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(12) Patent Application Publication (10) Pub. No.: US 2004/0161992 A1 Clark Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2004/0161992 A1 Clark Et Al US 2004O161992A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2004/0161992 A1 Clark et al. (43) Pub. Date: Aug. 19, 2004 (54) FINE MULTICOMPONENT FIBER WEBS Publication Classification AND LAMINATES THEREOF (76) Inventors: Darryl Franklin Clark, Alpharetta, GA (51) Int. Cl. .............................. D04H 1700; D04H 3/00; (US); Justin Max Duellman, Little D04H 5/00; B32B5/26 Rock, AR (US); Bryan David Haynes, (52) U.S. Cl. ......................... 442/340; 442/361; 442/362; Cumming, GA (US); Matthew Boyd 442/364; 442/381; 442/400; Lake, Cumming, GA (US); Jeffrey 442/401; 442/409 Lawrence McManus, Canton, GA (US); Kevin Edward Smith, Knoxville, TN (US) (57) ABSTRACT Correspondence Address: KIMBERLY-CLARK WORLDWIDE, INC. The present invention provides multicomponent fine fiber 401 NORTH LAKE STREET WebS and multilayer laminates thereof having an average fiber diameter less than about 7 micrometers and comprising NEENAH, WI 54956 a first olefin polymer component and a Second distinct polymer component Such as an amorphous polyolefin or (21) Appl. No.: 10/777,803 polyamide. Multilayer laminates incorporating the fine mul (22) Filed: Feb. 12, 2004 ticomponent fiber WebS are also provided Such as, for example, Spunbond/meltblown/spunbond laminates or spun Related U.S. Application Data bond/meltblown/meltblown/spunbond laminates. The fine multicomponent fiber webs and laminates thereof provide (62) Division of application No. 09/465,298, filed on Dec. laminates having excellent Softness, peel Strength and/or 17, 1999, now Pat. No. 6,723,669. controlled permeability. 90A 190 Patent Application Publication Aug. 19, 2004 Sheet 1 of 6 US 2004/0161992 A1 Patent Application Publication Aug. 19, 2004 Sheet 2 of 6 US 2004/0161992 A1 FIG 3 Patent Application Publication Aug. 19, 2004 Sheet 3 of 6 US 2004/0161992 A1 FIG. 4A A FIG. 4B Patent Application Publication Aug. 19, 2004 Sheet 5 of 6 US 2004/0161992 A1 Patent Application Publication Aug. 19, 2004 Sheet 6 of 6 US 2004/0161992 A1 <C WO CO s US 2004/O161992 A1 Aug. 19, 2004 FINE MULTICOMPONENT FIBER WEBS AND 0005. However, there exists a need for multicomponent LAMINATES THEREOF meltblown fiber webs which can be utilized to provide nonwoven webs and laminates thereof with varied structures FIELD OF THE INVENTION and/or improved physical properties Such as Softness, Strength, uniformity, peel Strength and/or controlled barrier 0001. The present invention relates to meltblown fiber properties. Further, there exists a need for efficient and WebS and, in particular, to multicomponent meltblown fiber economical methods for making the same. WebS and laminates thereof. BRIEF SUMMARY OF THE INVENTION BACKGROUND OF THE INVENTION 0006 The aforesaid needs are fulfilled and the problems 0002 Multicomponent spunbond fibers refer to fibers experienced by those skilled in the art overcome by non which have been formed from at least two polymer streams woven webs of the present invention comprising fine mul but spun together to form a unitary fiber. The individual ticomponent fibers having a first polymeric component and components comprising the multicomponent fiber are usu a Second polymeric component positioned in distinct Zones ally different polymers and are arranged in distinct Zones or within the fiber's cross-section and which extend Substan regions that extend continuously along the length of the tially continuously along the length of the fibers. The fibers. The configuration of Such fibers can vary and com randomly interlaid web of extruded multicomponent fibers monly the individual components of the fiber are positioned have an average fiber diameter less than 7 micrometers and in a Side-by-side arrangement, sheath/core arrangement, pie comprise a first olefin polymer component and a Second or wedge arrangement, islands-in-Sea arrangement or other amorphous olefin polymer component. In one aspect, the configuration. Multicomponent fibers and methods of mak first polymeric component comprises a crystalline propylene ing the same are known in the art and, by way of example, polymer and the Second polymeric component comprises an are generally described in U.S. Pat. No. 5,344,297 to Hills; amorphous propylene polymer. Further, the nonwoven web U.S. Pat. No. 5,336,552 to Strack et al. and U.S. Pat. No. may have a hydrohead in excess of 50 mbar and a Frazier air 5,382,400 to Pike et al. permeability in excess of 100 cubic feet/minute/square foot. 0.003 Generally, methods for making spunbond fiber 0007. In a further aspect of the present invention, non nonwoven WebS include extruding molten thermoplastic woven web laminates are provided comprising (i) a first polymer through a spinneret, quenching the filaments and nonwoven web of multicomponent fibers having a first then drawing the quenched filaments with a stream of high polymeric component and a Second polymeric component in velocity air to form a web of randomly arrayed fibers on a distinct Zones acroSS the cross-section of the fibers which collecting Surface. AS examples, methods for making the extend Substantially continuously along the length of the same are described in U.S. Pat. No. 4,692,618 to Dorschner fibers, Said multicomponent fiberS having an average fiber et al., U.S. Pat. No. 4,340,563 to Appel et al. and U.S. Pat. diameter less than about 7 micrometers; (ii) a second non No. 3,802,817 to Matsuki et al. However, meltblown fabrics woven web of continuous fibers having an average fiber comprise a class of melt formed nonwoven fabrics which is diameter greater than about 10 micrometers; and (iii) a third distinct from those of spunbond fiber webs. Meltblown fiber nonwoven web of continuous fibers having an average fiber WebS are generally formed by extruding a molten thermo diameter greater than about 10 micrometers wherein the first plastic material through a plurality of fine, usually circular, layer is positioned between the Second and third layerS and die capillaries as molten threads or filaments into converging further wherein the multilayer laminate has a hydrohead of high Velocity, air Streams which attenuate the filaments of at least 50 mbars, a Frazier air permeability in excess of 70 molten thermoplastic material to reduce their diameter. cubic feet/minute/Square foot and cup crush energy of leSS Thereafter, the meltblown fibers are deposited on a collect than about 2150 g-mm. Desirably, the first layer comprises ing Surface to form a web of randomly dispersed meltblown a meltblown fiber web and the second and third layers fibers. Meltblown fiber processes are disclosed in, for comprise Spunbond fiber layers. In Still a further aspect, the example, U.S. Pat. No. 3,849,241 to Butin et al.; U.S. Pat. multilayer laminate may further comprise a fourth layer, No. 5,160,746 to Dodge et al.; U.S. Pat. No. 4,526,733 to Such as a monocomponent meltblown fiber web, which is Lau; and others. Meltblown fibers may be continuous or adjacent the first layer and also positioned between the discontinuous and are generally Smaller than about 10 Second and third layers. microns in average diameter. In addition, meltblown fibers are generally tacky when deposited onto a collecting Surface BRIEF DESCRIPTION OF THE DRAWINGS or other fabric. 0008 FIG. 1 is a partially broken-away view of a mul 0004 Multicomponent meltblown fibers have been made tilayer nonwoven laminate incorporating a multicomponent heretofore. AS an example, multicomponent meltblown meltblown fiber web. fibers have been made to form a thermally moldable face 0009 FIG. 2 is a partially broken-away view of a mul mask such as, for example, as described in U.S. Pat. No. tilayer nonwoven laminate incorporating a multicomponent 4,795,668 to Krueger et al. Similarly, European Patent meltblown fiber web. Application No. 91305974.4 (Publication No. 0466381A1) teaches a conjugate meltblown fiber web suitable for ther 0010 FIG. 3 is a cross-sectional view of a meltblowing mally molding to the shape of a filter cartridge. In addition, die Suitable for making multicomponent meltblown fabrics. U.S. Pat. No. 5,935,883 to Pike describes split multicom 0011 FIG. 4A is a schematic drawing illustrating the ponent meltblown fibers and laminates thereof suitable for croSS Section of a multicomponent, fiber Suitable for use with use in filter applications, wipers, personal care products and the present invention, with the polymer components A and other uses. B in a side-by-side arrangement. US 2004/O161992 A1 Aug. 19, 2004 0012 FIG. 4B is a schematic drawing illustrating the 0019. Also, the multicomponent meltblown fiber webs croSS Section of a multicomponent fiber, Suitable for use with can comprise crimped or uncrimped fibers. Crimp may be the present invention, with the polymer components A and induced in multicomponent fibers by Selecting polymeric B in an eccentric sheath/core arrangement. components that have disparate StreSS or elastic recovery properties and/or crystallization rates. Such multicomponent 0013 FIG. 5 is a schematic representation of an elevated fibers can form crimped fibers having a helical crimp perspective view of a die Suitable for practicing present wherein one polymer will Substantially continuously be invention. located on the inside of the helix. 0.014 FIG. 6 is a schematic representation of a cross 0020 Desirably the multicomponent meltblown fiber Sectional view of the meltblowing nozzle, looking in the web has a basis weight of between about 5 g/m and about direction of arrows numbered 102-102 in FIG. 5. 300 g/m° and still more desirably between about 10 g/m· and 0.015 FIG. 7 is a schematic representation of a process about 64 g/m. When used in a laminate structure the line Suitable for forming multicomponent meltblown web meltblown fiber web desirably has a basis weight between laminates of the present invention.
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