Knit like nonwoven fabric composite
AssigneeKimberly-Clark Corporation
InventorsSteven R. Stopper, Susan C. Paul, Jon E. Tinsley
Life of this patent
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Abstract
The present invention provides a natural fiber knit-like multi-layer composite containing at least one layer of a nonwoven fiber web and at least one layer of an elastomeric material, wherein the nonwoven web layer is joined to the elastic layer at spaced-apart locations and is gathered between said spaced-apart locations. The nonwoven fiber web is fabricated from multicomponent conjugate fibers or filaments that contain at least one polyolefin, and is a spunbond fiber web, staple fiber web or hydroentangled web. The composite exhibits soft, cloth-like texture of natural fiber knits as well as highly useful elastic properties.
Claims19
A multi-layer composite fabric comprising an elastic layer and a nonwoven web layer joined to said elastic layer at spaced-apart locations, said nonwoven web layer being gathered between the spaced-apart locations and wherein:
- said nonwoven layer comprises crimped conjugate fibers having an average crimp level in the range of from about 3 to about 20 crimps per extended inch, as measured in accordance with ASTM D-3937 and which fibers comprise a first and a second polymeric component, said first component comprising a polymer selected from the group consisting of polyethylenes, polypropylenes, polybutylenes, polypentenes, polyvinyl acetates, and blends and copolymers thereof;
- and
- said nonwoven web layer has a cup crush energy equal to or less than 200 g-mm and a cup crush peak load equal to or less than 20 g.
A natural fiber composite fabric comprising an elastic layer and a nonwoven layer joined to said elastic layer at spaced-apart locations, said nonwoven layer being gathered between the spaced apart locations and wherein:
- said nonwoven layer comprises conjugate fibers having an average crimp level in the range of up to about 20 crimps per extended inch, as measured in accordance with ASTM D-3937 and which fibers comprise a first and a second polymer component, said first component comprising a polymer selected from the group consisting of polyethylenes, polypropylenes, polybutylenes, polypentenes, polyvinyl acetates, and blends and copolymers thereof;
- said elastic layer comprises an elastic material selected from the group consisting of elastomers of styrenic block copolymers, thermoplastic polyurethanes, thermoplastic copolyesters, thermoplastic polyamides, isoprene and blends thereof;
- and
- said nonwoven web layer has a cup crush energy equal to or less than 200 g-mm and a cup crush peak load equal to or less than 20 g.
A natural fiber knit-like composite fabric comprising an elastic layer and a nonwoven layer joined to said elastic layer at spaced-apart locations, said nonwoven layer being gathered between the spaced-apart locations and wherein:
- said nonwoven layer comprises crimped conjugate fibers having an average crimp level of up to about 20 crimps per extended inch as measured in accordance with ASTM D-3937, said fibers comprise a first and a second polymer component, said first component comprising a polymer selected from the group consisting of polyethylenes, polypropylenes, polybutylenes, polypentenes, polyvinyl acetates, and blends and copolymers thereof;
- said elastic layer comprises an elastic material selected from the group consisting of elastomers of styrenic block copolymers, thermoplastic polyurethanes, thermoplastic copolyesters, thermoplastic polyamides, isoprene and blends thereof;
- and
- said nonwoven web layer has a cup crush energy equal to or less than 200 g-mm and a cup crush peak load equal to or less than 20 g.
Dependencies are inferred from the claim text.