Area bonded nonwoven fabric from single polymer system
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United States of America Patent
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Jun 18, 2013
Grant Date -
Sep 22, 2011
app pub date -
Jun 1, 2011
filing date -
Aug 17, 2007
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Abstract
A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.
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