Nonwoven loop material and process and products relating thereto

Abstract

The present invention provides nonwoven fiber materials, and methods for making the same, useful for loop materials in hook and loop mechanical attachment systems, the nonwoven materials having crimped monocomponent fibers having substantially circular cross sections, and the webs may further contain uncrimped fibers. The invention also provides disposable articles comprising nonwoven loop materials including disposable personal care absorbent articles such as diapers, feminine care sanitary napkins, and adult incontinence articles, and disposable protective articles such as surgical drapes and gowns and other protective apparel.

1 . A nonwoven loop material for a personal care article, said loop material comprising helically crimped continuous monocomponent fibers having a substantially circular cross section, said nonwoven loop material having a first plane surface and a second plane surface, said nonwoven loop material further having a plurality of discrete unbonded areas defined by substantially continuous bonded areas, wherein said unbonded areas comprise about 85 to about 50 percent of said second plane surface of said nonwoven loop material.  
     
     
         2 . The nonwoven loop material of  claim 1  wherein said helically crimped continuous monocomponent fibers comprise thermoplastic polymer selected from the group consisting of polyolefins and copolymers thereof.  
     
     
         3 . The nonwoven loop material of  claim 2  wherein said thermoplastic polymer is a random copolymer of olefins.  
     
     
         4 . The nonwoven loop material of  claim 2  wherein said nonwoven loop material further comprises uncrimped continuous fibers.  
     
     
         5 . The nonwoven loop material of  claim 4  wherein said crimped monocomponent fibers comprise a random copolymer of propylene and ethylene and wherein said uncrimped fibers comprise polypropylene.  
     
     
         6 . The nonwoven loop material of  claim 5  wherein said first plane surface comprises a majority of said uncrimped fibers and further wherein said second plane surface comprises a majority of said crimped fibers.  
     
     
         7 . The nonwoven loop material of  claim 6  having a basis weight of about 20 to about 100 grams per square meter.  
     
     
         8 . The nonwoven loop material of  claim 7  having a basis weight of about 40 to about 80 grams per square meter.  
     
     
         9 . The nonwoven loop material of  claim 7  having a bulk of about 0.4 millimeters to about 1.2 millimeters.  
     
     
         10 . The nonwoven loop material of  claim 9  wherein said crimped fibers are about 3 to about 6 denier and wherein said uncrimped fibers are about 2 to about 5 denier.  
     
     
         11 . A disposable article comprising the nonwoven loop material of  claim 1 .  
     
     
         12 . A disposable article comprising the nonwoven loop material of  claim 6 .  
     
     
         13 . A process for making a nonwoven material comprising the steps of: 
 a) providing a fiber forming thermoplastic polymer composition;    b) forming a plurality of molten monocomponent fibers from said thermoplastic polymer composition, said molten monocomponent fibers having a substantially circular cross section;    c) differentially quenching said molten fibers to form crimped monocomponent fibers having a substantially circular cross section;    d) depositing said crimped monocomponent fibers upon a forming surface to form a nonwoven web material; and thereafter    e) bonding said nonwoven web material with heat and pressure to form a pattern of substantially continuous bonded areas defining a plurality of discrete unbonded areas, and wherein said nonwoven material has an unbonded area of from about 85 percent to about 50 percent.    
     
     
         14 . The process of  claim 13  further comprising the step of providing upon said forming surface a plurality of uncrimped fibers before the step of depositing said crimped fibers.  
     
     
         15 . The process of  claim 14  wherein said fiber forming thermoplastic polymer composition is a random copolymer of olefins and further wherein said uncrimped fibers comprise polypropylene.  
     
     
         16 . The process of  claim 15  wherein said fiber forming thermoplastic polymer composition is a random copolymer of propylene and ethylene.  
     
     
         17 . The process of  claim 16  further comprising the step of subjecting the nonwoven material to a stretching force after said bonding step.  
     
     
         18 . The process of  claim 17  wherein said stretching force is a 5 percent to 15 percent longitudinal stretching force.  
     
     
         19 . A disposable article comprising: 
 an inner body contacting side and an outer non-body contacting side,    a hook material, and    a nonwoven loop material, wherein said loop material comprises at least a portion of said outer non-body contacting side, and further wherein said nonwoven loop material comprises a plurality of helically crimped continuous monocomponent fibers having a substantially circular cross section.    
     
     
         20 . The disposable article of  claim 19  wherein said nonwoven loop material comprises first and second plane surfaces, wherein said first plane surface comprises a majority of said uncrimped fibers and said second plane surface comprises a majority of said crimped fibers, and further wherein said second plane surface is exposed on said outer non-body contacting side of said article.  
     
     
         21 . The disposable article of  claim 20  wherein said crimped fibers comprise a random copolymer of propylene and ethylene and wherein said uncrimped fibers comprise polypropylene.  
     
     
         22 . The disposable article of  claim 20  further comprising a tab and wherein said hook material is located on said tab, and further wherein said tab and said hook material are adapted to be superposable and engagable with said loop material.  
     
     
         23 . The disposable article of  claim 21  further comprising a tab and wherein said hook material is located on said tab, and further wherein said tab and said hook material are adapted to be superposable and engagable with said loop material.  
     
     
         24 . The disposable article of  claim 22  wherein said loop material comprises on its surface a point unbonded bond pattern, said point unbonded bond pattern comprising a plurality of discrete unbonded areas defined by substantially continuous bonded areas.  
     
     
         25 . The disposable article of  claim 22  wherein said loop material comprises on its surface a point bonded bond pattern, said point bonded bond pattern comprising a plurality of discrete bonded areas separated by substantially unbonded areas.  
     
     
         26 . The disposable article of  claim 23  wherein said loop material comprises on its surface a point unbonded bond pattern, said point unbonded bond pattern comprising a plurality of discrete unbonded areas defined by substantially continuous bonded areas, wherein said unbonded areas comprise about 85 to about 50 percent of said second plane surface of said nonwoven loop material.  
     
     
         27 . A disposable diaper comprising: a body contacting liner, an outer cover, an absorbent core disposed between said liner and said outer cover, and a mechanical fastening system, said mechanical fastening system comprising a nonwoven loop material and a tab comprising a hook material, said nonwoven loop material comprising at least a portion of said outer cover and having a first plane surface comprising a majority of uncrimped fibers and a second plane surface comprising a majority of helically crimped continuous monocomponent fibers having a substantially circular cross section, and wherein said second plane surface of said nonwoven loop material is exposed.  
     
     
         28 . The disposable diaper of  claim 27  wherein said crimped monocomponent fibers comprise a random copolymer of propylene and ethylene and said uncrimped fibers comprise polypropylene.  
     
     
         29 . The disposable diaper of  claim 28  wherein said loop material comprises on a surface a point bonded bond pattern, said point bonded bond pattern comprising a plurality of discrete bonded areas separated by substantially unbonded areas.  
     
     
         30 . The disposable diaper of  claim 28  wherein said loop material comprises on a surface a point unbonded bond pattern, said point unbonded bond pattern comprising a plurality of discrete unbonded areas defined by substantially continuous bonded areas.  
     
     
         31 . The disposable diaper of  claim 30  wherein said unbonded areas comprise about 85 to about 50 percent of said second plane surface of said nonwoven loop material.