US4443513A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Soft thermoplastic fiber webs and method of making
Assignee: Kimberly Clark Worldwide Inc
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Filing: 1982-02-24
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Granted: 1984-04-17
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Expires: 2002-02-24
Abstract
Abstract A soft nonwoven web of entangled fibers or filaments having a pattern of fused bond areas and a stretched, loopy filament configuration outside of the patterned bond areas. The result is a soft web with high bulk that retains to a high degree the original bonded strength properties. In one embodiment, product may be obtained by pattern bonding a meltblown microfiber web under conditions of heat and pressure and then stretching the web under controlled conditions up to preferably about 140% of its original dimension in at least one direction. When relaxed, the stretched filaments bulk and loop except in the fused bond areas where they retain bonding properties. Preferred stretching conditions include room temperature and the use of draw rolls at speed differentials producing the desired stretch. Examples of thermoplastics polymers useful in accordance with the invention include polypropylene, polyethylene, polyesters and polyamides, as well as copolymers and polymer blends. Laminates of these nonwoven webs may also be treated. Uses for the material of the invention include any of those nonwoven fabric applications where softness and bulk are desired attributes such as, for example, wipers, garments, surgical drapes, and the like.
Inventors
- 👤 Gary H. Meitner
- 👤 Patrick J. Notheis
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 12:23
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B32B5/02; B32B5/022; D; D04; D04H; D04H1/00; D04H1/40; D04H1/54; D04H1/559; B32B2323/00; B32B2323/04; B32B2323/10; B32B2367/00; B32B2377/00; Y; Y10; Y10S; Y10S428/00; Y10S428/903; Y10S428/91; Y10T; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24595; Y10T428/24603; Y10T428/24802
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
102 words
Nonwoven web comprising thermoplastic staple length or longer fibers or filaments containing a pattern of fused bond areas over about 9 to 35% of the web surface separated by areas of substantially unbonded fibers or filaments extending out of the plane of the fused bonds wherein said web is extended to up to about 140% of its original dimension in at least one direction resulting in increased bulk and improved softness and an improvement in effective capacity of at least 35% with an increase in pores in excess of 40 microns of at least about 10% when compared with the unextended web.
Claim 2
Dependent Claim
102 words
Nonwoven web comprising thermoplastic staple length or longer fibers or filaments containing a pattern of fused bond areas over about 9 to 35% of the web surface separated by areas of substantially unbonded fibers or filaments extending out of the plane of the fused bonds wherein said web is extended to up to about 140% of its original dimension in at least one direction resulting in increased bulk and improved softness and an improvement in effective capacity of at least 35% with an increase in pores in excess of 40 microns of at least about 10% when compared with the unextended web.
Claim 3
Dependent Claim
10 words
The web of claim 1 wherein said thermoplastic is polypropylene.
Claim 4
Dependent Claim
26 words
The web of claim 1 wherein said thermoplastic is selected from the group consisting of polypropylene, polyethlene, polyesters, copolyesters, polyamides and blends of any of these.
Claim 5
Dependent Claim
24 words
The web of claims 1 or 2 wherein said fibers or filaments are microfibers having an average diameter of less than about 10 microns.
Claim 6
Dependent Claim
18 words
The web of claim 1 comprising a laminate containing a plurality of layers of thermoplastic fibers or filaments.
Claim 7
Dependent Claim
31 words
The web of claim 5 wherein the laminate comprises at least one spunbonded layer and at least one microfiber layer having an average fiber diameter of less than about 10 microns.
Claim 8
Dependent Claim
13 words
The web of claim 6 wherein the thermoplastic in said layers is polypropylene.
Claim 9
Dependent Claim
37 words
The web of claim 1 wherein the increase in pores in excess of 40 microns is at least about 15% and the effective capacity of these pores is at least 50% greater when compared with unextended webs.
Claim 10
Dependent Claim
24 words
The web of claim 1 or 8 wherein the bond density is in the range of from about 30 to 200 pins/in 2 .
Claim 11
Dependent Claim
9 words
A wiper formed from the web of claim 4.
Claim 12
Dependent Claim
128 words
Method of improving properties of a nonwoven web comprising the steps of, (a) providing a nonwoven web of thermoplastic staple length or longer fibers or filaments containing a pattern of fused bond areas over about 9 to 35% of the web surface and interbonded fibers or filaments between said fused bond areas, (b) stretching said web at a temperature below the melt softening point of the thermoplastic up to about 140% of the original web dimension and less than the breaking point of the fibers or filaments in at least one direction breaking said interfiber or interfilament bonds by straightening said fibers or filaments while substantially maintaining said fused bonds, and (c) allowing said fabric to relax under low or no tension for at least about 0.25 second.
Claim 13
Dependent Claim
128 words
Method of improving properties of a nonwoven web comprising the steps of, (a) providing a nonwoven web of thermoplastic staple length or longer fibers or filaments containing a pattern of fused bond areas over about 9 to 35% of the web surface and interbonded fibers or filaments between said fused bond areas, (b) stretching said web at a temperature below the melt softening point of the thermoplastic up to about 140% of the original web dimension and less than the breaking point of the fibers or filaments in at least one direction breaking said interfiber or interfilament bonds by straightening said fibers or filaments while substantially maintaining said fused bonds, and (c) allowing said fabric to relax under low or no tension for at least about 0.25 second.
Claim 14
Dependent Claim
10 words
The method of claim 11 wherein said thermoplastic is polypropylene.
Claim 15
Independent Claim
24 words
The method of claims 11 or 12 wherein said fibers or filaments are microfibers having an average diameter of less than about 10 microns.
Claim 16
Dependent Claim
21 words
The method of claim 11 wherein said web comprises a laminate containing a plurality of layers of thermoplastic fibers or filaments.
Claim 17
Dependent Claim
30 words
The method of claim 14 wherein the laminate comprises at least one spunbonded layer and at least one microfiber layer having an average diameter of less than about 10 microns.
Claim 18
Dependent Claim
13 words
The method of claim 15 wherein the thermoplastic in said layers is polypropylene.
Claim 19
Dependent Claim
30 words
The method of claim 11 wherein said stretching increases the fluid capacity of pores in excess of 40 microns by at least about 10% when compared with the unstretched web.
Claim 20
Dependent Claim
14 words
The method of claim 11 including a repetition of the stretching and relaxing steps.
Claim 21
Dependent Claim
12 words
The method of claim 11 including stretching by increments prior to relaxation.
Claim 22
Dependent Claim
26 words
The method of claim 11 wherein the thermoplastic is selected from the group consisting of polypropylene, polyethylene, polyesters, copolyesters, polyamides and blends of any of these.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-04-17 | 1987-10-17 | 1988-04-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-04-17 | 1991-10-17 | 1992-04-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-04-17 | 1995-10-17 | 1996-04-17 | $7700.00 | Window Closed / Lapsed |