# US 10,307,309 B2 · Carded staple fiber nonwovens > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,307,309 B2 - Document ID: US10307309B2 - Status: Granted - Kind: B2 - Application number: 14/731,802 - Filed: 2015-06-05 - Published: 2015-12-10 - Granted: 2019-06-04 - Earliest claimed: 2014-06-06 - Assignees: The Procter & Gamble Company - Applicants: The Procter & Gamble Company - Inventors: Gerard A. Viens; Stephen Lebeuf Hardie; Edward Paul Carlin; Ronda Lynn Glassmeyer - Web page: https://patentgrep.com/patent/US10307309B2 ## CPC - A61F 13/51121: {characterised by the material} - A61F 13/537: characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer {(A61F13/538 takes precedence)} - A61F 13/5376: {characterised by the performance of the layer, e.g. acquisition rate, distribution time, transfer time} - D04H 1/425: Cellulose series - D04H 1/4291: Olefin series - D04H 1/435: Polyesters - D04H 1/43828: {sheath-core} - D04H 1/43832: {side-by-side} - D04H 1/43835: {Mixed fibres, e.g. at least two chemically different fibres or fibre blends} - D04H 1/43912: {fibres with noncircular cross-sections} - D04H 1/43914: {hollow fibres} - D04H 1/43918: {nonlinear fibres, e.g. crimped or coiled fibres} - D04H 1/46: by needling or like operations to cause entanglement of fibres (D04H1/45 takes precedence; needling machines D04H18/00) - D04H 1/492: by fluid jet (D04H1/49 takes precedence) - A61F: FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS (dental prosthetics A61C) - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) ## Abstract A carded staple fiber nonwoven having a basis weight of between about 45 grams per square meter (gsm) and about 150 gsm, includes a blend of absorbing fibers, stiffening fibers and filler fibers. The carded staple fiber nonwoven is non-heat stiffened, has an air permeability of between about 100 m3/m2/min and about 500 m3/m2/min, and a pore radius mode of between about 60 μm and about 120 μm. ## Claims ### Claim 1 A carded staple fiber nonwoven having a basis weight of between about 40 grams per square meter (gsm) and about 150 gsm, the carded staple fiber nonwoven comprising a blend of absorbing fibers, stiffening fibers and filler fibers, wherein the carded staple fiber nonwoven is non-heat stiffened, has an air permeability of between about 100 m3/m2/min and about 500 m3/m2/min, and a pore volume radius mode of between about 60 μm and about 120 μm, wherein the stiffening fibers form about 10% to about 50%, by weight, of the carded staple fiber nonwoven, wherein the absorbing fibers form about 10% to about 50%, by weight, of the carded staple fiber nonwoven, and wherein the filler fibers form about 60% or less, by weight, of the carded staple fiber nonwoven. ### Claim 2 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the carded staple fiber nonwoven has a caliper of between about 0.08 mm and about 0.20 mm per 10 gsm of basis weight. ### Claim 3 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the carded staple fiber nonwoven has a caliper of between about 0.5 mm to about 3 mm. ### Claim 4 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the carded staple fiber nonwoven has a basis weight of between about 45 gsm to about 85 gsm. ### Claim 5 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the carded staple fiber nonwoven has an MD flexural rigidity of less than about 4.8 mNcm. ### Claim 6 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the carded staple fiber nonwoven has a pore volume ratio of greater than about 8. ### Claim 7 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the stiffening fibers comprise hollow, spiral fibers formed from polyethylene terephthalate (PET), wherein the stiffening fibers have a linear density of between about 6 dtex and about 15 dtex. ### Claim 8 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the absorbing fibers comprise tri-lobal fibers formed from rayon, wherein the absorbing fibers have a linear density of between about 2 dtex and about 6 dtex. ### Claim 9 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the filler fibers comprise solid, round fibers formed from polypropylene (PP), wherein the filler fibers have a linear density of about 3 dtex or greater. ### Claim 10 A carded staple fiber nonwoven, comprising: a) about 10% to about 50%, by weight, of stiffening fibers comprising hollow, spiral fibers formed from polyethylene terephthalate (PET), wherein the stiffening fibers have a linear density of between about 6 dtex and about 15 dtex; b) about 10% to about 50%, by weight, of absorbing fibers comprising tri-lobal fibers formed from rayon, wherein the absorbing fibers have a linear density of between about 2 dtex and about 6 dtex; and c) about 1% to about 60%, by weight, of filler fibers comprising solid, round fibers formed from polypropylene (PP), wherein the filler fibers have a linear density of about 3 dtex or greater; wherein the carded staple fiber nonwoven has a basis weight of between about 40 grams per square meter (gsm) and about 150 gsm, is non-heat stiffened, has an air permeability of between about 100 m3/m2/min and about 500 m3/m2/min, and a pore radius mode of between about 60 μm and about 120 μm. ### Claim 11 (depends on 10) The carded staple fiber nonwoven of claim 10, comprising: about 20% to about 30%, by weight, of the stiffening fibers; about 30% to about 40%, by weight, of the absorbing fibers; and about 1% to about 50%, by weight, of the filler fibers. ### Claim 12 (depends on 11) The carded staple fiber nonwoven of claim 11, comprising: about 25%, by weight, of the stiffening fibers; about 35%, by weight, of the absorbing fibers; and about 40%, by weight, of the filler fibers. ### Claim 13 (depends on 10) The carded staple fiber nonwoven of claim 10, wherein the carded staple fiber nonwoven has a caliper of between about 0.9 mm and about 1.2 mm, a basis weight of between about 45 gsm and about 85 gsm, and a density of between about 0.065 g/cc and about 0.094 g/cc. ### Claim 14 (depends on 10) An absorbent article, comprising: a topsheet; an absorbent core; and a secondary topsheet positioned between the topsheet and the absorbent core, wherein the secondary topsheet comprises the carded staple fiber nonwoven of claim 10. ### Claim 15 (depends on 14) The absorbent article of claim 14, wherein the secondary topsheet is bonded to the topsheet. ### Claim 16 (depends on 1) The carded staple fiber nonwoven of claim 1, wherein the carded staple fiber nonwoven web has a pore volume factor greater than 500. ### Claim 17 A carded staple fiber nonwoven, comprising: a) about 15% to about 35%, by weight, of stiffening fibers comprising hollow, spiral fibers formed from polyethylene terephthalate (PET), wherein the stiffening fibers have a linear density of between about 6 dtex and about 15 dtex; b) about 10% to about 50%, by weight, of absorbing fibers comprising tri-lobal fibers formed from rayon, wherein the absorbing fibers have a linear density of between about 2 dtex and about 6 dtex; and c) about 1% to about 60%, by weight, of filler fibers comprising solid, round fibers formed from polypropylene (PP), wherein the filler fibers have a linear density of about 3 dtex or greater; wherein the carded staple fiber nonwoven has a basis weight of between about 40 grams per square meter (gsm) and about 150 gsm, is non-heat stiffened, has an air permeability of between about 100 m3/m2/min and about 500 m3/m2/min, and a pore volume radius mode of between about 60 μm and about 120 μm.