Low basis weight nonwoven webs and methods for making same

Abstract

Low basis weight, for example less than 5 gsm, nonwoven webs, rolls thereof, and methods for making same are provided.

What is claimed is: 
     
         1 . A low basis weight nonwoven web exhibiting a basis weight of less than 5 gsm, wherein the low basis weight nonwoven web comprises a plurality of hydroxyl polymer fibrous elements; wherein the hydroxyl polymer fibrous elements have an average fiber diameter of less than 4.5 microns as measured by the average fiber diameter method. 
     
     
         2 . The low basis weight nonwoven web according to  claim 1  wherein the low basis weight nonwoven web has a MD fail TEA greater than 13 g/in/per gsm. 
     
     
         3 . The low basis weight nonwoven web according to  claim 1  wherein the low basis weight nonwoven web exhibits a basis weight of less than 3 gsm. 
     
     
         4 . The low basis weight nonwoven web according to  claim 3  wherein the low basis weight nonwoven web exhibits a basis weight of less than 2 gsm. 
     
     
         5 . The low basis weight nonwoven web according to  claim 1  wherein the low basis weight nonwoven web exhibits a basis weight of greater than 0.25 gsm. 
     
     
         6 . The low basis weight nonwoven web according to  claim 5  wherein the low basis weight nonwoven web exhibits a basis weight of greater than 0.50 gsm. 
     
     
         7 . The low basis weight nonwoven web according to  claim 6  wherein the low basis weight nonwoven web exhibits a basis weight of greater than 0.75 gsm. 
     
     
         8 . The low basis weight nonwoven web according to  claim 7  wherein the low basis weight nonwoven web exhibits a basis weight of greater than 1 gsm. 
     
     
         9 . The low basis weight nonwoven web according to  claim 1  wherein the low basis weight nonwoven web exhibits a basis weight of greater than 0.25 gsm to less than 5 gsm. 
     
     
         10 . The low basis weight nonwoven web according to  claim 9  wherein the low basis weight nonwoven web exhibits a basis weight of greater than 0.50 gsm to less than 4 gsm. 
     
     
         11 . The low basis weight nonwoven web according to  claim 10  wherein the low basis weight nonwoven web exhibits a basis weight of greater than 0.75 gsm to less than 3 gsm. 
     
     
         12 . The low basis weight nonwoven web according to  claim 11  wherein the low basis weight nonwoven web exhibits a basis weight of from about 1 gsm to about 2 gsm. 
     
     
         13 . The low basis weight nonwoven web according to  claim 1  wherein the low basis weight nonwoven web exhibits a total dry tensile of greater than 75 g/in as measured according to the Tensile Test Method. 
     
     
         14 . The low basis weight nonwoven web according to  claim 13  wherein the low basis weight nonwoven web exhibits a total dry tensile of greater than 100 g/in as measured according to the Tensile Test Method. 
     
     
         15 . The low basis weight nonwoven web according to  claim 14  wherein the low basis weight nonwoven web exhibits a total dry tensile of greater than 150 g/in as measured according to the Tensile Test Method. 
     
     
         16 . The low basis weight nonwoven web according to  claim 15  wherein the low basis weight nonwoven web exhibits a total dry tensile strength of greater than 200 g/in as measured according to the Tensile Test Method. 
     
     
         17 . The low basis weight nonwoven web according to  claim 16  wherein the low basis weight nonwoven web exhibits a total dry tensile of greater than 300 g/in as measured according to the Tensile Test Method. 
     
     
         18 . The low basis weight nonwoven web according to  claim 17  wherein the low basis weight nonwoven web exhibits a total dry tensile of greater than 400 g/in as measured according to the Tensile Test Method. 
     
     
         19 . The low basis weight nonwoven web according to  claim 1  wherein the low basis weight nonwoven web exhibits a total dry tensile of less than 2000 g/in as measured according to the Tensile Test Method. 
     
     
         20 . The low basis weight nonwoven web according to  claim 19  wherein the low basis weight nonwoven web exhibits a total dry tensile of less than 1500 g/in as measured according to the Tensile Test Method. 
     
     
         21 . A method for making a low basis weight nonwoven web, the method comprising the steps of:
 a. providing a hydroxyl polymer composition;   b. spinning the hydroxyl polymer composition to form a plurality of hydroxyl polymer fibrous elements;   c. collecting the plurality of hydroxyl polymer fibrous elements on a collection device such that a low basis weight nonwoven web that exhibits a basis weight of less than 5 gsm is formed.   
     
     
         22 . The method according to  claim 21  wherein the method further comprises the step of winding the low basis weight nonwoven web convolutely about itself such that a roll of low basis weight nonwoven web is formed.