High Strength Low Weight Non-Woven Fabric And Containers Incorporating Same For Use In Preparing Beverages

Abstract

A non-woven fabric is provided having a high strength and a low basis weight. The fabric comprises a plurality of multi-component fibers that are bonded together into a web having a basis weight of 20 gsm or less, an air porosity of at least 1600 L/M2/s and a bonding area percentage in the range of 15-50%, wherein the multi-component fibers include a sheath and at least one core that are each formed of the same substantially pure polymer material. The invention further provides a method of making the non-woven fabric as well as a filtered container or beverage capsule formed with the non-woven fabric.

I/We claim: 
     
         1 . A non-woven fabric comprising a plurality of multi-component fibers that are formed together into a web having a basis weight of 20 gsm or less, an air porosity of at least 1600 L/M2/s and a plurality of bonds, said fabric having a bonding area percentage in the range of 15-50%, and wherein said multi-component fibers comprise a sheath and at least one core that are each formed of the same pure polymer material. 
     
     
         2 . The fabric of  claim 1  wherein said fabric is a spunbond fabric. 
     
     
         3 . The fabric of  claim 1  wherein said multi-component fibers have a diameter of at least two denier (D). 
     
     
         4 . The fabric of  claim 1  wherein said multi-component fibers are bonded together into a web with a curvilinear bonding pattern edge profile. 
     
     
         5 . The fabric of  claim 1  wherein said multi-component fibers are formed from resins having a notched Izod impact strength of at least 15 J/m at 23 degrees C. 
     
     
         6 . The fabric of  claim 1  wherein said pure polymer material is selected from PP, PET or PLA. 
     
     
         7 . The fabric of  claim 1  wherein said fabric has a material tear strength in the range of 5-10 N in both the Machine Direction (MD) and the Cross Direction (CD). 
     
     
         8 . A filtered container for use in forming a beverage, the filtered container comprising:
 a) at least one piece of non-woven fabric that is formed into a container defining an interior space, said at least one piece of non-woven fabric having a plurality of multi-component fibers that are bonded together into a web having a basis weight of 20 gsm or less, an air porosity of at least 1600 L/M2/s and a bonding area percentage in the range of 15-50%, wherein said multi-component fibers comprising a sheath and at least one core that are each formed of the same pure polymer material; and   b) ingredients disposed in said interior space to form the beverage.   
     
     
         9 . The filtered container of  claim 8  wherein said fabric is a spunbond fabric. 
     
     
         10 . The filtered container of  claim 8  wherein said multi-component fibers have a diameter of at least two denier (D). 
     
     
         11 . The filtered container of  claim 8  wherein said multi-component fibers are bonded together into a web with a curvilinear bonding pattern edge profile. 
     
     
         12 . The filtered container of  claim 8  wherein said multi-component fibers are formed from resins having a notched Izod impact strength of at least 15 J/m at 23 degrees C. 
     
     
         13 . The filtered container of  claim 8  wherein said pure polymer material is selected from PP, PET or PLA. 
     
     
         14 . A beverage capsule for use in a beverage preparing machine, the beverage capsule comprising:
 a) a body defining an interior space having an opening;   b) a non-woven fabric disposed in said interior space, said non-woven fabric having a plurality of multi-component fibers that are bonded together into a web having a basis weight of 20 gsm or less, an air porosity of at least 1600 L/M2/s and a bonding area percentage in the range of 15-50%, wherein said multi-component fibers comprising a sheath and at least one core that are each formed of the same pure polymer material;   c) ingredients disposed in said interior space to form the beverage; and   d) a cover disposed over said opening.   
     
     
         15 . The beverage capsule of  claim 14  wherein said fabric is a spunbond fabric. 
     
     
         16 . The beverage capsule of  claim 14  wherein said multi-component fibers have a diameter of at least two denier (D). 
     
     
         17 . The beverage capsule of  claim 14  wherein said multi-component fibers are bonded together into a web with a curvilinear bonding pattern edge profile. 
     
     
         18 . The beverage capsule of  claim 14  wherein said multi-component fibers are formed from resins having a notched Izod impact strength of at least 15 J/m at 23 degrees C. 
     
     
         19 . The beverage capsule of  claim 14  wherein said pure polymer material is selected from PP, PET or PLA. 
     
     
         20 . The beverage capsule of  claim 14  wherein said fabric has a material tear strength in the range of 5-10 N in both the Machine Direction (MD) and the Cross Direction (CD).