Multi-Layer Nonwoven In Situ Laminates and Method of Producing The Same

Abstract

Described herein is a meltspun laminate comprising two or more layers of meltspun fabrics, wherein layers that are adjacent to one another are in situ entangled with one another to define an interfacial region of mixed fibers between the layers. Also described herein is a method of making a meltspun in situ laminate comprising simultaneously meltspinning two or more polymer melts adjacent to one another to form adjacent fabrics, wherein layers that are adjacent to one another are in situ entangled with one another to form an interfacial region of mixed fibers between the layers. Also described herein is a meltspinning apparatus comprising one or more dies, each die comprising two or more meltspinning zones, wherein each zone comprises a plurality of nozzles that are fluidly connected to the corresponding zone, and wherein each zone is fluidly connected to a melt extruder.

1 . A meltspun in situ laminate comprising two or more layers of meltspun fabrics, wherein layers that are adjacent to one another are in situ entangled with one another to define an interfacial region of mixed fibers between the layers. 
     
     
         2 . The in situ laminate of  claim 1 , wherein adhesives are absent between the layers. 
     
     
         3 - 4 . (canceled) 
     
     
         5 . The in situ laminate of  claim 1 , wherein the two or more layers of meltspun fabrics are formed simultaneously or nearly simultaneously. 
     
     
         6 . The in situ laminate of  claim 1 , wherein at least one fabric layer is elastic. 
     
     
         7 . The in situ laminate of  claim 6 , wherein the elastic fabric comprises an elastomer selected from the group consisting of propylene-α-olefin elastomer, natural rubber, synthetic polyisoprene, butyl rubber, halogenated butyl rubbers, polybutadiene, styrene-butadiene rubber, styrenic block copolymers, nitrile rubber, hydrogenated nitrile rubbers, chloroprene rubber, polychloroprene, neoprene, ethylene-propylene rubber and ethylene-propylene-diene rubber, epichlorohydrin rubber, polyacrylic rubber, silicone rubber, fluorosilicone rubber, fluoroelastomers, perfluoroelastomers, polyether block amides, chlorosulfonated polyethylene, ethylene-vinyl acetate, ethylene-α-olefin random and block copolymers, thermoplastic elastomers, thermoplastic vulcanizates, thermoplastic polyurethane, thermoplastic olefins, polysulfide rubber, and blends of any two or more of these elastomers. 
     
     
         8 . The in situ laminate of  claim 6 , wherein the elastic fabric comprises a propylene-α-olefin elastomer having and an MFR of less than 80 dg/min, a H f  of less than 80 J/g, and comonomer-derived content within the range from 5 to 30 wt %, by weight of the propylene-α-olefin elastomer. 
     
     
         9 . The in situ laminate of  claim 1 , wherein the two or more layers of the meltspun fabrics comprise at least two facing layers and an elastic layer, the elastic fabric layer located between the two facing layers. 
     
     
         10 . The in situ laminate of  claim 9 , wherein the facing fabric layers comprise a material selected from the group consisting of polypropylene, polyethylene, functionalized polyolefins, plastomers (ethylene-α-olefin copolymers), polyurethane, polyesters such as polyethylene terephthalate, polylactic acid, polyvinyl chloride, polytetrafluoroethylene, styrenic block copolymers, ethylene vinyl acetate copolymers, polyamide, polycarbonate, cellulosics, an elastomer, poly(acetylene), poly(thiophene), poly(aniline), poly(fluorene), poly(pyrrole), poly(3-alkylhiophene), poly(phenylene sulphide), polynaphthalenes, poly(phenylene vinylene), poly(vinylidene fluoride), and blends of any two or more of these materials. 
     
     
         11 . The in situ laminate of  claim 9 , wherein the facing layers are intrinsically non-elastic such that when incorporated in the in situ laminate, the facing layers are non-constraining and extensible without any mechanical stretching. 
     
     
         12 . The in situ laminate of  claim 9 , wherein the facing layers have a basis weight within the range from 0.1 to 50 g/m 2 , wherein the basis weight of the facing layers is at least 5% less than the basis weight of the elastic layer. 
     
     
         13 . A composite comprising at least one in situ laminate of  claim 1 , wherein the composite comprises one or more secondary layers selected from coform fabrics, carded fabrics, wet-laid fabrics, dry-laid fabrics, meltspun fabrics, nets, scrims, textile fabrics, woven fabrics, and films. 
     
     
         14 . An absorbent or barrier product comprising the in situ laminate of  claim 1 , the articles comprising personal care products, baby diapers, training pants, absorbent underpads, swim wear, wipes, feminine hygiene products, bandages, wound care products, medical garments, surgical gowns, filters, adult incontinence products, surgical drapes, coverings, garments, protective apparel, clothing apparel, or cleaning articles and apparatus. 
     
     
         15 - 20 . (canceled) 
     
     
         21 . A meltspun in situ laminate comprising three or more layers of meltspun fabrics comprising at least two facing layers and an elastic inner layer located between the two facing layers,
 wherein layers that are adjacent to one another are in situ entangled with one another to define an interfacial region of mixed fibers between the layers,   wherein the inner elastic layer comprises a propylene-α-olefin elastomer having and an MFR of less than 80 dg/min, a H f  of less than 80 J/g, and comonomer-derived content within the range from 5 to 30 wt %, by weight of the propylene-α-olefin elastomer, and   wherein the facing layers comprise bicomponent fibers.   
     
     
         22 . The in situ laminate of  claim 21 , wherein adhesives are absent between the layers. 
     
     
         23 . The in situ laminate of  claim 21 , wherein the two or more layers of meltspun fabrics are formed simultaneously or nearly simultaneously. 
     
     
         24 . The in situ laminate of  claim 21 , wherein the facing layers have a basis weight within the range from 0.1 to 50 g/m 2 , wherein the basis weight of the facing layers is at least 5% less than the basis weight of the elastic layer. 
     
     
         25 . The in situ laminate of  claim 21 , wherein at least one of the facing layers comprises bicomponent fibers that comprise polypropylene and polyethylene. 
     
     
         26 . The in situ laminate of  claim 21 , wherein at least one of the facing layers comprises bicomponent fibers that comprise propylene-α-olefin elastomer and polypropylene. 
     
     
         27 . The in situ laminate of  claim 21 , wherein at least one of the facing layers comprises bicomponent fibers that comprise polypropylene and polyethylene terephthalate. 
     
     
         28 . The in situ laminate of  claim 21 , wherein at least one of the facing layers comprises bicomponent fibers that have a sheath-core structure.