a first polymer source configured to supply a stream of a first polymer in a molten or semi-molten state; A second polymer source is provided, configured to supply a stream of a second polymer in a molten or semi-molten state, wherein the second polymer is of a different type than the first polymer; The first polymer stream and the second polymer stream are introduced into a spin beam that is in fluid communication with the first polymer source and the second polymer source, wherein the spin beam comprises a zoned distribution plate located upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone configured and arranged to extrude a plurality of polymer streams into the spinneret, each of which is of a different polymer type than the polymer streams extruded by adjacent zones; Extruding the first stream of the first polymer from the spinneret as a first continuous filament; Extruding the second stream of the second polymer from the spinneret as a second continuous filament; and, The first continuous filament and the second continuous filament are collected on a collection surface located below the spinneret to form a single layer containing the first continuous filament and the second continuous filament of different types. The method, including the method described above. [Section 31] The method according to claim 30, wherein the zoned distribution plate comprises 2 to 10 zones. [Section 32] The method according to claim 30 or 31, wherein the zoned distribution plate comprises a first zone configured for producing a multi-component filament and a second zone configured for producing a single-component filament. [Section 33] The method according to any one of claims 30 to 32, wherein the first polymer source comprises polypropylene and the second polymer source comprises polypropylene. [Section 34] The method according to any one of claims 30 to 33, further comprising extruding the first stream of polymer through a first zone of the zoned distribution plate to produce a crimped filament, and extruding the second stream of polymer through a second zone of the zoned distribution plate to produce a non-crimped filament or a low-crimped filament. [Section 35] The method according to any one of claims 30 to 34, wherein the zoned distribution plate comprises a plurality of zones extending longitudinally in the direction of intersection of the spin beams. [Section 36] The method according to any one of claims 30 to 34, wherein the zoned distribution plate comprises a plurality of zones extending laterally in the mechanical direction of the spin beam. [Section 37] The method according to any one of claims 30 to 36, further comprising providing a third polymer source in fluid communication with the spin beam, wherein the third polymer source is configured to supply a stream of molten or semi-molten third polymer. [Section 38] The method according to any one of claims 30 to 37, wherein the first polymer source comprises a first polypropylene polymer, and the second polymer source comprises a second polypropylene polymer different from the first polypropylene polymer. [Section 39] The method according to any one of claims 30 to 38, wherein the first distribution zone is configured to extrude a polymer stream comprising a single-component filament, and the second distribution zone is configured to extrude a polymer stream having a sheath / core configuration comprising the first polypropylene polymer and the second polypropylene polymer. [Section 40] The method according to any one of claims 30 to 39, wherein the first polymer source comprises a first polymer, and the second polymer source comprises a second polymer which is blended with a functional additive not blended with the first polymer. [Section 41] The method according to claim 40, wherein the functional additive is selected from the group comprising colorants, UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblocking agents, slip agents, fluorescent whitening agents, flame retardants, and antibacterial agents. [Section 42] The method according to any one of claims 30 to 41, wherein the first distribution zone has about 10 to about 50 distribution openings arranged in the intersecting direction of the spin beam, and the second distribution zone has about 10 to about 50 distribution openings arranged in the intersecting direction of the spin beam. [Section 43] The method according to any one of claims 30 to 42, wherein the ratio of the number of rows of distribution openings in the first distribution zone to the number of rows of distribution openings in the second distribution zone is 30:70 to 70:30, in particular about 50:about 50. [Section 44] The method according to any one of claims 30 to 43, wherein the zoned distribution plate comprises a third distribution zone, and the second distribution zone is sandwiched between the first distribution zone and the third distribution zone. [Section 45] The method according to item 44, wherein the first distribution zone and the third distribution zone are in fluid communication with the first polymer source. [Section 46] The method according to claim 45, wherein the first distribution zone and the second distribution zone are configured to produce low-crepe filaments or non-crepe filaments, and the second distribution zone is configured to produce crimped filaments. [Section 47] The method according to any one of claims 30 to 46, wherein the system is configured to produce a layered woven fabric having two or more regions of different fiber types. [Section 48] The method according to any one of claims 30 to 46, wherein the spin beam is configured to produce a nonwoven fabric layer having a plurality of fiber types, wherein the plurality of fiber types are mixed throughout the entire thickness of the woven fabric layer. [Section 49] The method according to any one of claims 30 to 48, further comprising bonding the fibers of the fabric to form a cohesive fabric. [Section 50] Use of the method described in any one of paragraphs 30 to 49 in the manufacture of nonwoven fabrics. [Section 51] A spunbond nonwoven fabric having a single woven layer comprising a plurality of continuous filaments that adhere to each other to form a cohesive web, wherein the plurality of continuous filaments comprises a first fiber type and a second fiber type different from the first fiber type. [Section 52] The spunbond fabric according to claim 51, wherein the first fiber type and the second fiber type are mixed throughout the entire thickness of the single woven fabric layer. [Section 53] The spunbond fabric according to claim 51, wherein the single woven layer is a layered woven layer, wherein in the layered woven layer, the first fiber type is mainly arranged in a first region of the layered woven layer, and the second fiber type is mainly arranged in a second region of the layered woven layer. [Section 54] A spunbond fabric according to any one of items 51 to 53, further comprising a third type of fiber. [Section 55] The spunbond fabric according to any one of claims 51 to 53, wherein the first fiber type comprises a multi-component filament and the second fiber type comprises a single-component filament. [Section 56] A spunbond fabric according to any one of claims 51 to 55, wherein the first fiber type includes polypropylene and the second fiber type includes polypropylene. [Section 57] A spunbond fabric according to any one of claims 51 to 56, wherein the first fiber type includes crimped filaments, and the second fiber type includes non-crimped filaments or low-crimped filaments. [Section 58] A spunbond fabric according to any one of claims 51 to 57, wherein the first fiber type comprises a first polypropylene polymer, and the second fiber type comprises a second polypropylene polymer different from the first polypropylene polymer. [Section 59] The spunbond fabric according to claim 58, wherein the first fiber type comprises a multi-component filament having a sheath / core structure comprising the first polypropylene polymer and the second polypropylene polymer, and the second fiber type comprises a single-component filament comprising the first polypropylene polymer. [Section 60] The spunbond fabric according to claim 59, wherein the multi-component filaments comprise two-component fibers having a side-by-side configuration, an eccentric sheath / core configuration, or a D-centric sheath / core configuration. [Section 61] A spunbond fabric according to any one of claims 51 to 58, wherein the first fiber type comprises a first polymer, and the second fiber type comprises a second polymer which is blended with a functional additive not blended with the first polymer. [Section 62] The spunbond fabric according to claim 60, wherein the functional additive is selected from the group comprising colorants, UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblocking agents, slip agents, fluorescent whitening agents, flame retardants, polymer rheology modifiers, and antimicrobial agents. [Section 63] A composite sheet material comprising a spunbond fabric as described in any of items 51 to 62, and at least one meltblown fabric layer bonded to the surface of the spunbond fabric. [Section 64] The composite sheet material according to item 63, wherein the spunbond woven fabric layer is sandwiched between two meltblown layers. [Section 65] The composite sheet material according to claim 63, wherein at least one meltblown layer is sandwiched between two spunbond layers, wherein at least one of the spunbond layers comprises a single woven fabric layer comprising a first fiber type and a second fiber type different from the first fiber type. [Section 66] The composite sheet material according to any one of claims 63 to 65, wherein the single woven layer comprises both crimped filaments and non-crimped or low-crimped filaments.

Claims

1. A system for preparing a nonwoven fabric having a single woven layer, wherein the single woven layer comprises a plurality of different fiber types, and the system A first polymer source configured to supply a stream of a first polymer in a molten or semi-molten state; A second polymer source configured to supply a stream of a second polymer in a molten or semi-molten state, wherein the second polymer is of a different type than the first polymer; A spin beam is fluidly communicating with the first polymer source and the second polymer source, wherein the spin beam comprises a zoned distribution plate located upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone configured and arranged to extrude a plurality of polymer streams into the spinneret, each of which is of a different polymer type than the polymer streams extruded by adjacent zones; The collection surface located below the spinneret, on which continuous filaments are deposited to form a single layer containing two or more different types of fibers. It is equipped with, The zoned distribution plate comprises a first distribution zone configured to produce non-crinkled or low-crinkled filaments, and a second distribution zone configured to produce crimped filaments. The aforementioned system.

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

3. The system according to claim 1 or 2, wherein the zoned distribution plate comprises a first zone configured for producing a multi-component filament and a second zone configured for producing a single-component filament.

4. The system according to any one of claims 1 to 3, wherein the first polymer source comprises polypropylene and the second polymer source comprises polypropylene.

5. The system according to claim 1, wherein the first distribution zone is configured to produce a non-crimped or low-crimped multi-component filament having a sheath / core configuration, and the second distribution zone is configured to produce a crimped multi-component filament having a side-by-side configuration or an eccentric configuration.

6. The system according to any one of claims 1 to 5, wherein the zoned distribution plate comprises a plurality of zones extending longitudinally in the direction of intersection of the spin beams, or a plurality of zones extending transversely in the mechanical direction of the spin beams.

7. The system according to any one of claims 1 to 6, further comprising a third polymer source in fluid communication with the spin beam, wherein the third polymer source is configured to supply a stream of molten or semi-molten third polymer.

8. The system according to any one of claims 1 to 7, wherein the first polymer source comprises a first polymer, and the second polymer source comprises a second polymer which is blended with a functional additive not blended with the first polymer.

9. The system according to claim 8, wherein the functional additive is selected from the group consisting of colorants, UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblocking agents, slip agents, fluorescent whitening agents, flame retardants, polymer rheology modifiers, and antibacterial agents.

10. The system according to any one of claims 1 to 9, wherein one or more of the first polymer and the second polymer comprises a bio-based polymer.

11. The method according to any one of claims 1 to 10, wherein the single woven fabric layer having multiple different types of fibers is bonded to a film layer.

12. The zoned distribution plate has one of the following zoned distribution configurations: A first zoned distribution configuration, wherein the first zoned distribution configuration includes a first distribution zone and a second distribution zone that are in fluid communication with a first polymer source, and a third distribution zone located between the first distribution zone and the second distribution zone, wherein the first distribution zone and the second distribution zone are configured to produce a multi-component filament or a single-component filament, and the third distribution zone is configured to be in fluid communication with both the first polymer source and the second polymer source and to produce a multi-component filament. A second zoned distribution configuration, wherein the second zoned distribution configuration includes a first distribution zone and a second distribution zone that are in fluid communication with both the first polymer source and the second polymer source, and a third distribution zone located between the first distribution zone and the second distribution zone and also in fluid communication with the first polymer source, wherein the first distribution zone and the second distribution zone are configured to produce a multi-component filament, and the third distribution zone is configured to produce a single-component filament or a multi-component filament. The system according to any one of claims 1 to 11.

13. A system for preparing a nonwoven fabric having a single woven layer, wherein the single woven layer comprises a plurality of different fiber types. The aforementioned system A first polymer source configured to supply a stream of a first polymer in a molten or semi-molten state; A second polymer source configured to supply a stream of a second polymer in a molten or semi-molten state, wherein the second polymer is of a different type than the first polymer; A spin beam fluidly communicating with the first polymer source and the second polymer source, wherein the spin beam comprises a zoned distribution plate located upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone configured and arranged to extrude a plurality of polymer streams into the spinneret, each of which is a different polymer type from the polymer streams extruded by adjacent zones, wherein the zoned distribution plate comprises a first zoned distribution configuration including a first distribution zone and a second distribution zone fluidly communicating with the first polymer source, and a third distribution zone located between the first and second distribution zones, wherein the first and second distribution zones are configured to produce a first fiber type, and the third distribution zone is fluidly communicating with the second polymer source and is configured to produce a second fiber type different from the first fiber type; and, A collection surface located below the spinneret, wherein continuous filaments are deposited thereon, forming a single layer containing two or more types of fibers that are different from each other. The system including the above.

14. The system according to claim 13, wherein the zoned distribution plate comprises a plurality of zones extending longitudinally in the direction of intersection of the spin beams, or a plurality of zones extending transversely in the mechanical direction of the spin beams.

15. A method for preparing a nonwoven fabric having a single woven layer, wherein the single woven layer comprises a plurality of different fiber types. The method described above is Prepare a first polymer source configured to supply a stream of a first polymer in a molten or semi-molten state; A second polymer source is provided, configured to supply a stream of a second polymer in a molten or semi-molten state, wherein the second polymer is of a different type than the first polymer; The first polymer stream and the second polymer stream are introduced into a spin beam that is in fluid communication with the first polymer source and the second polymer source, wherein the spin beam comprises a zoned distribution plate located upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution openings arranged in a plurality of zones, each zone configured and arranged to extrude a plurality of polymer streams into the spinneret, each of a different polymer type than the polymer streams extruded by adjacent zones; Extruding the first stream of the first polymer from the spinneret as a first continuous filament; Extruding the second stream of the second polymer from the spinneret as a second continuous filament; and, The first continuous filament and the second continuous filament are collected on a collection surface located below the spinneret to form a single layer containing the first continuous filament and the second continuous filament of different types. Includes, The zoned distribution plate comprises a first distribution zone configured to produce non-crinkled or low-crinkled filaments, and a second distribution zone configured to produce crimped filaments. The aforementioned method.

16. The method according to claim 15, wherein the zoned distribution plate comprises a first zone configured for producing a multi-component filament and a second zone configured for producing a single-component filament.

17. The zoned distribution plate has multiple distribution zones arranged within one of the following zoned distribution configurations: A first zoned distribution configuration, wherein the first zoned distribution configuration includes a first distribution zone and a second distribution zone that are in fluid communication with a first polymer source, and a third distribution zone located between the first distribution zone and the second distribution zone, wherein the first distribution zone and the second distribution zone are configured to produce a multi-component filament or a single-component filament, and the third distribution zone is configured to be in fluid communication with both the first polymer source and the second polymer source and to produce a multi-component filament. A second zoned distribution configuration, wherein the second zoned distribution configuration includes a first distribution zone and a second distribution zone that are in fluid communication with both the first polymer source and the second polymer source, and a third distribution zone located between the first distribution zone and the second distribution zone and also in fluid communication with the first polymer source, wherein the first distribution zone and the second distribution zone are configured to produce a multi-component filament, and the third distribution zone is configured to produce a single-component filament or a multi-component filament. The method according to claim 16.

18. The method according to any one of claims 15 to 17, wherein the zoned distribution plate comprises 3 to 10 zones.

19. The first distribution zone and the second distribution zone of the first zoned distribution configuration are i. A device configured to produce a non-crimped or low-crimped multi-component filament having a sheath / core configuration, wherein the third distribution zone is configured to produce a crimped multi-component filament having a side-by-side configuration or an eccentric configuration; or, ii. A configuration for producing crimped multi-component filaments having a side-by-side configuration or an eccentric configuration, wherein the third distribution zone of the second zoned distribution configuration is configured for producing un-crimped or low-crimped multi-component filaments. The method according to claim 15.

20. The method according to any one of claims 15 to 19, wherein the zoned distribution plate comprises a plurality of zones extending longitudinally in the direction of intersection of the spin beams, or a plurality of zones extending transversely in the mechanical direction of the spin beams.

21. The system according to any one of claims 1 to 14, wherein the spinneret comprises a plurality of spinning orifices extending through the spinneret, the spinneret comprising a first plurality of spinning orifices configured to produce non-crimped filaments or low-crimped filaments, and a second plurality of spinning orifices configured to produce crimped filaments.

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

23. The system according to claim 22, wherein the spinneret comprises a plurality of first zones and a plurality of second zones.

24. The system according to claim 22 or 23, wherein the spinneret comprises a pair of the second zones, and the first zone is located between the pair of second zones.

25. The system according to claim 24, wherein the plurality of first zones and the plurality of second zones are arranged alternately across the spinneret.

26. The system according to claim 21, wherein the spinning orifice among the second plurality of spinning orifices is configured to produce fibers having a side-by-side configuration, a sheath / core configuration, an eccentric sheath / core configuration, a D-centric sheath / core configuration, an island-in-the-sea configuration, a three-component configuration, a bipartite pie configuration, or a combination thereof.

27. ​​The system according to any one of claims 1 to 14 and 21 to 26, wherein the single woven layer has a plurality of fibers comprising different fiber types, the first fiber type comprising crimped fibers, and the second fiber type comprising non-crimped fibers or low-crimped fibers.

28. The system according to claim 27, wherein the first fiber type and the second fiber type are mixed together throughout the entire thickness of the nonwoven fabric.

29. The system according to claim 27, wherein the nonwoven fabric comprises a first region mainly comprising crimped fibers and a second region mainly comprising non-crimped fibers or low-crimped fibers.

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

31. The system according to claim 29, wherein the second region is located between a pair of the first regions.

32. The system according to claim 29, wherein the first region defines a first outer surface of the nonwoven fabric, and the second region defines a second outer surface of the nonwoven fabric.

33. The system according to any one of claims 1 to 14 and 21 to 32, wherein the nonwoven fabric is used in the manufacture of an absorbent article.

34. The system according to any one of claims 1 to 14 and 21 to 33, wherein the nonwoven fabric is used to prepare a composite sheet material, and the composite sheet material comprises at least one meltblown fabric layer bonded to the surface of the nonwoven fabric.

35. A method for manufacturing an absorbent article, wherein a nonwoven fabric prepared by the system described in any one of claims 1 to 14 and 21 to 32 is used.

36. A method for manufacturing a composite sheet material, wherein the composite sheet material comprises at least one meltblown fabric layer adhered to the surface of the nonwoven fabric, and the manufacturing method uses a nonwoven fabric prepared by the system described in any one of claims 1 to 14 and 21 to 32.

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