High loft nonwoven fabrics
AssigneeBerry Global, Inc.
InventorsRalph A. Moody, III, Abhay Joijode, Mehmet Selcuk Sinangil
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Abstract
Nonwoven fabrics are provided that include a plurality of crimped bicomponent fibers having a first component comprising a first polymeric material comprising a first polymer or a first polymeric blend and a second component comprising a second polymeric material, in which the second polymeric material comprises a second polymeric blend of (i) at least one polypropylene polymer, (ii) at least one polyethylene polymer, and (iii) at least one compatibilizer comprising or consisting of at least one polypropylene-polyethylene copolymer.
Claims20
A method of making a nonwoven fabric, comprising:
- (a) forming a first polymeric melt comprising a first polymer or a first polymeric blend;
- (b) forming a second polymeric melt including a second polymeric blend of (i) at least one polypropylene polymer, (ii) at least one polyethylene polymer having a melt flow rate (MFR) from about 1 to about 15 g/10 min as determined by ASTM D1238 (190C° /2.16 kg), and (iii) at least one compatibilizer comprising a polypropylene-polyethylene copolymer;
- (c) forming a plurality of bicomponent fibers via melt-spinning the first polymeric melt and the second polymeric melt through a bicomponent spinnerette pack;
- (d) allowing the plurality of bicomponent fibers to crimp prior to or during laydown on a collection surface or subjecting the plurality of bicomponent fibers to a crimping operation to provide a plurality of crimped bicomponent fibers;
- and
- (e) consolidating the plurality of crimped bicomponent fibers to form the nonwoven fabric.
A method of making a nonwoven fabric, comprising:
- (a) forming a first polymeric melt comprising a first polymer or a first polymeric blend;
- (b) forming a second polymeric melt including a second polymeric blend of (i) at least one polypropylene polymer, (ii) at least one polyethylene polymer having a melt flow rate (MFR) from about 1 to about 15 g/10 min as determined by ASTM D1238 (190 C° /2.16 kg), and (iii) at least one compatibilizer comprising a polypropylene-polyethylene copolymer;
- (c) forming a plurality of bicomponent fibers via melt-spinning the first polymeric melt and the second polymeric melt through a bicomponent spinneret pack;
- (d) consolidating the plurality of bicomponent fibers to form an intermediate nonwoven fabric;
- and
- (e) subjecting the plurality of bicomponent fibers of the intermediate nonwoven fabric to a crimping operation to provide the nonwoven fabric.
Dependencies are inferred from the claim text.