Nonwoven with non-symmetrical bonding configuration

• US 6,610,390 B1
• Filed: 07/10/2000
• Issued: 08/26/2003
• Est. Priority Date: 08/13/1999
• Status: Expired due to Term

• Current Assignee: First Quality Nonwovens, Inc. (R2G Rohan SARL)
• Original Assignee: First Quality Nonwovens, Inc. (R2G Rohan SARL)
• Inventors: Turi, Mordechai, Kauschke, Michael
• Primary Examiner(s): Juska, Cheryl A.
• Assistant Examiner(s): Pratt, Christopher C
• Application Number:
  US09/613,192
• Time in Patent Office: 1,142 Days
• Field of Search: 428/195, 428/196, 428/198, 428/401, 442/328, 442/401, 442/381, 442/382, 442/394, 442/409
• US Class Current: 428/198
• CPC Class Codes: B32B 2305/20 in the form of a non-woven mat
• CPC Class Codes: B32B 2307/514 Oriented
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/30 one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 7/14 applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: D04H 1/54 by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485
• CPC Class Codes: D04H 1/555 by ultrasonic heating
• CPC Class Codes: D04H 3/14 with bonds between thermoplastic yarns or filaments produced by welding
• CPC Class Codes: D04H 3/16 with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
• CPC Class Codes: D04H 5/06 strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns
• CPC Class Codes: Y10T 428/24826 Spot bonds connect components
• CPC Class Codes: Y10T 442/57 Including particulate material other than fiber
• CPC Class Codes: Y10T 442/659 Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/66 Additional nonwoven fabric is a spun-bonded fabric
• CPC Class Codes: Y10T 442/674 Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/681 Spun-bonded nonwoven fabric
• CPC Class Codes: Y10T 442/69 Autogenously bonded nonwoven fabric

Abstract

A nonwoven has low tensile and high elongation in the first direction (typically the CD) and high tensile and low elongation in the second direction (typically the MD). The nonwoven has a plurality of bonding points defining a total bonding area along the second direction greater than along the first direction. Accordingly, the nonwoven has unbonded fiber portions and bonded fiber portions, with a bonded portion/unbonded portion ratio greater along the second direction than along the first direction. The bonding points are preferably either circular or oval in plan.

Claims

1. A nonwoven wherein orthogonally differential bonding provides high elongation in a first direction and low elongation in a second direction, said nonwoven having a plurality of bonding points defining a total bonding area along said second direction greater than along said first direction, said bonding points forming a uniform pattern of bond density in the first direction different from a uniform pattern of bond density in the second direction, said bonding points being closed figures elongated in said second direction and selected from the group consisting of closed figures:

(A) oriented in parallel along said second direction axis;

(B) oriented transverse to adjacent closed figures along said second direction axis; and

(C) oriented in sets with proximate closed figures so as to form therebetween a closed configuration elongated in said second direction.

2. The nonwoven of claim 1 wherein the closed figures elongated in said second direction are oriented in parallel along an MD axis.

3. The nonwoven of claim 1 wherein the closed figures elongated in said second direction are oriented transverse to adjacent closed figures along an MD axis.

4. The nonwoven of claim 1 wherein the closed figures elongated in said second direction are oriented in sets with proximate figures so as to form therebetween a closed configuration elongated in the MD.

5. A laminate comprising the nonwoven of claim 1 and a second nonwoven, said nonwoven having an embossed pattern of depressions and projections, with said second nonwoven entering the depressions of said nonwoven, said pattern defining closed figures elongated in said second direction.

6. The laminate of claim 5 wherein said closed figures elongated in said second direction are selected from the group consisting of closed figures:

(A) oriented in parallel along an MD axis;

(B) oriented transverse to adjacent closed figures along MD axis; and

(C) oriented in sets with proximate closed figures so as form therebetween a closed configuration elongated in the MD.

7. The laminate of claim 5, formed in a laminating station including a heated engraved hard roll adjacent one nonwoven and an unheated smooth soft roll adjacent the other nonwoven.

8. The laminate of claim 5 wherein said laminate after lamination has a high MVTR and substantially no holes therein.

9. The laminate of claim 5 wherein said second nonwoven is a spunbond.

10. The laminate of claim 9 wherein said nonwoven is a spunbond.

11. The laminate of claim 5 wherein said nonwoven is a spunbond.

12. A laminate comprising the nonwoven of claim 1 and an elastic film, said nonwoven having an embossed pattern of depressions and projections, with said elastic film entering the depressions of said nonwoven, said pattern defining closed figures elongated in said second direction.

13. The laminate of claim 12 wherein said closed figures elongated in said second direction are selected from the group consisting of closed figures:

(A) oriented in parallel along an MD axis;

(B) oriented transverse to adjacent closed figures along an MD axis; and

(C) oriented in sets with proximate closed figures so as to form therebetween a closed configuration elongated in the MD.

14. The laminate of claim 12, formed in a coating station including a nip roll adjacent said nonwoven and a chill roll adjacent said elastic film.

15. The laminate of claim 12 wherein said nonwoven and said elastic film have comparable physical characteristics under stress.

16. The laminate of claim 12 wherein said elastic film is coated onto said nonwoven.

17. The laminate of claim 12 wherein said elastic film is cast coated onto said nonwoven.

18. A laminate comprising the nonwoven of claim 1 and a second material, said second material being selected from the group consisting of a second nonwoven and an elastic film, said nonwoven having an embossed pattern of depressions and projections, with said second material entering the depressions of said nonwoven, said pattern defining closed figures elongated in said second direction.

19. A member having high elongation in a first direction and low elongation in a second direction, said member being selected from the group consisting of:

(A) a nonwoven characterized by orthogonally differential bonding and having high elongation in a first direction and low elongation in a second direction, said nonwoven having a plurality of bonding points defining a total bonding area along said second direction greater than along said first direction, said bonding points forming a uniform pattern of bond density in the first direction different from the uniform pattern of bond density in the second direction, said bonding points being closed figures elongated in said second direction and selected from the group consisting of closed figures;

(i) oriented in parallel along said second direction axis;

(ii) oriented transverse to adjacent closed figures along said second direction axis; and

(iii) oriented in sets with proximate closed figures so as to form therebetween a closed configuration elongated in said second direction;

(B) a laminate comprising said nonwoven and a second nonwoven, said nonwoven having an embossed pattern of depressions and projections, with said second nonwoven entering the depressions of said nonwoven, said pattern defining closed figures elongated in said second direction; and

(C) a laminate comprising said nonwoven and an elastic film, said nonwoven having an embossed pattern of depressions and projections, with said elastic film entering the depressions of said nonwoven, said pattern defining closed figures elongated in said second direction.