Nonwoven article with ribbon fibers

Abstract

Ribbon fibers, nonwoven articles derived therefrom, and their process of manufacture are provided. The ribbon fibers are derived from multicomponent fibers having a striped configuration and have a length of less than 25 millimeters, a minimum transverse dimension of less than 5 microns, and a transverse aspect ratio of at least 2:1. The ribbon fibers are formed from a water non-dispersible synthetic polymer. The nonwoven articles containing the ribbon fibers may be used for a wide array of products.

1 . A wet lap composition comprising water and a plurality of ribbon fibers, wherein said water makes up in the range of from 50 to 90 weight percent of said wet lap composition, wherein said ribbon fibers make up in the range of from 10 to 50 weight percent of said wet lap composition, wherein said water and said ribbon fibers in combination make up of at least 95 weight percent of said wet lap composition, wherein said ribbon fibers have a length of less than 25 millimeters, a minimum transverse dimension of less than 5 microns, and a transverse aspect ratio of at least 2:1, wherein said ribbon fibers are formed of a water non-dispersible synthetic polymer. 
     
     
         2 . The wet lap composition of  claim 1 , wherein said water makes up at least 50, 55, or 60 weight percent and/or not more than 90, 85, or 80 weight percent of said wet lap composition. 
     
     
         3 . The wet lap composition of  claim 1 , wherein said ribbon fibers make up at least 10, 15, or 20 weight percent and/or not more than 50, 45, or 40 weight percent of said wet lap composition. 
     
     
         4 . The wet lap composition of  claim 1 , wherein said water and said ribbon fibers in combination make of at least 95, 98, or 99 weight percent of said wet lap composition. 
     
     
         5 . The wet lap composition of  claim 1 , further comprising a fiber finishing composition. 
     
     
         6 . The wet lap composition of  claim 5 , wherein said fiber finishing composition comprising an oil, a wax, and/or a fatty acid. 
     
     
         7 . The wet lap composition of  claim 5 , wherein said fiber finishing composition comprises a naturally-derived fatty acid and/or a naturally-derived oil. 
     
     
         8 . The wet lap composition of  claim 5 , wherein said fiber finishing composition comprises mineral oil, stearate esters, and sorbitan esters. 
     
     
         9 . The wet lap composition of  claim 5 , wherein said fiber finishing composition comprises mineral oil. 
     
     
         10 . The wet lap composition of  claim 5 , wherein said fiber finishing composition makes up at least 10, 50, or 100 ppmw and/or not more than 5,000, 1000, 500 ppmw of said wet lap composition. 
     
     
         11 . The wet lap composition of  claim 1 , further comprising a water dispersible polymer in an amount of at least 0.001, 0.01, or 0.1 and/or not more than 5, 2, or 1 weight percent. 
     
     
         12 . The wet lap composition of  claim 11 , wherein said water dispersible polymer is a sulfopolyester. 
     
     
         13 . The wet lap composition of  claim 1 , wherein said ribbon fibers have a length of at least 0.25, 0.5, or 1.0 millimeter and/or not more than 25, 10, or 2 millimeter. 
     
     
         14 . The wet lap composition of  claim 1 , wherein said at least 90, 95, or 98 percent of the individual ribbon fibers that make up said plurality of ribbon fibers have an individual length that is within 90, 95, or 98 percent of the average length of all of said ribbon fibers. 
     
     
         15 . The wet lap composition of  claim 1 , wherein said ribbon fibers have an minimum transverse dimension of at least 0.1, 0.5, or 0.75 microns and/or not more than 10, 5, or 2 microns. 
     
     
         16 . The wet lap composition of  claim 1 , wherein said ribbon fibers have an transverse aspect ratio of at least 2:1, 6:1, or 10:1 and/or not more than 100:1, 50:1, or 20:1. 
     
     
         17 . The wet lap composition of  claim 1 , wherein said water non-dispersible synthetic polymer is selected from the group consisting of polyolefins, polyesters, copolyesters, polyamides, polylactides, polycaprolactones, polycarbonates, polyurethanes, cellulose esters, acrylics, polyvinyl chlorides, and blends thereof. 
     
     
         18 . The wet lap composition of  claim 17 , wherein said water non-dispersible synthetic polymer is selected from the group consisting of polyethylene terephthalate homopolymer, polyethylene terephthalate copolymers, polypropylene terephthalate, polybutylene terephthalate, polypropylene, nylon 6, nylon 66, and blends thereof. 
     
     
         19 . The wet lap composition of  claim 17 , wherein said water non-dispersible synthetic polymer is biodistintegratable as determined by DIN Standard 54900 or biodegradable as determined by ASTM Standard Method, D6340-98.