Absorbent nonwoven fabric containing staple length polyester/polyethylene conjugate fibers and absorbent fibers

Claim 2

An absorbent, thermal bonded nonwoven fabric having a bulk density below about 0.15 gram per cubic centimeter, said fabric comprising pulp length absorbent fibers and staple length conjugate fibers, said conjugate fibers being composed of polyethylene and polyester, wherein a substantial proportion of the surfaces of said conjugate fibers comprises said polyethylene.

Claim 3

The nonwoven fabric of claim 1 wherein the bulk density of said fabric is within the range of from about 0.02 to about 0.09 gram per cubic centimeter.

Claim 4

The nonwoven fabric of claim 1 or 2 wherein said fabric has an absorbent capacity of at least about 1400 per cent.

Claim 5

The nonwoven fabric of any one of claims 1 to 3 wherein the conjugate fibers are sheath/core bicomponent fibers.

Claim 6

The nonwoven fabric of any one of claims 1 to 4 wherein at least one surface of said fabric has a veneer of thermal bonded heat-fusible fibers.

Claim 7

The nonwoven fabric of claim 5 wherein said heat-fusible fibers are conjugate fibers.

Claim 8

The nonwoven fabric of any one of claims 1 to 6 wherein said absorbent fibers are wood pulp fibers.

Claim 9

The nonwoven fabric of any one of claims 1 to 6 wherein the absorbent fibers are rayon staple fibers.

Claim 10

The nonwoven fabric of any one of claims 1 to 8 wherein said fabric further comprises staple length polyester fibers.

Claim 11

The nonwoven fabric of any one of claims 1 to 9 wherein said fabric is hot embossed.

Claim 12

Process which comprises: (a) producing a web comprising pulp length absorbent fibers and staple length conjugate fibers, said conjugate fibers being composed of polyethylene and polyester, wherein a substantial proportion of the surface of said conjugate fibers comprises said polyethylene; (b) subjecting said web to temperature sufficient to fuse said polyethylene without fusing said polyester, while maintaining said web under minimal pressure; and (c) cooling said web to re-solidify said polyethylene, to thereby produce a low density, highly absorbent, thermal bonded nonwoven fabric.

Claim 13

Process which comprises: (a) producing a web comprising pulp length absorbent fibers and staple length conjugate fibers, said conjugate fibers being composed of polyethylene and polyester, wherein a substantial proportion of the surface of said conjugate fibers comprises said polyethylene; (b) subjecting said web to temperature sufficient to fuse said polyethylene without fusing said polyester, while maintaining said web under minimal pressure; and (c) cooling said web to re-solidify said polyethylene, to thereby produce a low density, highly absorbent, thermal bonded nonwoven fabric.

Claim 14

Process of claim 11 wherein said web includes at least one veneer layer comprising heat-fusible fibers.

Claim 15

Process of claim 11 or 12 wherein the nonwoven fabric product of step (c) is subjected to the additional step of hot embossing.

Claim 16

A catamenial device comprising the nonwoven fabric of any one of claims 1 to 10.

Claim 17

The catamenial device of claim 14 comprising the nonwoven fabric of any one of claims 1 to 10 having laminated thereto an impermeable layer, said impermeable layer having applied thereon a pressure-sensitive adhesive element for adhering to an undergarment, said pressure-sensitive element having a protective layer to protect the same prior to use.