ENHANCED CO-FORMED MELTBLOWN FIBROUS WEB STRUCTURE AND METHOD FOR MANUFACTURING

摘要

An enhanced, co-formed fibrous web structure is disclosed. The web structure may have a co-formed core layer sandwiched between two scrim layers. The core layer may be formed of a blend of cellulose pulp fibers and melt spun filaments. The scrim layers may be formed of melt spun filaments. Filaments of one or both of the scrim layers, and optionally the core layer, may also be meltblown filaments. The fibrous web structure may have a Consumer Preference Indication (governing allocation of melt spun filaments between core layer and scrim layers) greater than 0. Alternatively, the filaments forming the scrim layers may constitute from 1 to 13 percent of the weight of the structure. Alternatively, the scrim layers may have a combined basis weight of from 0.1 gsm to less than 3.0 gsm. A method for forming the structure, including direct formation of layers, is also disclosed.

主权项

1. A method for manufacturing a fibrous web structure, comprising the steps of:
melt spinning first polymer filaments and directing the first polymer filaments to a moving belt, thereby forming a first scrim layer of polymer filaments on the belt; downstream of the first scrim layer forming step, melt spinning second polymer filaments, blending the second polymer filaments with cellulose pulp fibers in a configuration of co-forming equipment, and directing the blend of second polymer filaments and cellulose pulp fibers at the belt and the first scrim layer to form a core layer overlying the first scrim layer; downstream of the core layer forming step, melt spinning third polymer filaments and directing the third polymer filaments at the belt and the core layer, thereby forming a second scrim layer overlying the core layer; conveying the first scrim layer, overlying core layer, and overlying second scrim layer into the nip between a pair of calender rollers, at least one of the rollers having thereon a pattern of bonding protrusions, the rollers having a source of heating energy supplied at the nip; and compressing the layers in the nip and beneath the bonding protrusions to form a pattern of thermal bonds bonding the scrim layers to and thereby complete the fibrous web structure.