Multicomponent fibers and fabrics made using the same

A multicomponent fiber comprising at least two polymer components arranged in structured domains, comprising:

• a first polymer component domain 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 wherein, said lower-melting continuous phase forming at least 50 percent by weight of the polymer blend and comprising a polyethylene polymer and said at least one higher-melting noncontinous phase comprising a polypropylene;
• and
• a second polymer component domain comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a higher-melting dominant continuous phase and at least one lower-melting noncontinuous phase dispersed therein, said higher-melting continuous phase comprising a propylene polymer and said at least one lower-melting noncontinuous phase comprising a polyethylene polymer, said multipolymer blend of said second polymer component domain further comprising at least one additional miscible or partially miscible polymer.

A nonwoven fabric comprising a plurality of multicomponent fibers comprising at least two polymer components arranged in structured domains, said fibers comprising:

• a first polymer component domain 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 polymer and said at least one higher-melting noncontinuous phase comprising a polypropylene;
• and
• a second polymer component domain comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a higher-melting dominant continuous phase and at least one lower-melting noncontinuous phase dispersed therein, said higher-melting continuous phase comprising a propylene polymer and said at least one lower-melting noncontinuous phase comprising a polyethylene polymer, said fibers bonded by a plurality of bonds to form a coherent extensible nonwoven fabric.

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, said fibers comprising:

• a first polymer component domain 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 comprising a polyethylene polymer and said at least one higher-melting noncontinuous phase comprising a polypropylene polymer;
• and
• a second polymer component domain comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a higher-melting dominant continuous phase and at least one lower-melting noncontinuous phase dispersed therein, said higher-melting continuous phase comprising a propylene polymer and said at least one lower-melting noncontinuous phase comprising a polyethylene polymer, said fibers bonded by a plurality of bonds to form a coherent extensible nonwoven fabric, 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 at least two polymer components arranged in structured domains, said fibers comprising:

• a first polymer component domain 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 comprising a polyethylene polymer and said at least one higher-melting noncontinuous phase comprising a polypropylene polymer;
• and
• a second polymer component domain comprising a multipolymer blend of at least two different polyolefin polymers, said polymers being present as a higher-melting dominant continuous phase and at least one lower-melting noncontinuous phase dispersed therein, said higher-melting continuous phase comprising a propylene polymer and said at least one lower-melting noncontinuous phase comprising a polyethylene polymer, said fibers bonded by a plurality of bonds to form a coherent extensible nonwoven fabric.