Elastomeric spun bonded fabric of polypropylene and process for making

Abstract

The present invention provides for a non-woven fabric composite consisting essentially of a mutually interbonded mixture of crimped isotactic polypropylene fiber segments and uncrimped hard elastic isotactic polypropylene fiber segments. A process to manufacture the non-woven fabric composite and textile goods fabricated from the disclosed non-woven fabric composite are also provided.

1 . A non-woven fabric composite consisting essentially of a mutually interbonded mixture of crimped isotactic polypropylene fiber segments and uncrimped hard elastic isotactic polypropylene fiber segments.  
   
   
       2 . The non-woven fabric composite of  claim 1  further comprising point-bonds, the total area of point-bonds in the range of 10-60% of the total fabric area.  
   
   
       3 . The non-woven fabric composite of  claim 2  wherein the point-bonds range in size from about 0.1 mm 2  to about 3 mm 2 .  
   
   
       4 . The non-woven fabric composite of  claim 1  wherein the fiber segments are characterized by an approximately circular cross-section of a diameter of 1 to 100 micrometers.  
   
   
       5 . The non-woven fabric composite of  claim 1  further characterized by a fabric basis weight of 8 to 80 g/m 2 .  
   
   
       6 . The non-woven fabric composite of  claim 1  wherein about 2 to about 25% of the fibers are in the uncrimped hard elastic form.  
   
   
       7 . A process for producing a non-woven fabric composite comprising exposing a spun bonded isotactic polypropylene fabric to a temperature of 150° C. to 170° C. over a period of 10 seconds to 5 minutes followed by cooling, the fabric being disposed in a manner to permit free-shrinkage in at least one dimension, which causes the fabric to at least double in thickness.  
   
   
       8 . The process of  claim 7  wherein the spun bonded isotactic polypropylene fabric further comprises point-bonds comprising 10-60% of the total fabric area.  
   
   
       9 . The process of  claim 8  wherein the point-bonds range in size from about 0.1 mm 2  to about 3 mm 2 .  
   
   
       10 . The process of  claim 7  wherein the spun bonded isotactic polypropylene fabric is characterized by fiber segments having an approximately circular cross-section of a diameter of 1 to 100 micrometers.  
   
   
       11 . The process of  claim 7  further characterized by a fabric basis weight of 8 to 80 g/m 2 .  
   
   
       12 . The process of  claim 7  further comprising disposing the fabric in such manner that it is under tension in one planar dimension but unconstrained in the orthogonal planar dimension.  
   
   
       13 . A textile product comprising a non-woven fabric composite consisting essentially of a mutually interbonded mixture of crimped isotactic polypropylene fiber segments and uncrimped hard elastic isotactic polypropylene fiber segments.  
   
   
       14 . The textile product of  claim 13  further comprising point-bonds, the total area of which is in the range of 10-60% of the total fabric area.  
   
   
       15 . The textile product of  claim 14  wherein the point-bonds range in size from about 0.1 mm 2  to about 3 mm 2 .  
   
   
       16 . The textile product of  claim 13  wherein the fiber segments are characterized by an approximately circular cross-section of a diameter of 1 to 100 micrometers.  
   
   
       17 . The textile product of  claim 13  further characterized by a fabric basis weight of 8 to 80 g/m 2 .  
   
   
       18 . The textile product of  claim 13  wherein about 2 to about 25% of the fibers are in the uncrimped hard elastic form.  
   
   
       19 . The textile product of  claim 13  in the form of a product selected from the group consisting of disposable apparel such as laboratory cover-alls including clean room suits, surgical gowns, surgical drapes, gloves, glove liners; components of disposable hygiene products such as diapers; and durable articles such as thermal underwear, shell fabrics for jackets and coats, blankets and bedding, upholstery fabrics, mattress ticking, and filtration components.  
   
   
       20 . A non-woven fabric composite made by the process of  claim 7.