High loft, nonwoven web exhibiting excellent recovery

Abstract

A high loft, nonwoven web exhibiting excellent recovery.

We claim: 
     
         1 . A high loft, nonwoven web comprising a three dimensional structure with fibers oriented in the x, y and z directions, said web having a thickness of less than about 250 millimeters and a basis weight ranging from between about 50 g/m 2  to about 3,000 g/m 2 , and a vertical cross-section of said web, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in said machine direction, and said web having a recovery value ranging from between about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes. 
     
     
         2 . The high loft, nonwoven web of  claim 1  wherein said web has a density ranging from between about 10 Kg/m 3  to about 250 Kg/m 3 . 
     
     
         3 . The high loft, nonwoven web of  claim 1  wherein said web is thermally bonded. 
     
     
         4 . The high loft, nonwoven web of  claim 1  wherein said web is chemically bonded. 
     
     
         5 . The high loft, nonwoven web of  claim 1  wherein said web is formed from polyolefin. 
     
     
         6 . The high loft, nonwoven web of  claim 1  wherein said web is formed from polypropylene having a melt flow rate ranging from between about 4 g/10 min. to about 6,000 g/10 min at a temperature of 230° C. and at a pressure of 2.16 kg. 
     
     
         7 . The high loft, nonwoven web of  claim 1  wherein said web contains an additive. 
     
     
         8 . The high loft, nonwoven web of  claim 7  wherein said additive is selected from the group consisting of: a superabsorbent, absorbent particles, polymers, nanoparticles, abrasive particulars, active particles, active compounds, ion exchange resins, zeolites, softening agents, plasticizers, ceramic particles pigments, dyes, flavorants, aromas, controlled release vesicles, binders, adhesives, tackifiers, surface modification agents, lubricating agents, emulsifiers, vitamins, peroxides, antimicrobials, deodorizers, fire retardants, flame retardants, antifoaming agents, anti-static agents, biocides, antifungals, degradation agents, stabilizing agents, conductivity modifying agents, or any combination thereof. 
     
     
         9 . The high loft, nonwoven web of  claim 1  wherein said web contains at least two separate and distinct layers, and said web has two major surfaces and at least one of these major surfaces is textured. 
     
     
         10 . A high loft, nonwoven web comprising at least two layers each having a three dimensional structure with fibers oriented in the x, y and z directions, said web having a thickness of less than about 200 millimeters and a basis weight of from between about 50 g/m 2  to about 2,000 g/m 2 , said web being through air bonded, and a vertical cross-section of each layer of said web, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in said machine direction, and said web having a recovery value ranging from between about 30% to about 95% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes. 
     
     
         11 . The high loft, nonwoven web of  claim 10  wherein said web is formed from a polymer selected from the group consisting of: polyolefins, polyesters, polyethylene terephthalates, polybutylene terephthalates, polycyclohexylene dimethylene terephthalates, polytrimethylene terephthalates, polymethyl methacrylates, polyamides, nylons, polyacrylics, polystyrenes, polyvinyls, polytetrafluoroethylenes, ultrahigh molecular weight polyethylenes, very high molecular weight polyethylenes, high molecular weight polyethylenes, polyether ether ketones, non-fibrous plasticized celluloses, polyethylenes, polypropylenes, polybutylenes, polymethylpentenes, low-density polyethylenes, linear low-density polyethylenes, high-density polyethylenes, polystyrenes, acrylonitrile-butadiene-styrenes, styrene-acrylonitriles, styrene-butadienes, styrene-maleic anhydrides, ethylene vinyl acetates, ethylene vinyl alcohols, polyvinyl chlorides, cellulose acetates, cellulose acetate butyrates, plasticized cellulosics, cellulose propionates, ethyl celluloses, natural fibers, any derivative thereof, any polymer blend thereof, any copolymer thereof or any combination thereof. 
     
     
         12 . The high loft, nonwoven web of  claim 10  wherein said web has two major surfaces and at least one of these major surfaces is textured. 
     
     
         13 . The high loft, nonwoven web of  claim 10  wherein said web has two major surfaces and both of these major surfaces is textured. 
     
     
         14 . The high loft, nonwoven web of  claim 10  wherein said additive is selected from the group consisting of: a superabsorbent, absorbent particles, polymers, nanoparticles, abrasive particulars, active particles, active compounds, ion exchange resins, zeolites, softening agents, plasticizers, ceramic particles pigments, dyes, flavorants, aromas, controlled release vesicles, binders, adhesives, tackifiers, surface modification agents, lubricating agents, emulsifiers, vitamins, peroxides, antimicrobials, deodorizers, fire retardants, flame retardants, antifoaming agents, anti-static agents, biocides, antifungals, degradation agents, stabilizing agents, conductivity modifying agents, or any combination thereof. 
     
     
         15 . A high loft, nonwoven web comprising at least two layers of fibers, each layer emitted from a different spinning head with a plurality of nozzles, said fibers being deposited on a forming wire to form a three dimensional structure with fibers oriented in the x, y and z directions, said web having a thickness of less than about 100 millimeters and a basis weight of from between about 50 g/m 2  to about 1,000 g/m 2 , said web being bonded, and a vertical cross-section of said web, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in said machine direction, and said web having a recovery value ranging from between about 40% to about 90% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes. 
     
     
         16 . The high loft, nonwoven web of  claim 15  wherein said web is thermally bonded. 
     
     
         17 . The high loft, nonwoven web of  claim 15  wherein said web is chemically bonded. 
     
     
         18 . The high loft, nonwoven web of  claim 15  wherein said web has two major surfaces and both of these major surfaces is textured. 
     
     
         19 . The high loft, nonwoven web of  claim 15  wherein said web is formed from a polymer which is selected from the group consisting of: polyolefins, polyesters, polyethylene terephthalates, polybutylene terephthalates, polycyclohexylene dimethylene terephthalates, polytrimethylene terephthalates, polymethyl methacrylates, polyamides, nylons, polyacrylics, polystyrenes, polyvinyls, polytetrafluoroethylenes, ultrahigh molecular weight polyethylenes, very high molecular weight polyethylenes, high molecular weight polyethylenes, polyether ether ketones, non-fibrous plasticized celluloses, polyethylenes, polypropylenes, polybutylenes, polymethylpentenes, low-density polyethylenes, linear low-density polyethylenes, high-density polyethylenes, polystyrenes, acrylonitrile-butadiene-styrenes, styrene-acrylonitriles, styrene-butadienes, styrene-maleic anhydrides, ethylene vinyl acetates, ethylene vinyl alcohols, polyvinyl chlorides, cellulose acetates, cellulose acetate butyrates, plasticized cellulosics, cellulose propionates, ethyl celluloses, natural fibers, any derivative thereof, any polymer blend thereof, any copolymer thereof or any combination thereof. 
     
     
         20 . The high loft, nonwoven web of  claim 10  wherein said web contains one or more additive selected from the group consisting of: a superabsorbent, absorbent particles, polymers, nanoparticles, abrasive particulars, active particles, active compounds, ion exchange resins, zeolites, softening agents, plasticizers, ceramic particles pigments, dyes, flavorants, aromas, controlled release vesicles, binders, adhesives, tackifiers, surface modification agents, lubricating agents, emulsifiers, vitamins, peroxides, antimicrobials, deodorizers, fire retardants, flame retardants, antifoaming agents, antistatics agents, biocides, antifungals, degradation agents, stabilizing agents, conductivity modifying agents, or any combination thereof.