Spunlaid fibers comprising coated calcium carbonate, processes for their production, and nonwoven products

Abstract

Disclosed herein are spunlaid fibers comprising at least one polymeric resin and at least one filler having an average particle size of less than or equal to about 5 microns and/or having a top cut of less than about 15 microns, wherein the at least one filler is present in an amount of less than about 40% by weight, relative to the total weight of the spunlaid fibers. Also disclosed herein is a method for producing spunlaid fibers comprising adding calcium carbonate to at least one polymeric resin and extruding the resulting mixture. Further disclosed herein are nonwoven fabrics comprising such spunlaid fibers and methods for producing them.

1 . A spunlaid fiber comprising at least one polymeric resin and at least one coated filler having an average particle size of less than or equal to about 3 microns, wherein the at least one coated filler is coated calcium carbonate and is present in the fiber in an amount less than about 40 wt %, relative to the total weight of the spunlaid fiber. 
     
     
         2 . The spunlaid fiber of  claim 1 , wherein the calcium carbonate is present in an amount less than about 25 wt %, relative to the total weight of the spunlaid fiber. 
     
     
         3 . (canceled) 
     
     
         4 . (canceled) 
     
     
         5 . The spunlaid fiber of  claim 1 , wherein the coating of the calcium carbonate is at least one organic material chosen from fatty acids and salts and esters thereof. 
     
     
         6 . The spunlaid fiber of  claim 5 , wherein the at least one organic material is chosen from stearic acid, stearate, ammonium stearate, and calcium stearate. 
     
     
         7 - 12 . (canceled) 
     
     
         13 . The spunlaid fiber of  claim 1 , wherein the calcium carbonate has an average particle size of less than or equal to about 2 microns. 
     
     
         14 - 16 . (canceled) 
     
     
         17 . The spunlaid fiber of  claim 1 , wherein the calcium carbonate has an average particle size of less than or equal to about 100% of the average diameter of the spunlaid fibers. 
     
     
         18 . The spunlaid fiber of  claim 1 , wherein the calcium carbonate has an average particle size ranging from about 1 micron to about 3 microns. 
     
     
         19 - 23 . (canceled) 
     
     
         24 . A nonwoven fabric comprising at least one spunlaid fiber of  claim 1 . 
     
     
         25 . The spunlaid fiber of  claim 1 , wherein the calcium carbonate has a top cut of about 15 microns or less. 
     
     
         26 . The spunlaid fiber of  claim 25 , wherein the calcium carbonate has a top cut of about 10 microns. 
     
     
         27 . (canceled) 
     
     
         28 . The spunlaid fiber of  claim 25 , wherein the calcium carbonate has a top cut ranging from about 4 microns to about 15 microns. 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . The spunlaid fiber of  claim 25 , wherein the calcium carbonate has a top cut of not more than about 100% of the average diameter of the spunlaid fiber. 
     
     
         32 . (canceled) 
     
     
         33 . (canceled) 
     
     
         34 . A spunlaid fiber comprising at least one polymeric resin and coated calcium carbonate having a top cut of about 15 microns or less, wherein the coated calcium carbonate is present in the fiber in an amount less than about 40 wt %, relative to the total weight of the spunlaid fiber. 
     
     
         35 - 37 . (canceled) 
     
     
         38 . The spunlaid fiber of  claim 34 , wherein the coating of the coated calcium carbonate is at least one organic material chosen from fatty acids and salts and esters thereof. 
     
     
         39 - 45 . (canceled) 
     
     
         46 . The spunlaid fiber of  claim 34 , wherein the calcium carbonate has a top cut of about 12 microns. 
     
     
         47 - 49 . (canceled) 
     
     
         50 . The spunlaid fiber of  claim 34 , wherein the calcium carbonate has a top cut ranging from about 4 microns to about 15 microns. 
     
     
         51 - 54 . (canceled) 
     
     
         55 . The spunlaid fiber of  claim 34 , wherein the calcium carbonate has a top cut of not more than about 100% of the average diameter of the spunlaid fiber. 
     
     
         56 . The spunlaid fiber of  claim 34 , wherein the calcium carbonate has an average particle size of less than or equal to about 5 microns. 
     
     
         57 - 114 . (canceled) 
     
     
         115 . A thermoformed spunlaid fiber comprising at least one polymeric resin and at least one coated filler having an average particle size of less than or equal to about 3 microns and having a top cut of about 15 microns or less, wherein the at least one coated filler is present in the fiber in an amount less than about 40 wt %, relative to the total weight of the thermoformed spunlaid fiber. 
     
     
         116 - 118 . (canceled) 
     
     
         119 . The thermoformed spunlaid fiber of  claim 115 , wherein the at least one coated filler comprises a coating, and the coating is at least one organic material chosen from fatty acids and salts and esters thereof.