Mixed denier fluid management layers

Abstract

There is provided a new nonwoven surge material for personal care products made of fibers, which is a nonwoven fabric made of a homogeneous blend of large and small denier fibers. The small or first denier fiber preferably has an average denier less than 2, is at least 3 denier less than the second or larger fiber and the large or second denier fiber has an average denier between 4 and 15. The first denier fiber may have a denier less than 1 and the second denier fiber may have a denier between 6 and 15. The nonwoven fabric is a mixture of these fibers in amounts of from 25 to 75 weight percent of each type of fiber. The fabric may have a basis weight between 30 and 200 gsm. The first denier fiber may be a bicomponent fiber which may be a sheath/core polyethylene/polypropylene bicomponent fiber. The second denier fiber may be made from a polyester. It is also possible that the fibers have a hydrophilic treatment added to their surface to increase their hydrophilicity. The material made from the homogeneous blend of mixed denier fibers may be used as a liner or as a surge material in personal care products like diapers, training pants, incontinence products, bandages, and sanitary napkins.

Dependencies are inferred from the claim text.