US2004198124A1PendingUtilityA1
High loft low density nonwoven webs of crimped filaments and methods of making same

Priority: Dec 21, 2001Filed: Dec 31, 2003Published: Oct 7, 2004
Est. expiryDec 21, 2021(expired)· nominal 20-yr term from priority
Inventors:Braulio Polanco Christopher Fenwick Darryl Clark Bryan D. Haynes Kurtis Lee Brown Chad Freese Eric Scott Kepner
D04H 1/50Y10T442/638D04H 3/16D04H 3/005Y10T442/681Y10T442/629Y10T428/2922Y10T442/632Y10T428/2924D04H 3/02
PatentIndex Score
Cited by
References
Claims
Abstract

High loft, low density nonwoven webs of increased uniformity are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A/B side by side morphology in an unheated fiber draw unit. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the z-direction and produce a web of lofted material. The resultant material is particularly suitable for use as an insulator. Particulates may be added to the webs if desired.
Claims

exact text as granted — not AI-modified
We claim:  
     
         1 . A nonwoven material comprising: 
 a) a web of substantially continuous A/B bicomponent crimped fibers,    b) the web having a percentage difference between a formation index of a top side of the web and a formation index of a wire side of the web of less than about 11%.    
     
     
         2 . The nonwoven material according to  claim 1  wherein: 
 a) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a bulk to about 0.1 inches in the Z axis, or wherein  
 b) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a bulk of over about 0.1 inches in the Z axis.  
 
     
     
         3 . The nonwoven material according to  claim 1  wherein: 
 a) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a bulk to about 0.1 inches in the Z axis, or wherein  
 b) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a bulk of over about 0.1 inches in the Z axis.  
 
     
     
         4 . The nonwoven material according to  claim 1  wherein: 
 a) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a basis weight of up to 1.5 osy, or wherein  
 b) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a basis weight of over about 1.5 osy.  
 
     
     
         5 . The nonwoven material according to  claim 1  wherein: 
 a) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a basis weight of up to 1.5 osy, or wherein  
 b) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a basis weight of over about 1.5 osy.  
 
     
     
         6 . The nonwoven material according to  claim 1  wherein: 
 i) the web has a formation index averaging above about 19.07 on the top side of the web when the web has a bulk of about 0.35 inches in the Z axis, or wherein  
 ii) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a bulk of about 0.12 inches in the Z axis, or wherein  
 iii) the web has a formation index averaging above about 28.73 on the top side of the web when the web has a bulk of about 0.1 inches in the Z axis, or wherein  
 iv) the web has a formation index averaging above about 34.63 on the top side of the web when the web has a bulk of about 0.08 inches in the Z axis, or wherein  
 v) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a bulk of about 0.07 inches in the Z axis.  
 
     
     
         7 . The nonwoven material according to  claim 1  wherein: 
 i) the web has a formation index averaging above about 31.6 on the wire side of the web when the web has a bulk of about 0.35 inches in the Z axis, or wherein  
 ii) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a bulk of about 0.12 inches in the Z axis, or wherein  
 iii) the web has a formation index averaging above about 35.37 on the wire side of the web when the web has a bulk of about 0.1 inches in the Z axis, or wherein  
 iv) the web has a formation index averaging above about 38.98 on the wire side of the web when the web has a bulk of about 0.08 inches in the Z axis, or wherein  
 v) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a bulk of about 0.07 inches in the Z axis.  
 
     
     
         8 . The nonwoven material according to  claim 1  wherein: 
 i) the web has a formation index averaging above about 19.07 on the top side of the web when the web has a basis weight of about 6.0 osy, or wherein  
 ii) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a basis weight of about 2.5 osy, or wherein  
 iii) the web has a formation index averaging above about 30.27 on the top side of the web when the web has a basis weight of about 2.25 osy, or wherein  
 iv) the web has a formation index averaging above about 28.73 on the top side of the web when the web has a basis weight of about 1.5 osy, or wherein  
 v) the web has a formation index averaging above about 31.07 on the top side of the web when the web has a basis weight of about 1.2 osy, or wherein  
 vi) the web has a formation index averaging above about 34.63 on the top side of the web when the web has a basis weight of about 1.0 osy, or wherein  
 vii) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a basis weight of about 0.75 osy.  
 
     
     
         9 . The nonwoven material according to  claim 1  wherein: 
 i) the web has a formation index averaging above about 31.6 on the wire side of the web when the web has a basis weight of about 6.0 osy, or wherein  
 ii) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a basis weight of about 2.5 osy, or wherein  
 iii) the web has a formation index averaging above about 35.03 on the wire side of the web when the web has a basis weight of about 2.25 osy, or wherein  
 iv) the web has a formation index averaging above about 35.37 on the wire side of the web when the web has a basis weight of about 1.5 osy, or wherein  
 v) the web has a formation index averaging above about 37.15 on the wire side of the web when the web has a basis weight of about 1.2 osy, or wherein  
 vi) the web has a formation index averaging above about 38.98 on the wire side of the web when the web has a basis weight of about 1.0 osy, or wherein  
 vii) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a basis weight of about 0.75 osy.  
 
     
     
         10 . The nonwoven material of  claim 1  wherein the fibers have a fiber denier of between about 0.1 dpf to about 9.0 dpf.  
     
     
         11 . The nonwoven material of  claim 10  wherein the fibers have a fiber denier of between about 0.1 dpf to about 6.0 dpf.  
     
     
         12 . The nonwoven material of  claim 10  wherein the fibers have a fiber denier of between about 0.1 dpf to about 5.0 dpf.  
     
     
         13 . The nonwoven material of  claim 1  wherein the fibers have a fiber denier of between about 0.1 dpf to about 4.2 dpf.  
     
     
         14 . The nonwoven material of  claim 12  wherein the fibers have a fiber denier of between about 0.1 dpf to about 3.3 dpf.  
     
     
         15 . The nonwoven material of  claim 10  wherein the fibers have a fiber denier of between about 3.4 dpf to about 4.2 dpf.  
     
     
         16 . The nonwoven material of  claim 15  wherein the fibers have a substantially white color.  
     
     
         17 . The nonwoven material of  claim 16  wherein the fibers have a TiO 2  percentage of about 0.1% to about 5%.  
     
     
         18 . The nonwoven material of  claim 17  wherein the fibers have a TiO 2  percentage of about 2%.  
     
     
         19 . The nonwoven material according to  claim 1  wherein the fibers of the nonwoven web are integrally bonded.  
     
     
         20 . The nonwoven web according to  claim 2  wherein: 
 a) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a bulk to about 0.1 inches in the Z axis, or wherein  
 b) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a bulk of over about 0.1 inches in the Z axis.  
 
     
     
         21 . The nonwoven web according to  claim 20  wherein: 
 a) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a basis weight of up to 1.5 osy, or wherein  
 b) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a basis weight of over about 1.5 osy.  
 
     
     
         22 . The nonwoven web according to  claim 21  wherein: 
 a) the web having a formation index averaging above about 43.76 on the wire side of the web when the web has a basis weight of up to 1.5 osy, or wherein  
 b) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a basis weight of over about 1.5 osy.  
 
     
     
         23 . The nonwoven web according to  claim 22  wherein: 
 i) the web has a formation index averaging above about 19.07 on the top side of the web when the web has a bulk of about 0.35 inches in the Z axis, or wherein  
 ii) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a bulk of about 0.12 inches in the Z axis, or wherein  
 iii) the web has a formation index averaging above about 28.73 on the top side of the web when the web has a bulk of about 0.1 inches in the Z axis, or wherein  
 iv) the web has a formation index averaging above about 34.63 on the top side of the web when the web has a bulk of about 0.08 inches in the Z axis, or wherein  
 v) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a bulk of about 0.07 inches in the Z axis.  
 
     
     
         24 . The nonwoven web according to  claim 23  wherein: 
 i) the web has a formation index averaging above about 31.6 on the wire side of the web when the web has a bulk of about 0.35 inches in the Z axis, or wherein  
 ii) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a bulk of about 0.12 inches in the Z axis, or wherein  
 iii) the web has a formation index averaging above about 35.37 on the wire side of the web when the web has a bulk of about 0.1 inches in the Z axis, or wherein  
 iv) the web has a formation index averaging above about 38.98 on the wire side of the web when the web has a bulk of about 0.08 inches in the Z axis, or wherein  
 v) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a bulk of about 0.07 inches in the Z axis.  
 
     
     
         25 . The nonwoven web according to  claim 24  wherein: 
 i) the web which has a formation index averaging above about 19.07 on the top side of the web when the web has a basis weight of about 6.0 osy, or wherein  
 ii) the web which has a formation index averaging above about 32.03 on the top side of the web when the web has a basis weight of about 2.5 osy, or wherein  
 iii) the web which has a formation index averaging above about 30.27 on the top side of the web when the web has a basis weight of about 2.25 osy, or wherein  
 iv) the web which has a formation index averaging above about 28.73 on the top side of the web when the web has a basis weight of about 1.5 osy, or wherein  
 v) the web which has a formation index averaging above about 31.07 on the top side of the web when the web has a basis weight of about 1.2 osy, or wherein  
 vi) the web which has a formation index averaging above about 34.63 on the top side of the web when the web has a basis weight of about 1.0 osy, or wherein  
 vii) the web which has a formation index averaging above about 37.6 on the top side of the web when the web has a basis weight of about 0.75 osy.  
 
     
     
         26 . The nonwoven web according to  claim 25  wherein: 
 i) the web which has a formation index averaging above about 31.6 on the wire side of the web when the web has a basis weight of about 6.0 osy, or wherein  
 ii) the web which has a formation index averaging above about 35.03 on the wire side of the web when the web has a basis weight of about 2.25 osy, or wherein  
 iii) the web which has a formation index averaging above about 37.09 on the wire side of the web when the web has a basis weight of about 2.5 osy, or wherein  
 iv) the web which has a formation index averaging above about 35.37 on the wire side of the web when the web has a basis weight of about 1.5 osy, or wherein  
 v) the web which has a formation index averaging above about 37.15 on the wire side of the web when the web has a basis weight of about 1.2 osy, or wherein  
 vi) the web which has a formation index averaging above about 38.98 on the wire side of the web when the web has a basis weight of about 1.0 osy, or wherein  
 vii) the web which has a formation index averaging above about 43.76 on the wire side of the web when the web has a basis weight of about 0.75 osy.  
 
     
     
         27 . The web of  claim 26  wherein the fibers have a fiber denier of between about 0.1 dpf to about 6.0 dpf.  
     
     
         28 . The web of  claim 27  wherein the fibers have a fiber denier of between about 0.1 dpf to about 4.2 dpf.  
     
     
         29 . The web of  claim 28  wherein the fibers have a fiber denier of between about 0.1 dpf to about 3.3 dpf.  
     
     
         30 . The web of  claim 27  wherein the fibers have a fiber denier of between about 3.4 dpf to about 4.2 dpf.  
     
     
         31 . The web of  claim 26  wherein the fibers have a substantially white color.  
     
     
         32 . The web of  claim 31  wherein the fibers have a TiO 2  percentage of about 0.1% to about 5%.  
     
     
         33 . The web of  claim 32  wherein the fibers have a TiO 2  percentage of about 2%.  
     
     
         34 . The nonwoven web according to  claim 26  wherein the fibers of the nonwoven web are integrally bonded.  
     
     
         35 . A nonwoven web comprising: 
 a) substantially continuous A/B bicomponent crimped fibers;    b) the web having a formation index averaging above about 37.6 on the top side of the web when the web has a bulk to about 0.1 inches in the Z axis, or    c) the web having a formation index averaging above about 32.03 on the top side of the web when the web has a bulk of over about 0.1 inches in the Z axis.    
     
     
         36 . The nonwoven web according to  claim 35  wherein: 
 a) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a bulk to about 0.1 inches in the Z axis, or wherein  
 b) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a bulk of over about 0.1 inches in the Z axis.  
 
     
     
         37 . The nonwoven web according to  claim 35  wherein: 
 a) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a basis weight of up to 1.5 osy, or wherein  
 b) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a basis weight of over about 1.5 osy.  
 
     
     
         38 . The nonwoven web according to  claim 35  wherein: 
 a) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a basis weight of up to 1.5 osy, or wherein  
 b) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a basis weight of over about 1.5 osy.  
 
     
     
         39 . The nonwoven web according to  claim 35  wherein: 
 i) the web has a formation index averaging above about 19.07 on the top side of the web when the web has a bulk of about 0.35 inches in the Z axis, or wherein  
 ii) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a bulk of about 0.12 inches in the Z axis, or wherein  
 iii) the web has a formation index averaging above about 28.73 on the top side of the web when the web has a bulk of about 0.1 inches in the Z axis, or wherein  
 iv) the web has a formation index averaging above about 34.63 on the top side of the web when the web has a bulk of about 0.08 inches in the Z axis, or wherein  
 v) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a bulk of about 0.07 inches in the Z axis.  
 
     
     
         40 . The nonwoven web according to  claim 35  wherein: 
 i) the web has a formation index averaging above about 31.6 on the wire side of the web when the web has a bulk of about 0.35 inches in the Z axis, or wherein  
 ii) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a bulk of about 0.12 inches in the Z axis, or wherein  
 iii) the web has a formation index averaging above about 35.37 on the wire side of the web when the web has a bulk of about 0.1 inches in the Z axis, or wherein  
 iv) the web has a formation index averaging above about 38.98 on the wire side of the web when the web has a bulk of about 0.08 inches in the Z axis, or wherein  
 v) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a bulk of about 0.07 inches in the Z axis.  
 
     
     
         41 . The nonwoven web according to  claim 35  wherein: 
 i) the web has a formation index averaging above about 19.07 on the top side of the web when the web has a basis weight of about 6.0 osy, or wherein  
 ii) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a basis weight of about 2.5 osy, or wherein  
 iii) the web has a formation index averaging above about 30.27 on the top side of the web when the web has a basis weight of about 2.25 osy, or wherein  
 iv) the web has a formation index averaging above about 28.73 on the top side of the web when the web has a basis weight of about 1.5 osy, or wherein  
 v) the web has a formation index averaging above about 31.07 on the top side of the web when the web has a basis weight of about 1.2 osy, or wherein  
 vi) the web has a formation index averaging above about 34.63 on the top side of the web when the web has a basis weight of about 1.0 osy, or wherein  
 vii) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a basis weight of about 0.75 osy.  
 
     
     
         42 . The nonwoven web according to  claim 35  wherein: 
 i) the web has a formation index averaging above about 31.6 on the wire side of the web when the web has a basis weight of about 6.0 osy, or wherein  
 ii) the web has a formation index averaging above about 35.03 on the wire side of the web when the web has a basis weight of about 2.25 osy, or wherein  
 iii) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a basis weight of about 2.5 osy, or wherein  
 iv) the web has a formation index averaging above about 35.37 on the wire side of the web when the web has a basis weight of about 1.5 osy, or wherein  
 v) the web has a formation index averaging above about 37.15 on the wire side of the web when the web has a basis weight of about 1.2 osy, or wherein  
 vi) the web has a formation index averaging above about 38.98 on the wire side of the web when the web has a basis weight of about 1.0 osy, or wherein  
 vii) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a basis weight of about 0.75 osy.  
 
     
     
         43 . A nonwoven web comprising: 
 a) substantially continuous A/B bicomponent crimped fibers;    b) the web having a formation index averaging above about 43.76 on the wire side of the web when the web has a bulk to about 0.1 inches in the Z axis, or    c) the web having a formation index averaging above about 37.09 on the wire side of the web when the web has a bulk of over about 0.1 inches in the Z axis.    
     
     
         44 . The nonwoven web according to  claim 43  wherein: 
 a) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a basis weight of up to 1.5 osy, or wherein  
 b) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a basis weight of over about 1.5 osy.  
 
     
     
         45 . The nonwoven web according to  claim 43  wherein: 
 a) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a basis weight of up to 1.5 osy, or wherein  
 b) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a basis weight of over about 1.5 osy.  
 
     
     
         46 . The nonwoven web according to  claim 43  wherein: 
 i) the web has a formation index averaging above about 19.07 on the top side of the web when the web has a bulk of about 0.35 inches in the Z axis, or wherein  
 ii) the web has a formation index averaging above about 32.03 on the top side of the web when the web has a bulk of about 0.12 inches in the Z axis, or wherein  
 iii) the web has a formation index averaging above about 28.73 on the top side of the web when the web has a bulk of about 0.1 inches in the Z axis, or wherein  
 iv) the web has a formation index averaging above about 34.63 on the top side of the web when the web has a bulk of about 0.08 inches in the Z axis, or wherein  
 v) the web has a formation index averaging above about 37.6 on the top side of the web when the web has a bulk of about 0.07 inches in the Z axis.  
 
     
     
         47 . The nonwoven web according to  claim 43  wherein: 
 i) the web has a formation index averaging above about 31.6 on the wire side of the web when the web has a bulk of about 0.35 inches in the Z axis, or wherein  
 ii) the web has a formation index averaging above about 37.09 on the wire side of the web when the web has a bulk of about 0.12 inches in the Z axis, or wherein  
 iii) the web has a formation index averaging above about 35.37 on the wire side of the web when the web has a bulk of about 0.1 inches in the Z axis, or wherein  
 iv) the web has a formation index averaging above about 38.98 on the wire side of the web when the web has a bulk of about 0.08 inches in the Z axis, or wherein  
 v) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a bulk of about 0.07 inches in the Z axis.  
 
     
     
         48 . The nonwoven web according to  claim 43  wherein: 
 i) the web has a formation index averaging above about 19.07 on the top side of the web having a basis weight of about 6.0 osy, or wherein  
 ii) the web has a formation index averaging above about 32.03 on the top side of the web having a basis weight of about 2.5 osy, or wherein  
 iii) the web has a formation index averaging above about 30.27 on the top side of the web having a basis weight of about 2.25 osy, or wherein  
 iv) the web has a formation index averaging above about 28.73 on the top side of the web having a basis weight of about 1.5 osy, or wherein  
 v) the web has a formation index averaging above about 31.07 on the top side of the web having a basis weight of about 1.2 osy, or wherein  
 vi) the web has a formation index averaging above about 34.63 on the top side of the web having a basis weight of about 1.0 osy, or wherein  
 vii) the web has a formation index averaging above about 37.6 on the top side of the web having a basis weight of about 0.75 osy.  
 
     
     
         49 . The nonwoven web according to  claim 43  wherein: 
 i) the web has a formation index averaging above about 31.6 on the wire side of the web when the web a basis weight of about 6.0 osy, or wherein  
 ii) the web has a formation index averaging above about 35.03 on the wire side of the web when the web a basis weight of about 2.25 osy, or wherein  
 iii) the web has a formation index averaging above about 37.09 on the wire side of the web when the web a basis weight of about 2.5 osy, or wherein  
 iv) the web has a formation index averaging above about 35.37 on the wire side of the web when the web a basis weight of about 1.5 osy, or wherein  
 v) the web has a formation index averaging above about 37.15 on the wire side of the web when the web a basis weight of about 1.2 osy, or wherein  
 vi) the web has a formation index averaging above about 38.98 on the wire side of the web when the web a basis weight of about 1.0 osy, or wherein  
 vii) the web has a formation index averaging above about 43.76 on the wire side of the web when the web has a basis weight of about 0.75 osy.
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