CA2116954C - Process for forming liquid impermeable sheet material having a fibrous surface and products formed thereby - Google Patents

Process for forming liquid impermeable sheet material having a fibrous surface and products formed thereby Download PDF

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Publication number
CA2116954C
CA2116954C CA002116954A CA2116954A CA2116954C CA 2116954 C CA2116954 C CA 2116954C CA 002116954 A CA002116954 A CA 002116954A CA 2116954 A CA2116954 A CA 2116954A CA 2116954 C CA2116954 C CA 2116954C
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Canada
Prior art keywords
fibers
sheet
fibrous
forming
skin
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Expired - Fee Related
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CA002116954A
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French (fr)
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CA2116954A1 (en
Inventor
Robert Lewis Isaac
Bernard Cohen
Lee Kirby Jameson
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Kimberly Clark Worldwide Inc
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Kimberly Clark Worldwide Inc
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Publication of CA2116954A1 publication Critical patent/CA2116954A1/en
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Publication of CA2116954C publication Critical patent/CA2116954C/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/00987—Apparatus or processes for manufacturing non-adhesive dressings or bandages
    • A61F13/00991—Apparatus or processes for manufacturing non-adhesive dressings or bandages for treating webs, e.g. for moisturising, coating, impregnating or applying powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/006—Pressing and sintering powders, granules or fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0065—Permeability to gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0065—Permeability to gases
    • B29K2995/0067—Permeability to gases non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0068—Permeability to liquids; Adsorption
    • B29K2995/0069—Permeability to liquids; Adsorption non-permeable
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1056—Perforating lamina
    • Y10T156/1057—Subsequent to assembly of laminae
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24826—Spot bonds connect components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2139—Coating or impregnation specified as porous or permeable to a specific substance [e.g., water vapor, air, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2861—Coated or impregnated synthetic organic fiber fabric
    • Y10T442/2893—Coated or impregnated polyamide fiber fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2861—Coated or impregnated synthetic organic fiber fabric
    • Y10T442/291—Coated or impregnated polyolefin fiber fabric
    • Y10T442/2918—Polypropylene fiber fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/68—Melt-blown nonwoven fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/681—Spun-bonded nonwoven fabric

Abstract

Disclosed are a number of processes for forming a liquid-impermeable sheet having a fibrous cloth-like surface. In one embodiment the process includes the steps of: (1) forming a sheet having first and second fibrous surfaces; and subjecting the sheet to pressure and a z-gradient temperature differential sufficient to melt the fibers of the first surface and form the melt into a liquid impermeable skin without significantly altering the fibers of the second surface. In another embodiment, the process includes the steps of: (1) forming a sheet having first and second fibrous surfaces wherein, upon the sheet being subjected to a sufficient temperature, the fibers forming the first fibrous surface are adapted to substantially completely melt prior to the fibers forming the second fibrous surface significantly melting; and (2) subjecting the sheet to a sufficient pressure and temperature to melt the fibers of the first surface and form the melt into a liquid impermeable skin without significantly altering the fibers of the second surface. In some embodiments the liquid impermeable skin is subsequently apertured to make the sheet breathable. Products formed by these processes are also disclosed.

Claims (47)

1. A process for forming a liquid-impermeable, breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface;
subjecting the sheet to pressure and a z-gradient temperature differential sufficient to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface;
depositing fibers upon the skin while the skin is at least semi-molten to form a fibrous/skin/fibrous material; and aperturing the liquid impermeable, non-breathable skin to make it breathable, while the skin remains liquid-impermeable.
2. The process according to claim 1, wherein the z-gradient temperature differential is at least about 140 degrees C.
3. The process according to claim 1, wherein the z-gradient temperature differential is at least about 150 degrees C.
4. The process according to claim 1, wherein the z-gradient temperature differential is at least about 160 degrees C.
5. The process according to claim 1, wherein the apertures are microapertures.
6. A process for forming a liquid-impermeable, breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface wherein, upon the sheet being subjected to a sufficient temperature, the fibers comprising the first fibrous surface are adapted to substantially completely melt prior to the fibers comprising the second fibrous surface significantly melting; and subjecting the sheet to a sufficient pressure and temperature to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface; and aperturing the liquid impermeable, non-breathable skin to make it breathable while the skin remains liquid-impermeable.
7. The process according to claim 6, wherein the fibers forming the first surface are formed from a material having a melt flow rate which is at least 25 percent greater than the melt flow rate of the material forming the fibers of the second surface.
8. The process according to claim 6, wherein the fibers forming the first surface are formed from a material having a melt flow rate which is at least 50 percent greater than the melt flow rate of the material forming the fibers of the second surface.
9. The process according to claim 6, wherein the fibers forming the first surface are formed from a material having a melt flow rate which is at least 100 percent greater than the melt flow rate of the material forming the fibers of the second surface.
10. The process according to claim 6, wherein the fibers forming the first and second surfaces are formed from one or more materials selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes and polyetheresters.
11. The process according to any one of claims 6 to 10, wherein the fibers forming the first surface have an average diameter which is at least about 90 percent less than the average diameter of the fibers forming the second surface.
12. The process according to any one of claims 6 to 10, wherein the fibers forming the first surface have an average diameter which is at least about 75 percent less than the average diameter of the fibers forming the second surface.
13. The process according to any one of claims 6 to 10, wherein the fibers forming the first surface have an average diameter which is at least about 50 percent less than the average diameter of the fibers forming the second surface.
14. The process according to any one of claims 6 to 13, wherein the apertures are microapertures.
15. The process according to any one of claims 6 to 14, wherein the step of subjecting the sheet to pressure and temperature includes subjecting the sheet to a z-gradient temperature differential whereby the fibers comprising the first fibrous surface are subjected to a higher temperature than the fibers comprising the second fibrous surface.
16. A process for forming a liquid-impermeable, non-breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface;
subjecting the sheet to pressure and a z-gradient temperature differential sufficient to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface; and depositing fibers upon the skin while the skin is at least semi-molten to form a fibrous/skin/fibrous material.
17. The process according to claim 16, wherein the z-gradient temperature differential is at least about 140 degrees C.
18. The process according to claim 16, wherein the z-gradient temperature differential is at least about 150 degrees C.
19. The process according to claim 16, wherein the z-gradient temperature differential is at least about 160 degrees C.
20. A process for forming a liquid-impermeable, non-breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface wherein, upon the sheet being subjected to a sufficient temperature, the fibers comprising the first fibrous surface are adapted to substantially completely melt prior to the fibers comprising the second fibrous surface significantly melting; and subjecting the sheet to a sufficient pressure and temperature to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface.
21. A process for forming a liquid-impermeable, breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface;
subjecting the sheet to pressure and a z-gradient temperature differential sufficient to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface;
depositing particulates upon the skin while the skin is at least semi-molten to form a fibrous/skin/particulate material; and aperturing the liquid impermeable, non-breathable skin to make it breathable, while the skin remains liquid-impermeable.
22. The process according to claim 21, wherein the z-gradient temperature differential is at least about 140 degrees C.
23. The process according to claim 21, wherein the z-gradient temperature differential is at least about 150 degrees C.
24. The process according to claim 21, wherein the z-gradient temperature differential is at least about 160 degrees C.
25. The process according to any one of claims 21 to 24, wherein the apertures are microapertures.
26. A process for forming a liquid-impermeable, breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface wherein, upon the sheet being subjected to a sufficient temperature, the fibers comprising the first fibrous surface are adapted to substantially completely melt prior to the fibers comprising the second fibrous surface significantly melting; and subjecting the sheet to a sufficient pressure and temperature to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface;
depositing fibers upon the skin while the skin is still at least semi-molten to form a fibrous/skin/fibrous material; and aperturing the liquid impermeable, non-breathable skin to make it breathable while the skin remains liquid-impermeable.
27. A process for forming a liquid-impermeable, breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface wherein, upon the sheet being subjected to a sufficient temperature, the fibers comprising the first fibrous surface are adapted to substantially completely melt prior to the fibers comprising the second fibrous surface significantly melting;
subjecting the sheet to a sufficient pressure and temperature to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface;
depositing particulates upon the skin while the skin is still at least semi-molten to form a fibrous/skin/particulate material; and aperturing the liquid impermeable, non-breathable skin to make it breathable while the skin remains liquid-impermeable.
28. A process for forming a liquid-impermeable, non-breathable sheet having a fibrous surface, the process, comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface;
subjecting the sheet to pressure and a z-gradient temperature differential sufficient to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface; and depositing particulates upon the skin while the skin is at least semi-molten to form a fibrous/skin/particulate material.
29. The process according to claim 28, wherein the z-gradient temperature differential is at least about 140 degrees C.
30. The process according to claim 28, wherein the z-gradient temperature differential is at least about 150 degrees C.
31. The process according to claim 28, wherein the z-gradient temperature differential is at least about 160 degrees C.
32. A process for forming a liquid-impermeable, non-breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface wherein, upon the sheet being subjected to a sufficient temperature, the fibers comprising the first fibrous surface are adapted to substantially completely melt prior to the fibers comprising the second fibrous surface significantly melting;
subjecting the sheet to a sufficient pressure and temperature to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface; and depositing fibers upon the skin while the skin is still at least semi-molten to form a fibrous/skin/fibrous material.
33. A process for forming a liquid-impermeable, non-breathable sheet having a fibrous surface, the process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface wherein, upon the sheet being subjected to a sufficient temperature, the fibers comprising the first fibrous surface are adapted to substantially completely melt prior to the fibers comprising the second fibrous surface significantly melting;
subjecting the sheet to a sufficient pressure and temperature to melt the fibers of the first surface and form the melt into a liquid impermeable, non-breathable skin without significantly altering the fibers of the second surface; and depositing particulates upon the skin while the skin is still at least semi-molten to form a fibrous/skin/particulate material.
34. A liquid-impermeable, water vapor permeable sheet having a fibrous surface and a liquid-impermeable skin, the sheet obtainable by a process comprising the steps of:
forming a sheet having a first fibrous surface and a second fibrous surface;
subjecting the sheet to pressure and a z-gradient temperature differential sufficient to melt the fibers of the first surface and form the melt into a liquid-impermeable skin without significantly altering the fibers of the second surface; and aperturing the liquid-impermeable skin.
35. The product of claim 34, wherein the product has a water vapor transmission rate of at least about 500 grams per square meter per day when measured in accordance with ASTM 96-80.
36. The product of claim 34 or 35, wherein the product has a hydrohead of at least about 50 centimeters of water when measured in accordance with Federal Test Method 55-14 (standard number 191A).
37. A liquid-impermeable, water vapor permeable sheet having a fibrous surface and a liquid-impermeable skin, the sheet obtainable by a process comprising the steps of:
forming a sheet of polymeric fibers, said sheet having a first fibrous surface and a second fibrous surface wherein, upon the sheet being subjected to a sufficient temperature, the fibers comprising the first fibrous surface are adapted to substantially completely melt prior to the fibers comprising the second fibrous surface significantly melting; and subjecting the sheet to a sufficient pressure and, generally uniform, temperature to melt the fibers of the first surface and form the melt into a liquid-impermeable skin without significantly altering the fibers of the second surface; and aperturing the liquid-impermeable skin.
38. The product of claim 37, wherein the product has a water vapor transmission rate of at least about 500 grams per square meter per day when measured in accordance with ASTM 96-80.
39. The product of claim 37 or 38, wherein the product has a hydrohead of at least about 50 centimeters of water when measured in accordance with Federal Test Method 55-14 (standard number 191A).
40. A sheet comprising:
a first fibrous layer including first polymeric fibers; and a second fibrous layer including second polymeric fibers, said second fibrous layer situated adjacent to said first fibrous layer such that said first fibrous layer forms a first fibrous surface of said sheet and said second fibrous layer forms a second fibrous surface of said sheet, said first polymeric fibers and said second polymeric fibers having a disparate melt characteristic selected from the group consisting of (1) the fibers forming the first surface are formed from a material having a melt flow rate which is at least 25 per cent greater than the melt flow rate of the material forming the fibers of the second surface and (2) the fibers forming the first surface having an average diameter at least about 50 per cent less than the average diameter of the fibres forming the second surface; and wherein, upon the sheet being subjected to a sufficient, generally uniform, temperature, the fibers comprising the first fibrous surface are adapted to substantially completely melt prior to the fibers comprising the second fibrous surface significantly melting.
41. The sheet according to claim 40, wherein the fibers forming the first surface are formed from a material having a melt flow rate which is at least percent greater than the melt flow rate of the material forming the fibers to the second surface.
42. The sheet according to claim 40, wherein the fibers forming the first surface are formed from a material having a melt flow rate which is at least percent greater than the melt flow rate of the material forming the fibers of the second surface.
43. The sheet according to claim 40, wherein the fibers forming the first surface are formed from a material having a melt flow rate which is at least percent greater than the melt flow rate of the material forming the fibers of the second surface.
44. The sheet according to any one of claims 40 to 43, wherein the fibers forming the first surface are formed from at least one material selected from the group consisting of polyolefins, polyesters, polyamides, polyurethanes and polyetheresters.
45. The sheet according to any one of claims 40 to 44, wherein the fibers forming the first surface have an average diameter which is at least about 90 percent less than the average diameter of the fibers forming the second surface.
46. The sheet according to any one of claims 40 to 44, wherein the fibers forming the first surface have an average diameter which is at least about 75 percent less than the average diameter of the fibers forming the second surface.
47. The sheet according to any one of claims 40 to 44, wherein the fibers forming the first surface have an average diameter which is at least about 50 percent less than the average diameter of the fibers forming the second surface.
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