Multicomponent fibers and fabrics made using the same

A multicomponent fiber comprising at least two polymer components arranged in structured domains, at least one of said polymer components comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein, said lower-melting continuous phase forming at least 50 percent by weight of the polymer blend and comprising a polyethylene and said at least one higher-melting noncontinuous phase comprising at least one copolymer or terpolymer of propylene.

A nonwoven fabric comprising a plurality of multicomponent fibers comprising at least two polymer components arranged in structured domains, at least one of said polymer components comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein, said lower-melting continuous phase forming at least 50 percent by weight of the polymer blend and comprising a linear low density polyethylene polymer of a melt index of greater than 10 and a density of 0.945 g/cc or less and said at least one higher-melting noncontinuous phase comprising a polypropylene polymer with melt flow rate of greater than 20 g/10 min., said fibers bonded by a plurality of bonds to form a coherent extensible nonwoven fabric.

A nonwoven fabric comprising a plurality of multicomponent fibers comprising at least two polymer components arranged in structured domains, at least one one of said polymer components comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein, said lower-melting continuous phase forming at least 50 percent by weight of the polymer blend and comprising a polyethylene and said at least one higher-melting noncontinuous phase comprising at least one copolymer or terpolymer of propylene.

A composite nonwoven fabric of at least two layers, said composite fabric comprising a first layer containing a plurality of multicomponent fibers comprising at least two polymer components arranged in structured domains, at least one of said polymer components comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein, said lower-melting continuous phase forming at least 50 percent by weight of the polymer blend and comprising a linear low density polyethylene polymer of a melt index of greater than 10 and a density of 0.945 g/cc or less and said at least one higher-melting noncontinuous phase comprising a polypropylene polymer with melt flow rate of greater than 20 g/10 min., said fibers bonded by a plurality of bonds to form a coherent nonwoven web, said composite fabric comprising a second layer attached to said first layer.

A composite nonwoven fabric of at least two layers, said composite fabric composing a first layer containing a plurality of multicomponent fibers comprising at least two polymer components arranged in structured domains, at least one of said polymer components comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein, said lower-melting continuous phase forming at least 50 percent by weight of the polymer blend and comprising a polyethylene and said at least one higher-melting noncontinuous phase comprising at least one copolymer or terpolymer of propylene, said fibers bonded by a plurality of bonds to form a coherent nonwoven web, said composite fabric comprising a second layer attached to said first layer.

A disposable absorbent personal care product comprising a plurality of layers, at least one of said layers comprising a nonwoven fabric comprised of fibrous material in the form of continuous filaments or staple fibers comprising first and second polymer components, at least one of said first and second polymer components comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein, said lower-melting continuous phase forming at least 50 percent by weight of the polymer blend and comprising a linear low density polyethylene polymer of a melt index of greater than 10 and a density of 0.945 g/cc or less and said at least one higher-melting noncontinuous phase comprising a polypropylene polymer with melt flow rate of greater than 20 g/10 min., said fibers bonded by a plurality of bonds to form a coherent nonwoven web.

A disposable absorbent personal care product comprising a plurality of layers, at least one of said layers comprising a nonwoven fabric comprised of fibrous material in the form of continuous filaments or staple fibers comprising first and second polymer components, at least one of said first and second polymer components comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein, said lower-melting continuous phase forming at least 50 percent by weight of the polymer blend and comprising a polyethylene and said at least one higher-melting noncontinuous phase comprising at least one copolymer or terpolymer of propylene, said fibers bonded by a plurality of bonds to form a coherent nonwoven web.