US2003203691A1PendingUtilityA1

Nonwoven materials having surface features

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Assignee: KIMBERLY CLARK COPriority: Apr 30, 2002Filed: Apr 30, 2002Published: Oct 30, 2003
Est. expiryApr 30, 2022(expired)· nominal 20-yr term from priority
Inventors:Christopher FenwickBryan David HaynesKurtis Lee BrownSusan Carol PaulChristian TrusockMelpo LambidonisStephen A. Baratian
D04H 13/00D04H 3/16B29C 59/02B31F 1/07B29L 2031/4878Y10T442/60D04H 3/14B29C 59/022Y10T442/3195
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Claims

Abstract

A three-dimensional nonwoven web having a regional, bulk density of less than 0.04 grams per cubic centimeter, a top-side base surface that defines an x,y-plane and at least one macroscopic surface feature extending out of the x,y-plane wherein a macroscopic surface feature is characterized as a feature having an apex that extends at least about 1 millimeter above the x,y-plane of the top-side base surface is provided. The macroscopic feature maintains a height of at least 1 millimeter above the x,y-plane of the top-side base surface under a 1.2 kPa load (P f ) and results in contact of an object resting on the macroscopic feature such that the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) is less than 50 percent of the bulk area of the nonwoven web supporting the article.

Claims

exact text as granted — not AI-modified
We claim:  
     
         1 . A three-dimensional nonwoven web having a regional, bulk density of less than 0.04 grams per cubic centimeter and comprising 
 a top-side base surface that defines an x,y-plane and    at least one macroscopic surface feature extending out of the x,y-plane wherein a macroscopic surface feature is characterized as a feature having an apex that extends at least about 1 millimeters above the x,y-plane of the top-side base surface and the maintains a height of at least 1 millimeter above the x,y-plane of the top-side base surface under a 1.2 kPa load (P f ) 
 wherein the at least one macroscopic feature results in contact of an object resting on the macroscopic feature such that the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) is less than 50 percent of the bulk area of the nonwoven web supporting the article.  
   
     
     
         2 . The nonwoven web of  claim 1 , wherein a macroscopic feature is characterized as a feature having an apex that extends at least 1.5 millimeters above the x,y-plane.  
     
     
         3 . The nonwoven web of  claim 1 , wherein a macroscopic feature is characterized as a feature having an apex that extends at least 3 millimeters above the x,y-plane.  
     
     
         4 . The nonwoven web of  claim 1 , wherein a macroscopic feature is characterized as a feature having an apex that extends at least 5 millimeters above the x,y-plane.  
     
     
         5 . The nonwoven web of  claim 1 , wherein a macroscopic feature is characterized as a feature having an apex that extends at least about 6 millimeters above the x,y-plane.  
     
     
         6 . The nonwoven web of  claim 1 , wherein the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) is less than 40 percent of the bulk area of the nonwoven web supporting the article.  
     
     
         7 . The nonwoven web of  claim 1 , wherein the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) is less than 30 percent of the bulk area of the nonwoven web supporting the article.  
     
     
         8 . The nonwoven web of  claim 1 , wherein the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) is less than 25 percent of the bulk area of the nonwoven web supporting the article.  
     
     
         9 . The nonwoven web of  claim 1 , wherein the nonwoven web comprises a plurality of macroscopic features and the frequency of macroscopic features is at least 1 macroscopic surface feature per 100 square centimeters of nonwoven web in the in the x,y-plane.  
     
     
         10 . The nonwoven web of  claim 1 , wherein the nonwoven web comprises a plurality of macroscopic features and the frequency of macroscopic features is at least 1 macroscopic surface feature per 50 square centimeters of nonwoven web in the in the x,y-plane.  
     
     
         11 . The nonwoven web of  claim 1 , wherein the nonwoven web comprises a plurality of macroscopic features and the frequency of macroscopic features is at least 1 macroscopic surface feature per 10 square centimeters of nonwoven web in the in the x,y-plane.  
     
     
         12 . The nonwoven web of  claim 1 , wherein the nonwoven web comprises a plurality of macroscopic features and the frequency of macroscopic features is at least 1 macroscopic surface feature per 1 square centimeter of nonwoven web in the in the x,y-plane.  
     
     
         13 . The nonwoven web of  claim 1 , wherein the regional bulk density of the nonwoven web is less than 0.03 grams per cubic centimeter.  
     
     
         14 . The nonwoven web of  claim 1 , wherein the e regional bulk density of the nonwoven web is less than 0.02 grams per cubic centimeter.  
     
     
         15 . The nonwoven web of  claim 9 , wherein the macroscopic features maintain a height of at least 1.5 millimeters above the x,y-plane of the top-side base surface under a 1.2 kPa load (P f ).  
     
     
         16 . The nonwoven web of  claim 9 , wherein the macroscopic features maintain a height of at least 3 millimeters above the x,y-plane of the top-side base surface under a 1.2 kPa load (P f ).  
     
     
         17 . The nonwoven web of  claim 9 , wherein the macroscopic features maintain a height of at least 6 millimeters above the x,y-plane of the top-side base surface under a 1.2 kPa load (P f ).  
     
     
         18 . The nonwoven web of  claim 1 , wherein the macroscopic feature maintains a height of at least 1 millimeter above the x,y-plane of the top-side base surface under a 1.8 kPa load (P f ).  
     
     
         19 . The nonwoven web of  claim 1 , wherein the macroscopic feature maintains a height of at least 1.5 millimeters above the x,y-plane of the top-side base surface under a 1.8 kPa load (P f ).  
     
     
         20 . The nonwoven web of  claim 1 , wherein the macroscopic feature maintains a height of at least 3 millimeters above the x,y-plane of the top-side base surface under a 1.8 kPa load (P f ).  
     
     
         21 . The nonwoven web of  claim 1 , wherein the macroscopic feature maintains a height of at least 6 millimeters above the x,y-plane of the top-side base surface under a 1.8 kPa load (P f ).  
     
     
         22 . The nonwoven web of  claim 1 , wherein the macroscopic feature maintains a height of at least 1 millimeter above the x,y-plane of the top-side base surface under a 10 kPa load (P f ).  
     
     
         23 . The nonwoven web of  claim 1 , wherein the macroscopic feature maintains a height of at least 1.5 millimeters above the x,y-plane of the top-side base surface under a 10 kPa load (P f ).  
     
     
         24 . The nonwoven web of  claim 1 , wherein the macroscopic feature maintains a height of at least 3 millimeters above the x,y-plane of the top-side base surface under a 10 kPa load (P f ).  
     
     
         25 . The nonwoven web of  claim 1 , wherein the macroscopic feature maintains a height of at least 6 millimeters above the x,y-plane of the top-side base surface under a 10 kPa load (P f ).  
     
     
         26 . The nonwoven web of  claim 9 , wherein the macroscopic features provide at least 0.08 cubic centimeters of air space between the top surface of the nonwoven web and an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) of article to contact area of nonwoven web per 1.0 square centimeter of nonwoven web.  
     
     
         27 . The nonwoven web of  claim 9 , wherein the macroscopic features provide at least 0.09 cubic centimeters of air space between the top surface of the nonwoven web and an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) of article to contact area of nonwoven web per 1.0 square centimeter of nonwoven web.  
     
     
         28 . The nonwoven web of  claim 9 , wherein the macroscopic features provide at least 0.10 cubic centimeters of air space between the top surface of the nonwoven web and an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) of article to contact area of nonwoven web per 1.0 square centimeter of nonwoven web.  
     
     
         29 . The nonwoven web of  claim 1 , wherein the nonwoven web has a uniform composition in the x and y directions.  
     
     
         30 . The nonwoven web of  claim 1 , wherein the nonwoven web comprises a laminate.  
     
     
         31 . The nonwoven web of  claim 1 , wherein the nonwoven web comprises bicomponent fibers.  
     
     
         32 . A three-dimensional, nonwoven web having a regional, bulk density of less than 0.03 grams per cubic centimeter and comprising 
 a top-side base surface that defines an x,y-plane and    a plurality of macroscopic surface features extending out of the x,y-plane at a frequency of at least one macroscopic feature per 100 square centimeter of nonwoven web wherein a macroscopic surface feature is characterized as a feature having an apex that extends at least about 3 millimeters above the x,y-plane of the top-side base surface and the maintains a height of at least 3 millimeters above the x,y-plane of the top-side base surface under a 1.2 kPa load (P f ) p 2  wherein the macroscopic features results in contact of an object resting on the macroscopic feature such that the percent contact area of the nonwoven web with an article resting on the macroscopic surface features at a 1.2 kPa load (P f ) less than 40 percent of the bulk area of the nonwoven web supporting the article.    
     
     
         33 . The nonwoven web of  claim 32 , wherein a macroscopic feature is characterized as a feature having an apex that extends at least 5 millimeters above the x,y-plane.  
     
     
         34 . The nonwoven web of  claim 32 , wherein a macroscopic feature is characterized as a feature having an apex that extends at least about 6 millimeters above the x,y-plane.  
     
     
         35 . The nonwoven web of  claim 32 , wherein the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) is less than 30 percent of the bulk area of the nonwoven web supporting the article.  
     
     
         36 . The nonwoven web of  claim 32 , wherein the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (P f ) is less than 25 percent of the bulk area of the nonwoven web supporting the article.  
     
     
         37 . A three-dimensional, embossed nonwoven web having a regional, bulk density of less than 0.03 grams per cubic centimeter and comprising 
 a top-side base surface that defines an x,y-plane and    a plurality of macroscopic surface features extending out of the x,y-plane at a frequency of at least one macroscopic feature per 1 square centimeter of nonwoven web wherein a macroscopic surface feature is characterized as a feature having an apex that extends at least about 5 millimeters above the x,y-plane of the top-side base surface and the maintains a height of at least 3 millimeters above the x,y-plane of the top-side base surface under a 1.8 kPa load (P f ) 
 wherein the macroscopic features results in contact of an object resting on the macroscopic feature such that the percent contact area of the nonwoven web with an article resting on the macroscopic surface features at a 1.8 kPa load (P f ) is less than 40 percent of the bulk area of the nonwoven web supporting the article.

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