Multi-component polymeric strands including a butene polymer and nonwoven fabric and articles made therewith

• US 5,512,358 A
• Filed: 09/22/1993
• Issued: 04/30/1996
• Est. Priority Date: 09/22/1993
• Status: Expired due to Term

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Corporation
• Inventors: Strack, David C., Shawver, Susan E., McDowall, Debra J., Timmons, Terry K.
• Primary Examiner(s): WITHERS, JAMES
• Application Number:
  US08/125,624
• Time in Patent Office: 951 Days
• Field of Search: 428/373, 428/374, 428/284, 428/286, 428/288, 428/296, 428/298, 428/302
• US Class Current: 442/362
• CPC Class Codes: A61L 15/225 Mixtures of macromolecular compounds
• CPC Class Codes: A61L 31/041 Mixtures of macromolecular compounds
• CPC Class Codes: C08L 23/06 Polyethene
• CPC Class Codes: C08L 23/12 Polypropene
• CPC Class Codes: C08L 23/20 having four to nine carbon atoms
• CPC Class Codes: D01F 8/06 with at least one polyolefin as constituent
• CPC Class Codes: D01G 25/00 Lap-forming devices not integral with machines specified above forming mats or batts of continuous filaments for non-woven fabrics D04H
• CPC Class Codes: D04H 3/007 Addition polymers
• CPC Class Codes: D04H 3/147 Composite yarns or filaments
• CPC Class Codes: Y10T 428/2929 Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
• CPC Class Codes: Y10T 428/2931 Fibers or filaments nonconcentric [e.g., side-by-side or eccentric, etc.]
• CPC Class Codes: Y10T 442/638 Side-by-side multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/641 Sheath-core multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/66 Additional nonwoven fabric is a spun-bonded fabric

Abstract

Multicomponent polymeric strands including a polymer blend of a butene polymer, a polyolefin other than butene, and up to 10% by weight of ethylene in polymeric form. The blend is in one side or the sheath of the multi-component strands. Fabric made with such strands is also disclosed and has enhanced softness properties. Composite materials including the foregoing fabric bonded to both sides of an inner meltblown layer and garments and other articles made with the fabric are also disclosed.

Claims

1. A multi-component polymeric spunbond strand including first and second polymeric components and having a cross-section, a length, and a peripheral surface wherein:

the first and second polymeric components are arranged in substantially distinct zones across the cross-section of the strand and extend continuously along the length of the strand;

the first polymeric component is a portion of the peripheral surface of the strand continuously along the length of the strand and comprises a blend of a butene polymer and a first polyolefin other than a butene polymer having up to about 10 weight percent of ethylene in polymeric form said butene polymer comprising butene in an amount from about 90 to about 100% by weight of the butene polymer;

the second polymeric component comprises a second polyolefin having ethylene in an amount less than 10 weight percent.

2. A polymeric strand as in claim 1 wherein the butene polymer is present in the first polymeric component in an amount from about 2 to about 50% by weight of the first component.

3. A polymeric strand as in claim 1 wherein the butene polymer is selected from the group consisting of homopolymer of butene-1 and copolymer of butene-1 and another olefin, the butene-1 being present in the copolymer in an amount from about 90 to about 100% by weight of the copolymer.

4. A polymeric strand as in claim 1 wherein the first polyolefin is present in the first polymeric component in an amount from about 98 to about 50% by weight of the first component, the butene polymer is present in an amount from about 2 to about 50% by weight of the first component, and the butene polymer comprises butene-1 in an amount from about 90 to about 100% by weight of the butene polymer.

5. A polymeric strand as in claim 1 wherein the first polyolefin of the first polymeric component is selected from the group consisting of polypropylene, and copolymers of propylene and ethylene with ethylene being present in an amount from about 1 to about 10% by weight of the copolymer.

6. A polymeric strand as in claim 1 wherein the first polyolefin is present in the first polymeric component in an amount from about 98 to about 50% by weight of the first component, the butene polymer is present in an amount from about 2 to about 50% by weight of the first component, and the butene polymer is selected from the group consisting of homopolymer of butene-1 and copolymer of butene-1 and another olefin, the butene-1 being present in the copolymer in an amount from about 90 to about 100% by weight of the copolymer.

7. A polymeric strand as in claim 1 wherein the second component comprises a second polyolefin including ethylene in an amount up to about 10% by weight of the second component.

8. A polymeric strand as in claim 7 wherein the second polyolefin is selected from the group consisting of polypropylene and copolymers of propylene and ethylene with ethylene being present in an amount from about 1 to about 10% by weight of the copolymer.

9. A polymeric strand as in claim 8 wherein the butene polymer is selected from the group consisting of homopolymer of butene-1 and copolymer of butene-1 and another olefin, the butene-1 being present in the copolymer in an amount from about 90 to about 100% by weight of the copolymer.

10. A polymeric strand as in claim 8 wherein the first polyolefin is present in the first polymeric component in an amount from about 98 to about 50% by weight of the first component, the butene polymer is present in an amount from about 2 to about 50% by weight of the first component, and the butene polymer is selected from the group consisting of homopolymer of butene-1 and copolymer of butene-1 and another olefin, the butene-1 being present in the copolymer in an amount from about 90 to about 100% by weight of the copolymer.

11. A polymeric strand as in claim 1 wherein the first and second components are arranged in a side-by-side configuration.

12. A polymeric strand as in claim 1 wherein the first and second components are arranged in a sheath/core configuration.

13. A polymeric strand as in claim 1 wherein the strands are continuous filaments.

14. A garment comprising a layer of the nonwoven fabric of claim 10.

15. A garment as in claim 14 wherein the garment is one of the group of medical apparel articles.

16. A garment as in claim 14 wherein the garment is a workwear article.

17. A cleaning article comprising a layer of the nonwoven fabric of claim 10.

18. A personal care absorbent article comprising a layer of the nonwoven fabric of claim 10.

19. A personal care absorbent article as in claim 18 wherein the absorbent article is an adult incontinence product.

20. A personal care absorbent article as in claim 18 wherein the absorbent article is an infant diaper.

21. A personal care absorbent article as in claim 18 wherein the absorbent article is a training pant.

22. A personal care absorbent article as in claim 18 wherein the absorbent article is a feminine care absorbent product.

23. A nonwoven fabric comprising the multi-component spunbond strands of claim 1 as a first web.

24. The nonwoven fabric of claim 23 further comprising a second web of extruded polymeric meltblown strands wherein the first and second webs are positioned in laminar surface-to-surface relationship and bonded together to form an integrated fabric.

25. The nonwoven fabric of claim 24 further comprising a third spunbond web of extruded polymeric strands bonded to said second web on the side opposite said first web.

26. A nonwoven fabric comprising the multi-component strands of claim 10 as a first web.

27. The nonwoven fabric of claim 26 further comprising a second web of extruded polymeric meltblown stands wherein the first and second webs are positioned in laminar surface-to-surface relationship and bonded together to form an integrated fabric.

28. The nonwoven fabric of claim 27 further comprising a third spunbond web of extruded polymeric strands bonded to said second web on the side opposite said first web.