Three-dimensional polymer webs with improved physical properties
AssigneeKimberly-Clark Corporation
InventorsSharon L. Watkins, Hugo P. Watts
Life of this patent
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Abstract
There is disclosed a three dimensional nonwoven web consisting of drawn and unoriented thermoplastic fibers formed from a blend of polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene. The blend can be a blend of a homopolymer of polypropylene and a homopolymer of polybutylene; a homopolymer of polypropylene and a copolymer of polybutylene; a copolymer of polypropylene and a homopolymer of polybutylene; and a copolymer of polypropylene and a copolymer of polybutylene. In addition, ternary blends comprising polypropylene, polybutylene, and terpolymer (propylene, ethylene, and 1-butene) are useful. The resulting nonwoven webs have enhanced strength, toughness, and tear resistance.
Claims67
A three dimensional nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
A three dimensional nonwoven web comprising at least one layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
A method for forming a layer of three dimensional nonwoven web consisting of thermoplastic fibers, comprising the steps of:
- a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
- b. heating the blend to form a melt;
- c. extruding the melt through an orifice to form thermoplastic fibers;
- d. initially drawing the fibers to a ratio of greater than 14 to 1;
- and
- e. depositing the fibers onto a forming surface to form a first layer.
A method for forming a layer of three dimensional nonwoven web consisting of thermoplastic fibers, comprising the steps of:
- a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
- b. heating the ternary blend to form a melt;
- c. extruding the melt through an orifice to form thermoplastic fibers;
- d. initially drawing the fibers to a ratio of greater than 14 to 1;
- and
- e. depositing the fibers onto a forming surface to form a first layer.
A three dimensional nonwoven wiper comprising a web consisting of drawn thermoplastic fibers, wherein the fibers are formed from a blend comprising polypropylene and polybutylene to form thermoplastic fibers wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
A three dimensional nonwoven wiper consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer wherein the ternary blend by weight is from 10% to 30% polybutylene.
A method for forming a three dimensional nonwoven wiper consisting of thermoplastic fibers comprising the steps of:
- a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
- b. heating the blend to form a melt;
- c. extruding the melt through an orifice to form thermoplastic fibers;
- d. initially drawing the fibers to a ratio of greater than 14 to 1;
- and
- e. depositing the fibers onto a forming surface to form a first layer.
A method for forming a three dimensional nonwoven wiper consisting of thermoplastic fibers comprising the steps of:
- a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
- b. heating the ternary blend to form a melt;
- c. extruding the melt through an orifice to form thermoplastic fibers;
- d. initially drawing the fibers to a ratio of greater than 14 to 1;
- and
- e. depositing the fibers onto a forming surface to form a first layer.
A laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
A laminate material comprising at least one three dimensional layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
A method for forming a laminate material comprising at least one three dimensional layer consisting of thermoplastic fibers, comprising the steps of:
- a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene;
- b. heating the blend to form a melt;
- c. extruding the melt through an orifice to form thermoplastic fibers;
- d. initially drawing the fibers to a ratio of greater than 14 to 1;
- and
- e. depositing the fibers onto a forming surface to form a first layer.
A method for forming a laminate material comprising at least one three dimensional layer consisting of thermoplastic fibers, comprising the steps of:
- a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene;
- b. heating the ternary blend to form a melt;
- c. extruding the melt through an orifice to form thermoplastic fibers;
- d. initially drawing the fibers to a ratio of greater than 14 to 1;
- and
- e. depositing the fibers onto a forming surface to form a first layer.
A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
Dependencies are inferred from the claim text.