US5165979A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Three-dimensional polymer webs with improved physical properties
Assignee: Kimberly Clark Worldwide Inc
•
Filing: 1990-12-13
•
Granted: 1992-11-24
•
Expires: 2010-12-13
Abstract
Abstract There is disclosed a three dimensional nonwoven web consisting of drawn and unoriented thermoplastic fibers formed from a blend of polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene. The blend can be a blend of a homopolymer of polypropylene and a homopolymer of polybutylene; a homopolymer of polypropylene and a copolymer of polybutylene; a copolymer of polypropylene and a homopolymer of polybutylene; and a copolymer of polypropylene and a copolymer of polybutylene. In addition, ternary blends comprising polypropylene, polybutylene, and terpolymer (propylene, ethylene, and 1-butene) are useful. The resulting nonwoven webs have enhanced strength, toughness, and tear resistance.
Inventors
- 👤 Sharon L. Watkins
- 👤 Hugo P. Watts
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 15:15
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B32B37/00; B32B37/14; B32B37/15; B32B37/153; B32B5/02; B32B5/022; D; D04; D04H; D04H1/00; D04H1/40; D04H1/42; D04H1/4282; D04H1/4291; D04H1/4374; D04H1/4382; D04H1/43825; D04H1/54; D04H1/541; D04H1/542; D04H1/544; D04H1/559; D04H1/56; D04H3/00; D04H3/08; D04H3/16; B32B2262/00; B32B2262/02; B32B2262/0253; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24124; Y10T428/24273; Y10T428/24298; Y10T428/24306; Y10T428/24322; Y10T428/24331; Y10T428/24355; Y10T428/24479; Y10T428/24496; Y10T428/24612; Y10T428/24628; Y10T428/24669; Y10T442/00; Y10T442/10; Y10T442/184; Y10T442/188; Y10T442/19; Y10T442/60; Y10T442/647; Y10T442/651; Y10T442/68; Y10T442/681
Claims Analysis
Total Claims: 81
Claim 1
Independent Claim
42 words
A three dimensional nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
Claim 2
Dependent Claim
42 words
A three dimensional nonwoven web comprising at least one layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
Claim 3
Dependent Claim
38 words
The three dimensional nonwoven web of claim 1, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 4
Dependent Claim
20 words
The three dimensional nonwoven web of claim 2, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 5
Dependent Claim
38 words
A three dimensional nonwoven web comprising at least one layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
Claim 6
Dependent Claim
38 words
A three dimensional nonwoven web comprising at least one layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
Claim 7
Dependent Claim
16 words
The three dimensional nonwoven web of claim 4, wherein the terpolymer comprises propylene, ethylene, and 1-butene.
Claim 8
Dependent Claim
38 words
The three dimensional nonwoven web of claim 4, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 9
Dependent Claim
20 words
The three dimensional nonwoven web of claim 6, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 10
Independent Claim
92 words
A method for forming a layer of three dimensional nonwoven web consisting of thermoplastic fibers, comprising the steps of: a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene; b. heating the blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 11
Independent Claim
92 words
A method for forming a layer of three dimensional nonwoven web consisting of thermoplastic fibers, comprising the steps of: a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene; b. heating the blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 12
Dependent Claim
18 words
The method of claim 8, wherein the fibers are quenched prior to being deposited on the forming surface.
Claim 13
Dependent Claim
17 words
The method of claim 8 or 9, wherein after the fibers are deposited, the layer is bonded.
Claim 14
Dependent Claim
37 words
The method of claim 8 or 9, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 15
Dependent Claim
17 words
The method of claim 11, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 16
Independent Claim
91 words
A method for forming a layer of three dimensional nonwoven web consisting of thermoplastic fibers, comprising the steps of: a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene; b. heating the ternary blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 17
Independent Claim
91 words
A method for forming a layer of three dimensional nonwoven web consisting of thermoplastic fibers, comprising the steps of: a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene; b. heating the ternary blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 18
Dependent Claim
13 words
The method of claim 13, wherein the terpolymer comprises propylene, ethylene, and 1-butene.
Claim 19
Dependent Claim
35 words
The method of claim 13, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 20
Dependent Claim
17 words
The method of claim 15, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 21
Dependent Claim
20 words
The method of claim 13 or 14, wherein the fibers are quenched prior to being deposited on the forming surface.
Claim 22
Dependent Claim
15 words
The method of claim 17, wherein after the fibers are deposited, the layer is bonded.
Claim 23
Dependent Claim
46 words
A three dimensional nonwoven wiper comprising a web consisting of drawn thermoplastic fibers, wherein the fibers are formed from a blend comprising polypropylene and polybutylene to form thermoplastic fibers wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
Claim 24
Dependent Claim
46 words
A three dimensional nonwoven wiper comprising a web consisting of drawn thermoplastic fibers, wherein the fibers are formed from a blend comprising polypropylene and polybutylene to form thermoplastic fibers wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
Claim 25
Dependent Claim
38 words
The three dimensional nonwoven wiper of claim 19, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 26
Dependent Claim
20 words
The three dimensional nonwoven wiper of claim 20, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 27
Dependent Claim
33 words
A three dimensional nonwoven wiper consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer wherein the ternary blend by weight is from 10% to 30% polybutylene.
Claim 28
Dependent Claim
33 words
A three dimensional nonwoven wiper consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer wherein the ternary blend by weight is from 10% to 30% polybutylene.
Claim 29
Dependent Claim
16 words
The three dimensional nonwoven wiper of claim 22, wherein the terpolymer comprises propylene, ethylene, and 1-butene.
Claim 30
Dependent Claim
38 words
The three dimensional nonwoven wiper of claim 22, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 31
Dependent Claim
20 words
The three dimensional nonwoven wiper of claim 24, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 32
Independent Claim
90 words
A method for forming a three dimensional nonwoven wiper consisting of thermoplastic fibers comprising the steps of: a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene; b. heating the blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 33
Independent Claim
90 words
A method for forming a three dimensional nonwoven wiper consisting of thermoplastic fibers comprising the steps of: a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene; b. heating the blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 34
Dependent Claim
18 words
The method of claim 26, wherein the fibers are quenched prior to being deposited on the forming surface.
Claim 35
Dependent Claim
17 words
The method of claim 26 or 27, wherein after the fibers are deposited, the wiper is bonded.
Claim 36
Dependent Claim
37 words
The method of claim 26 or 27, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 37
Dependent Claim
20 words
The three dimensional nonwoven web of claim 29, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 38
Independent Claim
89 words
A method for forming a three dimensional nonwoven wiper consisting of thermoplastic fibers comprising the steps of: a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene; b. heating the ternary blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 39
Independent Claim
89 words
A method for forming a three dimensional nonwoven wiper consisting of thermoplastic fibers comprising the steps of: a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene; b. heating the ternary blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 40
Dependent Claim
13 words
The method of claim 31, wherein the terpolymer comprises propylene, ethylene, and 1-butene.
Claim 41
Dependent Claim
35 words
The method of claim 31, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 42
Dependent Claim
17 words
The method of claim 33, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 43
Dependent Claim
20 words
The method of claim 31 or 32, wherein the fibers are quenched prior to being deposited on the forming surface.
Claim 44
Dependent Claim
15 words
The method of claim 35, wherein after the fibers are deposited, the wiper is bonded.
Claim 45
Dependent Claim
42 words
A laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
Claim 46
Dependent Claim
42 words
A laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
Claim 47
Dependent Claim
36 words
The laminate material of claim 37, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 48
Dependent Claim
18 words
The laminate material of claim 38, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 49
Dependent Claim
38 words
A laminate material comprising at least one three dimensional layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
Claim 50
Dependent Claim
38 words
A laminate material comprising at least one three dimensional layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
Claim 51
Dependent Claim
14 words
The laminate material of claim 40, wherein the terpolymer comprises propylene, ethylene, and 1-butene.
Claim 52
Dependent Claim
36 words
The laminate material of claim 40, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 53
Dependent Claim
18 words
The laminate material of claim 42, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 54
Independent Claim
95 words
A method for forming a laminate material comprising at least one three dimensional layer consisting of thermoplastic fibers, comprising the steps of: a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene; b. heating the blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 55
Independent Claim
95 words
A method for forming a laminate material comprising at least one three dimensional layer consisting of thermoplastic fibers, comprising the steps of: a. mixing polypropylene and polybutylene to form a blend, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene; b. heating the blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 56
Dependent Claim
18 words
The method of claim 44, wherein the fibers are quenched prior to being deposited on the forming surface.
Claim 57
Dependent Claim
18 words
The method of claim 44 or 45, wherein after the fibers are deposited, the first layer is bonded.
Claim 58
Dependent Claim
37 words
The method of claim 44 or 45, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 59
Dependent Claim
17 words
The method of claim 47, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 60
Dependent Claim
32 words
The method of claim 48, wherein the first layer is bonded to a second layer selected from the group of materials consisting of foam, meltblown, coform, spunbond, scrim, and three dimensional meltblown.
Claim 61
Dependent Claim
15 words
The method of claim 49, wherein the second layer is bonded to a third layer.
Claim 62
Dependent Claim
32 words
The method of claim 50, wherein the second layer is bonded to a third layer selected from the group of materials consisting of foam, meltblown, coform, spunbond, scrim, and three dimensional meltblown.
Claim 63
Independent Claim
94 words
A method for forming a laminate material comprising at least one three dimensional layer consisting of thermoplastic fibers, comprising the steps of: a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene; b. heating the ternary blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 64
Independent Claim
94 words
A method for forming a laminate material comprising at least one three dimensional layer consisting of thermoplastic fibers, comprising the steps of: a. mixing polypropylene, polybutylene, and a terpolymer to form a ternary blend, wherein the ternary blend by weight is from 10% to 30% polybutylene; b. heating the ternary blend to form a melt; c. extruding the melt through an orifice to form thermoplastic fibers; d. initially drawing the fibers to a ratio of greater than 14 to 1; and e. depositing the fibers onto a forming surface to form a first layer.
Claim 65
Dependent Claim
13 words
The method of claim 52, wherein the terpolymer comprises propylene, ethylene, and 1-butene.
Claim 66
Dependent Claim
35 words
The method of claim 52, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 67
Dependent Claim
18 words
The laminate material of claim 54, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 68
Dependent Claim
20 words
The method of claim 52 or 53, wherein the fibers are quenched prior to being deposited on the forming surface.
Claim 69
Dependent Claim
16 words
The method of claim 56, wherein after the fibers are deposited, the first layer is bonded.
Claim 70
Dependent Claim
32 words
The method of claim 57, wherein the first layer is bonded to a second layer selected from the group of materials consisting of foam, meltblown, coform, spunbond, scrim, and three dimensional meltblown.
Claim 71
Dependent Claim
15 words
The method of claim 58, wherein the second layer is bonded to a third layer.
Claim 72
Dependent Claim
32 words
The method of claim 59, wherein the second layer is bonded to a third layer selected from the group of materials consisting of foam, meltblown, coform, spunbond, scrim, and three dimensional meltblown.
Claim 73
Dependent Claim
48 words
A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
Claim 74
Dependent Claim
48 words
A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn and unoriented thermoplastic fibers formed from a blend comprising polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene.
Claim 75
Dependent Claim
38 words
The three dimensional nonwoven wiper of claim 61, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 76
Dependent Claim
20 words
The three dimensional nonwoven wiper of claim 62, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
Claim 77
Dependent Claim
44 words
A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
Claim 78
Dependent Claim
44 words
A three dimensional nonwoven wiper comprising a laminate material comprising at least one three dimensional layer consisting of drawn thermoplastic fibers formed from a ternary blend comprising polypropylene, polybutylene, and a terpolymer, wherein the ternary blend by weight is from 10% to 30% polybutylene.
Claim 79
Dependent Claim
16 words
The three dimensional nonwoven wiper of claim 64, wherein the terpolymer comprises propylene, ethylene, and 1-butene.
Claim 80
Dependent Claim
38 words
The three dimensional nonwoven wiper of claim 64, wherein the polypropylene is selected from the group consisting of polypropylene homopolymers and polypropylene copolymers and the polybutylene is selected from the group consisting of polybutylene homopolymers and polybutylene copolymers.
Claim 81
Dependent Claim
20 words
The three dimensional nonwoven wiper of claim 66, wherein the polypropylene copolymer and the polybutylene copolymer are copolymers of ethylene.
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