# US 10,870,936 B2 · Soft and durable nonwoven composite

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- Number: US 10,870,936 B2
- Document ID: US10870936B2
- Status: Granted
- Kind: B2
- Application number: 15/028,953
- Filed: 2014-11-18
- Published: 2016-09-01
- Granted: 2020-12-22
- Earliest claimed: 2013-11-20
- Assignees: Kimberly-Clark Worldwide, Inc.
- Applicants: Kimberly-Clark Worldwide, Inc.
- Inventors: Lei Huang; Mark G. Kupelian; Prasad Potnis
- Web page: https://patentgrep.com/patent/US10870936B2

## CPC

- D04H 1/4291: Olefin series
- A61F 13/00: Bandages or dressings (radioactive dressings {A61N5/1029}); Absorbent pads
- A61F 13/51: characterised by the outer layers of the pads (A61F13/20 takes precedence)
- A61F 13/51478: {being a laminate, e.g. multi-layered or with several layers}
- A61F 13/5148: {having an impervious inner layer and a cloth-like outer layer}
- B32B 5/022: {Non-woven fabric}
- B32B 5/08: the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/05: the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection (using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14)
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/322: {comprising halogenated polyolefins, e.g. PTFE}
- B32B 27/327: {comprising polyolefins obtained by a metallocene or single-site catalyst}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- D04H 1/4374: using different kinds of webs, e.g. by layering webs
- D04H 3/007: Addition polymers
- A61F 2013/51026: {being in thermoplastic material}
- B32B 2250/02: 2 layers
- B32B 2250/03: 3 layers
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2262/0253: Polyolefin fibres
- B32B 2307/50: having particular mechanical properties
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2432/00: Cleaning articles, e.g. mops or wipes
- B32B 2439/46: Bags
- B32B 2535/00: Medical equipment, e.g. bandage, prostheses or catheter
- B32B 2555/00: Personal care
- B32B 2555/02: Diapers or napkins
- 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)
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A nonwoven composite that contains a first nonwoven web positioned adjacent to a second nonwoven web is provided. The first nonwoven web contains a plurality of fibers that are formed from a first polyolefin composition, and the second nonwoven web contains a plurality of fibers that are formed from a second polyolefin composition. The first polyolefin composition contains an ethylene polymer, which and car; provide a soft feel to a surface of the first nonwoven web. The second polyolefin composition likewise contains a rigid propylene polymer, which can provide good strength and durability to the second nonwoven web. The second polyolefin composition also contains a ductile propylene polymer and a fatty acid derivative.

## Claims

### Claim 1

A nonwoven composite comprising:
a first nonwoven web containing a plurality of fibers formed from a first polyolefin composition, wherein the first polyolefin composition contains at least one ethylene polymer, wherein the ethylene polymer constitutes at least 80 wt. % of the polymer content of the first polyolefin composition and has a modulus of elasticity of from 50 to 500 MPa as determined in accordance with ASTM D638-10; and
a second nonwoven web positioned adjacent to the first nonwoven web, the second nonwoven web containing a plurality of fibers formed from a second polyolefin composition, wherein the second polyolefin composition contains at least one rigid propylene polymer, 0.1 wt. % to about 15 wt. % of at least one ductile propylene homopolymer, and at least one fatty acid derivative, wherein the at least one ductile propylene polymer and the at least one fatty acid derivative are contained in the second polyolefin composition at a ratio of the at least one ductile propylene polymer to the at least one fatty acid derivative of about 10 to about 50; and
wherein the nonwoven composite exhibits a machine direction peak load of 2,000 grams-force or more and/or a cross-machine direction peak load of 1,200 grams-force or more, as determined in accordance with ASTM Standard D-5034; and
wherein the nonwoven composite exhibits a machine direction peak elongation of 20% or more and/or a cross-machine direction peak elongation of 35% or more, as determined in accordance with ASTM Standard D-5034.

### Claim 2 (depends on 1)

The nonwoven composite of claim 1, wherein the first polyolefin composition has a melting temperature of from 50° C. to 145° C.

### Claim 3 (depends on 1)

The nonwoven composite of claim 1, wherein the ethylene polymer is linear low density polyethylene.

### Claim 4 (depends on 1)

The nonwoven composite of claim 1, wherein the rigid propylene polymer has a modulus of elasticity of from 800 to 4,000 MPa, as determined in accordance with ASTM D638-10.

### Claim 5 (depends on 1)

The nonwoven composite of claim 1, wherein the rigid propylene polymer is an isotactic homopolymer of propylene.

### Claim 6 (depends on 1)

The nonwoven composite of claim 1, wherein rigid propylene polymer constitutes from 80 wt. % to 99.5 wt. % of the second polyolefin composition.

### Claim 7 (depends on 1)

The nonwoven composite of claim 1, wherein the ratio of the modulus of elasticity of the rigid propylene polymer to the modulus of elasticity of the ductile propylene polymer is from 1 to 50, as determined in accordance with ASTM D638-10.

### Claim 8 (depends on 7)

The nonwoven composite of claim 7, wherein the modulus of elasticity of the ductile polymer is from 1 to 500 MPa, as determined in accordance with ASTM D638-10.

### Claim 9 (depends on 1)

The nonwoven composite of claim 1, wherein the ductile polymer has a melting temperature of from 40° C. to 120° C.

### Claim 10 (depends on 1)

The nonwoven composite of claim 1, wherein the ductile polymer has a degree of crystallinity of from 1% to 35%, as determined using differential scanning calorimetry in accordance with ASTM D-3417.

### Claim 11 (depends on 1)

The nonwoven composite of claim 1, wherein the ductile polymer is a metallocene-catalyzed homopolymer of propylene.

### Claim 12 (depends on 1)

The nonwoven composite of claim 1, wherein the width at the half height of the endothermic peak of the second polyolefin composition is 5° C. or more, as determined using differential scanning calorimetry in accordance with ASTM D-3417.

### Claim 13 (depends on 1)

The nonwoven composite of claim 1, wherein the ductile propylene polymer constitutes from 0.2 wt. % to 12 wt. % of the second polyolefin composition and/or the fatty acid derivative constitutes from 0.01 wt. % to 5 wt. % of the second polyolefin composition.

### Claim 14 (depends on 1)

The nonwoven composite of claim 1, wherein the weight ratio of the ductile polymer to the fatty acid derivative in the second polyolefin composition is from 15 to 40.

### Claim 15 (depends on 1)

The nonwoven composite of claim 1, wherein the fatty acid derivative is a fatty acid amide.

### Claim 16 (depends on 1)

The nonwoven composite of claim 1, wherein the second polyolefin composition further comprises a propylene/α-olefin copolymer.

### Claim 17 (depends on 1)

The nonwoven composite of claim 1, wherein the first nonwoven web, the second nonwoven web, or both are a spunbond web.

### Claim 18 (depends on 1)

The nonwoven composite of claim 1, wherein the first nonwoven web constitutes from 20 wt. % to 80 wt. % of the composite and the second nonwoven web constitutes from 20 wt. % to 80 wt. % of the composite.

### Claim 19 (depends on 1)

The nonwoven composite of claim 1, wherein the composite exhibits a cup crush load of 200 grams-force or less and/or a coefficient of friction in the machine direction of 0.885 or less.

### Claim 20 (depends on 1)

A multi-layered laminate comprising the nonwoven composite of claim 1 and an additional layer, which is a nonwoven web, film, or a combination thereof.

### Claim 21 (depends on 1)

An absorbent article comprising an absorbent core positioned between a backsheet and a topsheet, wherein the backsheet, topsheet, or both contains the nonwoven composite of claim 1.

### Claim 22 (depends on 1)

The nonwoven composite of claim 1, wherein the nonwoven composite exhibits a machine direction peak elongation of 30% or more and/or a cross-machine direction peak elongation of 45% or more, as determined in accordance with ASTM Standard D-5034.

### Claim 23 (depends on 1)

The nonwoven composite of claim 1, wherein the fatty acid derivative constitutes from 2 wt. % to 5 wt. % of the second polyolefin composition.

### Claim 24 (depends on 15)

The nonwoven composite of claim 15, wherein the fatty acid amide comprises erucamide, oleamide, or a combination thereof.