Fine denier spunbond process and products thereof

Abstract

A nonwoven fabric comprising one or more fine-denier spunbond layers and one or more barrier layers. Each spunbond layer comprises continuous filaments having a denier between 0.7 and 1.2, which filaments are chosen from polyesters, polyolefins, and blends thereof.

What is claimed is:  
     
         1 . A nonwoven barrier fabric, comprising 
 a) a fine-denier spunbond layer comprising a plurality of continuous thermoplastic filaments having a denier of between 0.7 and 1.2 denier;    b) a barrier layer material deposited uniformly onto the fine denier spunbond layer and the layers consolidated to form a composite fabric; and    c) said composite fabric having a hydrostatic head to barrier layer basis weight ratio of about at least 4.9 cm/gsm.    
     
     
         2 . A nonwoven barrier fabric as in  claim 1 , wherein: 
 said thermoplastic filaments are chosen from the group consisting of polyolefins, polyesters and the blends thereof.    
     
     
         3 . A nonwoven barrier fabric as in  claim 2 , wherein: 
 said polyolefins are chosen from the group consisting of polypropylene, polyethylene, and blends thereof.    
     
     
         4 . A nonwoven barrier fabric as in  claim 1 , wherein: the continuous filaments may comprise bicomponent, multicomponent profiles and the blends thereof.  
     
     
         5 . A nonwoven barrier fabric as in  claim 1 , wherein the barrier layer is selected from the group consisting of melt-blown, cellulosic pulp, microporous film and monolithic film.  
     
     
         6 . A nonwoven barrier fabric as in  claim 5 , wherein: 
 said melt-blown barrier layer having fiber diameters in the range of about 1 to 10 microns and a basis weight of less than or equal to about 10 grams/meter 2 .    
     
     
         7 . A nonwoven barrier fabric as in  claim 6 , wherein: 
 said melt-blown barrier layer having a basis weight in the range of 1 to 8 grams/meter −2 .    
     
     
         8 . A nonwoven barrier fabric as in  claim 1 , wherein: 
 said means of consolidation are chosen from the group consisting of pressure bonding, thermal calendering, and through-air bonding.    
     
     
         9 . A nonwoven barrier fabric, comprising: 
 a) a first fine-denier spunbond layer comprising a plurality of continuous thermoplastic filaments having a denier of between 0.7 and 1.2 denier;    b) a barrier layer material deposited onto the first fine denier spunbond layer;    c) a second spunbond layer deposited onto the barrier layer;    d) the first fine denier spunbond layer, the barrier layer, and the second spunbond layer being consolidated into a composite fabric structure; and    e) said composite fabric having a hydrostatic head to barrier layer basis weight ratio of about at least 4.9 cm/gsm.    
     
     
         10 . A nonwoven barrier fabric as in  claim 9 , wherein the second spunbond layer is a fine-denier spunbond layer comprising a plurality of continuous thermoplastic filaments having a denier of between 0.7 and 1.2 denier.  
     
     
         11 . A nonwoven barrier fabric as in  claim 9 , wherein: 
 said thermoplastic filaments are chosen from the group consisting of polyolefins, polyesters and blends thereof.    
     
     
         12 . A nonwoven barrier fabric as in  claim 9 , wherein: said thermoplastic filaments of the first fine denier spunbond layer and the second spunbond layer comprise different thermoplastic polymers.  
     
     
         13 . A nonwoven barrier fabric as in  claim 10 , wherein: 
 said barrier layer is a melt-blown barrier layer having fiber diameters in the range of 1 to 10 microns and a basis weight less than or equal to about 10 grams/meter 2 .    
     
     
         14 . A nonwoven barrier fabric, comprising: 
 a) a first fine-denier spunbond layer comprising a plurality of continuous thermoplastic filaments having a denier of between 0.7 and 1.2 denier;    b) a first barrier layer material deposited onto the first fine denier spunbond layer;    c) a second barrier layer deposited onto the first barrier layer;    d) a second spunbond layer deposited onto the second barrier layer;    e) said layers being consolidated into a composite fabric structure; and    f) said composite fabric having a hydrostatic head to barrier layer basis weight ratio of about at least 4.9 cm/gsm.    
     
     
         15 . A nonwoven fabric as in  claim 14 , wherein the second spunbond layer is a fine-denier spunbond layer comprising a plurality of continuous thermoplastic filaments having a denier of between 0.7 and 1.2 denier.  
     
     
         16 . A nonwoven fabric, as in  claim 14 , wherein: 
 said consolidation method includes thermal calendering said laminate fabric structure to exhibit a hydrostatic head rating of at least about 50 cm.    
     
     
         17 . A disposable waste-containment garment, comprising; 
 an absorbent core,    a liquid pervious topsheet,    a liquid impervious backsheet,    said liquid impervious backsheet comprising a fine-denier composite fabric,    said fine-denier composite fabric having a hydrostatic head to barrier layer basis weight ratio greater than 4.9 cm/gsm.    
     
     
         18 . A disposable waste-containment garment as in  claim 17 , wherein the garment is a diaper.  
     
     
         19 . A disposable waste-containment garment as in  claim 17 , wherein the garment is a catamenial device.  
     
     
         20 . A disposable garment comprising, 
 a gown having a front panel, a pair of back panels extending from opposed sides of the front panel, and a pair of sleeve panels, wherein one or more of the respective panels are comprised of a fine denier composite fabric having a hydrostatic head to barrier basis weight ratio of about at least 4.9 cm/gsm.    
     
     
         21 . A disposable garment as in  claim 20  wherein said gown is a medical gown.  
     
     
         22 . A disposable garment as in  claim 20  wherein said gown is an industrial protective garment.  
     
     
         23 . A battery separator, comprising 
 a) a first fine-denier spunbond layer comprising a plurality of continuous polyolefin filaments having a denier of between 0.7 and 1.2 denier;    b) a barrier layer material deposited onto the first fine denier spunbond layer;    c) the first fine denier spunbond layer, the barrier layer, and the second spunbond layer being consolidated into a battery separator; and    e) said battery separator having a hydrostatic head to barrier layer basis weight ratio of about at least 4.9 cm/gsm.    
     
     
         24 . A battery separator as in  claim 24 , wherein the barrier layer comprises one or more layers of melt-blown polyolefin microfibers.