Soft extensible nonwoven webs containing fibers with high melt flow rates

Abstract

The present invention provides a polymer composition that enables a nonwoven web to possess high extensibility. The polymer composition comprises a polypropylene having a melt flow rate of from about 100 to about 1000 grams per 10 minutes and a second polymer having a melt flow rate of from about 10 to about 80 grams per 10 minutes. Additionally, the present invention provides low denier fibers that possess softness and enable the formation of nonwoven webs with high extensibility.

1 . A nonwoven web comprising fibers having a polymer composition comprising: 
 a. from about 50% to about 95% of a polypropylene having a melt flow rate of from about 100 to about 1000 grams per 10 minutes, and    b. from about 5 to about 50% of a polymer having a melt flow rate of from about 10 to about 80 grams per 10 minutes.    
     
     
         2 . The nonwoven web according to  claim 1  wherein the polymer is selected from the group consisting of polypropylenes, polyethylene, and polyolefin copolymers or terpolymers, and combinations thereof.  
     
     
         3 . The nonwoven web according to  claim 2  wherein the polymer is polypropylene.  
     
     
         4 . The nonwoven web according to  claim 1  wherein the polypropylene has a melt low rate of from about 100 to about 600 grams per 10 minutes and the polymer has a melt flow rate of from about 15 to about 70 grams per 10 minutes.  
     
     
         5 . The nonwoven web according to  claim 1  wherein the melt flow rate of the polymer composition is from about 100 to about 800 grams per 10 minutes.  
     
     
         6 . The nonwoven web according to  claim 1  wherein the nonwoven web has a basis weight of from about 5 to about 100 grams per square meter.  
     
     
         7 . The nonwoven web according to  claim 1  wherein the fibers having a diameter of from about 5 to about 50 microns.  
     
     
         8 . The nonwoven web according to  claim 1  additionally comprising different fibers.  
     
     
         9 . The nonwoven web according to  claim 1  wherein the nonwoven web has a strain at peak load in at least one direction of greater than about 80 percent.  
     
     
         10 . The nonwoven web according to  claim 1  wherein the nonwoven web has an extension ratio of greater than about 1.  
     
     
         11 . The nonwoven web according to  claim 1  wherein the nonwoven web is produced by a spunbond process.  
     
     
         12 . The nonwoven web according to  claim 1  wherein the polymer composition comprises an additional ingredient.  
     
     
         13 . The nonwoven web according to  claim 1  wherein the web is an article selected from the group consisting of a topsheet for feminine hygiene pad, diaper, and/or adult incontinence product, stretchable ears for diapers, wipe for cleaning a hard surface or skin, and combinations thereof.  
     
     
         14 . A disposable article comprising the nonwoven web according to  claim 1 .  
     
     
         15 . A fiber comprising a polymer composition wherein the polymer composition comprises: 
 a. from about 50% to about 95% of polypropylene having a melt flow rate of from about 100 to about 1000 grams per 10 minutes, and    b. from about 5 to about 50% of a polymer having a melt flow rate of from about 10 to about 80 grams per 10 minutes.    
     
     
         16 . The fiber according to  claim 15  wherein the polymer is selected from the group consisting of polypropylenes, polyethylene, and polyolefin copolymers or terpolymers, and combinations thereof.  
     
     
         17 . The fiber according to  claim 15  wherein the polymer is polypropylene.  
     
     
         18 . The fiber according to  claim 15  wherein the fiber has a diameter of from about 5 to about 50 microns.  
     
     
         19 . The fiber according to  claim 15  wherein the fiber is a multicomponent fiber with the polymer composition comprising one component of the fiber.  
     
     
         20 . A laminate nonwoven web comprising one layer comprising fibers having a polymer composition comprising: 
 a. from about 50% to about 95% of a polypropylene having a melt flow rate of from about 100 to about 1000 grams per 10 minutes, and    b. from about 5 to about 50% of a polymer having a melt flow rate of from about 10 to about 80 grams per 10 minutes.