Spunbond-meltblown-spunbond laminates made from biconstituent meltblown materials
OwnerThomas Brock, Mark Cupta +3inventors
InventorsThomas Brock, Mark Cupta, Brian Forbes, John Lassig, Vicky Smith
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Abstract
Spunbond-meltblown-spunbond nonwoven fabrics having good softness, drape and extensibility, in addition to strength and barrier, are formed from combinations of bicomponent spunbond fibers having low fiber denier and biconstituent meltblown fibers. The spunbond fibers include an outer sheath portion formed using a first polyolefin and an inner core portion formed using a second polyolefin or polyester. The meltblown fibers include first meltblown fibers formed using a polyolefin and second meltblown fibers formed using a polyester.
Claims23
A nonwoven fabric, comprising:
- a) an inner layer of meltblown fibers including about 25-85% by weight first meltblown fibers, the first meltblown fibers including at least 50% by weight polyolefin, and about 15-75% by weight second meltblown fibers, the second meltblown fibers including at least 50% by weight polyester and having a composition different from the first meltblown fibers;
- and
- b) two outer layers of spunbond fibers having an average denier not more than about 1.1, the spunbond fibers including an outer sheath which includes at least 50% by weight of a first polyolefin and an inner core which includes at least 50% by weight of a second polyolefin or a polyester.
A nonwoven fabric, comprising:
- a) an inner layer of meltblown fibers including about 25-85% by weight first meltblown fibers, the first meltblown fibers including at least 75% by weight polyolefin, and about 15-75% by weight second meltblown fibers, the second meltblown fibers including at least 75% by weight polyester;
- and
- b) two outer layers of spunbond fibers having an average denier not more than about 1.1, the spunbond fibers including an outer sheath which includes at least 75% by weight of a first polyolefin and an inner core which includes at least 75% by weight of a second polyolefin or a polyester.
A nonwoven fabric, comprising:
- a) an inner layer of meltblown fibers including about 40-80% by weight first meltblown fibers, the first meltblown fibers including a polypropylene homopolymer or random propylene-ethylene copolymer, and about 20-60% by weight second meltblown fibers, the second meltblown fibers including polybutylene terephthalate;
- and
- b) two outer layers of spunbond fibers having an average denier not more than about 1.1, the spunbond fibers including about 20-80% by weight of an outer sheath, the outer sheath including a propylene-ethylene copolymer, and about 20-80% by weight of an inner core, the inner core including polypropylene.
A nonwoven fabric, comprising:
- a) an inner layer of meltblown fibers including about 40-80% by weight first meltblown fibers, the first meltblown fibers including polyethylene, and about 20-60% by weight second meltblown fibers, the second meltblown fibers including polyethylene terephthalate;
- and
- b) two outer layers of spunbond fibers having an average denier not more than about 1.1, the spunbond fibers including about 20-80% by weight of an outer sheath, the outer sheath including polyethylene, and about 20-80% by weight of an inner core, the inner core including polyethylene terephthalate.
Dependencies are inferred from the claim text.