WO2014055098A1

WO2014055098A1 - High performance filamentous material

Info

Publication number: WO2014055098A1
Application number: PCT/US2013/000227
Authority: WO
Inventors: Thomas Dort; Yan BEKMAN; Edward BRADSHAW; Nick Carter; Asaf KOTZER; Gary Holt; Kevin Osborne; Gilad Reich; Ariel Yedvab
Original assignee: Avgol Ltd.
Priority date: 2012-10-05
Filing date: 2013-10-03
Publication date: 2014-04-10

Abstract

The present invention is directed to a construct comprising filamentous material, and more particularly to a filamentous material exhibiting useful physical performance while retaining suitable attributes to allow for mechanical processing of that material into useful products. The filamentous material includes at least one integrating network of essentially continuous filaments formed from at least one polymeric material. To said integrating network of continuous filaments is added at least one performance modifying filamentous component, wherein the addition and integration of the performance modifying filamentous component results in a composite material exhibiting a useful function of tactile and ductile softness while retaining finite control of fluids. Representative means and methods for fabricating such filamentous materials from the aforementioned integrating network and performance modifying filamentous components are provided herein.

Description

HIGH PERFORMANCE FILAMENTOUS MATERIAL Docket PS12-05B - Nonprovisional Patent Application

INVENTORS

Yan Bekman

Edward Bradshaw

Nick Carter

Tom Dort

Gary Holt

Asaf Kotzer

Kevin Osborne

Gilad Reich

Ariel Yedvab

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. 1 19(e) of U.S. provisional applications Ser. No. 61/744,944 filed October 5, 2012, which is incorporated by reference herein in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable

BACKGROUND OF THE INVENTION

[0001] The present invention is directed to a construct comprising filamentary components and more particularly to a filamentous material exhibiting useful physical performance while retaining suitable attributes to allow for mechanical processing of that material into useful consumer products. The filamentous material includes at least one integrating network of essentially continuous filaments formed from at least one polymeric material. To said integrating network of continuous filaments is added at least one performance modifying filamentous component, wherein the addition and integration of the performance modifying filamentous component results in a composite material exhibiting a useful function of tactile and ductile softness while retaining finite control of fluids. Such finite fluid control includes management of both liquids and gases in the same composite while providing favorable consumer perceived "fabric" or "flannel" like characteristics as well as retaining attributes such as strength and elongation to allow for subsequent converting processes. Representative means and methods for fabricating such filamentous materials from the aforementioned integrating network and performance modifying filamentous components are provided herein.

[0002] Early prior art first address the means and methods of forming a basic spunmelt (as exemplified by spunbond and meltblown nonwoven technologies), such as exemplified in U.S. Patent No.'s , 3,849,241 to Butin, et al., 3,855,046 to Hansen, 4,041,203 to Brock, et al. and 7,61 1 ,594 to Sommer et al. Various methods of fabricating laminate materials into nonwoven fabrics include disclosure in the prior art of layered meltspun components mechanically engaged by application of hydraulic energy to influence filament displacement beginning with U.S. Patent No. 3,485,706 to Evans. U.S. Patent No's 4,879170, 4,931,355, 4,950,531 and 4,939,016 to Radwanski, et al., disclose lay-down of multiple meltspun nonwoven fabrics materials or coforms with hydraulic energy used as a means of engaging said meltspun layers. U.S. Patent No. 5,023,130 to Simpson, et al. presents a high pressure means to attain total impact energies of 0.7MJ-N Kg to form an integrated web. Similarly, Japanese Patent Application offer a means of fracturing filaments at self fused zones wherein total impact energies of 1.4MJ-N/Kg or greater are used. An alternate means of filament control is disclosed in U.S. Patent No. 6,321,425 to Putnam, et al. wherein foraminous surfaces are used to support and direct filament movement under the influence of hydraulic energy. U.S. Patent No. 4,329,763 to Alexander et al., is directed to a softening process for thermal point bonded fabrics wherein a 25% reduction in bending modulus occurs. U.S. Patent No. 5,023,130 to Simpson et al., teaches a method by which unbonded continuous filaments are hydroentangled through application of high energy water jets. U.S. Patent No.'s 7,858,544 and 8,093,163 to Turi, et al. offer an approach wherein to attain suitable filament movement and integration it is necessary to have either a low thermal point bond of less than 10% of the material surface area or an anisoptropic bond pattern allowing for sufficient free filament length and engagement thereof. Each of the aforementioned prior art patents are incorporated by reference in their respective entireties. While each of the above methods may produce a nonwoven fabric of multiple combined spunmelt layers, the means of such production result in either material of unfavorable consumer perceived qualities, complex or difficult production processes including additional chemical or mechanical modification steps, and/or materials that are problematic to convert into useful consumer products.

[0003] There remains an unmet need for a filamentous material that exhibits functional and aesthetic/physical features appealing to end-use customers, including tactile and ductile softness, while supporting conversion of the base material into products to be offered to such end-use consumers.

SUMMARY OF THE INVENTION

[0004] An object of the invention is a filamentous material exhibiting useful physical performance while retaining suitable attributes to allow for mechanical processing of that material into useful products. The filamentous material includes at least one integrating network of essentially continuous filaments formed from at least one polymeric material. To said integrating network of continuous filaments is added at least one performance modifying filamentous component, wherein the addition and integration of the performance modifying filamentous component results in a composite material exhibiting a useful function of tactile and ductile softness while retaining finite control of fluids.

[0005] A further object of the present invention is a filamentous material wherein the integration of the continuous filament integrating network and the performance modifying filamentous component is by the application of hydraulic energy.

[0006] A further object of the present invention is a filamentous material comprising a contiguous bonding pattern wherein said contiguous bonding pattern exhibits a pattern of thermal point bonds wherein the pattern is comprised of a first and a second repeating unit surface area. The first and second repeating surface areas are proximal to one another such that pattern of repeating surface areas extending in both the machine direction of production (length) and the cross direction of production (width). The first repeating unit surface area includes a thermal bond area of 1.) of at least 30% of the total area making up the first repeating unit surface area or 2.) a single bonding point extending completely though the machine direction, cross direction or combined machine and cross direction of the first repeating unit surface area. The second repeating unit surface area comprises a thermal bond area of less than 10% of the total area making up the second repeating unit surface area.

[0007] A further object of the present invention is a filamentous material comprising a contiguous bonding pattern wherein a first repeating unit surface area is comprised of a thermal point bonds induced by a plurality of individual contact elements on a contact surface whereby the distance between any two individual contact elements is less than 0.5mm.

[0008] A further object of the present invention is a filamentous material having retention of form and function when subjected to external forces, such as those imparted by stretching, loading, straining, wetting, or abrasion, whether such forces are of a singular, periodic, cyclical, or variable nature.

[0009] A further object of the present invention is a filamentous material having finite fluid control wherein such control includes management of both liquids and gases in the same composite.

[0010] A further object of the present invention is a filamentous material which provides favorable consumer perceived "fabric" or "flannel" like characteristics.

[0011] A further object of the present invention is a filamentous material which exhibits attributes such as strength and elongation to allow and facilitate subsequent converting processes.

[0012] A further object of the present invention is a filamentous material having a liquid absorbency in the absence of chemical modification in one or more elements of the continuous filament integrating network.

[0013] A further object of the present invention is a filamentous material having a liquid absorbency in the absence of chemical modification in one or more elements of the performance modifying filamentous components.

[0014] A further object of the present invention is a means for the production of a filamentous material comprising an integrating network and performance modifying filamentous component. [0015] A further object of the present invention is a filamentous material having a liquid absorbency in the presence of chemical modification in one or more elements of either the continuous filament integrating network or the performance modifying filamentous components.

[0016] A further object of the present invention wherein the continuous filament integrating network is comprised of a spunbond nonwoven material.

[0017] A further object of the present invention wherein the performance modifying filamentous components is comprised of a meltblown nonwoven material.

[0018] A further object of the present invention wherein the ratio by weight of continuous filament integrating network to performance modifying filamentous component is greater than or equal to 4:1.

[0019] A further object of the present invention wherein the ratio by weight of continuous filament integrating network to performance modifying filamentous component is greater than or equal to 5:1.

[0020] A further object of the present invention wherein the filamentous material exhibits an air permeability of 250 1/sqm/sec or greater per gram/square meter material construct total or final weight.

[0021] A further object of the present invention wherein the filamentous material exhibits a fiber volume, as defined by the basis weight divided by bulk, in the range of 0.05 milligrams/cubic centimeter to 0.40 milligrams/cubic centimeter.

[0022] A further object of the present invention wherein the filamentous material exhibiting fabric or flannel like characteristics whereby production includes an initial application of thermal bonding step through use of a symmetric pattern of point bonds, followed by application of hydraulic energy and then by application of thermal bonding step though use of point bonds. Optionally, the secondary application of a thermal point bonding step uses a contiguous pattern.

[0023] Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The invention will be more easily understood by a detailed explanation of the invention including drawings. Accordingly, drawings, which are particularly suited for explaining the inventions, are attached herewith; however, it should be understood that such drawings are for descriptive purposes only and as thus are not necessarily to scale beyond the measurements provided. The drawings are briefly described as follows:

[0025] FIGURE 1 is a representative method of producing filamentous material in accordance with the present invention.

[0026] FIGURE 2 is a representative method of producing filamentous material in accordance with the present invention.

[0027] FIGURE 3 is a representative method of producing filamentous material in accordance with the present invention.

[0028] FIGURE 4 is a representative method of producing filamentous material in accordance with the present invention.

[0029] FIGURE 5 is a representative method of producing filamentous material in accordance with the present invention. [0030] FIGURE 6 is a representative method of producing filamentous material in accordance with the present invention.

[0031] FIGURE 7 is a prior art method utilizing an asymmetric or anisotropic thermal bond pattern.

[0032] FIGURE 8 is a prior art method utilizing an asymmetric or anisotropic thermal bond pattern.

[0033] FIGURE 9 is a prior art method utilizing an asymmetric or anisotropic thermal bond pattern.

[0034] FIGURE 10 is a representative method of producing filamentous material in accordance with the present invention utilizing a contiguous thermal bond pattern comprising thermal point bonds induced by a plurality of individual contact elements on a contact surface whereby the distance between any two individual contact elements is less than 0.5mm .

[0035] FIGURE 1 1 is a representative method of producing filamentous material in accordance with the present invention utilizing a contiguous thermal bond pattern comprising a single bonding point extending completely though the machine direction, cross direction or combined machine and cross direction of the first repeating unit surface area.

[0036] FIGURE 12A is a representative method of producing filamentous material in accordance with the present invention utilizing a contiguous thermal bond pattern comprising a single bonding point extending completely though the machine direction, cross direction or combined machine and cross direction of the first repeating unit surface area wherein a relative positions of repeating surface areas are depicted.

[0037] FIGURE 12B is a representative method of producing filamentous material in accordance with the present invention utilizing a contiguous thermal bond pattern comprising a single bonding point extending completely though the machine direction, cross direction or combined machine and cross direction of the first repeating unit surface area wherein a relative positions of repeating surface areas are depicted.

[0038] FIGURE 13 is a representative method of producing filamentous material in accordance with the present invention.

[0039] FIGURE 14 is a representative method of producing filamentous material in accordance with the present invention.

[0040] FIGURE 15 is a representative method of producing filamentous material in accordance with the present invention.

[0041] FIGURE 16 is a representative method of producing filamentous material in accordance with the present invention.

[0042] FIGURE 17 is a representative method of producing filamentous material in accordance with the present invention.

[0043] FIGURE 18 is a representative method of producing filamentous material in accordance with the present invention.

LIST OF REFERENCE NUMERALS Not Applicable

DETAILED DESCRIPTION OF THE INVENTION

[0044] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.

[0045] The present invention is directed to a construct comprising filamentous material, and more particularly to a filamentous material exhibiting useful physical performance while retaining suitable attributes to allow for mechanical processing of that material into useful products. The filamentous material includes at least one integrating network of essentially continuous filaments and one performance modifying filamentous component, both of which are formed from at least one polymeric material. Suitable polymeric materials include thermal melt and thermoset polymers, with thermal melt plastics being particularly preferred. Thermal melt plastics include polyolefins, and more preferably polypropylene or polyethylene. Other polymers suitable for use include polyesters, such as polyethylene terephthalate; polyamides; polyacrylates; polystyrenes; thermoplastic elastomers, block polymers, polymer alloys; and blends of these and other known fiber forming thermoplastic materials.

[0046] Representative methods of producing a filamentous material in accordance with present invention are depicted in FIGURES 1 through 6. It should be noted that consolidation, pre-treatment by chemical or mechanical modification, and application of hydraulic energy may be effected by at various stages of lay-down of one or more integrating networks and one or more performance modifying filamentous components.

[0047] A representative means for production of an integrating network of continuous filaments includes those produced by spunbond nonwoven technology, though other woven, knitted or continuous spinning technologies are equally suitable. The spunbond continuous filaments used in the present invention have a basis weight of preferably at least about 3 gsm. [0048] A process for the formation of spunbond involves supplying a molten thermal melt polymer, which is then extruded under pressure through a plate known as a spinneret or die head. The die head includes a spaced array of die orifices having diameters of generally about 0.1 to about 1.0 millimeters (mm). The resulting continuous filaments are quenched and drawn by any of a number of methods, such as slot draw systems, attenuator guns, or Godet rolls. The continuous filaments are collected as a loose web upon a moving collection surface, such as a wire mesh conveyor belt. When more than one spinneret is used in line for the purpose of forming a multi- layered fabric, the subsequent webs of filaments are collected upon the uppermost surface of the previously formed layer or web either continuously or in separately initiated batch processes.

[0049] The individual or combined layers or webs may be optionally consolidated at any step in the overall process, whether in an intermediate form or in a final, pre-conversion roll for, such as by means involving; 1.) heat and pressure, such as by thermal point bonding, 2.) application of hydraulic energy, such as by direct pressurized streams or sprays of water, 3.) chemical bonding, such as by glues or adhesives, 4) thermal bonding, such as passage of elevated of elevated temperature air through the material, and 5.) combinations thereof. When a thermal point bond consolidation method is used, the web or layers of webs come into contact with a thermal conductive rolls, which may be either smooth or with an embossed pattern of individual contact elements to impart and achieve the desired degree of point bonding, usually on the order of 1 to 40 percent of the overall surface area being so bonded. These thermal point bonds may remain present in the final material, partially removed due to the application of a first degree of applied hydraulic energy, or essentially removed due to the application of a second degree of applied hydraulic energy. Further, the pattern or profile of the embossed roll may include a cross directional bias to the elements which impart the partial or complete consolidation of the fibrous components so as to alter the response of the fibrous components to force vector imparted by an applied hydraulic energy.

[0050] The formation of thermal point bonds by application of pressure and/or heat through direct contact of the integrating network of continuous filaments, the performance modifying filamentous component, or combinations thereof with one or more patterned rolls or rollers can exhibit particularly useful attributes in terms of both mode of integration and material formation, as well as resulting performance attributes in the finished article. U.S. Patent numbers 6,537,644 and 6,610,390 to auschke, et al., hereby incorporated by reference in their respective entireties, in conjunction with the previously referenced U.S. Patent No.'s 7,858,544 and 8,093, 163 to Turi, et al., direct their focus to fibrous materials exhibiting a defined nature of a bonding pattern to achieve a desired result (reference Figures 7, 8 and 9). Specifically, the referenced patents disclose nonwovens having a non-symmetrical pattern of fusion bonds (that is, an anisotropic or asymmetrical pattern). As disclosed in these documents, bonds in an asymmetrical pattern may have a common orientation and common dimensions, yet define a total bond area along one direction (e.g., the MD) greater than along another direction (e.g., the CD) which is oriented orthogonally to the first direction, such that the points form a uniform pattern of bond density in one direction different from the uniform pattern of bond density in the other direction. Alternatively, as also disclosed in these documents, the bonds themselves may have varying orientations or varying dimensions, thereby to form a pattern of bond density which differs along the two directions. The bonds may be simple fusion bonds or closed figures elongated in one direction. The bonds may be closed figures elongated in one direction and selected from the group consisting of closed figures (a) oriented in parallel along the one direction axis, (b) oriented transverse to adjacent closed figures along the one direction axis, and (c) oriented sets with proximate closed figures so as to form there between a closed configuration elongated along the one direction axis.

[0051] While practice of an asymmetrical bonding pattern can be used to beneficially impact the production and performance of spunmelt nonwoven fabric, the inventors have found that similar or enhanced properties can be obtained through a contiguous bonding pattern methodology. A contiguous bonding pattern is defined as a pattern of thermal point bonds wherein the pattern is comprised of a first and a second repeating unit surface area. The first and second repeating surface areas are proximal to one another such that pattern of repeating surface areas extending in both the machine direction of production (length) and the cross direction of production (width). The first repeating unit surface area includes a thermal bond area of 1.) of at least 30% of the total area making up the first repeating unit surface area or 2.) a single bonding point extending completely though the machine direction, cross direction or combined machine and cross direction of the first repeating unit surface area. The second repeating unit surface area comprises a thermal bond area of less than 10% of the total area making up the second repeating unit surface area.

[0052] In the instance whereby the first repeating unit surface area is comprised of a thermal point bond of at least 30% of the total surface area of the first repeating unit surface area, the thermal point bond may be induced by a plurality of individual contact elements on a contact surface whereby the distance between any two individual contact elements is less than 0.5mm, as represented by Figure 11. As exemplified in Figure 11, multiple thermal point bonds are induced in a the first repeating unit surface area ("SAl") to create a higher degree of bonding than are created in the adjacent second repeating unit surface area ("SA2"). It should be noted that the repeating unit surface area for SAl and SA2 are defined as being rectilinear boundaries having the same total area. Further, it should be noted that a given SAl will be circumscribed by a total of four (4) identical SA1 units, wherein each SA1 comes into contact with the vertex of an SA1 unit, (Figure 12A) and four (4) identical SA2 units, wherein each SA2 unit comes into contact with the side of an SA1 unit (Figure 12B). Conversely, it should be noted that a given SA2 will be circumscribed by a total of four (4) identical SA2 units, wherein each SA2 comes into contact with the vertex of an SA2 unit, and four (4) identical SA1 units, wherein each SA1 unit comes into contact with the side of an SA2 unit.

[0053] To further form the filamentous material of the present invention, the aforementioned integrating network of continuous filaments receives at least one performance modifying filamentous component, wherein the addition and integration of the performance modifying filamentous component results in a composite material exhibiting a useful function of tactile and ductile softness while retaining finite control of fluids. Such finite fluid control includes management of both liquids and gases in the same composite while providing favorable consumer perceived "fabric" or "flannel" like characteristics as well as retaining attributes such as strength and elongation to allow for subsequent converting processes. A particularly preferred mode of attaining a filamentous material having fabric or flannel like characteristics is wherebyproduction includes an initial application of thermal bonding step through use of a symmetric pattern of point bonds, followed by application of hydraulic energy and then by application of thermal bonding step though use of point bonds. Optionally, the secondary application of a thermal point bonding step uses a contiguous pattern.

[0054] Representative means and methods for fabricating such performance modifying filamentous components includes those produced by the meltblown nonwoven technology, though other technologies which produce fibrous elements of less than 10 micrometers in diameter, such as flash-spinning and nanofiber. [0055] A representative meltblown process is similar in nature to the aforementioned spunbond process, which in place of essentially continuous filaments, this process involves the formation of discontinuous filamentary material. Again, a molten thermal melt polymer is extruded under pressure through orifices in a spinneret or die. High velocity air impinges upon and entrains the filaments as they exit the die. The energy of this step is such that the formed filaments are greatly reduced in diameter and are fractured so that microfibers of finite length are produced. This differs from the spunbond process whereby the continuity of the filaments is preserved. The process to form either a single layer or a multiple-layer fabric is continuous, that is, the process steps are uninterrupted from extrusion of the filaments to form the first layer until the bonded web is wound into a roll. Methods for producing these types of fabrics are described in U.S. Pat. No. 4,041,203, incorporated by reference in its entirety. The cross-sectional profile of individual elements within the integrating network or the performance modifying filamentous components is not a critical limitation to the practice of the present invention.

[0056] The individual elements within the integrating network or the performance modifying filamentous components may further be of homogenous or heterogeneous composition, include performance or aesthetic modifying melt additives, and be comprised of monocomponent, bicomponent, and/or multicomponent filament or fiber construction. Further, it is anticipated and within the purview of the present invention that one or more continuous filament integrating networks may be layered with one or more performance modifying filamentous components such that in the manufacturing or lay-down process: 1.) the components of each type alternate in order of lay-down; 2.) two or more layers of a component type are sequentially ordered for lay-down; 3.) an equal number of component type are used; 4.) and odd number of component types are used; 5.) the amount of component types are introduced in equal mass, composition or diameter; 6.) the amount of component types are introduced in different, varying, or incremental adjustment of introduced mass, composition, or diameter; and, 7.) combinations thereof. As mentioned previously, one or more consolidation step may be used between one or more lay-down steps in the manufacturing process.

Chemical based performance and/or aesthetic modifying melt additives includes those chemistries which result in modified properties of the filaments or fibers, such as to render the fibrous element hydrophobic, hydrophihc, enhance absorbency, render anti-static or flame retardant, modify crystallinity or strength, alter melt-flow rheology, and the like.

[0057] The filamentous material in accordance with the present invention, including selective application to continuous filament integrating network elements, to performance modifying filamentous components, or precursor combinations thereof, are subjected to water jet treatment. The water jet treatment allows for hydraulic energy to be imparted as a force on the elements in the filamentous material being produced. This hydraulic energy acts to displace or motivate elements with the filamentous material to inter-engage and form a composite performance, with such processes being known in the art as being "hydroentangled" or "hydroengorged". Application of hydraulic energy may occur upon either expansive plane or face of the filamentous material being produced and may occur in one or more sequential or alternating steps. The water jets are preferably present in an amount of 1-10 heads or manifolds per side and the water is provided at a pressure predetermined by the quality of the resultant fabric desired. Preferably the pressure of the water in the jets is in a range of about 50-about 400 bar per head, with the range of 100 to 300 bar being preferred. Unique to the produced filamentous material of the present invention, a high degree of integration is obtained wherein the fiber volume, as defined by the basis weight divided by bulk, in the range of 0.05 milligrams/cubic centimeter to 0.40 milligrams/cubic centimeter and exhibits an air permeability of 250 1/sqm/sec or greater per gram/square meter material construct total or final weight. Through a combination of manufacturing controls and specific management of the filamentary and fibrous composition, production and lay-down, we have identified means by which to allow effective application of hydraulic energy to filamentous material having a low volume of filamentary and fibrous targets by which to impinge said hydraulic energy and induce movement by relative force vectors imparted thereby.

[0058] Following water jet treatment, and preferably before drying of the resultant filamentous material, the filamentous material can be treated with one or more chemical agents to further affect, e.g., enhance or modify, web secondary properties such as flame retardancy, anti-static nature, and the like. The chemical agents may be topically applied over the entire surface of the filamentous material or within preselected zones. These zones may be provided with the same surfactant or additive or a different surfactant or additive in order to provide zones with different or the same properties. An example of topical treatment suitable for use is described in U.S. Pat. Nos. 5,709,747 and 5,885,656.

[0059] A variation upon the topical treatment of the filamentous material is that the surfactants can be applied as an array or in discrete strips across the width of the filamentous material in order to create zone treatments to which different performance, functional and/or aesthetic properties can be provided.

[0060] The invention allows for the production of a filamentous material in one continuous process including various features to provide new or enhanced properties within the filamentous material, in particular with respect to absorbency and softness. However, the invention also allows for the production of the nonwoven filamentous material in different individual process stages, e.g., as a two or more step process wherein one is the manufacture of the integrating network of continuous filaments, one is the application or manufacture of performance modifying filamentous components and one involving hydraulic processing of the composite. This versatility allows for cost savings since a continuous line does not have to be provided in one place or utilized at one continuous time. For example, a composite including an integrating network and a performance modifying filamentous component can be produced and then wound for temporary storage before being subjected to water jet treatment. Further, the layers may be subjected to water jet treatment to provide for a filamentous material of the invention which is usable as such or may be placed in storage and subsequently treated based upon a desired end use for the filamentous material. This versatility provides for cost efficiency in terms of plant space required for the provision of equipment, versatility in the use of different equipment with respect to timing and products and the ability to provide filamentous material with varying properties based on the application to which the material will be put.

[0061] The filamentous material of the present invention exhibits retention of form and function when subjected to external forces, such as those imparted by stretching, loading, straining, wetting, or abrasion, whether such forces are of a singular, periodic, cyclical, or variable nature. This durability aspect of the filamentous material is useful in the making of numerous end-use consumer products, including but not limited to hygiene products, personal and surface wipes as well as medical products. Of particular importance, the durable aesthetic and physical performance relative to basis weight embodied by the inventive filamentous material offers desirable integration as one or more components of a diaper, incontinence device, or catamenial device. Such material may be used in affixing the diaper to the wearer and/or skin contact and skin health properties when subjected to liquid insult suggestive of use in diaper constructs, are beneficial in view of the simultaneous presence of strength, elongation and low-linting performance that influence the materials convertibility by high-speed automated platforms and end use application. When a material of the present invention further embodies air permeability and liquid barrier properties, such material is advantageously employed in the construction of outer layer or layers away from the wearer such that a durable material with both aesthetic and performance properties are utilized, such as in the construction of a back sheet element.

[0044] Apparatus useful in preparing the filamentous material of the invention is conventional in nature and known to one skilled in the art. Such apparatus includes extruders, conveyor lines, water jets, rewinders or unwinders, topical applicators, calenders or compactors, and the like.

EXAMPLE 1-

Materials were formed in accordance with the present invention and tested per the following protocols or standards:

Run-off [%] WSP 80.9

Air permeability [l/sqm/sec] WSP 70.1 (05)

Fabric thickness [mm] ASTM D645

MD linting E-side [gr] WSP 400.0

MD linting S-side [gr] WSP 400.0

Example #1 : a 22.1 gsm material produced in accordance with the present invention was found to exhibit the following results:

Example #2: a 22.3 gsm spunbond/meltblown/spunbond material produced in accordance with the present invention at a moderate kiss roll speed was found to exhibit the following results:

Example #3: a 23.0 gsm spunbond/meltblown/spunbond material produced in accordance with the present at a lower kiss roll speed invention was found to exhibit the following results:

Test Average

Basis weight [gsm] 23.0, with hydrophilic topical modifier

Ratio of Components 8gsm Spunbond/4gsm Meltblown/

8gsm Spunbond

MD tensile [N/5 cm] 60

CD tensile [N/5 cm] 27.3

MD Elongation [%] 109.8

CD Elongation [%] 171.8

MD HOM [gf] 12

CD HOM [gf] 4

Strike through [sec] 2.9

Rewet [gr] 0.14

Air permeability 315

[200Pa m³/m²/min]

Fabric thickness [mm] 0.28

MD linting E-side [gr] 0.68

MD linting S-side [gr] 1.0 Example #4: a 23.2 gsm spunbond/meltblown/spunbond material produced in accordance with the present invention a higher kiss roll speed was found to exhibit the following results:

Example #5: a 22.7 gsm spunbonoVmeltblown/spunbond material produced in accordance with the present invention with a hydroentangled integrating network was found to exhibit the following results:

Table #1 : Plural Sample Test

[0062] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.

Claims

What is claimed is:

1. A filamentous material comprised of: at least one integrating network, at least one performance modifying filamentous component, wherein the said integrating network and said performance modifying filamentous component are combined through the application of a contiguous thermal bonding pattern, wherein said continuous bonding pattern comprises a first and a second repeating surface areas such that pattern of repeating surface areas extend in both the machine direction of production (length) and the cross direction of production (width).

2. A filamentous material as claimed in Claim 1 , wherein said first and second repeating surfaces areas are proximal to one another.

3. A filamentous material as claimed in Claim 1 , wherein said first repeating unit surface area includes a thermal bond area of at least 30% of the total area making up the first repeating unit surface area.

4. A filamentous material as claimed in Claim 3, wherein said thermal point bond area may be induced by a plurality of individual contact elements on a contact surface whereby the distance between any two individual contact elements is less than 0.5mm.

5. A filamentous material as claimed in Claim 1, wherein said first repeating surface area and said second repeating surface area are defined as being rectilinear in shape.

6. A filamentous material as claimed in Claim 1, wherein said first repeating surface area and said second repeating surface area having the same defined total surface area

7. A filamentous material as claimed in Claim 1 , wherein said first repeating unit surface area includes a thermal bond area a single bonding point extending completely though the machine direction, cross direction or combined machine and cross direction of the first repeating unit surface area.

8. A filamentous material as claimed in Claim 1 , wherein said first repeating surface area will be circumscribed by a total of four (4) equivalent first repeating surface areas, wherein each first repeating surface areas comes into contact with a vertex of said first repeating surface areas unit.

9. A filamentous material as claimed in Claim 1 , wherein said first repeating surface area will be circumscribed by a total of four (4) second repeating surface areas, wherein each second repeating surface areas comes into contact with a side of said first repeating surface areas unit.

10. A filamentous material as claimed in Claim 1, wherein said second repeating unit surface area comprises a thermal bond area of less than 10% of the total area making up the second repeating unit surface area.

1 1. A filamentous material as claimed in Claim 1, wherein said filamentous material includes at least one consolidation step consisting of: thermal point bonding, application of hydraulic, chemical bonding, thermal bonding, and combinations thereof.

12. A filamentous material as claimed in Claim 1 1 , wherein said thermal point bonding includes a pattern or profile having cross-directional orientation.

13. A filamentous material as claimed in Claim 1 1 , wherein said consolidation step occurs prior to application of said hydraulic energy.

14. A filamentous material as claimed in Claim 1 1 , wherein said consolidation step occurs after application of said hydraulic energy.

15. A filamentous material as claimed in Claim 1 1 , wherein thermal point bonding is a symmetrical pattern.

16. A filamentous material as claimed in Claim 1 1, wherein thermal point bonding is an asymmetrical pattern.

17. A filamentous material as claimed in Claim 1 , wherein said integrating network includes at least one consolidation step consisting of: thermal point bonding, application of hydraulic, chemical bonding, thermal bonding, and combinations thereof.

18. A filamentous material as claimed in Claim 1, wherein said performance modifying filamentous material includes at least one consolidation step consisting of: thermal point bonding, application of hydraulic, chemical bonding, thermal bonding, and combinations thereof.

19. A filamentous material as claimed in Claim 1 , wherein a ratio by weight of continuous filament integrating network to performance modifying filamentous component is greater than or equal to 4: 1.

20. A method for producing a filamentous material comprised of: at least one integrating network, at least one performance modifying filamentous component, wherein the said integrating network and said performance modifying filamentous component are combined through the application of a contiguous thermal bonding pattern, wherein said contiguous bonding pattern comprises a first and a second repeating surface areas such that pattern of repeating surface areas extend in both the machine direction of production (length) and the cross direction of production (width).