Foam-formed fibrous sheets with crimped staple fibers

Abstract

A method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 1% by weight crimped synthetic fibers and at least 1% by weight binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate. A substrate includes an aqueous-based polymer foam including at least 1% by weight crimped synthetic fiber and at least 1% by weight binder fiber, wherein the substrate is free of superabsorbent material. A method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 2% by weight crimped binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate, wherein the foam-formed substrate is free of superabsorbent material, and wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

1 .- 20 . (canceled) 
     
     
         21 . A method for producing a foam-formed substrate, the method comprising:
 producing an aqueous-based foam including at least 1% by weight crimped synthetic fibers and at least 1% by weight binder fibers; wherein the crimped synthetic fibers have a length from 5 mm to 60 mm and have a diameter of at least 3 dtex;   forming a wet sheet from the aqueous-based foam; and   drying the wet sheet to obtain the foam-formed substrate;   wherein the foam-formed substrate exhibits at least a 30% reduction in density compared to the same foam-formed substrate with non-crimped fiber replacing the crimped synthetic fibers.   
     
     
         22 . The method of  claim 21 , wherein the foam-formed substrate has a dry density between 0.02 g/cc and 0.1 g/cc. 
     
     
         23 . The method of  claim 21 , wherein the crimped synthetic fibers have a length from 5 mm to 30 mm and a diameter of at least 4 dtex. 
     
     
         24 . The method of  claim 21 , wherein the crimped synthetic fibers have a three-dimensional kinked or curly structure. 
     
     
         25 . The method of  claim 21 , wherein producing includes at least 5% by weight crimped synthetic fibers and at least 5% by weight binder fibers. 
     
     
         26 . The method of  claim 21 , wherein the crimped synthetic fibers have a Tg greater than or equal to 0° C. 
     
     
         27 . The method of  claim 21 , wherein the foam-formed substrate is free of superabsorbent material. 
     
     
         28 . A substrate comprising:
 at least 1% by weight crimped synthetic fibers; the crimped synthetic fibers having a length from 5 mm to 60 mm and a diameter of at least 3 dtex; and   at least 1% by weight binder fibers;   wherein the substrate exhibits at least a 30% reduction in density compared to the same substrate with non-crimped fiber replacing the crimped synthetic fibers.   
     
     
         29 . The substrate of  claim 28 , wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc. 
     
     
         30 . The substrate of  claim 28 , wherein the crimped synthetic fibers have a length from 5 mm to 30 mm and a diameter of at least 4 dtex. 
     
     
         31 . The substrate of  claim 28 , wherein the crimped synthetic fibers have a three-dimensional kinked or curly structure. 
     
     
         32 . The substrate of  claim 28 , wherein the substrate includes at least 5% by weight crimped synthetic fibers and at least 5% by weight binder fibers. 
     
     
         33 . The substrate of  claim 28 , wherein the crimped synthetic fibers have a Tg greater than or equal to 0° C. 
     
     
         34 . The substrate of  claim 29 , wherein the substrate is free of superabsorbent material. 
     
     
         35 . A substrate comprising:
 at least 1% by weight crimped synthetic fibers; the crimped synthetic fibers having a length from 5 mm to 60 mm and a diameter of at least 3 dtex; and   at least 1% by weight binder fibers;   wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc.   
     
     
         36 . The substrate of  claim 35 , wherein the crimped synthetic fibers have a length from 5 mm to 30 mm and a diameter of at least 4 dtex. 
     
     
         37 . The substrate of  claim 35 , wherein the crimped synthetic fibers have a three-dimensional kinked or curly structure. 
     
     
         38 . The substrate of  claim 35 , wherein the substrate includes at least 5% by weight crimped synthetic fibers and at least 5% by weight binder fibers. 
     
     
         39 . The substrate of  claim 35 , wherein the crimped synthetic fibers have a Tg greater than or equal to 0° C. 
     
     
         40 . The substrate of  claim 35 , wherein the substrate is free of superabsorbent material.