Article with nonwoven web component formed with loft-enhancing calendar bond shapes and patterns

摘要

An article having as a component a section of nonwoven web formed predominately of polymeric fibers is disclosed. The section of nonwoven web may have a pattern of consolidating bonds impressed on the surface. The bonds may have at least one bond shape; and the bond shape may have a perimeter with a greatest measurable length and greatest measurable width. The perimeter may have a convex portion and an aspect ratio of length/width of at least 2.5. Other features may be imparted relating to the density and orientations of the bonds relative machine and cross directions of the web. The bond shape reflects the shape of a corresponding bonding protrusion on a bonding roller. It is believed that the shape, density and/or orientation of the bonding protrusions affect air flow through the bonding nip in a way that may be utilized to enhance loft of the resulting bonded nonwoven web.

主权项

1. An article of manufacture having as a component a section of a nonwoven web having a macroscopic surface approximating a plane, a machine direction and a cross direction perpendicular to the machine direction, the nonwoven web formed predominately of polymeric fibers and comprising a series of one or more consolidating thermal bonds impressed on the surface, the one or more consolidating thermal bonds having at least one bond shape; wherein the series is repeated to form a pattern of consolidating thermal bonds; wherein the series is repeated in at least four rows extending predominately in the cross direction, and the series is repeated in at least four columns extending predominately in the machine direction; and wherein the bond shape has a perimeter with a greatest measurable length and a greatest measurable width, and the perimeter:
has a convex portion; has an aspect ratio of the greatest measurable length to the greatest measurable width of at least 2.5; and is oriented such that a line intersecting the perimeter along which the greatest measurable length exists intersects an axis lying on the surface along the machine direction to form a smaller angle of between 1 degree and 20 degrees; and the pattern has a nip airflow restriction ratio of 0.40 or less; the pattern has a pattern angle greater than 0 and less than or equal to 4 degrees; and the pattern reflects a bonding area percentage of from 4.0% to 18.0%.