Kimberly-clark Corporation

Tony J Wisneski

Michael Tod Morman

Thomas M Killian

Frank Paul Abuto

Edward E Werner

Leon E Chambers, Jr

F Lee Dickenson

John S Kieffer

The present invention relates to a multicomponent fibrous nonwoven structure and the process and apparatus for producing the same. More specifically, the present invention relates to a process for forming nonwoven materials using a forming chamber in conjunction with multiple fiber sources and a forming surface to create multicomponent nonwoven materials with varying features. The materials so produced are suitable for use in a wide variety of applications including personal care products such as diapers, feminine pads and adult incontinence products.

Multicomponent nonwoven fibrous web

Process and apparatus for forming nonwovens within a forming chamber

An elastomeric nonwoven web is formed by meltblowing fibers composed of a polyether block amide copolymer.

Elastomeric polyether block amide nonwoven web

Composite elastomeric polyether block amide nonwoven web

An extrudable composition for forming nonwoven elastomeric material having pressure sensitive adhesive properties, nonwoven elastomeric sheet material (e.g., fibrous nonwoven webs) formed of such composition, stretch bonded laminates using such sheets, and methods of forming such sheets and such laminates, are disclosed. The composition includes an elastomeric polymer and a tackifying resin, and can also include a polyolefin. The nonwoven sheet material can be a meltblown nonwoven web. The laminate can be formed by tensioning the elastomeric sheet material and bonding a gatherable web (e.g., a spunbond polypropylene web) to the tensioned sheet material by application of pressure, the bonding being accomplished due to the adhesivity of the elastomeric sheet material and without application of heat for softening the sheet material and/or gatherable web.

Ambient temperature bondable elastomeric nonwoven web

An elastomeric nonwoven web is formed by meltblowing fibers composed of a polyetherester. Nonelastic fibers and/or particulate materials may also be included in the web.

Elastic polyetherester nonwoven web

Elastomeric materials such as elastomeric nonwoven webs of elastomeric meltblown fibers, elastomeric films or elastomeric molded materials are attained by forming, e.g., extruding or meltblowing, a polystyrenic poly(ethylenebutylene) thermoplastic block copolymer at elevated temperatures of at least about 290 degrees Centigrade, e.g., from about 290 degrees Centigrade to 345 degrees Centigrade. The resulting products retain good elastic elongation and strength properties. In the case of elastomeric nonwoven webs of elastomeric fibers, other fibers such as cellulosic fibers, e.g., cotton fibers, may be combined with the elastomeric fibers by known methods to provide an elastomeric nonwoven web comprising a blend of the elastomeric fibers with other fibers. Such web or film materials are useful generally in applications utilizing webs or sheets of elastic fabrics or the like, for example, in making composite materials in which an elastic layer of material is bonded to a gatherable web.

High temperature method of making elastomeric materials and materials

The disclosure is generally directed to an extrudable elastomeric composition formed by blending from at least 10 percent, by weight, of an A-B-A' block copolymer where 'A' and 'A'' are each a thermoplastic endblock which includes a styrenic moiety and where 'B' is an elastomeric poly(ethylene-butylene) midblock with up to at least about 90 percent, by weight, of at least one polyolefin which, when blended with the A-B-A' block copolymer and subjected to an effective combination of elevated temperature and elevated pressure conditions, is adapted to be extruded in blended form, with the A-B-A' block copolymer. Fibrous nonwoven elastomeric webs may be formed from the extrudable composition and processes for forming the fibrous nonwoven elastomeric webs are also disclosed.

Polyolefin-containing extrudable compositions and methods for their

Garments having a medial section which includes a gathered crotch portion and transversely opposed side sections are made by stretching an elastic layer transversely of the garment and stretch-bonding it to a gatherable non-elastic layer. Upon release of the elongating forces, the medial portion of the resulting composite contracts to form gathers and provides an elasticized portion which enhances fit and comfort of the garment. The elastic material may be liquid-impervious and the non-elastic material may be breathable whereby the medial portion of the garment, which may comprise a disposable diaper or panty, is rendered leak-proof or at least leak-resistant and the side portions are breathable for enhanced comfort. A method for making the garment comprises stretching the elastic material transversely to elongate it and maintaining it in its transversely elongated condition while bonding it by any suitable means to the gatherable non-elastic material.

Elasticized garment and method of making the same

A specific class of thermoplastic polymers with improved processability resulting from initial partial degradation of high molecular weight polymers using a chemical prodegradant present in excess of the amount reacted during pelletization. This class of polymers includes polymers and copolymers of polypropylene and butylene. After pelletizing, the polymer including unreacted prodegradant can be safely handled and shipped without difficulty. When remelted by extruding or the like, the prodegradant in the pellets reacts, further reducing the molecular weight as well as narrowing the molecular weight distribution of the polymer to a point where high capacity production of quality fibers and extruded products can be obtained. The prodegradant is preferably of the type that predictably and controllably affects the polymer molecular properties without being significantly affected by minor fluctuations in the polymer producer's or processor's manufacturing steps. Specific preferred embodiments include 2,5-dimethyl - 2,5 bis-(t-butylperoxy) hexyne-3; 3,6,6,9,9-pentamethyl-3-(ethyl acetate)-1,2,4,5-textraoxy cyclononane; .alpha.,.alpha.'-bis (t-butylperoxy) diispropyl benzene and 2, 5-dimethyl-2, 5-di (t-butylperoxy) hexane as the prodegradant added in an amount providing an amount of unreacted prodegradant after pelletizing of about 0.01 to 10.0 percent based on the weight of polymer. The present invention reduces the safety hazards present when handling free radical prodegradants by the polymer processor and avoids the need for multiple addition of prodegradants while still producing a material that can be processed easily by the polymer producer and processor.

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Kimberly, WI, United States of America

Tony J Wisneski