Nonwoven substrate comprising fibers comprising an engineering thermoplastic polymer

Patent metadata

Field	Value
Publication number	US-9580845-B2
Application number	US-201414299050-A
Country	US
Kind code	B2
Filing date	Jun 9, 2014
Priority date	Jun 9, 2014
Publication date	Feb 28, 2017
Grant date	Feb 28, 2017

Abstract

A nonwoven substrate comprising a polyolefin and an engineering thermoplastic polymer. The engineering thermoplastic polymer may be present in the nonwoven substrate at a level of between about 1% and about 20% by weight of the nonwoven substrate. The layer of fibers is free of a compatibilizer.

First claim

What is claimed is:

1. A nonwoven substrate comprising:
a layer of fibers, wherein the fibers comprise a polyolefin and an engineering thermoplastic polymer, wherein the engineering thermoplastic polymer is present in the range of from about 1% to about 20% by weight of the nonwoven substrate, and wherein the layer of fibers is free of a compatibilizer; and wherein the engineering thermoplastic polymer comprises a component selected from the group consisted of polylactic acid (PLA), Polyimides, acrylates, methacrylates, styrenics, Polycarbonates (PC), Polytetrafluoroethylene (PTFE/Teflon), Acrylonitrile butadiene styrene (ABS), Polyphenylene oxide (PPO), Polysulphone (PSU), Polyetherketone (PEK), Polyetheretherketone (PEEK), Polyphenylene sulfide (PPS), Polyoxymethylene plastic (POM/Acetal), polyvinyl chloride, and mixtures thereof; and the nonwoven substrate having a basis weight of less than about 50 gsm.

2. The nonwoven substrate of claim 1 , wherein the engineering thermoplastic polymer is present in the range of from about 1% to about 10% by weight of the nonwoven substrate.

3. The nonwoven substrate of claim 1 , wherein the engineering thermoplastic polymer is present in the range of from about 2% to about 7% by weight of the nonwoven substrate.

4. The nonwoven substrate of claim 1 , wherein the engineering thermoplastic polymer comprises polylactic acid.

5. The nonwoven substrate of claim 1 , wherein the polyolefin comprises polypropylene.

6. The nonwoven substrate of claim 1 , wherein the polyolefin comprises polyethylene.

7. The nonwoven substrate of claim 1 , further comprising a plasticizer.

8. The nonwoven substrate of claim 7 , wherein the plasticizer is present in the range of from about 1% to about 20% by weight of the nonwoven substrate.

9. The nonwoven substrate of claim 7 , wherein the plasticizer is selected from the group consisted of Citrates, Adipates, Esters, Glycerols, oils, phthalate free plasticizers, bio-based plasticizers, and mixtures thereof.

10. The nonwoven substrate of claim 1 , comprising a second layer of fibers free of the engineering thermoplastic polymer.

11. The nonwoven substrate of claim 1 wherein the nonwoven substrate is selected from the group consisting of spunbond, carded, meltblown fibers, and microfibers.

12. The nonwoven substrate of claim 1 wherein the nonwoven substrate is selected from the group consisting of monocomponent fibers, bicomponent fibers, and multicomponent fibers.

13. The nonwoven substrate of claim 1 , wherein the average MD Tensile Modulus is greater than about 3.5 N/mm.

14. The nonwoven substrate of claim 1 , wherein the indexed MD Tensile Modulus is greater than about 20% higher than a nonwoven substrate not comprising the engineering thermoplastic polymer.

15. The nonwoven substrate of claim 1 , wherein the ratio of MD Tensile Modulus to basis weight of the nonwoven substrate is from about 0.10 to about 1.0.

16. The nonwoven substrate of claim 1 , wherein the CD Elongation at Break is greater than about 65%.

17. The nonwoven substrate of claim 1 , wherein the nonwoven substrate is present in an absorbent article selected from the group consisting of a pant, a taped diaper, a feminine hygiene product, and adult incontinence product.

18. A nonwoven substrate consisting essentially of:
a layer of fibers, wherein the fibers comprise a polyolefin and an engineering thermoplastic polymer, wherein the engineering thermoplastic polymer is present in the range of from about 10% to about 20% by weight of the nonwoven substrate, wherein the engineering thermoplastic polymer is selected from the group consisting of polylactic acid (PLA), Polyimides, acrylates, methacrylates, styrenics, Polycarbonates (PC), Polytetrafluoroethylene (PTFE/Teflon), Acrylonitrile butadiene styrene (ABS), Polyphenylene oxide (PPO), Polysulphone (PSU), Polyetherketone (PEK), Polyetheretherketone (PEEK), Polyphenylene sulfide (PPS), Polyoxymethylene plastic (POM/Acetal), polyvinyl chloride, and mixtures thereof; and the nonwoven substrate having a basis weight of less than about 50 gsm.

19. A laminate comprising:
a nonwoven substrate comprising a layer of fibers, wherein the fibers comprise a polyolefin and an engineering thermoplastic polymer selected from the group consisting of polylactic acid (PLA), Polyimides, acrylates, methacrylates, styrenics, Polycarbonates (PC), Polytetrafluoroethylene (PTFE/Teflon), Acrylonitrile butadiene styrene (ABS), Polyphenylene oxide (PPO), Polysulphone (PSU), Polyetherketone (PEK), Polyetheretherketone (PEEK), Polyphenylene sulfide (PPS), Polyoxymethylene plastic (POM/Acetal), polyvinyl chloride, and mixtures thereof,
wherein the engineering thermoplastic polymer is present in the range of from about 1% to about 20% by weight of the nonwoven substrate, and wherein the layer of fibers is free of a compatibilizer; and
an additional material, wherein the nonwoven substrate is joined to a side of the additional material.

Assignees

• Procter & Gamble

Inventors

• Ashraf Arman

Classifications

• B32B2262/023

  Aromatic vinyl resin, e.g. styrenic (co)polymers · CPC title

• B32B5/08

  the fibres or filaments of a layer being of different substances {, e.g. conjugate fibres, mixture of different fibres} · CPC title

• B32B2307/718

  Weight, e.g. weight per square meter · CPC title

• Y10T442/637

  Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material · CPC title

• D01D5/0985

  by means of a flowing gas (e.g. melt-blowing) · CPC title