Fluid permeable structured fibrous web

Abstract

The present invention is directed to a fluid permeable structured fibrous web comprising thermally stable, fibers that are thermally bonded together using heat producing a base substrate that is thermally stable. The base substrate is textured via mechanical treatment producing a structured fibrous web having an aged caliper of less than 1.5 mm, a vertical wicking height of at least 5 mm, a permeability of at least 10,000 cm 2 /(Pa·s) and a specific volume of at least 5 cm 3 /g. The structured fibrous web provides optimal fluid wicking and the fluid acquisition capabilities and is directed toward fluid management applications.

1 . A fluid permeable structured fibrous web comprising thermoplastic fibers wherein the fibrous web has an aged caliper of less than 1.5 mm, vertical wicking height of at least  5  mm, a permeability of at least 10,000 cm 2 /(Pa·s), and a structured substrate specific volume of at least 5 cm 3 /g. 
     
     
         2 . The fibrous web of  claim 1  wherein the fibers are thermally stable. 
     
     
         3 . The fibrous web of  claim 1  wherein the fibers are continuous, uncrimped spunbond fibers. 
     
     
         4 . The fibrous web of  claim 1  wherein the fibers are thermally point bonded. 
     
     
         5 . The fibrous web of  claim 4  wherein the fibrous web is fully bonded. 
     
     
         6 . The fibrous web of  claim 1  wherein the vertical wicking height is at least 20 mm. 
     
     
         7 . The fibrous web of  claim 1  wherein the vertical wicking height is at least 50 mm. 
     
     
         8 . The fibrous web of  claim 1  wherein the structured substrate specific volume is at least 10 cm 3 /g. 
     
     
         9 . The fibrous web of  claim 1  wherein the structured substrate specific volume is at least 12 cm 3 /g. 
     
     
         10 . The fibrous web of  claim 1  wherein the fibrous web has an MD horizontal transport (horizontal wicking distance) of at least 10 cm. 
     
     
         11 . The fibrous web of  claim 1  wherein the fibrous web has a permeability of at least 20,000 cm 2 /(Pa·s). 
     
     
         12 . The fibrous web of  claim 1  wherein the fibers comprise PET. 
     
     
         13 . The fibrous web of  claim 1  wherein the fibers comprise PET and coPET. 
     
     
         14 . The fibrous web of  claim 1  wherein the fibers comprise shaped fibers. 
     
     
         15 . The fibrous web of  claim 14  wherein the fibers are multilobal. 
     
     
         16 . The fibrous web of  claim 1  wherein the fibrous web has an aged second strike through of less than 2 seconds. 
     
     
         17 . The fibrous web of  claim 1  wherein the fibrous web has an aged second strike through of less than 1 seconds. 
     
     
         18 . The fibrous web of  claim 1  wherein the fibrous web has a rewet of less than 3.0 g. 
     
     
         19 . The fibrous web of  claim 1  wherein the fibrous web has a rewet of less than 1.5 g. 
     
     
         20 . The fibrous web of  claim 1  wherein the fibrous web has a basis weight of between 30 and 80 g/m 2 . 
     
     
         21 . The fibrous web of  claim 1  wherein the aged caliper is greater than 0.5 mm. 
     
     
         22 . The fibrous web of  claim 1  wherein the fibrous web has fiber content comprising at least 50% thermoplastic fibers.