Differential basis weight nonwoven webs

Abstract

Differential basis weight nonwoven webs and a process for producing the webs is disclosed. In particular, the webs contain areas of higher basis weight and areas of lower basis weight. For instance, in one embodiment, the higher basis weight areas and the lower basis weight areas form alternating columns. The webs can be made according to a spunbond process or a meltblown process using a thermoplastic polymer or an air laid process using pulp fibers. The nonwoven webs are particularly well suited for use in diapers and other liquid absorbent products.

1 - 48 . (canceled)  
     
     
         49 . A liquid absorbable product that is intended to absorb liquids exuded by a wearer, the liquid absorbable product comprising: 
 a liquid permeable liner material that is configured to be placed adjacent to a wearer's body and an outer cover, wherein liquids contacting the liner material are drawn away from the wearer and absorbed into an interior of the product, the liner material comprising a nonwoven web made from thermoplastic fibers, the nonwoven web defining a first area having a first basis weight and a second area having a second basis weight being located on the nonwoven web according to a predetermined pattern, the first basis weight being at least 1.5 times greater than the second basis weight, the first area comprising from about 25% to about 75% of the nonwoven web.    
     
     
         50 . A liquid absorbable product as defined in  claim 49 , wherein the nonwoven web is compressed and thermally bonded together.  
     
     
         51 . A liquid absorbable product as defined in  claim 49 , wherein the product comprises a diaper.  
     
     
         52 . A liquid absorbable product as defined in  claim 49 , wherein said nonwoven web comprises a spunbond web.  
     
     
         53 . A liquid absorbable product as defined in  claim 49 , wherein said first area and said second area form a repeating pattern.  
     
     
         54 . A liquid absorbable product as defined in  claim 53 , wherein said first area and said second area comprise alternating columns.  
     
     
         55 . A liquid absorbable product as defined in  claim 53 , wherein said first area surrounds said second area, said second area comprising discrete shapes.  
     
     
         56 . A liquid absorbable product as defined in  claim 53 , wherein said first area comprises alternating rows and alternating columns.  
     
     
         57 . A liquid absorbable product as defined in  claim 52 , wherein said fibers comprise polypropylene fibers.  
     
     
         58 . A liquid absorbable product as defined in  claim 49 , wherein said first basis weight and said second basis weight are from about 0.2 ounces per square yard to about 9 ounces per square yard.  
     
     
         59 . A liquid absorbable product as defined in  claim 49 , wherein said fibers comprise polymeric crimped fibers.  
     
     
         60 . A liquid absorbable product as defined in  claim 49 , wherein said first area comprises from about 40% to about 60% of said nonwoven web.  
     
     
         61 . A liquid absorbable product as defined in  claim 49 , wherein said nonwoven web comprises a meltdown web.  
     
     
         62 . A liquid absorbable product as defined in  claim 49 , wherein said polymeric fibers comprise multicomponent fibers.  
     
     
         63 . A liquid absorbable product as defined in  claim 49 , wherein the nonwoven web consists essentially of the thermoplastic fibers.  
     
     
         64 . A liquid absorbable product as defined in  claim 49 , wherein the liquid absorbable product defines a crotch area and wherein the second area is located within the crotch area.  
     
     
         65 . A diaper comprising: 
 an outer cover;    a liner material positioned to be adjacent a wearer's body; and    a nonwoven web comprising the liner material or a surge material, the nonwoven web being liquid permeable and being configured to permit liquids to be drawn into the interior of the diaper, the nonwoven web defining a first area having a first basis weight and a second area having a second basis weight being located on the nonwoven web according to a predetermined pattern, the first basis weight being at least 1.5 times greater than the second basis weight, the first area comprising from about 25% to about 75% of the nonwoven web.    
     
     
         66 . A diaper as defined in  claim 65 , wherein the nonwoven web comprises a spunbond web.  
     
     
         67 . A diaper as defined in  claim 65 , wherein the nonwoven web consists essentially of the thermoplastic fibers.  
     
     
         68 . A diaper as defined in  claim 65 , wherein the liquid absorbable product defines a crotch area and wherein the second area is located within the crotch area.