CONSUMER PRODUCT COMPONENT

Abstract

A fabric comprising a plurality of textile fibres, wherein said plurality of fibres comprises fibres that have been selected from two groups of fibres. The first group of fibres comprises multiple fibres having a first average length, and the second group of fibres comprises multiple fibres having a second average length, the first average length being shorter than the second average length. Further, the fibres of the first group have a first length variance being greater than a second length variance of the fibres of the second group. Thereby, the elongation properties of the fabric is changed in respect of the cross direction of the fabric, whilst maintaining almost unchanged strength in the longitudinal direction at a low basis weight. The elongation properties include a controlled reduction in the cross-directional tensile strength and a corresponding increase in cross-directional elongation, whilst still providing enough cover and longitudinal direction strength for the material to be made and formed in industrial processes. Thus, the extension profile may be said to be engineered when using fibres of different average lengths in a fabric as disclosed. Further, the possibility of controlling the average lengths of fibres through the right selection of groups of fibres provides a possibility of engineering the strength in detail. More specifically, according to the present invention, a weakness is engineered in the cross direction, whereby the maximum elongation length in said cross direction is increased compared to a conventional and comparable fabric not comprising groups of fibres selected according to the invention.

Claims

1. A non-woven fabric comprising a plurality of textile fibres, said plurality of fibres comprising fibres that have been selected from two groups of fibres comprising: a first group of fibres (F) comprising multiple fibres having a first average length (A1), and a second group of fibres (X) comprising multiple fibres having a second average length (A2), wherein said first average length (A1) is shorter than said second average length (A2), wherein the fibres of said fabric are oriented primarily in the same direction, characterised in that the fibres of the first group of fibres (F) have a first length variance (V1) being greater than a second length variance (V2) of the fibres of the second group of fibres (X), and that said average length (A2) of the fibers of said second group of fibres (X) is above 30 mm.

2. A fabric according to claim 1, wherein the first group of fibres comprises a blend of polyester (PES) fibres and polypropylene (PP) fibres.

3. A fabric according to claim 2, wherein the ratio between PES fibres and PP fibres in the first group of fibres is between 1:0 and 0:1.

4. A fabric according to claim 1, wherein the first group of fibres constitutes 50% of the fabric.

5. A fabric according to claim 1, wherein the second group of fibres comprises 50% polyethylene terephthalate (PET) fibres and 50% polypropylene (PP) fibres.

6. A fabric according to claim 1, wherein the fibres of the first group of fibres have an average length of 28.5 mm and a length variance of 9.5 mm.

7. A fabric according to claim 1, wherein the fibres of the second group of fibres have an average length of 39 mm and a length variance below 5 mm.

8. (canceled)

9. A fabric according to claim 1, wherein the plurality of fibres is chosen among polyester (PES) fibres, polyethylene terephthalate (PET) fibres, and polypropylene (PP) fibres.

10. A fabric according to claim 9, wherein the PP fibres constitute at least 50% of said fabric.

11. A fabric according to claim 1, wherein the density of the fibres used within the fabric is between 1.3 dtex and 1.7 dtex.

12. A fabric according to claim 1, wherein the basis weight of said fabric is between 15 gsm and 35 gsm, or between 20 gsm and 30 gsm.

13. A fabric according to claim 1, wherein said fabric is made using hydroentanglement.

14. A fabric according to claim 1, wherein said fabric is provided with a flexible element.

15. A method of making a non-woven fabric comprising a plurality of textile fibres, said method comprising: selecting fibres from two groups of fibres comprising: a first group of fibres (F) comprising multiple fibres having a first average length (A1) and a first length variance (V1), and a second group of fibres (X) comprising multiple fibres having a second average length (A2) and a second length variance (V2), where the first average length (A1) is shorter than said second average length (A2), and combining said fibres by hydroentanglement, characterised in that the first length variance (V1) is greater than said second length variance (V2), and that said second average length (A2) of the fibres of said second group of fibres (X) is above 30 mm.

Description

SHORT LIST OF THE DRAWINGS

[0046] In the following, example embodiments are described according to the invention, where

[0047] FIG. 1 illustrates a diaper comprising a fabric according to the invention.

[0048] FIG. 2 illustrates the selection process of selecting fibres constituting a fabric according to the invention.

[0049] FIG. 3 illustrates a fabric according to the invention.

[0050] FIG. 4 illustrates the process of making a fabric according to the invention.

[0051] FIG. 5 illustrates a first and a second normal distribution related to the invention.

DETAILED DESCRIPTION OF DRAWINGS

[0052] In the following the invention is described in detail through embodiments thereof that should not be thought of as limiting to the scope of the invention.

[0053] FIG. 1 illustrates a conceptual diaper 10 comprising a fabric 100 according to the invention. The diaper 10 comprises a front 11, a back 12, and an intermediate section 13, said intermediate section 13 comprising an absorbing pad 14. The back 12 comprises a set of ears 15, said ears 15 further comprising a first attachment means 16. Said first attachment means 16 is for engaging with a second attachment means 17 arranged on the front 11. Preferably, the attachment means 16,17 are hook-and-loop fasteners, i.e. the first attachment means 16 may be a plurality of hooks, and the second attachment means 17 may be a plurality of loops. Alternatively, the plurality of loops is omitted since a fabric as disclosed inherently comprises suitable loops for engaging with the hooks in the first attachment means 16. The fabric 100 is at least embodied in the ears 15, but may be embodied in the entire diaper 10. Further, at least the ears 15 are equipped with a stretch engine (not shown) for providing a stretch and recovery effect of the ears 15. When putting on the diaper 10, the first attachment means 16 engages with the second attachment means 17, such that a closure around the waist of the wearer is provided. The presence of the fabric 100 according to the invention in the ears 15 provides an enhanced flexibility in combination with the stretch engine since said fabric 100 comprises advantageous elongation properties in the cross direction, and said stretch engine contributes to a recovery effect. Said cross direction of the fabric 100 is arranged such that the advantageous elongation properties are parallel to the waist of the diaper 10 and the wearer. The advantageous elongation properties are mainly an ability to elongate a greater distance in the cross direction without tearing compared to the longitudinal direction in the same fabric or in a comparable fabric without engineered elongation properties.

[0054] FIG. 2a illustrates the selection process when making a fabric 100 according to the invention. The selection S in the present embodiment comprises a first group of fibres F and a second group of fibres X, said second group X comprising a plurality of a first fibre 131 (solid) and a plurality of a second fibre 132 (dashed). Said first group F comprises a plurality of polyester (PES) fibres 111 (solid) and a plurality of polypropylene (PP) fibres 112 (dashed). The ratio of PES fibres 111 to PP fibres 112 may be 1:1, i.e. the first group F comprises 50% PES fibres 111 and 50% PP fibres 112. However, the ratio between PES fibres 111 and PP fibres 112 may vary from 1:0 and 0:1 according to the invention. It should be noted how the depicted PES fibres 111 and PP fibres 112 within the first group F are shorter than the depicted first 131 and second fibres 132 within the second group X. Thereby, the depicted selection S is in accordance with the invention. The group X may be seen as a blend of multiple different fibres. Nevertheless, the average length of the fibres within the second group X should be longer than the average length of fibres within the first group F. Further, the length variance of the fibres within the second group X should be smaller than the length variance of the fibres within the first group F according to an embodiment of the invention.

[0055] FIG. 2b illustrates a conceptual depiction of the average lengths and length variances of fibres within the selection S. A first average length Al relates to the average length of fibres within the first group F, whereas a second average length A2 relates to the average length of fibres within the second group X. Likewise, a first length variance V1 relates to the length variance of the fibres within the first group F, whereas a second length variance V2 relates to the length variance of the fibres within the second group X. As shown, the first average length Al is shorter than the second average length A2 (i.e. A1<A2). Likewise, it is shown how the first length variance V1 is greater than the second length variance V2 (i.e. V1>V2). The maximum length of a given fibre within the first group F may be equal to or less than the second average length A2 of fibres within the second group X.

[0056] FIG. 3 illustrates a fabric 100 according to the invention. A longitudinal direction L and a cross direction C have been indicated. A first zoom Z illustrates microscopic details of the fabric 100. More specifically, the first zoom Z illustrates a plurality of fibres, said plurality of fibres constituting the selection S of fibres according to the invention. For details regarding the constituents of said selection S, see FIG. 2 and the corresponding description. It should be noted how a majority of the plurality of fibres in the selection S are arranged in parallel to the longitudinal direction L. Said longitudinal direction L is also known as the machine direction. When laying a fibrous web of fibres to be bonded in a fabric 100 as disclosed, said fibres are likely to be arranged in said longitudinal direction L. The arrangement of fibres causes the fabric 100 to have a higher tensile strength in the longitudinal direction L than in the cross direction C. Further, the arrangement of the fibres effect the elongation properties of the fabric. The presence of a selection S according to the invention provides the ability to engineer the elongation properties in both the longitudinal direction L and in the cross direction C through the fibres comprising different average lengths and variances. Further, the fabrication technique arranging the fibres primarily in the longitudinal direction provides a second possibility of engineering the elongation properties. The fibres, or at least a part of the fibres, constituting the selection S may be textured or crimped.

[0057] In an embodiment, at least one side of the fabric 100 is provided with a stretch engine 200. Preferably, said stretch engine 200 is a stretch-film laminated onto a surface of the fabric 100 through glue, heat application, or similar methods for bonding the materials. However, the stretch engine 200 may likewise be an adhesive prodiving similar stretch and recovery properties. The stretch engine 200 is capable of a reversible extension when exposed to opposite-directed external forces, i.e. said stretch engine inherently comprises a recovery effect. When the stretch engine 200 is combined with the fabric 100, said recovery effect ensures that said fabric 100 may return from an elongated state to its relaxed state when no opposite-directed external forces are applied.

[0058] A first set of arrows 1a, 1b indicates a first pull in the cross direction C. Said first pull may be said to be opposite-directed external forces, i.e. the pull aims to extend the fabric 100 in the cross direction C. Likewise, a second set of arrows 2a, 2b indicates a second pull in the longitudinal direction L. The combination of fibres within the selection S according to the invention gives the fabric 100 engineered elongation properties, including an altered stress/strain curve, compared to a selection without a selection and combination of fibres as disclosed. Further, said engineered elongation properties include a reduced tensile strength and a greater maximum elongation length which is desired in the intended use of the fabric although other uses are foreseen. Further, the selection S causes the longitudinal tensile strength to be reduced compared to a selection without a selection and combination of fibres as disclosed. The increased maximum elongation length compared to a conventional and comparable fabric may be desired when a highly flexible and stretchable fabric is needed, such as in use in diapers.

[0059] FIG. 4 illustrates the process of making a fabric 100 according to the invention. FIG. 4a illustrates a side view of the process, whereas FIG. 4b illustrates a top view of the embodiment shown in FIG. 4a. A card 20 is provided with a selection S of fibres according to the invention. Said selection S comprises a first group F and a second group X of fibres. Said second group X may comprise multiple fibres made of different materials or having different average lengths and length variances. However, according to the invention, the first group F comprises a plurality of fibres having an average length being shorter than the average length of the fibres within the second group X. Further, said fibres within the first group F may have a length variance being greater than the length variance of the fibres within the second group X. The card 20 lays a fibrous web 21 comprising the fibres within the selection S on a conveyor belt 22, said conveyor belt 22 moving the fibrous web 21 into a hydroentanglement station 31. The direction of the conveyor belt 22 is indicated by the arrow 29. The hydroentanglement station 31 applies a plurality of water jets 32 onto the fibrous web 21, whereby the fibres within said fibrous web 21 are bonded/entangled. The end product of the process is a fabric 100 according to the invention which is bonded using hydroentanglement. Further processing may include providing the fabric 100 with a stretch engine or shaping of the fabric 100 into a desired product. Said shaping procedure may include the use of sonic bonding.

[0060] It should be understood, that the above-disclosed process of making a fabric according to the invention is not limiting to the scope of the invention. For example, multiple cards may be used each providing different groups of fibres, just as other aspects may vary in production.

[0061] FIG. 5 illustrates a first N1 and a second N2 normal distribution of the lengths related to the first group of fibres and the second group of fibres, respectively. The first standard deviation D1 and the second standard deviation D2 are indicated as well, the first standard deviation D1 relating to the first group of fibres, and the second standard deviation D2 relating to the second group of fibres. From the size of the standard deviations, it is seen how the first group of fibres (resembled by the first normal distribution N1) has a greater variance than the fibres of the second group of fibres (resembled by the second normal distribution N2) according to an embodiment of the invention. The skilled person is aware that the standard deviation is related to the variance through the standard deviation being the square root of the variance. In an embodiment, at least the first normal distribution N1 is skewed, and especially the first normal distribution N1 may be negatively (left) skewed.

[0062] Further, it is noticed how the mean M2 of the second normal distribution N1 is lower (see orientation of axis K, said axis denoting the length of fibres within the first and second group of fibres) than the mean M1 of the first normal distribution N1 according to a preferred embodiment of the invention. The nomination of mean instead of average length as used above is used in accordance with common nomenclature in statistics.

[0063] The separation of the first N1 and second N2 normal distributions may be described through the size of the first standard deviation D1. In an embodiment of the invention, the separation of the two normal distributions may be at least two standard deviations, where said at least two standard deviations are measured using the second standard deviation D2. This minimum separation is indicated using the juxtaposed set of arrows D2, each of said arrows being equal in size to the second standard deviation D2.

REFERENCE NUMBERS

[0064] A1 First average length

[0065] A2 Second average length

[0066] C Cross direction

[0067] D1 First standard deviation

[0068] D2 Second standard deviation

[0069] D2 Minimum separation

[0070] F First group of fibres

[0071] K Axis

[0072] L Longitudinal direction

[0073] M1 Mean of the first normal distribution N1

[0074] M2 Mean of the second normal distribution N2

[0075] N1 First normal distribution

[0076] N2 Second normal distribution

[0077] S Selection

[0078] V1 First length variance

[0079] V1 Second length variance

[0080] X Second group of fibres

[0081] Z Zoom

[0082] 1a First pull

[0083] 1b First pull

[0084] 2a Second pull

[0085] 2b Second pull

[0086] 10 Diaper

[0087] 11 Front

[0088] 12 Back

[0089] 13 Intermediate section

[0090] 14 Absorbing pad

[0091] 15 Ears

[0092] 16 First attachment means

[0093] 17 Second attachment means

[0094] 20 Card

[0095] 21 Fibrous web

[0096] 22 Conveyor belt

[0097] 29 Moving direction of conveyor belt 22

[0098] 31 Hydroentanglement station

[0099] 32 Water jets

[0100] 100 Fabric

[0101] 111 PES fibres

[0102] 112 PP fibres

[0103] 131 First fibres

[0104] 132 Second fibres

[0105] 200 Stretch engine