Fibers for non-woven fabrics having blends of polymers with high and low melt flow rates
AssigneeO&M Halyard, Inc.
InventorsPrasad S. Potnis, Jeffrey L. McManus
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Abstract
A spunbond non-woven fabric includes a plurality of fibers. The fibers are formed from a polymer blend that includes at least one first polymer and at least one second polymer. A melt flow rate of the at least one first polymer is greater than a melt flow rate of the at least one second polymer, and the melt flow rate of the at least one second polymer is about 9 g/10 min to less than 18 g/10 min. The blend may include a percentage by weight of the second polymer that is greater than a percentage by weight of the first polymer.
Claims20
A spunbond non-woven fabric comprising a plurality of fibers, wherein the fibers are formed from a polymer blend comprising at least one first polymer and at least one second polymer,
- wherein a melt flow rate (MFR) of the at least one first polymer is greater than a MFR of the at least one second polymer,
- wherein the MFR of the at least one second polymer is from 9 g/10 min to less than 18 g/10 min,
- wherein the MFR of the at least one first polymer is from 18 g/10 min to 40 g/10 min,
- wherein the polymer blend comprises a percentage by weight of the second polymer that is greater than a percentage by weight of the first polymer, wherein the polymer blend comprises up to 30% by weight of the first polymer and at least 70% by weight of the second polymer, and
- wherein an average diameter of each fiber is less than or equal to 30 microns.
A spunbond non-woven fabric comprising a plurality of fibers, wherein the fibers are formed from a polymer blend comprising at least one first polymer and at least one second polymer,
- wherein a melt flow rate (MFR) of the at least one first polymer is from about 19 g/10 min to about 40 g/10 min,
- wherein a MFR of the at least one second polymer is about 9 g/10 min to about 18 g/10 min,
- wherein the polymer blend comprises 10% to 30% by weight of the at least one first polymer and 70% to 90% by weight of the at least one second polymer, and
- wherein an average diameter of each fiber is from about 13 microns to about 22 microns.
A spunbond non-woven fabric comprising a plurality of fibers, wherein the fibers are formed from a polymer blend comprising at least one first polymer and at least one second polymer,
- wherein a melt flow rate (MFR) of the at least one first polymer is greater than a MFR of the at least one second polymer,
- wherein the MFR of the at least one second polymer is from 9 g/10 min to less than 18 g/10 min,
- wherein the MFR of the at least one first polymer is from 18 g/10 min to 40 g/10 min, wherein the polymer blend comprises a percentage by weight of the second polymer that is greater than a percentage by weight of the first polymer,
- wherein the polymer blend comprises 20-30% by weight of the first polymer,
- wherein the fibers each comprise a fiber body that surrounds and defines a cavity,
- wherein the fiber body and the cavity together define a total volume, and
- wherein the fibers comprise a hollowness of greater than 0% up to about 25% by volume of the total volume.
Dependencies are inferred from the claim text.