BACKGROUND OF THE DISCLOSURE

[0001] Fibers forming nonwoven webs are generally oriented in the x-y plane of the web, resulting in a nonwoven web material that is relatively thin, and lacking in loft or thickness. Loft or thickness in a nonwoven web suitable for use in personal care absorbent articles promotes comfort (softness) to the user, surge management and fluid distribution to adjacent layers. In order to impart loft or thickness to a nonwoven web, it is generally desirable that at least a portion of the fibers forming the web be oriented in the z-direction. Conventionally, lofty nonwoven webs are produced using staple fibers that can be entangled or rely on pre-forming processes such as fiber crimp formed on a flat wire or drum, and postforming processes such as creping or pleating of the formed web.

[0002] For instance, in one method utilized to increase the bulk or loft of nonwoven webs for improved fluid management performance or for enhanced "cloth-like" feel of the webs, the filaments or fibers are often crimped. Multicomponent filaments may be either mechanically crimped or, if the appropriate polymers are used, naturally crimped. Difficulties have been experienced in the past, however, in producing filaments that will crimp naturally to the extent required for the particular application. Also, it has been found to be very difficult to produce naturally crimped fine filaments, such as filaments having a linear density of less than two denier. Specifically, the draw force used to produce fine filaments usually prevents or removes any meaningful latent crimp attributes that may be contained in the filaments.

[0003] Furthermore, lofty nonwoven materials with desirable combinations of physical properties, especially combinations of softness, strength, and absorbency, have been produced, but limitations have been encountered. For example, for some applications, polymeric materials such as polypropylene may have a desirable level of strength but not a desirable level of softness. On the other hand, materials such as polyethylene may, in some cases, have a desirable level of softness but not a desirable level of strength.

[0004] In an effort to produce nonwoven materials having desirable combinations of physical properties, spunbond nonwoven polymeric fabrics made from multicomponent or bicomponent filaments and fibers have been developed. Typically, one component exhibits different properties than the other so that the filaments exhibit properties of the two components. For example, one component may be polypropylene which is relatively strong and the other component may be polyethylene which is relatively soft. The end result is a strong yet soft nonwoven fabric. However, use of different polymers in the multicomponent filaments can make recycling the multicomponent filaments and webs made therefrom impractical or impossible if one of the polymers is not recyclable, as it would be difficult to separate the polymers to extract the recyclable one.

[0005] In addition, such bicomponent fibers require the use of through-air bonding, or the like, in order to maintain the fibers into a nonwoven structure. Namely, due to the use of more than one component, more strong and resistant methods, such as point bonding, cannot be utilized, as it would result in melting of the fibers utilized to improve the softness of the bicomponent fiber.

[0006] As such, it would be a benefit to provide a nonwoven web formed from a fiber having enhanced inherent crimp properties without the need for the use of separate crimping treatments (e.g . , mechanical crimping). It would also be a benefit to provide a nonwoven web formed from an inherently crimped fiber that can be easily recycled. It would yet another benefit to provide a nonwoven web formed from a crimped fibers that have undergone point bonding. In addition, it would be a benefit to provide a nonwoven web that can be recycled without sacrificing one or more of loft, softness, strength, and absorbency.

SUMMARY OF THE DISCLOSURE

[0007] The present disclosure is generally directed to a nonwoven web that contains a multicomponent fiber. The multicomponent fiber includes a first polymer containing component and a second polymer containing component, where the second polymer containing component includes a rapid crystallization additive, and has a solidification and/or crystallization rate that is at least about 10% or more than a solidification and/or crystallization rate of the first polymer containing component, and where the first polymer component and/or the second polymer component comprises one or more polymers having a melting temperature of at least about 130°C or greater, such as 135°C or greater, such as 140°C or greater, such as 145°C or greater, such as 150°C or greater. Moreover, the nonwoven web exhibits a TS7 softness value of about 6 or less, measured as an output of an EMTEC Tissue Softness Analyzer (“TSA”).

[0008] In one aspect, the nonwoven web has a thickness of about 0.5 mm or greater. Additionally or alternatively, in an aspect, the nonwoven web has a thickness normalized for basis weight of about 0.015 mm per gsm (gram per square meter) or greater. In yet another aspect, the nonwoven web has a density of about 76 kg/m ³ or less, and/or has a TSA stiffness of about 3.25 mm/N or less. In one aspect, the nonwoven web exhibits a tensile peak load of about 4.5 Ibf or greater.

[0009] Furthermore, in an aspect, at least one of the first polymer containing component and the second polymer containing component includes greater than about 90% polypropylene by weight, based upon the weight of the respective component. In another aspect, the multicomponent fiber includes greater than about 70% polypropylene by weight, based upon the weight of the fiber. In one aspect, the multicomponent fibers includes greater than about 90 wt.% polypropylene, based upon a total weight of polymers present in the fiber.

[0010] Additionally or alternatively, in an aspect, the rapid crystallization additive is present in the second polymer containing component in an amount of about 5 wt.% to about 50 wt.%, preferably about 20 wt.% to about 30 wt.% based on the weight of the second polymer containing component. In a further aspect, the multicomponent fiber includes an average of at least about 8 crimps per cm and has a denier of about 5 or less. Moreover, in one aspect, the rapid crystallization additive has a melt flow rate (mfr) between about 81 g/10 min and about 50 g/10 min as measured at a temperature of 230 °C and a load of 2.16 kg as determined in accordance with ASTM D1238. In yet a further aspect, the rapid crystallization additive is a polypropylene polymer, preferably, in one aspect, wherein a polypropylene homopolymer.

[0011] In yet another aspect, at least one of the first polymer containing component and second polymer containing component includes 50 wt.% or more, preferably, in one aspect, from about 90 wt.% to about 100 wt.%, based upon a total weight of polymer in the respective polymer containing component, of a polymer having a melting temperature of about 130°C or more, preferably, in one aspect, wherein at least one of the first polymer containing component and second polymer containing component is generally free of polyethylene polymers or copolymers. In one aspect, the polymer can have a melting point of about 135°C or greater, such as about 140°C or greater, such as about 145°C or greater, such as about 150°C or greater.

[0012] The present disclosure is also generally directed to an absorbent article including the nonwoven web according to any one or more of the above aspects.

[0013] The present disclosure is also generally directed to a method for forming a nonwoven web that includes: spinning a fiber having at least a first polymer containing component and a second polymer containing component, wherein the second polymer containing component contains a rapid crystallization additive, and has a solidification and/or crystallization rate that is at least about 10% or more than a solidification and/or crystallization rate of the first polymer containing component; drawing the fibers; depositing the fibers onto a forming surface; and subjecting the fibers to a high temperature bonding treatment of about 130°C or more.

[0014] In one aspect, at least one of the first polymer containing component and the second polymer containing component includes greater than about 90% polypropylene by weight, based upon the weight of the respective component Additionally or alternatively, in an aspect, the fibers include greater than about 70% polypropylene by weight, based upon the weight of the fiber. In yet a further aspect, the fibers include greater than about 90 wt.% polypropylene, based upon a total weight of polymers present in the fiber. [0015] Additionally or alternatively, the multicomponent filaments are continuous or discontinuous. In yet a further aspect, the fibers include an average of at least about two crimps per cm without heat treatment. Moreover, in one aspect, the high temperature bonding treatment is thermal point bonding, and/or wherein the nonwoven web has a total bond area of less about 30% or less.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

[0017] FIG. 1 is a schematic drawing of a process line for making an embodiment of the present invention;

[0018] FIG. 2A is a schematic drawing illustrating the cross section of a filament made according to an embodiment of the present invention with the polymer components A and B in a side-by-side arrangement;

[0019] FIG. 2B is a schematic drawing illustrating the cross section of a filament made according to an embodiment of the present invention with the polymer components A and B in an eccentric sheath/core arrangement;

[0020] FIG. 3A is a top-down SEM photograph of Sample 1 of the examples of the present disclosure;

[0021] FIG. 3B is a top-down SEM photograph of Control 1 of the examples of the present disclosure;

[0022] FIG. 3C is a top-down SEM photograph of Control 2 of the examples of the present disclosure;

[0023] FIG. 3D is a top-down SEM photograph of Control 3 of the examples of the present disclosure;

[0024] FIG. 4A is a cross-sectional SEM photograph of Sample 1 ; and

[0025] FIG. 4B is a cross-sectional SEM photograph of Control 1 .

[0026] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.

DETAILED DESCRIPTION OF REPRESENTATIVE ASPECTS

Definitions

[0027] As used herein, the terms "about," “approximately,” or “generally,” when used to modify a value, indicates that the value can be raised or lowered by 10%, such as, such as 7.5%, 5%, such as 4%, such as 3%, such as 2%, such as 1%, and remain within the disclosed aspect. Moreover, the term "substantially free of’ when used to describe the amount of substance in a material is not to be limited to entirely or completely free of and may correspond to a lack of any appreciable or detectable amount of the recited substance in the material. Thus, e.g., a material is "substantially free of' a substance when the amount of the substance in the material is less than the precision of an industry-accepted instrument or test for measuring the amount of the substance in the material. In certain example embodiments, a material may be “substantially free of’ a substance when the amount of the substance in the material is less than 10%, less than 9%, less than 8%, less than 7%, less than 6%, less than 5%, less than 4%, less than 3%, less than 2%, less than 1%, less than 0.5%, or less than 0.1 % by weight of the material.

[0028] As used herein, the term “elastomeric” and “elastic” and refers to a material that, upon application of a stretching force, is stretchable in at least one direction (such as the CD or MD direction), and which upon release of the stretching force, contracts/returns to approximately its original dimension. For example, a stretched material may have a stretched length that is at least 50% greater than its relaxed unstretched length, and which will recover to within at least 50% of its stretched length upon release of the stretching force. A hypothetical example would be a one (1) inch sample of a material that is stretchable to at least 1 .50 inches and which, upon release of the stretching force, will recover to a length of not more than 1 .25 inches. Desirably, the material contracts or recovers at least 50%, and even more desirably, at least 80% of the stretched length.

[0029] As used herein, the term “fibers” generally refer to elongated extrudates that may be formed by passing a polymer through a forming orifice, such as a die. Unless noted otherwise, the term “fibers” includes discontinuous fibers having a definite length (e.g., stable fibers) and substantially continuous filaments. Substantially filaments may, for instance, have a length much greater than their diameter, such as a length to diameter ratio (“aspect ratio”) greater than about 15,000 to 1 , and in some cases, greater than about 50,000 to 1 .

[0030] As used herein the term “extensible” generally refers to a material that stretches or extends in the direction of an applied force (e.g., CD or MD direction) by about 50% or more, in some aspects about 75% or more, in some aspects about 100% or more, and in some aspects, about 200% or more of its relaxed length or width.

[0031] As used herein the term “nonwoven web” generally refers to a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. Examples of suitable nonwoven fabrics or webs include, but are not limited to, meltblown webs, spunbond webs, bonded carded webs, airlaid webs, coform webs, hydraulically entangled webs, and so forth. [0032] As used herein, the term “meltblown web” generally refers to a nonwoven web that is formed by a process in which a molten thermoplastic material is extruded through a plurality of fine, usually circular, die capillaries as molten fibers into converging high velocity gas (e.g ., air) streams that attenuate the fibers of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Patent No. 3,849,241 to Butin, et al., which is incorporated herein in its entirety by reference thereto for all purposes. Generally speaking, meltblown fibers may be microfibers that are substantially continuous or discontinuous, generally smaller than 10 microns in diameter, and generally tacky when deposited onto a collecting surface.

[0033] As used herein, the term “spunbond web” generally refers to a web containing small diameter substantially continuous fibers. The fibers are formed by extruding a molten thermoplastic material from a plurality of fine, usually circular, capillaries of a spinnerette with the diameter of the extruded fibers then being rapidly reduced as by, for example, eductive drawing and/or other well- known spunbonding mechanisms. The production of spunbond webs is described and illustrated, for example, in U.S. Patent Nos. 4,340,563 to Appel, et al., 3,692,618 to Dorschner, et al., 3,802,817 to Matsuki, et al., 3,338,992 to Kinney, 3,341 ,394 to Kinney, 3,502,763 to Hartman, 3,502,538 to Levy, 3,542,615 to Dobo, et al., and 5,382,400 to Pike, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers may sometimes have diameters less than about 40 microns, and are often between about 5 to about 20 microns.

[0034] As used herein, the term "coform" generally refers to composite materials comprising a mixture or stabilized matrix of thermoplastic fibers and a second non-thermoplastic material. As an example, coform materials may be made by a process in which at least one meltblown die head is arranged near a chute through which other materials are added to the web while it is forming. Such other materials may include, but are not limited to, fibrous organic materials such as woody or non- woody pulp such as cotton, rayon, recycled paper, pulp fluff and also superabsorbent particles, inorganic and/or organic absorbent materials, treated polymeric staple fibers and so forth. Some examples of such coform materials are disclosed in U.S. Patent Nos. 4,100,324 to Anderson, et al., 5,284,703 to Everhart, et al., and 5,350,624 to Georger, et al., each of which are incorporated herein in their entirety by reference thereto for all purposes.

[0035] As used herein, the term "thermal point bonding” generally refers to a process performed, for example, by passing a material between a patterned roll (e.g., calender roll) and another roll (e.g., anvil roll), which may or may not be patterned. One or both of the rolls are typically heated. [0036] As used herein, the term "ultrasonic bonding” generally refers to a process performed, for example, by passing a material between a sonic horn and a patterned roll (e.g., anvil roll). For instance, ultrasonic bonding through the use of a stationary horn and a rotating patterned anvil roll is described in U.S. Patent Nos. 3,939,033 to Grgach, et al., 3,844,869 to Rust Jr., and 4,259,399 to Hill, which are incorporated herein in their entirety by reference thereto for all purposes. Moreover, ultrasonic bonding through the use of a rotary horn with a rotating patterned anvil roll is described in U.S. Patent Nos. 5,096,532 to Neuwirth, et al., 5,110,403 to Ehlert, and 5,817,199 to Brennecke, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Of course, any other ultrasonic bonding technique may also be used in the present disclosure.

[0037] As used herein, a “mechanically crimped filament" is a filament that is crimped by activating a latent crimp contained in the filaments. For instance, in one embodiment, filaments can be mechanically crimped by subjecting the filaments to a gas, such as a heated gas, during or after being drawn or through air drying or the use of an air knife.

[0038] As used herein, “inherent crimping” means that the multicomponent filaments crimp upon solidifying and/or crystallizing without the use of any further crimping treatments, i.e. , treatments to produce or activate crimp. Namely, the multicomponent filaments of the present disclosure may generally refer to “inherently crimped fibers or filaments” that exhibit a high degree of crimp without the use of any additional or subsequent crimping treatments.

[0039] Accordingly, the present invention allows for simplified and less energy intensive processes for the production of highly crimped multicomponent filaments and nonwoven webs formed therefrom.

DETAILED DESCRIPTION

[0040] Generally speaking, the present disclosure is directed to a nonwoven web that has a unique and beneficial array of properties. Namely, the present disclosure has surprisingly found that by utilizing a rapid crystallization additive, fibers may be formed that are generally free of low melting point polymers that are often necessary for imparting softness. Thus, in addition to having a high level of inherent crimp, due at least in part to the rapid crystallization additive, the fibers can be formed from one or more polymers having a melting temperature of at least about 130°C or greater, examples of which will be discussed in greater below. The melting temperature, for instance, can be about 135°C or greater, such as about 140°C or greater, such as about 145°C or greater, such as about 150°C or greater.

[0041] Without wishing to be bound by theory, it is believed that the rapid crystallization additive imparts a crystallization gradient within the fiber, yielding a different crystallization and/or solidification rate between two or more components within the fiber such that the fiber can undergo inherent crimping. More particularly, the rapid crystallization additive can impart one of the fiber components with a faster solidifying and/or crystallizing rate than at least one of the polymeric components, yielding crimping properties similar to those achieved via mechanical crimping to the fiber, and also without the need for low melting temperature components. Furthermore, it was surprisingly found that the combination of the multicomponent fibers including one or more high melting temperature polymers and a rapid crystallization additive imparts softness properties to the fibers not normally exhibited in the absence of a low melting point component. Thus, as will be discussed in greater detail, nonwoven webs according to the present disclosure exhibit a unique blend of properties, such as softness and loft, without sacrificing abrasion resistance, and/or other properties.

[0042] For instance, as noted above, nonwoven webs according to the present disclosure have excellent loft, even at low basis weights. For instance, in one aspect, a nonwoven web according to the present disclosure has a thickness of about 0.5 millimeters (mm) or greater, such as about 0.55 mm or greater, such as about 0.6 mm or greater, such as about 0.65 mm or greater, such as about 0.7 mm or greater, up to about 1 mm or less, such as about 0 9 mm or less, such as about 0.8 mm or less, or any ranges or values therebetween.

[0043] In a further aspect, a nonwoven web according to the present disclosure has a basis weight of about 50 gsm or less, such as about 47.5 gsm or less, such as about 45 gsm or less, such as about 42.5 gsm or less, such as about 40 gsm or less, such as 37.5 gsm or less, such as greater than about 25 gsm, such as greater than about 30 gsm, or any ranges or values therebetween.

[0044] Thus, in one aspect, a nonwoven web according to the present disclosure has a thickness (loft) normalized for basis weight of about 0.015 mm/gsm (grams per square meter) or greater, such as about 0.016 mm/gsm or greater, such as about 0.017 mm/gsm or greater, such as about 0.018 mm/gsm or greater, such as about 0.019 mm/gsm or greater, such as about 0.02 mm/gsm or greater, up to about 0.03 mm/gsm or less, such as about 0.028 mm/gsm or less, such as about 0.025 mm/gsm or less, or any ranges or values therebetween.

[0045] Moreover, as should be understood from the above, a nonwoven formed according to the present disclosure may also exhibit improved loft without sacrificing strength and/or softness. Without wishing to be bound by theory, the helical crimp of the filaments creates an open web structure with substantial void portions between filaments and the filaments are bonded at points of contact. In an embodiment, the nonwoven web of the present invention has a density of about 76 kg/m ³ or less, such as about 75 kg/m ³ or less, such as about 70 kg/m ³ or less, such as about 60 kg/m ³ or less, such as about 50 kg/m ³ or less, such as about 40 kg/m ³ or less, such as about 30 kg/m ³ or less, such as about 25 kg/m ³ or less, such as about 20 kg/m ³ or less, such as about 10 kg/m ³ or less, or any ranges or values therebetween. [0046] Surprisingly, the nonwoven according to the present disclosure also exhibits excellent softness without the use of a low melting point polymer in the fiber as discussed above. For instance, in one aspect, a nonwoven web according to the present disclosure exhibits a TS7 value of about 6 or less, such as about 5.5 or less, such as about 5 or less, such as about 4.5 or less, such as about 4 or less, such as about 3.5 or less, such as about 3 or less, such as about 2.5 or less, or any ranges or values therebetween. As used herein, the terms “TS7" and “TS7 value" refer to an output of an EMTEC Tissue Softness Analyzer (“TSA”) (Emtec Electronic GmbH, Leipzig, Germany) as described in the Test Methods section. The units of the TS7 value are dB V ² rms, however, TS7 values are often referred to herein without reference to units. Furthermore, the nonwoven web according to the present disclosure also exhibits excellent stiffness. For instance, as measured utilizing TSA stiffness, the method of which is discussed below, a nonwoven according to the present disclosure can exhibit a stiffness of about 3.25 mm/N or less, such as about 3 mm/N or less, such as about 2.75 mm/N or less, such as about 2.5 mm/N or less, or any ranges or values therebetween.

[0047] An alternative measure of softness may be the cup crush softness, which will be discussed in greater detail below. In one aspect, the nonwoven according to the present disclosure can exhibit a cup crush total energy of about 7.5 N-mm or less, such as about 7 N-mm or less, such as about 6 N- mm or less, such as about 5 N-mm or less, such as about 4 N-mm or less, such as about 3 N-mm or less, or any ranges or values therebetween. Similarly, in an aspect, the nonwoven according to the present disclosure can exhibit a cup crush peak load of about 45 gf or less, such as about 40 gf or less, such as about 35 gf or less, such as about 30 gf or less, such as about 25 gf or less, or any ranges or values therebetween.

[0048] The nonwoven web according to the present disclosure may also exhibit excellent drape, such as about 4.25 cm or less, such as about 4 cm or less, such as about 3.75 cm or less, such as about 3.5 cm or less, such as about 3.25 cm or less, such as about 3 cm or less, or any ranges or values therebetween.

[0049] Moreover, in an aspect, a nonwoven web according to the present disclosure also exhibits excellent abrasion resistance. In one aspect, a nonwoven web according to the present disclosure exhibits a Martindale Abrasion rating of about 2 or more, such as about 2.5 or more, such as about 3 or more, such as about 3.5 or more such as about 4 or more, up to about 5 or less, or any ranges or values therebetween, after 25 cycles, as discussed in the test methods below.

[0050] Similarly, the nonwoven web according to the present disclosure can exhibit a tensile peak load of about 12.5 Ibf (pounds force) or less, such as about 11 Ibf or less, such as about 10 Ibf or less, such as about 9.5 Ibf or less, such as about 9 Ibf or less, or such as about 4.5 Ibf or greater, such as about 5 Ibf or greater, such as about 6 Ibf or greater, such as about 7 Ibf or greater, such as about 8 Ibf or greater, or any ranges or values therebetween. Additionally or alternatively, the nonwoven web according to the present disclosure can exhibit a Young’s modulus of about 4000 psi or less, such as about 3500 psi or less, such as about 3000 psi or less, such as about 2500 psi or less, such as about 2000 psi or less, such as about 1500 psi or less, such as about 1000 psi or less, such as about 500 psi or less, or such as about 250 psi or more, or any ranges or values therebetween.

[0051] In addition, a nonwoven web according to the present disclosure may exhibit excellent intake speeds (saline uptake), such as about 7.5 seconds or less, such as about 7.25 seconds or less, such as about 7.0 seconds or less, such as about 6.75 seconds or less, or any ranges or values therebetween, as measured according the examples below. In addition, the nonwoven web exhibit excellent rewet, or amount of flow back to the surface of the nonwoven web, such as about 1 .5 g or less, such as about 1 .25 g or less, such as about 1 g or less, or any ranges or values therebetween, as measured according to the examples below.

[0052] Similarly, in an aspect, the nonwoven web exhibits a Lister strike-through of about 15 seconds or less, such as about 13 seconds or less, such as about 12 seconds or less.

[0053] In addition, the nonwoven web according to the present disclosure can exhibit an air permeability of about 475 (ft3/ft2/min) or more, such as about 485 (ft3/ft2/min) or more, such as about 495 (ft3/ft2/min) or more, such as about 500 (ft3/ft2/min) or more, such as about 510 (ft3/ft2/min) or more, such as about 520 (ft3/ft2/min) or more, such as about 530 (ft3/ft2/min) or more, such as about 1000 (ft3/ft2/min) or less, such as about 900 (ft3/ft2/min) or less, such as about 800 (ft3/ft2/min) or less, such as about 750 (ft3/ft2/min) or less, or any ranges or values therebetween.

[0054] Nonetheless, as discussed above, the solidification and/or crystallization rate of a polymer refers to the rate at which a softened or melted polymer hardens and forms a fixed structure. The solidification and/or crystallization rate of a polymer is influenced by different parameters including the melting temperature and the rate of crystallization of the polymer. As discussed above, it is believed that the inherent crimping of the fibers is due at least in part to the differences in the shrinkage properties, i.e., differences in the rates of solidification and/or crystallization, between two or more components of a multicomponent fiber.

[0055] Namely, in one aspect, the fibers according to the present disclosure may have a side-by- side, eccentric, or sheath-core arrangement, and therefore be generally referred to as “multicomponent” e.g. having at least two distinct components formed from polymer containing compositions, where the composition forming at least one component of the fiber includes a rapid crystallization additive as discussed herein. In this manner, the differences between the solidification and/or crystallization rates of the two (or more) polymer containing components results in a fiber exhibiting an inherent crimping. [0056] Thus, in one aspect, the fibers according to the present disclosure can have an average of at least about 2 crimps per cm, such as an average of about 4 crimps per cm or more, such as an average of about 8 crimps per cm or more, such as an average of about 12 crimps per cm or more, such as an average of about 16 crimps per cm or more, such as an average of about 20 crimps per cm or more, or any ranges or values therebetween. Further, as noted above, such crimping is exhibited without mechanical intervention or further treatments.

[0057] In one aspect, such an inherent crimp may lead to improved surface properties which are discussed in greater detail in the examples below. For instance, the nonwoven web may have randomness or fiber orientation of about 0.35 or greater, such as about 0.4 or greater, such as about 0.5 or greater, such as about 0.6 or greater, such as about 0.7 or greater, or any ranges or values therebetween. The nonwoven web may also, in one aspect, have an average height of surface of greater than about 75 micrometers, such as about 77.5 micrometers or more, such as about 80 micrometers or more. In an aspect, the nonwoven web can also have a surface area of greater than about 7 micrometers, such as about 7.1 micrometers or more, such as about 7.2 micrometers or more, such as about 7.3 micrometers or more, such as about 7.4 micrometers or more, or any ranges or values therebetween. In one aspect, the nonwoven web can also have a profile height of about 325 micrometers or more, such as about 350 micrometers or more, such as about 375 micrometers or more, such as about 380 micrometers or more, such as about 390 micrometers or more, or any ranges or values therebetween.

[0058] Moreover, as noted above, it was surprisingly found that the excellent inherent crimping was exhibited in fine fibers, having lower denier than generally possible with crimped fibers. In one aspect, the fibers according to the present disclosure have denier of about 5 or less, such as bout 4.5 or less, such as about 4 or less, such as about 3.5 or less, such as about 3 or less, such as about 2.5 or less, such as about 2 or less, or, about 0.5 or greater, such as about 1 or greater, or any ranges or values therebetween.

[0059] In one aspect, the rapid crystallization additive is a polyolefin having a latent heat of fusion (AHr), which is an indicator of the degree of crystallinity, of from about 25 to about 210 Joules per gram (“J/g”), in some aspects from about 35 to about 150 J/g, in some aspects from about 50 to about 100 J/g, and in some aspects, from 60 to about 90 J/g, or any ranges or values therebetween. As will be discussed in greater detail below, while the rapid crystallization additive can have one or more of the above latent heat of fusion values, in one aspect, the rapid crystallization additive has a latent heat of fusion that is about 1 .05 times the latent heat of fusion of at least one of the polymer components of the fiber, such as about 1.1 times or greater, such as about 1.15 times or greater, such as about 1 .2 times or greater, such as about 1 .25 times or greater than a latent heat of fusion of at least one of the polymer components of the multicomponent fiber. However, it should be understood that, in one aspect, the above ratios are relative to two (or more, if present) of the polymeric fiber components, and in one aspect, the ratio is relative to all of the polymeric components of the fiber.

[0060] Furthermore, in one aspect, the rapid crystallization additive is a polyolefin having an mfr (melt flow rate) of about 1 gram per 10 minutes to about 50 grams per 10 minutes, such as from about 2.5 grams per 10 minutes to about 40 grams per 10 minutes, such as about 5 grams per ten minutes to about 30 grams per ten minutes, such as about 7.5 grams per ten minutes to about 20 grams per ten minutes, such as about 10 grams per ten minutes to about 17.5 grams per ten minutes, or any ranges or values therebetween, at a load of 2.16 kg as determined in accordance with ASTM D1238 and a density of 0.9 g/cm ³ . The latent heat ef fusion (AHt) and melting temperature may be determined using differential scanning calorimetry (“DSC”) in accordance with ASTM D-3417 as is well known to those skilled in the art.

[0061] For instance, in one aspect, the rapid crystallization additive is a polypropylene polymer, which, can, in one aspect, be a polypropylene homopolymer. An example of such a polymer may be Achieve Advanced PP3684 from ExxonMobil. Furthermore, in one aspect, the rapid crystallization additive is generally free of phthalates

[0062] Nonetheless, regardless of the rapid crystallization additive selected, in one aspect, the rapid crystallization additive is present in at least one of the one or more polymer containing components in an amount of about 50 wt.% or less, such as about 45 wt.% or less, such as about 40 wt.% or less, such as about 35. wt.% or less, such as about 30 wt.% or less, based upon the weight of the respective component, or any ranges or values therebetween. Furthermore, in an aspect, the rapid crystallization additive is present in the entire fiber forming composition in an amount of about 25 wt.% or less, such as about 20 wt.% or less, such as about 15 wt.% or less, such as about 12.5 wt.% or less, such as about 10 wt.% or less, or any ranges or values therebetween, based upon the weight of the fiber forming composition.

[0063] Regardless of the rapid crystallization additive used, fibers of the present disclosure are formed from continuous or discontinuous multicomponent polymeric filaments that include at least first and second polymer containing components. In one aspect, the fibers include a bicomponent fiber, that can be continuous, that includes a first polymer containing component A and a second polymer containing component B. As noted above, the first and second components A and B are arranged in substantially distinct zones across the cross-section of the fiber and extend continuously along the length of the fiber in a side-by-side, eccentric, or sheath-core arrangement.

[0064] In one aspect, as illustrated in FIG. 2A and 2B, a fiber having two polymer containing components can be arranged such that first and second polymer containing components A and B, for example, are arranged in either a side-by-side arrangement as shown in FIG. 2A or an eccentric sheath/core arrangement as shown in FIG. 2B so that the resulting filaments exhibit an inherent helical crimp. In such an illustration, polymer containing component A is the core of the filament and polymer containing component B is the sheath in the sheath/core arrangement However, as would be understood, a sheath/core arrangement could be achieved with B in the core and A as a sheath. Methods for extruding multicomponent polymeric fibers into such arrangements are well-known to those of ordinary skill in the art, and will be discussed in greater detail below.

[0065] Nonetheless, as noted above, in one aspect, one of the polymer containing components exhibits one or more properties resulting in a faster solidification and/or crystallization rate than the other polymer containing component(s). For instance, in one aspect, one of the two or more polymer containing components has a higher melting temperature than the other polymer containing component(s). Further, in one aspect, the rate of solidification and/or crystallization of one of the polymer containing components is about 5% faster or more than the rate of solidification and/or crystallization of the other polymer containing component(s), such as about 10% faster or more, such as at least about 15% faster or more, such as about 20% faster or more, such as about 25% faster or more, such as about 30% faster or more, such as about 40% faster or more, such as about 50% faster or more, such as about 60% faster or more, such as about 70% faster or more, such as about 80% faster or more, such as about 90% faster or more, such as about 100% faster than the rate of solidification and/or crystallization of one or more of the further polymer containing component(s).

[0066] Nonetheless, in one aspect, one or more of the polymer containing components can include any one or more of the following polymers:

[0067] Exemplary semi-crystalline polyolefins include polyethylene, polypropylene, as well as their blends and copolymers thereof. In one particular aspect, a polyethylene is employed that is a copolymer of ethylene and an a-olefin, such as a C3-C20 a-olefin or C3-C12 a-olefin. Suitable a-olefins may be linear or branched (e.g. , one or more C1-C3 alkyl branches, or an aryl group). Specific examples include 1 -butene; 3-methyl-1 -butene; 3, 3-dimethyl-1 -butene; 1 -pentene; 1 -pentene with one or more methyl, ethyl, or propyl substituents; 1-hexene with one or more methyl, ethyl, or propyl substituents; 1- heptene with one or more methyl, ethyl or propyl substituents; 1-octene with one or more methyl, ethyl or propyl substituents; 1-nonene with one or more methyl, ethyl or propyl substituents; ethyl, methyl or dimethyl-substituted 1 -decene; 1 -dodecene; and styrene. In one aspect, a-olefin comonomers are 1- butene, 1-hexene, and 1-octene. The ethylene content of such copolymers may be from about 60 mole% to about 99 mole%, in some aspects from about 80 mole% to about 98.5 mole%, and in some aspects, from about 87 mole% to about 97.5 mole%. The a-olefin content may likewise range from about 1 mole% to about 40 mole%, in some aspects from about 1 .5 mole% to about 15 mole%, and in some aspects, from about 2.5 mole% to about 13 mole%.

[0068] The density of the polyethylene may vary depending on the type of polymer employed, but generally ranges from about 0.85 g/cm ³ to about 0.96 g/cm ³ . Polyethylene "plastomers", for instance, may have a density in the range of from 0.85 g/cm ³ to 0.91 g/cm ³ . Likewise, "linear low density polyethylene" (“LLDPE") may have a density in the range of from about 0.91 g/cm ³ to about 0.94 g/cm ³ ; “low density polyethylene” (“LDPE”) may have a density in the range of from about 0.91 g/cm ³ to about 0.94 g/cm ³ ; and “high density polyethylene” (“HDPE”) may have density in the range of from 0.94 g/cm ³ to 0.96 g/cm ³ . Densities may be measured in accordance with ASTM 1505.

[0069] In one aspect, suitable polyethylene copolymers are those that are “linear" or “substantially linear.” The term “substantially linear” means that, in addition to the short chain branches attributable to comonomer incorporation, the ethylene polymer also contains long chain branches in the polymer backbone. “Long chain branching” refers to a chain length of at least 6 carbons. Each long chain branch may have the same comonomer distribution as the polymer backbone and be as long as the polymer backbone to which it is attached. Preferred substantially linear polymers are substituted with from 0.01 long chain branch per 1000 carbons to 1 long chain branch per 1000 carbons, and in some aspects, from 0.05 long chain branch per 1000 carbons to 1 long chain branch per 1000 carbons. In contrast to the term “substantially linear”, the term “linear" means that the polymer lacks measurable or demonstrable long chain branches. That is, the polymer is substituted with an average of less than 0.01 long chain branch per 1000 carbons.

[0070] Suitable plastomers for use in the present disclosure are ethylene-based copolymer plastomers available under the designation EXACT™ from ExxonMobil Chemical Company of Houston, Texas, ENGAGE™ and AFFINITY™ from Dow Chemical Company of Midland, Michigan, and olefin block copolymers available from Dow Chemical Company of Midland, Michigan under the trade designation INFUSE™, such as INFUSE™ 9807. A polyethylene that can be used in a fiber of the present disclosure is DOW™ 61800.41 . Still other suitable ethylene polymers are available from The Dow Chemical Company under the designations DOWLEX™ (LLDPE), ASPUN™ (LLDPE), and ATTANE™ (ULDPE). Other suitable ethylene polymers are described in U.S. Patent Nos. 4,937,299 to Ewen et al.; 5,218,071 to Tsutsui et al.; 5,272,236 to Lai, et al.; and 5,278,272 to Lai, et al., which are incorporated herein in their entirety by reference thereto for all purposes.

[0071] Nonetheless, it should be understood that, in one aspect, the polymer components is/are formed from one or more ethylene or propylene polymers, such as one or more generally non- elastomeric ethylene or propylene polymers. Thus, in one aspect, the non-elastomeric polyolefin may include generally inelastic polymers, such as conventional polyolefins, (e.g., polyethylene), low density polyethylene (LDPE), Ziegler-Natta catalyzed linear low density polyethylene (LLDPE), etc.), ultra low density polyethylene (ULDPE), polypropylene, polybutylene, etc.; polytetrafluoroethylene; polyesters, e.g ., polyethylene terephthalate (PET), etc.; polyvinyl acetate; polyvinyl chloride acetate; polyvinyl butyral; acrylic resins, e.g., polyacrylate, polymethylacrylate, polymethylmethacrylate, etc.; polyamides, e.g., nylon; polyvinyl chloride; polyvinylidene chloride; polystyrene; polyvinyl alcohol; polyurethanes; polylactic acid; copolymers and mixtures thereof; and so forth. For instance, one or more of the polymer compoments can include an LLDPE available from Dow Chemical Co. of Midland, Mich., such as DOWLEX™ 2517 or DOWLEX™ 2047, or a combination thereof, or Westlake Chemical Corp, of Houston, Tex. Furthermore, in one aspect, one or more of the polymer components may be other suitable ethylene polymers, such as those available from The Dow Chemical Company under the designations ASPUNTM (LLDPE) and ATTANE™ (ULDPE). available from The Dow Chemical Company under the designations DOWLEX™ (LLDPE), ASPUN™ (LLDPE), and ATTANE™ (ULDPE). [0072] Propylene polymers are also suitable for use as a semi-crystalline polyolefin. Suitable plastomeric propylene polymers may include, for instance, copolymers or terpolymers of propylene include copolymers of propylene with an a-olefin (e.g., C3-C20), such as ethylene, 1 -butene, 2-butene, the various pentene isomers, 1 -hexene, 1 -octene, 1 -nonene, 1 -decene, 1 -unidecene, 1 -dodecene, 4- methyl-1 -pentene, 4-methyl-1-hexene, 5-methyl-1 -hexene, vinylcyclohexene, styrene, etc. The comonomer content of the propylene polymer may be about 35 wt.% or less, in some aspects from about 1 wt.% to about 20 wt.%, and in some aspects, from about 2 wt.% to about 10 wt.%. Preferably, the density of the polypropylene (e.g., propylene/a-olefin copolymer) may be 0.91 grams per cubic centimeter (g/cm ³ ) or less, in some aspects, from 0.85 to 0.88 g/cm ³ , and in some aspects, from 0.85 g/cm ³ to 0.87 g/cm ³ . Suitable propylene-based copolymer plastomers are commercially available under the designations VISTAMAXX™ (e.g., 2330, 6202, and 6102), a propylene-ethylene copolymer-based plastomer from ExxonMobil Chemical Co. of Houston, Texas; FINA™ (e.g., 8573) from Atofina Chemicals of Feluy, Belgium; TAFMER™ available from Mitsui Petrochemical Industries; and VERSIFY™ available from Dow Chemical Co. of Midland, Michigan. Other examples of suitable propylene polymers are described in U.S. Patent No. 6,500,563 to Datta, et al.; 5,539,056 to Yang, et aL; and 5,596,052 to Rescon I, et al., which are incorporated herein in their entirety by reference thereto for all purposes.

[0073] However, it should be understood that, in one aspect, one or more of the polymers in one or more of the polymer containing components is formed from a propylene polymer and/or copolymer, such as, in one aspect, a polypropylene homopolymer. In one aspect, the polyolefin is a propylene homopolymer or copolymer (e.g., random or block) containing about 10 wt. % or less of co-monomers (e.g., a-olefins), and in some embodiments, about 2 wt. % or less. If desired, the propylene polymer may be syndiotactic or isotactic. The term “syndiotactic" generally refers to a tacticity in which a substantial portion, if not all, of the methyl groups alternate on opposite sides along the polymer chain. On the other hand, the term “isotactic” generally refers to a tacticity in which a substantial portion, if not all, of the methyl groups are on the same side along the polymer chain. Such polymers are typically formed using a Ziegler-Natta catalyst, either alone or in combination with a small amount of an o-olefin co-monomer. Isotactic polymers, for instance, typically have a density in the range of from 0.90 to 0.94 g/cm ³ , such as determined in accordance with ASTM 1505-10. Commercially available propylene homopolymers may include, for instance, Metocene™ MF650Y and MF650X (Basell Polyolefins); PP2252E1 , PP 3155 or PP 2252 (ExxonMobil); and M3661 PP (Total Refining and Chemicals). Other examples of suitable propylene polymers may be described in U.S. Pat. No. 6,500,563 to Datta, et al.; U.S. Pat. No. 5,539,056 to Yang, et al.; and U.S. Pat. No. 5,596,052 to Resconi, et al. Additionally or alternatively, one or more of the polymer components is formed from a propylene-based copolymer plastomers, such as a propylene-based copolymer commercially available under the designations VISTAMAXX™ (e.g., 2330, 6202, 6102, and 7050), a propylene-ethylene copolymer-based plastomer from ExxonMobil Chemical Co. of Houston, Texas; Fl NA™ (e.g., 8573) from Atofina Chemicals of Feluy, Belgium; TAFMER™ available from Mitsui Petrochemical Industries; VERSIFY™ available from Dow Chemical Co. of Midland, Michigan.

[0074] Nonetheless, as noted above, in one aspect, one or more of the polymers in one or more of the polymer containing components includes a spunbond grade polypropylene with no a-olefin comonomer, such as a polypropylene homopolymer, also referred to as a spunbond grade polypropylene. [0075] In one aspect, a polypropylene homopolymer is present in one or more of the polymer containing components in an amount of about 15 wt.% or more, such as about 20 wt.% or more, such as about 25 wt.% or more, such as about 30 wt.% or more, such as about 35 wt.% or more, such as about 40 wt.% or more, such as about 45 wt.% or more, such as about 50 wt.% or more, such as about 55 wt.% or more, based upon the weight of any one or more of the polymer containing components. Furthermore, in one aspect, a polypropylene homopolymer is present in an amount of about 50 wt.% or more, such as about 55 wt.% or more, such as about 60 wt.% or more, such as about 65 wt.% or more, such as about 70 wt.% or more, based upon the total weight of the fiber forming composition.

[0076] Furthermore, in one aspect, a polypropylene utilized in one or more of the polymer components can have a melt flow rate of about 5 to about 200 grams per 10 minutes, such as from about 15 to about 150 grams per 10 minutes, such as from about 17.5 to about 100 grams per 10 minutes, such as from about 20 grams to about 55 grams per ten minutes at 230 °C and a load of 2.16 kg as determined in accordance with ASTM D1238. [0077] Moreover, in one aspect, polypropylene co-polymers having small co-monomer amounts of ethylene may be present in one or more of the polymer containing components of the fiber forming composition. When present, the ethylene co-monomer is present in an amount of about 10 wt.% or less, such as about 7.5 wt.% or less, such as about 5 wt.% or less, such as about 2.5 wt.% or less, such as about 1 wt.% or less, such as about 0.5 wt.% or less, such as about 0.1 wt.% or less, or, in one aspect, the propylene co-polymer may be generally free of non-polypropylene monomers, such as polyethylene co-monomers, based upon the total weight of polymers in the fiber forming composition. Alternatively, as noted above, in one aspect, the percentage of non-polypropylene polymers can refer to polymers having a melting temperature of less than 130°C, including polypropylene homopolymers or copolymers having a melting temperature of less than 130°C. Namely, as noted above, it was surprisingly found that the inclusion of a rapid crystallization additive improves the softness and crystallization of the multicomponent fiber without the use of low melting point polymers. Further, such a fiber forming composition allows the use of more temperature intensive bonding processes, such as point bonding, which will be discussed in greater detail below, allowing the nonwoven web formed from the fibers of the present disclosure to exhibit both softness and strength properties, in addition to the improved loft.

[0078] Nonetheless, as will be discussed in greater detail below, it should be understood that, in one aspect, each of the one or more of the polymer containing components may contain a two or more, such as three or more, such as four or more, such as five or more distinct polymers. However, as noted above, it should be understood that, in one aspect, regardless of the number of polymers in each polymer containing component, in one aspect, each of the polymers is from the same general polyolefin class, such as, in one aspect, each of the polymers is a polypropylene polymer containing less than 10% comonomers as discussed above. Further, regardless of the number of polymers contained in the one or more polymer containing components, the polymer(s) may be generally free of comonomers, and may therefore all be homopolymers, which, as noted above, can further improve the recyclability of the nonwovens of the present disclosure.

[0079] Any of a variety of known techniques may generally be employed to form polyolefin polymers. For instance, olefin polymers may be formed using a free radical or a coordination catalyst (e.g., Ziegler-Natta). Preferably, the olefin polymer is formed from a single-site coordination catalyst, such as a metallocene catalyst. Such a catalyst system produces ethylene copolymers in which the comonomer is randomly distributed within a molecular chain and uniformly distributed across the different molecular weight fractions. Metallocene-catalyzed polyolefins are described, for instance, in U.S. Patent. Nos. 5,571 ,619 to McAlpin et al.; 5,322,728 to Davis et al.; 5,472,775 to Obijeski et al.; 5,272,236 to Lai et al.; and 6,090,325 to Wheat, et al., which are incorporated herein in their entirety by reference thereto for all purposes. Examples of metallocene catalysts include bis(n- butylcyclopentadienyl)titanium dichloride, bis(n-butylcyclopentadienyl)zirconium dichloride, bis(cyclopentadienyl)scandium chloride, bis(indenyl)zirconium dichloride, bis(methylcyclopentadienyl)titanium dichloride, bis(methylcyclopentadienyl)zirconium dichloride, cobaltocene, cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride, isopropyl(cyclopentadienyl,-1 -flourenyl)zirconium dichloride, molybdocene dichloride, nickelocene, niobocene dichloride, ruthenocene, titanocene dichloride, zirconocene chloride hydride, zirconocene dichloride, and so forth. Polymers made using metallocene catalysts typically have a narrow molecular weight range. For instance, metallocene-catalyzed polymers may have polydispersity numbers (Mw/M _n ) of below 4, controlled short chain branching distribution, and controlled isotacticity.

[0080] Nonetheless, as noted above, in an example such as FIG. 2A and 2B, polymer containing component A includes a polypropylene polymer and polymer containing component B includes a polypropylene polymer In one aspect, the ratio of the first polymer containing component (component A) to the second polymer containing component (component B) is from about 50:50 to about 90:10 by weight, such as from about 50:50 to about 65:35, or from about 50:50 to about 75:25 by weight.

[0081] Nonetheless, as noted above, one or more of the polymer containing components also include additional ingredients in one aspect. Generally, additional ingredients are present in an amount of about 30 wt.% or less, such as about 25 wt.% or less, such as about 22.5 wt.% or less, such as about 20 wt.% or less, such as about 17.5 wt.% or less, such as about 15 wt.% or less, such as about 12.5 wt.% or less, such as about 10 wt.% or less, such as about 7.5 wt.% or less, such as about 5 wt.% or less, based upon the weight of any respective individual polymer containing component or based upon the entire weight of the fiber forming composition. Suitable additional ingredients for use in the multicomponent filaments of the present invention include softness/loft enhancers, pigments, fillers, and slip aids, for example only. Other inert additives as known in the art may be included as would be understood by one having skill in the art.

[0082] For instance, in one aspect, one or more of the polymer containing components can include one or more inorganic fillers. Thus, in one aspect, the one or more of the polymer containing components include one or more of calcium carbonate (CaCOa), various kinds of clay, silica (SO2), alumina, barium sulfate, sodium carbonate, talc, magnesium sulfate, titanium dioxide, zeolites, aluminum sulfate, cellulose-type powders, diatomaceous earth, magnesium sulfate, magnesium carbonate, barium carbonate, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder, cellulose derivative, polymer particles, chitin and chitin derivatives. In one aspect, the inorganic particles may include calcium carbonate, diatomaceous earth, or combinations thereof. [0083] In one aspect, one or more of the polymer containing components can include one or more pigment particles. In one aspect, one or more pigment particles are included in one or more of the polymer containing components in an amount of about 0.1 % to about 5% by weight pigment particles based upon the total weight of the component, such as about 0.5% to about 4.5%, such as about 1 % to about 4%, such as about 1 .5% to about 3.5%, or any ranges or values therebetween. Suitable pigments can include white pigments such as titanium dioxide and/or zinc dioxide. In one aspect, the pigment is a white pigment such as SCC-4837, titanium dioxide, available from the Standridge Color Corporation, Social Circle, Ga.

[0084] Suitable softness/loft enhancers include polypropylene/polyethylene copolymers, such as Vistamaxx 7050, a polypropylene/polyethylene copolymer containing 13% by weight of ethylene and having a mass flow rate of 45 g/10 min at 230 °C and a load of 2.16 kg as determined in accordance with ASTM D1238, available from ExxonMobil and Americhem 48137, a secondary fatty acid amide, available from Americhem of Cuyahoga Falls, OH.

[0085] Suitable slip aids include primary and secondary amides. In one aspect, the slip aid is a fatty acid amide, such as a suitable amide compound derived from the reaction between a fatty acid and ammonia or an amine-containing compound (e.g . , a compound containing a primary amine group or a secondary amine group) to yield a secondary amide. The fatty acid may be any suitable fatty acid, such as a saturated or unsaturated C8-C28 fatty acid or a saturated or unsaturated C12-C28 fatty acid. In certain aspects, the fatty acid may be erucic acid (i.e., cis-13-docosenoic acid), oleic acid (i.e., cis-9- octadecenoic acid), stearic acid (octadecanoic acid), behenic acid (i.e., docosanoic acid), arachic acid (i.e., arachidinic acid or eicosanoic acid), palmitic acid (i.e., hexadecanoic acid), and mixtures or combinations thereof. The amine-containing compound can be any suitable amine-containing compound, such as fatty amines (e.g., stearylamine or oleylamine), ethylenediamine, 2,2'- iminodiethanol, and 1 ,T-iminodipropan-2-ol.

[0086] In one aspect, the secondary amide may be a fatty acid amide having the structure of one of Formula (l)-(lll): wherein,

R14, R15, R , and R are independently selected from C7-C27 alkyl groups and C7-C27 alkenyl groups, and in some aspects, C11-C27 alkyl groups and C11-C27 alkenyl groups; and

R17 is selected from C8-C28 alkyl groups and C8-C28 alkenyl groups, and in some aspects, C12- C28 alkyl groups and C12-C28 alkenyl groups.

[0087] For example, the fatty acid amide may have the structure of Formula (I) where R14 is - CH2(CH ₂ )IOCH=CH(CH ₂ ) CH3 (erucamide) and R15 is -CF^CFhJisCHs, or where R15 is - CH2(CH ₂ )6CH=CH(CH2)7CH ₃ (oleamide) and R15 is -CH2(CH2)i3CH3. Likewise, in yet other aspects, the fatty acid amide may have the structure of Formula (II) where R is CH2(CH2)i5CH ₃ or - CH2(CH2)6CH=CH(CH2)7CH ₃ . The secondary amide may also contain a mixture of two or more such fatty acid amides. Nonetheless, in one aspect, such as the examples discussed below, the secondary amide additive is erucamide, oleamide, oleyl palmitamide, ethylene bis-oleamide, stearyl erucamide, or combinations thereof. Of course, it should be understood that, in one aspect, the secondary amide may be a non-fatty acid amide.

[0088] Preferably, the slip aid is present in at least one of the one or more polymer containing components in an amount between about 0.1 % and about 1 % by weight or between about 0.2% and about 0.5% based on the weight of the respective polymer containing component.

[0089] Regardless of the components selected/formed, nonwoven webs formed according to the present disclosure are particularly useful for making various products including liquid and gas filters, personal care articles and garment materials, such as, surge layers for personal care products, acoustic and thermal insulation, packing material, padding, absorbents, filtering, and cleaning materials.

Personal care articles include infant care products such as disposable baby diapers, child care products such as training pants, and adult care products such as incontinence products and feminine care products. Suitable garments include safety apparel, work wear, and the like.

[0090] Nonetheless, the present disclosure is also generally directed to a method for forming a nonwoven web as discussed above. One process for producing nonwoven webs according to the present disclosure will now be discussed in detail with reference to FIG. 1 . The following process is similar to the process described in U.S. Pat. No. 5,382,400 to Pike et al., which is incorporated herein by reference in its entirety.

[0091] Turning to FIG 1 , a process line 10 for preparing an aspect of the present disclosure is disclosed. In one aspect, the filaments described herein, for example, can be made through either a “closed” or “open” spunbond system, as described below. The process line 10 is arranged to produce bicomponent continuous fibers, but it should be understood that the present disclosure comprehends nonwoven fabrics made with multicomponent fibers having more than two components. For example, the nonwoven of the present disclosure can be made with fibers having three or four or more components as discussed above. [0092] The process line 10 includes a pair of extruders 12a and 12b for separately extruding a polymer containing component A and a polymer containing component B. Polymer containing component A is fed into the respective extruder 12a from a first hopper 14a and polymer containing component B is fed into the respective extruder 12b from a second hopper 14b. Polymer containing component A are fed from the extruders 12a and 12b through respective polymer conduits 16a and 16b to a spinneret 18. As would be understood by one having skill in the art, any polymers contained the respective polymer containing component can be dry mixed in the hopper or prior to incorporation into the hopper with any other additives. Thus, in one aspect, if the polymer containing component is the faster crystallizing component, the polymer may be dry mixed with the rapid crystallization agent, as well as any desired additives, such as slip aids, pigments, and the like, prior to extrusion.

[0093] Spinnerets for extruding multicomponent fibers are well-known to those of skill in the art and thus are not described here in detail. Nonetheless, generally, a spinneret 18 includes a housing containing a spin pack which includes a plurality of plates stacked one on top of the other with a pattern of openings arranged to create flow paths for directing polymer containing components A and B separately through the spinneret. The spinneret 18 has openings arranged in one or more rows. The spinneret openings form a downwardly extending curtain of filaments when the polymers are extruded through the spinneret. For the purposes of the present disclosure, spinneret 18 may be arranged to form side-by-side, eccentric, or sheath/core multicomponent fibers illustrated in FIGS. 2A and 2B. [0094] The process line 10 also includes a quench blower 20 positioned adjacent the curtain of fibers extending from the spinneret 18. Air from the quench air blower 20 quenches the filaments extending from the spinneret 18. The quench air can be directed from one side of the filament curtain as shown FIG. 1 , or both sides of the filament curtain.

[0095] A fiber draw unit or aspirator 22 is positioned below the spinneret 18 and receives the quenched fibers. Fiber draw units or aspirators for use in melt spinning or spunbond polymers are well- known as discussed above. Suitable fiber draw units for use in the process of the present disclosure include a linear fiber aspirator of the type shown in U S Pat. No. 3,802,817 and educative guns of the type shown in U.S. Patent Nos. 3,692,618 and 3,423,266, the disclosures of which are incorporated herein by reference.

[0096] Deposition of the fibers is aided by an under-wire vacuum supplied by a suction box 30 that pulls down the fibers onto the forming wire 26. The forming wire 26 is porous so that vertical air flow created by the suction box 30 can cause the fibers to lie down. In one aspect of the present disclosure, the flow rate of this air flow can be kept relatively low to enhance the tendency of the fibers to remain oriented in the MD direction. Alternatively, the suction box can contain sections that extend in the machine direction to disrupt the vertical air flow with at the point where the fibers are laid onto the moving web, thereby allowing the fibers to have a higher degree of orientation in the machine direction. One example of such a technique is described, for instance, in U.S. Patent No. 6,331 ,268. Of course, other techniques may also be employed to help fibers remain oriented in the machine direction. For example, deflector guide plates or other mechanical elements can be employed, such as described in U.S. Patent Nos. 5,366,793 and 7,172,398. The direction of the air stream used to attenuate the fibers as they are formed can also be used to adjusted to affect the machine direction orientation, such as described in U.S. Patent No. 6,524,521. Apart from process described above, other known techniques may also be employed to form the fibers. In one aspect, for example, the fibers may be quenched after they are formed and then directly deposited onto a forming wire without first being drawn in the manner described above. In such aspects, as described above, the flow rate of this air flow can be kept relatively low to enhance the tendency of the fibers to remain oriented in the MD direction, however, it should be understood that, in one aspect, the fibers are not oriented in primarily the MD direction. [0097] Surprisingly, the present disclosure has found that the fibers formed according to the present disclosure can have further loft and texture by utilizing a textured forming wire. Namely, the inherent crimp and high temperature properties of the fibers allow the fibers to maintain a textured surface imparted by the textured forming wire 26. Without wishing to be bound by theory, it is believe that such features may be due at least in part to the ability of the inherently crimped fibers to maintain their shape, as well as their ability to withstand high temperature bonding methods. Namely, as will be discussed, high temperature bonding methods, such as point bonding, can be carefully selected to maintain imparted texture, whereas lower temperature methods and mechanical crimp activation can remove texture from the nonwoven. Nonetheless, any texture may be imparted by utilizing a suitable forming wire 26.

[0098] In any event, the resulting fibers may then be bonded to form a consolidated, coherent nonwoven web structure. Any suitable bonding technique may generally be employed in the present disclosure, such as adhesive or autogenous bonding (e.g. , fusion and/or self-adhesion of the fibers without an applied external adhesive). Autogenous bonding, for instance, may be achieved through contact of the fibers while they are semi-molten or tacky, or simply by blending a tackifying resin and/or solvent with polymer composition used to form the fibers. Suitable autogenous bonding techniques may include ultrasonic bonding, thermal bonding, through-air bonding, and so forth. Thermal point bonding, for instance, typically employs a nip formed between two rolls, at least one of which is patterned. Ultrasonic bonding, on the other hand, typically employs a nip formed between a sonic horn and a patterned roll.

[0099] Nonetheless, as noted above, it should be understood that the fibers according to the present disclosure are particularly suited for high temperature bonding methods, such as thermal point bonding. Namely, the present disclosure has surprisingly found that the combination of rapid crystallization additive and high melt temperature polymer(s) allows a nonwoven according to the present disclosure to be thermal point bonded without melt damage to the web. Thus, in one aspect, as noted above, the nonwoven web according to the present disclosure may be subjected to a high temperature bonding process, such as thermal point bonding, such that the nonwoven web exhibits improved abrasion resistance and strength as compared to low temperature bonding applications, such as through air bonding, in addition to the beneficial properties already discussed.

[0100] Regardless, the particular nature of the bonding pattern can vary as desired. One suitable bond pattern, for instance, is known as an "S-weave” pattern and is described in U.S. Patent No.

5,964,742 to McCormack, et al. Another suitable bonding pattern is known as the “rib-knit” pattern and is described in U.S. Patent No. 5,620,779 to Levy, et al. Yet another suitable pattern is the “wire weave” pattern, which bond density of from about 200 to about 500 bond sites per square inch, and in some aspects, from about 250 to about 350 bond sites per square inch. Of course, other bond patterns may also be used, such as described in U.S. Patent Nos. 3,855,046 to Hansen et al.; 5,962,112 to Haynes et al.; 6,093,665 to Sayovitz et al.; D375,844 to Edwards, et al.; 0428,267 to Romano et al.; and 0390,708 to Brown. Furthermore, a bond pattern may also be employed that contains bond regions that are generally oriented in the machine direction and have an aspect ratio of from about 2 to about 100, in some aspects from about 4 to about 50, and in some aspects, from about 5 to about 20. The pattern of the bond regions is also generally selected so that the nonwoven web has a total bond area of less than about 50% (as determined by conventional optical microscopic methods), and in some aspects, about 30% or less, such about 25% or less, such as about 20% or less, such as about 17.5% or less, such about 15% or less, such as about 12.5% or less, such as about 10% or less, or any ranges or values therebetween, in one aspect.

[0101] Thus, as shown in Fig. 1 , the process line 10 further includes a bonding apparatus such as thermal point bonding rollers 34 (shown in phantom) or a through-air bonder 36. Thermal point bonders and through-air bonders are well-known to those skilled in the art and are not disclosed here in detail. Generally described, the through-air bonder 36 includes a perforated roller 38, which receives the web, and a hood 40 surrounding the perforated roller. Lastly, the process line 10 includes a winding roll 42 for taking up the finished fabric.

[0102] Lastly, the bonded nonwoven web is wound onto the winding roller 42 and is ready for further treatment or use. When used to make liquid absorbent articles, the fabric of the present invention may be treated with conventional surface treatments or contain conventional polymer additives to enhance the wettability of the fabric. For example, the fabric of the present invention may be treated with polyalkylene-oxide modified siloxanes and silanes such as polyalkylene-oxide modified polydimethyl-siloxane as disclosed in U.S. Pat. No. 5,057,361. Such a surface treatment enhances the wettability of the fabric.

[0103] The spunbond web may also be subjected to one or more additional post-treatment steps as is known in the art. For example, the spunbond web may be stretched in the cross-machine direction using known techniques, such as tenter frame stretching, groove roll stretching, etc. The spunbond web may also be subjected to other known processing steps, such as aperturing, heat treatments, etc. [0104] In one aspect, the spunbond web formed according to the present disclosure may form all or a part of a nonwoven facing of a composite. Of course, it should also be understood that the nonwoven facing may contain additional layers (e.g., nonwoven webs, films, strands, etc.) if so desired. For example, the facing may contain two (2) or more layers, and in some aspects, from three (3) to ten (10) layers (e.g., 3 or 5 layers). In one aspect, for instance, the nonwoven facing may contain an inner nonwoven layer (e.g., meltblown or spunbond) positioned between two outer nonwoven layers (e.g., spunbond). For example, the inner nonwoven layer may be formed from the spunbond web of the present disclosure and one or both of the outer nonwoven layers may be formed from the spunbond web of the present disclosure or a conventional nonwoven web. Alternatively, the inner nonwoven layer may be formed from the spunbond web of the present disclosure or a conventional nonwoven web and one or both of the outer nonwoven layers may be formed from the spunbond web of the present disclosure. Various techniques for forming laminates of this nature are described in U.S. Patent Nos. 4,041 ,203 to Brock et al.; 5,213,881 to Timmons, et al.; 5,464,688 to Timmons, et al.; 4,374,888 to Bornslaeger; 5,169,706 to Collier, et al.; and 4,766,029 to Brock et al. The facing may have other configurations and possess any desired number of layers, such as a spunbond-meltblown-meltblown- spunbond ("SMMS”) laminate, spunbond-meltblown (“SM”) laminate, etc.

[0105] Regardless of the method in which the spunbond nonwoven web is formed, or the number of layers in the facing, in one aspect, the nonwoven facing may be used in a laminate by laminating the nonwoven facing to an elastic film or other backing, or any other layer as discussed above. Lamination may be accomplished using a variety of techniques, such as by adhesive bonding, thermal point bonding, ultrasonic bonding, etc. The particular bond pattern is not critical to the present disclosure, and any bond pattern, aperture forming, and stretching discussed above in regards to the spunbond web may also be employed for lamination.

[0106] For instance, in one aspect, a stretch ratio of about 1.5 or more, or 2 to 6 or 2.5 to 7.0, or 3.0 to 5.5, is used to achieve the desired degree of tension in the film during lamination The stretch ratio may be determined by dividing the final length of the film by its original length. The stretch ratio may also be approximately the same as the draw ratio, which may be determined by dividing the linear speed of the film during lamination (e.g., speed of the nip rolls) by the linear speed at which the film is formed (e.g., speed of casting rolls or blown nip rolls).

[0107] Whether laminated to a backing or used alone as a nonwoven web, the spunbond web may be used in a wide variety of applications. For example, as indicated above, the spunbond web may be used in an absorbent article. An “absorbent article” generally refers to any article capable of absorbing water or other fluids. Examples of some absorbent articles include, but are not limited to, personal care absorbent articles, such as diapers, training pants, absorbent underpants, incontinence articles, feminine hygiene products (e.g., sanitary napkins, pantiliners, etc.), swim wear, baby wipes, and so forth; medical absorbent articles, such as garments, fenestration materials, underpads, bedpads, bandages, absorbent drapes, and medical wipes; food service wipers; clothing articles; and so forth, and may be uniquely situated for wearable articles due to its improved garment-like feel.

[0108] Several examples of such absorbent articles are described in U.S. Patent Nos. 5,649,916 to DiPalma, et al.; 6,110,158 to Kielpikowski; 6,663,611 to Blaney, et al. Still other suitable articles are described in U.S. Patent Application Publication No. 2004/0060112 A1 to Fell et al., as well as U.S.

Patent Nos. 4,886,512 to Damico et al.; 5,558,659 to Sherrod et al.; 6,888,044 to Fell et al.; and

6,511 ,465 to Freiburger et al. Materials and processes suitable for forming such absorbent articles are well known to those skilled in the art. Typically, absorbent articles include a substantially liquid- impermeable layer (e.g., outer cover), a liquid-permeable layer (e.g., bodyside liner, surge layer, etc.), and an absorbent core. In one particular aspect, the nonwoven according to the present disclosure may be suitable for any one or more liquid-permeably layers.

[0109] The present disclosure may be better understood with reference to the following examples.

Test Methods:

TSA

[0110] TS7 and TS750 values were measured using an EMTEC Tissue Softness Analyzer (“TSA") (Emtec Electronic GmbH, Leipzig, Germany) The TSA comprises a rotor with vertical blades which rotate on the test piece applying a defined contact pressure. Contact between the vertical blades and the test piece creates vibrations, which are sensed by a vibration sensor. The sensor then transmits a signal to a PC for processing and display. The signal is displayed as a frequency spectrum. For measurement of TS7 and TS750 values the blades are pressed against sample with a load of 100 mN and the rotational speed of the blades is 2 revolutions per second.

[0111] To measure TS7 and TS750 values two different frequency analyses are performed. The first frequency analysis is performed in the range of approximately 200 Hz to 1000 Hz, with the amplitude of the peak occurring at 750 Hz being recorded as the TS750 value. The TS750 value represents the surface smoothness of the sample. A high amplitude peak correlates to a rougher surface. A second frequency analysis is performed in the range from 1 to 10 kHZ, with the amplitude of the peak occurring at 7 kHz being recorded as the TS7 value. The TS7 value represents the softness of sample. A lower amplitude correlates to a softer sample. Both TS750 and TS7 values have the units dB V ² rms. The samples were measured in an environment having 50% relative humidity and at 22 °C. [0112] To measure the stiffness properties of the test sample, the rotor is initially loaded against the sample to a load of 100 mN. Then, the rotor is gradually loaded further until the load reaches 600 mN. As the sample is loaded the instrument records sample displacement (pm) versus load (mN) and outputs a curve over the range of 100 to 600 mN. The modulus value “E” is reported as the slope of the displacement versus loading curve for this first loading cycle, with units of mm displacement/N of loading force. After the first loading cycle from 100 to 600 mN is completed, the instrument reduces the load back to 100 mN and then increases the load again to 600 mN for a second loading cycle. The slope of the displacement versus loading curve from the second loading cycle is called the “D" modulus value.

Cup Crush Softness:

[0113] The softness of a sample may also be measured according to the “cup crush” test according to WSP Standard Test No. 402.0 (09), which evaluates softness by measuring the peak load (“cup crush load”) that is required for a straight shaped foot (15mm diameter, model 12) to crush a sample (153mm x 153 mm) into an inverted cup shape while the cup-shaped sample remains surrounded by a forming cup/cylinder (approximately 58 mm tall with a 35 mm diameter) to maintain uniform deformation. An average of 5 readings is used. The foot and cup are aligned to avoid contact between the cup walls and the foot which could affect the readings. The peak load is measured while the foot is descending at a rate of about 380 mm per minute and is measured in grams. The cup crush test also yields a value for the total energy required to crush a sample (the cup crush energy), which is the energy from the start of the test to the peak load point, i.e. the area under the curve formed by the load in grams on the one axis and the distance the foot travels in millimeters on the other. Cup crush energy is therefore reported in g*mm. Lower cup crush values indicate a softer material. One suitable device for measuring cup crush is a model FTD-G-500 load cell (500 gram range) available from the Schaevitz Company of Pennsauken, N.J.

Tensile Peak Load

[0114] The sample (3” CD x 6” MD) was held between grips having a front and back face measuring 25.4 millimeters x 76 millimeters. The grip faces were rubberized, and the longer dimension of the grip was perpendicular to the direction of pull. The grip pressure was pneumatically maintained at a pressure of 60 pounds per square inch. The tensile test was run at a 305-mi Hi meter per minute rate with a gauge length of 76 millimeters and a break sensitivity of 65%.

[0115] Five samples were tested by applying the test load along the machine-direction. The peak tensile loads from each specimen tested were arithmetically averaged to determine the MD tensile strength.

Air Permeability

[0116] Air Permeability was measured in cubic feet of air per minute passing through a 38 square cm area (circle with 7 cm diameter) using a Textest FX3300 air permeability tester manufactured by Textest Ltd., Zurich, Switzerland. All tests were conducted in a laboratory with a temperature of 23±2° C. and 50±5% relative humidity. Specifically, a nonwoven sheet is allowed to dry out and condition for at least 12 hours in the 23±2° C. and 50±5% relative humidity laboratory before testing. The nonwoven sheet is clamped in the 7 cm diameter sheet test opening and the tester is set to a pressure drop of 125 Pa. Placing folds or crimps above the fabric test opening is to be avoided if at all possible. The unit is turned on by applying clamping pressure to the sample. The air flow under the 125 Pa pressure drop is recorded after 15 seconds of airflow to achieve a steady state value.

Lister Intake:

[0117] The Lister test is used to determine the liquid strike-th rough time of a test sample of nonwoven fabric. The strike-through time is the time taken by a specified amount of liquid to be absorbed in the nonwoven fabric. One suitable test procedure is the EDANA test No. 150.9-1 (liquid strike-through time test). According to one method, a 4 inch by 4 inch (10.2 cmx10.2 cm) sample of the selected nonwoven fabric material is weighed and placed on a 4 inch by 4 inch (10.2 cmx10.2 cm) assembly of 5-ply filter paper, type ERT FF3 (available from: Hollingsworth and Vose Co., East Walpole, Mass.). The sample assembly is then placed under a Lister tester. A suitable Lister tester is available from W. Fritz Mezger Inc., Spartanburg, S.C. A strike-through plate is employed for the testing, and is positioned over the test sample and under the Lister test equipment. A 5 mL amount of 0.9% saline is delivered onto the sample assembly. The time to absorb the liquid (strike-through time) is measured automatically by the Lister testing equipment and displayed. Subsequently, a new 5-ply blotter assembly is quickly placed underneath the nonwoven sample within 20 seconds, and the 5 mL delivery of saline is repeated. In total, the 5 mL delivery of liquid is performed 5 times on the selected nonwoven sample, and each strike-through time is recorded. The sample is weighed again after the sequence of 5 tests. For a given nonwoven fabric sample, the 5-sequence test is repeated five times, and the results are averaged to provide the strike-through time of the material. Drape Coefficient Test

[0118] The Cusick drape test can be performed using any suitable drape tester to obtain a drape coefficient. Commercially available drape testers include TF118 tester marked by Testex of Dongguam, China or Model 665 drape tester marketed by James H Heal & Co of Halifax, England. The drape test can be tested in accordance with ISO Test 9073-9 (2008).

Martindale Abrasion:

[0119] This test can measure the relative resistance of a sample to abrasion according to Worldwide Strategic Partners (“WSP”) Standard Test No. 20.5 (08). A circular specimen of 165 mm±6.4 mm in diameter with an area of 18,258 sq mm is subjected to a requested number of cycles (10 or 60) with an abradant under a pressure of 9 kilopascals (kPa). The abradant is a 36 inch by 4 inch by 0.05 thick silicone rubber wheel reinforced with fiberglass having a rubber surface hardness 81A Durometer, Shore A of 81 ±9. The specimen is examined for the presence of surface fuzzing (fiber lofting), pilling (small dumps of fibers), roping, delamination or holes and assigned a numerical rating of 1 , 2, 3, 4, or 5 based on comparison to a set of standard photographs similarly numbered, with “1” showing the greatest wear and “5” the least. The test is carried out with a Martindale Wear and Abrasion Tester such as Model No. 103 or 403 from James H. Heal & Company, Ltd of West Yorkshire, England.

Surface Roughness

[0120] Topographical maps were obtained of the surface of each spunbond web sample (10 mm by 10 mm portions of each sample) utilizing a confocal microscope (Keyence VK-X160K 3D Laser Confocal Microscope using the VKViewer software supplied with the microscope by Keyence). A background plane was subtracted from each map in order to flatten each map and correct for any tilt in samples. The data analysis was performed using the Multi FileAnalyze software provided by Keyence. The corrected maps were utilized in accordance with ISO Procedure 25178 and surface roughness measurements to calculate:

Sa -Average mean height of the surface (in micrometers) Sq -Root mean square (RMS) surface height (in micrometers) Str -Surface texture ratio (expressed as a unitless value) -indicates the uniformity of the surface texture (Str. Ranges from 1 for an isotropic surface to 0 for an oriented surface (i.e. a brushed surface))

Sdr-Developed interfacial area ratio (expressed as a unitless value), which is the ratio of area of the surface to a flat plane of the same size (where Sdr= 0 indicates a completely flat surface, higher values indicate a rougher surface) Profile height analysis: Two lines were drawn across each map and the height profile of the surface along that line was extracted. The height between the lower portion of the profile and the higher portion of the profile was measured.

Area step height analysis:

The Keyence software was used to isolate the bottom 10% of each topographic map and the average height of this area calculated.

The Keyence software was used to isolate the top 10% of each topographic map and the average height of this area calculated.

The difference between these two values was calculated to indicate a "step height” between the low and high areas of each map.

Cradle Test Method:

The Cradle Test replicates real-life positioning of a garment on a wearer, and can be used to determine intake rates, flowback, and fluid distribution of a garment. This method uses a slotted cradle, as shown in Figs. 4b and of US Patent No. 6,727,404, both made up of a water-resistant material such as acrylic plastic and simulating body curvature of a wearer.

The cradle (for diapers, etc.) has an overall length of 305 mm, a side-to-side width of 350 mm in the slot direction and a height of 255 mm (including 57 mm height below the slot). Material used in the construction varies in thickness from 6 mm to 12 mm. The cradle has a 6 mm wide slot at the lowest point which runs the length of the cradle. The curvature of the cradle is formed by a 60-degree angle.

1 . Product Preparation

A. For adult care garments, cut open the three-dimensional pant style products at the sides or side seams to make the product two-dimensional.

B. Do not snip the leg and containment flap elastics.

C. Weigh the product to the nearest 0.01 gram value and record the value.

D. Measure the pad length (using a light board) to the nearest 1 mm value and record the value.

E. Measure the product length and mark the center. F. Mark the insult area at a distance forward from the center of the product to the nearest 1 mm value. Center the measurement in the cross direction. The marked distance is as follows depending on the product tested:

Diaper Size-Weight Range (lb)

Diaper Pant Size (lb)

* Training Pant

“ Youth Pant

2. Product Testing (test fluid = 0.9 w/v% saline solution)

A. Verify that the pump delivers the required test fluid amount for the insult +/-

0.5 ml. The flow rate should be set at 8 ml/second. Test fluid amount will be 50 ml for adult care products or 85 ml for baby diaper products. The hose end or nozzle should have an exit diameter of 0.125 inches.

B. For the slotted cradle, place a capture container of known weight under the cradle slot to catch the fluid overflow. Measure the weight of the capture container to the nearest 0 01 grams. Note: low capacity products without flaps (i.e. , cloth underwear, cloth training pants, vinyl/cloth training pants) will be prone to overflow.

C. Position the specimen, liner/inside side up, with the "pre-marked" center of the product lined up with and touching the lowest point in the cradle. The entire length of the outer cover/outside of the product should make contact with the cradle. Clip or otherwise attach the product to the cradle at the front and back waist edges to keep it in place. Gently pull on the fron t/back waist of the specimen to smooth out any wrinkles or creases in the product. For the cradle testing, all product codes will be insulted at a point 95 mm forward from the center of the product. D. Hold the nozzle above the target area and perpendicular to the specimen. The bottom of the nozzle should be within 5 to 10 mm from the specimen.

E. Initiate the insult and start the stopwatch when the testing fluid leaves the nozzle. As soon as the insult is complete, move the nozzle aside to observe the testing fluid.

F. Stop the stopwatch immediately when the testing fluid is not visible on the specimen surface. Record the intake time to the nearest 0.01 second. If the fluid overflows into the capture container, the intake time will be recorded when no more fluid is visible on the surface.

G. Once the insult is absorbed, immediately set the timer for 15 mins. Leave the specimen in the cradle for the entire wait time.

H. Repeat steps D through G two more times for a total of 3 insults separated by 15 minutes.

I. For Flowback testing, after final loading has completed and intake time has been recorded, start timer for 2 minutes. Flowback is the amount of unabsorbed fluid after the third insult. More specifically, it is defined as the amount of fluid that can be absorbed from an insulted specimen onto a blotter as it is subjected to a predetermined vacuum pressure for a specified amount of time.

J. At the end of the wait period, immediately transfer the specimen from the cradle to a Saturated Capacity tester as described and illustrated in US Patent No. 6,727,404, which is incorporated herein by reference. Keep the specimen cradled during the transfer and then place flat (horizontal) on the Saturated Capacity tester box with the liner/inside side up. Center the specimen on the Saturated Capacity tester. Keeping test sample flat, place either one pre-weighed 228 mm x 300 mm (plus or minus 13 mm) blotter paper or two pre-weighed 88 mm x 300 mm (plus or minus 13 mm) blotter papers onto the specimen's absorbent side. The blotter paper has a basis weight of 300 gsm - VERIGOOD Grade 88. Place the blotter paper(s) approximately 6 mm from the front edge fluff of the specimen.

K. Cover the specimen and blotter papers with a latex rubber sheet as described in US Patent No. 6,727,404 and press the start button on the vacuum control box.

L. Maintain 0.5+/- 0.04 psi on the Saturated Capacity tester for 2 minutes. After the elapsed time, lift the latex rubber sheet to release the pressure from the Saturated Capacity tester. M. Immediately remove the blotter papers, weigh to the nearest 0.01 gram, and record the value of flowback. Flowback is determined from the weight of the blotter paper(s): (wet weight-dry weight)/dry weight).

EXAMPLES

EXAMPLE 1

[0121] Nonwoven webs were made according to the present disclosure as shown in Table 1 :

Table 1

A: Polypropylene homopolymer, an example of which is available as 3155 from Exxon Mobile

B: Masterbatch of 12.5 wt% modified siloxane in polypropylene, an example of which is available from

Americhem as a mixture of Masil SF-19 and Exxon 3155

C: a Propylene-ethylene copolymer-based plastomer with 14% ethylenefrom ExxonMobil Chemical Co available as VistaMaxx 7050

D: 50 wt.% Titanium dioxide particles in a polypropylene carrier resin, an example of which is available from

Standridge Color Corporation

E: Rapid crystallization additive, Polypropylene homopolymer, an example of which is available as Achieve™

Advanced PP 3684 from Exxon Mobil

F: Polyethylene plastomer, an example of which is available as Aspun 6840A from Dow Chemicals

[0122] The nonwoven webs were formed into liners as described above, and subjected to various testing, as illustrated in Table 2:

Table 2: Table 2 (Cont.)

[0123] The nonwoven webs were also formed into liners and incorporated as a liner over a surge layer, and subjected to various testing, as illustrated in Tables 3 to 5. In addition, SEM photographs showing the crimp and irregularity of each code is illustrated in Figs. 3A to 3D.

[0124] Absorbent articles were constructed from the liner and surge layer. In Tables 3 and 4 below, the absorbent article was tested for absorbency characteristics. In each example, the absorbent article contained an 80 gsm nonwoven absorbent structure containing superabsorbent particles and included a 74 mm x 178 mm surge layer.

[0125] Table 3 displays the results of the Cradle Test as described above.

Table 3

Table 4 [0126] As illustrated by the results in Tables 2 through 4, the nonwoven webs according to the present disclosure exhibited excellent absorbency and softness, while maintaining good stiffness and abrasion.

[0127] The nonwoven web liners formed from Sample 1 and Control 1 were subjected to surface roughness testing as discussed above, the results of which are illustrated in Table 5. As shown, Sample 1 exhibited improved surface roughness across all measurements than Control 1 , which is also illustrated in the cross-sectional SEM photographs Figs. 4A and 4B (SEM photographs of the samples prior to formation into a liner).

Table 5

[0128] The samples were also subjected to micro-CT and image analysis to determine percent porosity and projection height. A Bruker SKYSCAN 1272 Micro-CT was used to x-ray scan the samples under the following conditions:

Source Voltage = 30 kV

Source Current = 133 uA

Image pixel size = 10.0 urn

Exposure = 220 ms

Rotation Step = 0.2°

Frame Averaging = ON (6)

Random Movement = ON (1)

[0129] NRECON software was used to reconstruct the x-ray images into cross-sections. DATAVIEWER software was then used to extract a minimum of five transaxial view images per code. These images were then analyzed via the image analysis algorithm ‘Z-Projection Height (Micro-CT Slices)-1 ’ to arrive at the results presented below. A minimum of 12 measurements were made per code. CTAn software was used to acquire the 3D micro-CT results. The following results were obtained: Table 6

[0130] These and other modifications and variations to the present disclosure may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the invention so further described in such appended claims.