High elongation, low denier fibers using high extrusion rate spinning

Abstract

Low denier, high extensible fibers, soft extensible nonwoven webs comprising such fibers, and disposable articles comprising such nonwoven webs are obtained by spinning a polymer composition through small diameter holes.

What is claimed is:  
     
         1 . A fiber with a diameter in the range of 5 to 25 microns produced by melt spinning a polymer composition such that the mass throughput is in the range of 0.01 to 2.0 grams per minute per hole, the drawdown ratio is less than 400, and the spinnerette diameter is less than 200 microns.  
     
     
         2 . The fiber of  claim 1  wherein the fiber has a diameter in the range of 10 to 20 microns.  
     
     
         3 . The fiber of  claim 1  wherein the drawdown ratio is less than 150.  
     
     
         4 . The fiber of  claim 3  wherein the drawdown ratio is less than 50.  
     
     
         5 . The fiber of  claim 1  wherein the spinnerette diameter is less than 150 microns.  
     
     
         6 . The fiber of  claim 5  wherein the spinnerette diameter is less than 100 microns.  
     
     
         7 . The fiber of  claim 1  wherein the polymer composition comprises one or more polymers selected from the group consisting of polyolefins and polyesters.  
     
     
         8 . A nonwoven web comprising the fibers of  claim 1 .  
     
     
         9 . A disposable article comprising the nonwoven web of  claim 8 .  
     
     
         10 . A fiber with a diameter in the range of 5 to 25 microns produced by melt spinning a polymer composition such that the fiber elongation to break is greater than 400 percent, the drawdown ratio is less than 400, and the spinnerette diameter is less than 200 microns.  
     
     
         11 . The fiber of  claim 10  wherein the fiber has a diameter in the range of 10 to 20 microns.  
     
     
         12 . The fiber of  claim 10  wherein the fiber elongation to break is greater than 600 percent.  
     
     
         13 . The fiber of  claim 12  wherein the fiber elongation to break is greater than 800 percent.  
     
     
         14 . The fiber of  claim 10  wherein the drawdown ratio is less than 150.  
     
     
         15 . The fiber of  claim 14  wherein the drawdown ratio is less than 50.  
     
     
         16 . The fiber of  claim 10  wherein the spinnerette diameter is less than 150 microns.  
     
     
         17 . The fiber of  claim 16  wherein the spinnerette diameter is less than 100 microns.  
     
     
         18 . The fiber of  claim 10  wherein the polymer composition comprises one or more polymers selected from the group consisting of polyolefins and polyesters.  
     
     
         19 . A nonwoven web comprising the fibers of  claim 10 .  
     
     
         20 . A disposable article comprising the nonwoven web of  claim 19.