CA2250436C - Polypropylene fibers and items made therefrom - Google Patents

Abstract

Process of producing skin-core fibers and the resulting fibers and nonwoven materials and articles are described wherein the fibers are composed of a polymer blend of a polyolefin and polymeric bond curve enhancing agents, such as ethylene vinyl acetate polymers.

Description

POLYPROPYLENE FIBERS AND ITEMS MADE THEREFROM
BACKGROUND OF THE INVENTION
_. Field cf the Invention The present invention. relates to synthetic fibers especially useful in the manufacture of nonwoven fabrics. I::
particular, the present invention. relates to fibers ira ended for such use, including processes of their production, and compositions for producing the fibers, as well as nonwoven fabrics and articles containing these fibers. More specifically, the fibers of the present invention are capable of providing soft feeling nonwoven materials that have high tensile strength. Further, the nonwoven materials are thermally bondable at lower temperatures while having superior strength properties, including cross-directional strength.
The fibers of the present invention can be incorporated into lower basis weight nonwoven materials which have strength properties that are equal to or greater than nonwoven materials of higher basis weight. Still further, the fibers of the present invention are capable of being run on high speed machines, such as high speed carding and bonding machines.

2. Background Infnrmarion The requirements of nonwoven fabrics used in applications concerned with hygiene, medical fabrics, wipes and the like continue to grow. Moreover, utility and economy, and aesthetic qualities often must be met simultaneously. The market continues to expand for polyolefin fibers and items made therefrom having enhanced properties and improved softness.
The production of polymer fibers for nonwoven materials usually involves the use of a mix of at least one polymer witr.
nominal amounts of additives, such as stabilizers, pigments, antacids and the like. The mix is melt extruded and processed into fibers and fibrous products using conventional commercial processes. Nonwoven fabrics are typically made by making G
web, and then thermally bonding the fibers together. For example, staple fibers are converted into nonwoverj fabrics using, for example, a carding machin=, and the cardeu =abrlc is thermally bonded. The thermal bonding can be achieved using various heating techniques, including heating with heated rollers, hot air and heating through the use of ultrasonic welding.

Fibers can also be produced and consolidated into nonwovens in various other manners. For example, the fibers and nonwovens can be made by spunbonded processes. Also, consolidation processes can include needlepunching, through-air thermal bonding, ultrasonic welding and hydroentangling.

Conventional thermally bonded nonwoven fabrics exhibit good loft and softness properties, but less than optimal cross-directional strength, and less than optimal cross-directional strength in combination with high elongation. The strength of the thermally bonded nonwoven fabrics depends upon the orientation of the fibers and the inherent strength of the bond points.

Over the years, improvements have been made in fibers which provide stronger bond strengths. However, further improvements are needed to provide even higher fabric strengths at lower bonding temperatures and lower fabric basis weight to permit use of these fabrics in today's high speed converting processes for hygiene products, such as diapers and other types of incontinence products. In particular, there is a need for thermally bondable fibers, and the resulting nonwoven fabrics that possess high cross-directional strength, high elongation and excellent softness, with the high cross-directional strength (and softness) being obtainable at low bonding temperatures.

Further, there is a need to produce thermally bondable fibers that can achieve superior cross-directional strength, elongation and toughness properties in combination with fabric uniformity, loftiness and softness. In particular, there is a need to obtain fibers that can produce nonwoven materials, especially, carded, calendered fabrics with cross-directional properties on the order of at least about 200 to 400 g/in., more preferably 300 to 400 g/in, preferably greater than about 400 g/in, and more preferably as high as about 650 g/in or more, at speeds as high as about 500 ft/min, preferably as high as about 700 to 800 ft/min, and even more preferably as high as about 980 ft/min (300 m/min). Further, the fabrics can have an elongation of about 50-200%, and a toughness of about 200 to 700 g/in, preferably about 480-700 g/in for nonwoven fabrics having a basis weight of from about 10 g/yd2 to 20 g/yd2. Thus, it is preferred to have these strength properties at a basis weight of about 20 g/yd2, more preferably less than about 20 g/yd2, even more preferably less than about 17 to 18 g/yd2, even more preferably less than about 15 g/ydz, and even more preferably less than about 14 g/ydz and most preferably as low as 10 g/yd2, or lower.

Commercial fabrics produced today, depending upon use, have a basis weight of, for example, about 11-25 g/yd2, preferably 15-24 g/yd2.

Softness of the nonwoven material is particularly important to the ultimate consumer. Thus, products containing softer nonwovens would be more appealing, and thereby produce greater sales of the products, such as diapers including softer layers.

Various techniques are known for producing fibers that are able to be formed into nonwoven materials having superior properties, including high cross-directional strength and softness. For example, U.S. Patent Nos. 5,281,378, 5,318,735 and 5,431,994 to Kozulla are directed to processes for preparing polypropylene containing fibers by extruding polypropylene containing material having a molecular weight distribution of at least about 5.5 to form a hot extrudate having a surface, with quenching of the hot extrudate in an oxygen-containing atmosphere being controlled so as to effect oxidative chain scission degradation of the surface. In one aspect of the process disclosed in the Kozulla patents, the quenching of the hot extrudate in an oxygen-containing atmosphere can be controlled so as to maintain the temperature of the hot extrudate above about 250C for a period of time to obtain oxidative chain scission degradation of the surface.

As disclosed in these patents, by quenching to obtain oxidative chain scission degradation of the surface, such as by delaying cooling or blocking the flow of quench gas, the resulting fiber essentially contains a plurality of zones, defined by different characteristics including differences in melt flow rate, molecular weight, melting poi~t, birefringence, c>rientation and crystallinity. In particular, as disclosed in these patents, a fiber produced therei includes an inner zone identified by a substantial lack 0L
oxidative polymeric degradation, an outer zone of a i:igh concentration of oxidative chain scission degraded polymeric material, and an intermediate zone identified by an inside-~o-outside increa~~e in the amount of oxidative chain scission polymeric degradation. In other words, the quenching of the hot extrudate in an oxygen containing atmosphere can be controlled so ws to obtain a fiber having a decreasing weight average molecular weight towards the surface of the fiber, and an increasing melt flow rate towards the surface of the fiber.
For example, a preferred fiber comprises an inner zone having a weight average molecular weight of about 100,000 to 450,000 grams/mole, an outer zone, including the surface of the fiber, having a weight average molecular weight of less than about 10,000 grams/mole, and an intermediate zone positioned between the inner zone and the outer zone having a weight average molecular weight and melt flow rate intermediate the inner zone and the outer zone. Moreover, the inner, core zone has a melting point and orientation that is higher than the outer surface zone.
Further, European Patent Application No. 0 630 996 to Takeuchi et al. is directed to obtaining fibers having a skin core morphology, including obtaining fibers having a skin-core morphology in. a short spin process. In these applications, a sufficient environment is provided to the polymeric material in the vicinity of its extrusion from a spinnerette to enable the obtaining of a skin-core structure. For example, because this environment is not achievable in a short spin process solely by using a controlled quench, such as a delayed quench utilizable in the long spin process, the environment for obtaining a ~>kin-core fiber is obtained by using apparatus and procedures which promote at least partial surface degradation of the molten filaments when extruded through the spinnerette.
In particul~~r, various elements can be associated with the soinnerette, such as to heat -the spinnerette or a place _ 5 _ associated with the spinnerette, so as to provide a sufficient temperature environment, at least at the surface of the extruded polymeric material, to achieve a skin-core fiber structure.

Still further, European Patent Application No. 0 719 879 to Kozulla is directed to the production of skin-core fibers that can be produced under various conditions while ensuring the production of thermally bondable fibers that can provide nonwoven fabrics having superior cross-directional strength, elongation and toughness.

Still further, it is known that blends of materials can be extruded to obtain fibers. For example, U.S. Patent No.

3,433,573 to Holladay et al. is directed to compositions comprising blends of 5 to 95% by weight of a propylene polymer containing a major amount of propylene, and 95 to 5o by weight of a copolymer of ethylene with a polar monomer, such as vinyl acetate, methyl methacrylate, vinylene carbonate, alkyl acrylates, vinyl halides and vinylidene halides. Compositions within the broad scope of Holladay et al. include blends containing 5 to 95% polypropylene and correspondingly, from about 5 to 95% ethylene/vinyl acetate copolymer, expressed as weight percent of the ultimate blend. The compositions of Holladay et al. may be formed into fibers, films and molded articles of improved dyeability and low temperature characteristics.

Moreover, U.S. Patent No. 4,803,117 and European Patent Application No. 0 239 080 to Daponte are directed to melt-blowing of certain copolymers of ethylene into elastomeric fibers or microfibers. The useful copolymers are disclosed to be those of ethylene with at least one vinyl monomer selected from the group including vinyl ester monomers, unsaturated aliphatic monocarboxylic acids and alkyl esters of these monocarboxylic acids, where the amount of vinyl monomer is sufficient to impart elasticity to the melt-blown fibers. Exemplary copolymers disclosed by Daponte are those of ethylene with vinyl acetate (EVA) having a melt index in the range from 32 to 500 grams per ten minutes, when measured in accordance with ASTM D-1238-86 at condition E, and including from about 10% by weight to about 50o by weight of vinyl acetate monomer, more specifically from about 18% to about 36% by weight of vinyl acetate monomer, and most specifically from about 26% to about 30o by weight of vinyl acetate monomer, with an even more specific value being about 28o by weight.

The copolymer of Daponte can be mixed with a modifying polymer, which may be an olefin selected from the group including at least one polymer selected from the group including polyethylene, polypropylene, polybutene, ethylene copolymers (generally other than those with vinyl acetate), propylene copolymers, butene copolymers or blends of two or more of these materials. The extrudable blend of Daponte usually includes from at least 10o by weight of the ethylene/vinyl copolymer and from greater than 0% by weight to about 90o by weight of the modifying polymer.

WO 94/17226 to Gessner et al. is directed to a process for producing fibers and nonwoven fabrics from immiscible polymer blends wherein the polymer blend can include polyolefins, such as polyethylene and polypropylene.

Additionally, the blend may include up to about 20% by weight of one or more additional dispersed or continuous phases comprising compatible or immiscible polymers, for example, up to about 20o by weight of an adhesive promoting additive, which amongst other materials can be polyethylene vinyl acetate) polymers.

Still further, it is known that composite fibers, e.g., having a sheath-core or side-by-side structure, can be produced with different polymers in the different components making up the composite fibers. For example, U.S. Patent Nos.

4,173,504, 4,234,655, 4323,626, 4,500,384, 4,738,895, 4,818,587 and 4,840,846 disclose heat-adhesive composite fibers such as sheath-core and side-by-side structured fibers which, amongst other features, include a core that can be composed of polypropylene and a sheath that can be composed of ethylene vinyl acetate copolymer.

Further, U.S. Patent No. 5,456,982 discloses a bicomponent fiber wherein the sheath may additionally comprise a hydrophilic polymer or copolymer, such as (ethyl vinyl acetate) copolymer.

_ 6 (a~ _.
In a broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising pol~,rpropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure; wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains f:Lattening of a bond curve of cross-directional strength vs. temperature as compared to a nonwoven material produced under same conditions from fibers produced under same conditions 1~ except for absence of the polymeric bond curve enhancing agent.
In another broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that 1S the hot extrudate forms a fiber having a skin-core structure; wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains raining of at least some points of cross-directional strength of a bond curve of cross-directional strength vs.
temperature as compared to a nonwoven material produced under same 2~ conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.
In yet another broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and polymeric bond curve 2S enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure; wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains an increase in area over a defined temperature range under a bond curve of cross-directional strength vs. temperature as 30 compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

6 (b) -In another broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and polymeric bond curve $ enhancing agent as a hot extrudate, the polymeric bond curve enhancing agent being present in an amount less than 2o% by weight of the polymer blend; and providing conditions so that the hot extrudate forms a fiber havinc7 a skin-core structure.

In still another_ broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure;
wherein the skin-core fiber urhen processed into a thermally bonded nonwoven material obtains a % 1~A1 which is greater than that of a nonwoven material produced ~.mder same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

In another broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate fozms a fiber having a skin-core structure;
wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains a % DA1 and a % ~Am which is greater than that of a nonwoven material. produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

In still another broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate farms a fiber having a skin-core structure;
wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains a s L1A1 , a % ~A", and a % ~Ap which is greater - 6 (c) than that of a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.
In yet another broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure; wherein 1~ said polymeric bond curve enhancing agent comprises a plurality of polymeric bond curve enhancing agents.
In still another broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and ethylene vinyl acetate 1$ polymer as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure.

In another broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a polymer blend comprising polypropylene and an ethylene vinyl acetate 2~ polymer as a hot extrudate into an oxidative atmosphere, said polymer blend comprising at least about 90 percent by weight polypropylene, less than 10 percent by weight ethylene vinyl acetate polymer, and said ethylene vinyl acetate polymer contains about 20 to 40 weight percent vinyl acetate units; and providing conditions of the hot 25 extrudate in the oxidative atmosphere to form a fiber having a skin-core structure, said skin-core structure comprising a skin showing a ruthenium staining enrichment of at least about 0.2 Vim.

In yet another- broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a 30 polymer blend consisting essentially of polypropylene and ethylene vinyl acetate polymer as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure.

In still anotk~uer broad aspect, the present invention relates to a process for preparing a skin-core fiber, comprising: extruding a 35 polymer blend comprising polypropylene and a polymeric bond curve -- 6 (d) enhancing agent as a hot extrudate; and controlling conditions so that the hot extrudate forms a fiber having a. skin-core structure;

wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains an increase in area over a defined temperature range under a bond curve of cross-directional strength vs. temperature as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent, and said 1~ increase in area is provided by the bond curve being shifted to lower temperatures with the area under the bond curve in the defined temperature range being increased as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing 15 a---BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and characteristics thereof are illustrated in the annexed drawings showing non-limiting embodiments of the invention, in which:
Figs. 1(a) - 1(g) illustrate cross-sectional configurations of fibers according to the present invention without showing the skin-core structure of the fibers.
Fig. 2 schematically illustrates a skin-core fiber composed of a polymer blend according to the present invention having a gradient between the outer surface zone and the core.
Fig. 3 schematically illustrates a skin-core fiber composed of a polymer blend according to the present invention having a discrete step between the outer surface zone and the core.
Fig. 4 schematically illustrates a bicomponent sheath-core fiber comprising a sheath of a polymer blend according to the present invention having a skin-core structure.
Fig. 5 illustrates bonding curves of cross-directional strength vs. bonding temperature.
Fig. 6 illustrates bonding curves of cross-directional strength vs. bonding temperature for different basis weight nonwoven materials.
Fig. 7 illustrates the pattern for the calender roll utilized in the examples of present invention.
Fig. 8 schematically illustrates a curve of cross-directional strength (CDS) of nonwoven material vs. bonding temperature.
Fig. 9 illustrates a Differential Scanning Calorimetry (DSC) endotherm.
Figs. 10, 11a, 11b, 11c, 12a, 12b, 13a and 13b illustrate spinnerettes listed in Table 8.
DISCLOSURE AND DETAILED DESCRIPTION OF INVENTION
The present invention is directed to and provides:
(a) Thermal bonding fibers for making fabrics with high cross-directional strength, elongation and toughness;
(b) Fibers for making nonwoven materials that are softer than those made with polypropylene fibers;

g _ (c) Polypropylene fibers which thermally bond well at lower temperatures;
(d) Polypropylene fibers with a relatively flat bonding curve;
(e) Thermal bonding of fibers at lower bonding temperatures while maintaining high cross-directional strength, elongation and toughness of the resulting nonwoven material;
(f) A greater bonding window by obtaining a flatter curve of cross-directional strength vs. bonding temperature to permit thermal bonding of fibers at lower bonding temperatures while maintaining high cross-directional strength of the resulting nonwoven material, whereby lower bonding temperatures can be utilized to enable the obtaining of softer nonwoven materials;
(g) Lower basis weight nonwoven materials that have strength properties, such as cross-directional strength, elongation and toughness that are equal to or greater than these strength properties obtained with other polypropylene fibers at higher basis weights;
(h) Fibers and nonwovens that can be handled on high speed machines, including high speed carding and bonding machines, that run at speeds as great as about 980 ft/min (300 m/min); and/or (i) Biconstituent or multiconstituent fibers having a skin-core structure produced from blends of polypropylene and polymeric bond curve enhancing agent.
The present invention is directed to various forms of fibers, including filaments and staple fibers. These terms are used in their ordinary commercial meanings. Typically, herein, filament is used to refer to the continuous fiber on the spinning machine; however, as a matter of convenience, the terms fiber and filament are also used interchangeably herein.
"Staple fiber" is used to refer to cut fibers or filaments.
Preferably, for instance, staple fibers for nonwoven fabrics useful in diapers have lengths of about 1 to 3 inches (about 2.5 to 7.6 cm), more preferably about 1.25 to 2 inches (3.1 to 5 cm) .

_ g _ All references to bond or bonding curves, and bonding curves of cross-directional strength vs. temperature are to a curve plotted with temperature on the X-axis and cross-directional strength on the Y-axis, with temperatures increasing from left to right along the X-axis and cross-directional strength increasing upwardly along the Y-axis, such as illustrated in Fig. S.

It is noted that when the terminology cross-directional strength is utilized herein, it refers to the cross-directional strength of the nonwoven material.

The polymer blends of the instant invention can be spun into fibers by various processes including long spin and short spin processes, or spunbonding. The preferred fibers are staple fibers, and are produced using spin equipment which permits controlled quenching.

More specifically, with regard to known processes for making staple fiber, these processes include the older two-step "long spin" process and the newer one-step "short spin"

process. The long spin process involves first melt-extruding fibers at typical spinning speeds of 500 to 3000 meters per minute, and more usually depending on the polymer to be spun from 500 to 1500 meters per minute. Additionally, in a second step usually run at 100 to 250 meters per minute, these fibers are drawn, crimped, and cut into staple fiber. The one-step short spin process involves conversion from polymer to staple fibers in a single step where typical spinning speeds are in the range of 50 to 200 meters per minute or higher. The productivity of the one-step process is increased with the use of about 5 to 20 times the number of capillaries in the spinnerette compared to that typically used in the long spin process. For example, spinnerettes for a typical commercial "long spin" process would include approximately 50-4,000, preferably approximately 3,000-3,500 capillaries, and spinnerettes for a typical commercial "short spin" process would include approximately 500 to 100,000 capillaries preferably, about 30,000-70,000 capillaries. Typical temperatures for extrusion of the spin melt in these processes are about 250-325C. Moreover, for processes wherein bicomponent fibers are being produced, the numbers of capillaries refers to the number of filaments being extruded, and usually not the number of capillaries in the spinnerette.

The short spin process for manufacture of polypropylene fiber is significantly different from the conventional long spin process in terms of the quenching conditions needed for spin continuity. In the short spin process, with high hole density spinnerettes spinning around 100 meters/minute, quench air velocity is required in the range of about 3,000-8,000 ft/minute to complete fiber quenching within one inch below the spinnerette face. To the contrary, in the long spin process, with spinning speeds of about 1000-1500 meters/minute or higher, a lower quench air velocity in the range of about 50 to 500 ft./minute, preferably about 300 to 500 ft./minute, is used.

Still further, fibers can be spun by other processes, including those processes wherein the fibers produced from the polymer are directly made into a nonwoven material, such as being spunbond.

In a spunbond process, the polymer is melted and mixed in an extruder, and the melted polymer is forced by a spin pump through spinnerettes that have a large number of holes.

Air ducts located below the spinnerettes continuously cool the filaments with conditioned air. Draw down occurs as the filaments are sucked over the working width of the filaments through a high-velocity low-pressure zone to a distributing chamber where the filaments are entangled. The entangled filaments are randomly laid down on a moving sieve belt which carries the unbonded web through a thermal calender for bonding. The bonded web is then wound into a roll.

The polymer materials that can be used in the present invention include any blend of polypropylene and polymeric bond curve enhancing agent, such as ethylene vinyl acetate polymer, that can be extruded under suitable conditions to form a fiber having a skin-core structure, such as by long spin, short spin, or spunbond processes. Further, it is noted that the composition, i.e., the polymer blend, that is to be extruded, such as through a spinnerette, to produce filaments is generally referred to as either the polymer blend or the extrudable composition. Further, while fiber, filament and staple fiber, as discussed above, have different meanings, as a matter of convenience, these various terms are also collectively referred to as fiber throughout this disclosure.

Also, fibers having a skin-core structure can be prepared by extruding a polymer blend comprising polypropylene and a softening polymeric additive as a hot extrudate, and providing conditions so that the hot extrudate forms a fiber having a skin-core structure.

When referring to polymers, the terminology copolymer is understood to include polymers of two monomers, or two or more monomers, including terpolymers.

The polypropylene can comprise any polypropylene that is spinnable. The polypropylene can be atactic, heterotactic, syndiotactic, isotactic and stereoblock polypropylene -including partially and fully isotactic, or at least substantially fully isotactic - polypropylenes. The polypropylenes can be produced by any process. For example, the polypropylene can be prepared using Zeigler-Natta catalyst systems, or using homogeneous or heterogeneous metallocene catalyst systems.

Further, as used herein, the terms polymers, polyolefins, polypropylene, polyethylene, etc., include homopolymers, various polymers, such as copolymers and terpolymers, and mixtures (including blends and alloys produced by mixing separate batches or forming a blend in situ). For example, the polymer can comprise copolymers of olefins, such as propylene, and these copolymers can contain various components. Preferably, in the case of polypropylene, such copolymers can include up to about 20 weight %, and, even more preferably, from about 0 to 10 weight % of at least one of ethylene and butene. However, varying amounts of these components can be contained in the copolymer depending upon the desired fiber.

Further, the polypropylene can comprise dry polymer pellet, flake or grain polymers having a narrow molecular weight distribution or a broad molecular weight distribution, with a broad molecular weight distribution being preferred.

The term "broad molecular weight distribution" is here defined as dry polymer pellet, flake or grain preferably having an MWD

value (i.a., Wt.Av.Mol.Wt./I~o.Av.Mol.Wt. measured by SSC as discussed herein) of at least about 5.0, preferably at leas about 5.5, more preferably at least about 6.
Still further, the polypropylene can be linear or branched, such as disclosed by U.S. Patent No. 4,626,467 to Hostetter, and :is preferably linear. Additionally, in making the fiber of the present invention, the polypropylene to be made into fibers can include polypropylene compositions as taught in European Patent Application No. 0 552 013 to Gupta et al. Still further, polymer blends such as disclosed in European Patent Application No. 0719879 can also be utilized.
The melt flow rate (MFR) of the polypropylene polymer as described herein is determined according to ASTM D-1238-86 (condition L;:.~30/2.16), which. is incorporated by reference herein in its entirety.
The polymeric bond curve enhancing agent that can be used in the present invention can comprise any polymeric additive, or mixture of polymeric additives, i.e., which is additional to the polypropylene, that provides (a) a flattening of the bond curve, (b) raising of the bond curve, i.e., increase in cross-directional strength and/or (c) shifting to the left of the bond curve, i.e., to lower temperatures, of cross-directional stz.-ength vs. bonding temperature of a nonwoven material, so that the strength properties .of the nonwoven material, especially the cross-directional strength, are maintained or increased with a skin-core fiber. Preferably, the comparison of the flattening, raising and/or shifting of the bond curve is relative to the bond curve for nonwove~.
material. prodU.ced under the same conditions from fibers produced under the same conditions except for the absence of the polymeric bond curve enhancing agent.
Ths .raising of the cross-directional strength includes herein the raising of at least some points of the cross-directional strength of the bond curve, and preferably includes either raising of the peak cross-directional streng:.h of the bond curve or raising of strength points at temperatures lower than the temperature at which the peak cross-directional strength occurs.

To obtain the maintaining or increasing of the cross-directional strength, the bond curve preferably has an increased area over a defined temperature range with respect to the differential scanning calorimetry melting point as will be discussed later herein. This increased area can be obtained in a number of manners. For example, (a) the cross-directional strength, such as the peak cross-directional strength, can be the same, substantially the same or lower and the bond curve can be flattened to achieve an increased area, (b) the cross-directional strength, such as the peak cross-directional strength or cross-directional strength at points at temperatures lower than the peak cross-directional strength, can be increased and the bond curve can be flattened to achieve an increased area, (c) the bond curve can have the same or substantially the same shape, and have higher cross-directional strength points, such as the peak cross-directional strength, along the curve, or (d) the bond curve can be shifted to lower temperatures with the area of the bond curve in the predetermined temperature range being maintained or increased, such as by a flattening of the bond curve.

Preferably, the bond curve is flattened and raised, or flattened and shifted, or raised and shifted, and most preferably, the bond curve is flattened, raised and shifted.

Thus, in one aspect of the invention, it is noted that the polymeric bond curve enhancing agent can provide a flattening of the bonding curve, preferably with the maximum cross-directional strength being raised, and preferably with the area under the curve being increased as compared to the area under the bonding curve for nonwoven material produced under the same conditions from fibers also produced under the same conditions except for the absence of the polymeric bond curve enhancing agent. It is also noted that the polymeric bond curve enhancing agent can provide a raising of the maximum cross-directional strength as compared to processing of the fiber and nonwoven material under the same conditions except for the absence of the polymeric bond curve enhancing agent. Also, the polymeric bond curve enhancing agent can provide a shifting of the bond curve maximum cross-directional strength to the left as compared to processing of the fiber and nonwoven material under the same conditions except for the absence of the polymeric bond curve enhancing agent, so that the bond curve achieves higher cross-directional strength at lower bond temperatures. Preferably, the bond curve is flattened and has an increased area, so that bonding can be achieved over a wide temperature range to provide a broadening of the bonding window.

While the comparisons above are preferably being made with respect to skin-core fibers, which have high strength properties, it is noted that the polymeric bond curve enhancing agents also provide flatter bond curves, raising of the bond curve and/or shifting of the bond curve with respect to equivalently processed nonwovens that are made from fibers that do not have a skin-core structure (or from bicomponents that do not have a sheath with a skin-core structure) produced from the same or substantially the same polymer blend, preferably the same polymer blend.

The polymeric bond curve enhancing agents preferably have (a) a differential scanning calorimetry melting point (DSC

melting point) below about 230C, preferably below about 200C, and even more preferably below that of polypropylene, i.e., the polypropylene that is included in the polymer blend, and most preferably about 15 to 100C below that of the polypropylene that is included in the polymer blend, (b) and at least one of an elastic modulus (measured at 200C and 100 radians/second) less than polypropylene that is included in the polymer blend (e. g., about 5 to 1000 below) and a complex viscosity (measured at 200C and 100 radians/second) less than polypropylene that is included in the polymer blend (e. g., about 10 to 80o below). Even more preferably, both the elastic modulus and the complex viscosity of the polymeric bond curve enhancing agent are less than that of the polypropylene that is included in the polymer blend. Thus, preferred polymeric bond curve enhancing agents will include materials that have the above-noted DSC melting points and the above-noted elastic modulus and/or complex viscosity, such as the polymeric materials listed in Table 15. However, materials that do not include such DSC melting points and elastic modulus and/or complex viscosity, such as KRATONG1750, are also utilizable in the present invention as polymeric bond curve enhancing agents in that they provide (a) a flattening of the bond curve, (b) raising of the bond curve and/or (c) shifting to the left of the bond curve of a nonwoven material produced with a skin-core fiber.

While specific examples of preferred concentrations of certain polymeric bond curve enhancing agents are included in this description, including the examples, it is emphasized that one possessing ordinary skill in this art following the instant disclosure would be able to ascertain concentrations of various polymeric bond curve enhancing agents useable in the polymer blend that would enable the spinning of filaments to obtain skin-core fibers while achieving a flattening, raising and/or shifting of the bonding curve.

Examples of polymers that are includable as polymeric bond curve enhancing agents according to the present invention are alkene vinyl carboxylate polymers, such as alkene vinyl acetate copolymers, such as ethylene vinyl acetate polymers which will be more fully described below; polyethylenes including copolymers, e.g., those prepared by copolymerizing ethylene with at least one C3 - C12 alpha-olefin, with examples of polyethylenes being ASPUNT'''6835A, INSITET"'XU58200.02, INSITET"'XU58200 . 03 (now apparently 8803 ) and INSITET'"'XU58200 . 04 available from Dow Chemical Company, Midland, Michigan; alkene acrylic acids or esters, such as ethylene methacrylic acids including NUCREL~925 available from Dupont, Wilmington, Delaware; alkene co-acrylates, such as ethylene N-butyl acrylate glycidyl methacrylate (ENBAGMA} such as ELVALOY~AM

available from Dupont, Wilmington, Delaware, and alkene co-acrylate co-carbon monoxide polymers, such as ethylene N-butyl acrylate carbon oxides (ENBACO) such as ELVALOY~HP661, and ELVALOY~HP662 available from Dupont, Wilmington, Delaware; and acid modified alkene acrylates, such as acid modified ethylene acrylates including ethylene isobutyl acrylate-methyl acrylic acid (IBA-MAA) such as BYNEL~ 2002 available from Dupont, Wilmington, Delaware, and ethylene N-butyl acrylic methylacrylic acid such as BYNEL 2022 available from Dupont, Wilmington, Delaware; alkene acrylate acrylic acid polymers, such as ethylene acrylate methacrylic acid terpolymers, such as SURLYN~ RX9-1 available from Dupont, Wilmington, Delaware;

and polyamides, such as nylon 6 available from North Sea Oil, Greenwood, South Carolina. Preferably, the polymeric bond curve enhancing agents are ethylene vinyl acetate polymers, such as ethylene vinyl acetate copolymers and terpolymers, or mixtures of polymeric bond curve enhancing agents, with the preferred polymeric bond curve enhancing agent in the mixture being ethylene vinyl acetate polymers. For example, the plurality of bond curve enhancing agents can comprise at least one ethylene vinyl acetate polymer and at least one polyamide, or at least one ethylene vinyl acetate polymer and at least one polyethylene.

The above noted polymeric bond curve enhancing agents preferably have molecular weights of about 103 to 10', more preferably about 104 to 106. Still further, the number of alkene carbon atoms in the polymeric bond curve enhancing agents preferably ranges from about CZ - C12, more preferably about C2 - C6, with a preferred number of alkene carbon atoms being C2.

As noted above, the polymeric bond curve enhancing agents also provide nonwoven materials of high softness. Preferred polymeric bond curve enhancing agents for providing nonwoven materials of particularly high softness include ELVAX~3124, KRATON~G1750, ELVALOY~AM, combinations of ethylene vinyl acetate polymers with at least one of INSITET"'XU58200.02 and INSITET"'XU58200.03, BYNEL~ 2002, and NUCREL~925.

The polypropylene is the predominant material in the polymer blend, and is present in the polymer blend up to about 95.5% by weight, and can be present from about 99.5 to 80o by weight, more preferably about 99.5 to 90% by weight, even more preferably about 99.5 to 93o by weight, even more preferably 99 to 95o by weight, and most preferably about 97 to 95.50 by weight.

The polymeric bond curve enhancing agent or mixture of polymeric bond curve enhancing agents can be present in the polymer blend up to about 20% by weight of the polymer blend, more preferably less than about 10% by weight of the polymer blend, with a preferred range being about 0.5 to 7o by weight, a more preferred ranged being about 1 to 5o by weight, and a most preferred ranged being from about 1.5 to 4o by weight, with a more preferred value being about 3o by weight.

For example, with respect to ethylene vinyl acetate polymers, the ethylene vinyl acetate polymer that can be used in the polymer blend is readily commercially available, and includes various forms of ethylene vinyl acetate polymer, including ethylene vinyl acetate copolymer and terpolymer.

The ethylene vinyl acetate polymer is preferably present in the polymer blend to about loo by weight of the polymer blend, more preferably less than 10% by weight of the polymer blend, with a preferred range being about 0.5 to 7% by weight, a more preferred range being about 1 to 5 o by weight, and a most preferred range being from about 1.5 to 4% by weight, with a more preferred value being about 3o by weight.

In the case of ethylene vinyl acetate polymers, the percentage of vinyl acetate in the ethylene vinyl acetate polymers can vary within any concentration which permits the polymer blend to form a skin-core fiber. For most purposes, a useful percentage of vinyl acetate units in the ethylene vinyl acetate polymer would be about 0.5 to 50% by weight, more preferably about 5 to 50% by weight, even more preferably about 5 to 40% by weight, even more preferably about 5 to 30%

by weight, and most preferably about 9 to 28o by weight.

It is noted that increasing the concentration of vinyl acetate in the ethylene vinyl acetate polymers enables the obtaining of fibers that are capable of producing nonwoven materials that have a softer feel; whereas, lower concentrations of vinyl acetate in the ethylene vinyl acetate polymers, while still soft, enable increased processability.

A preferred percentage of the vinyl acetate units being about 28o by weight where increased softness is desired, and about 9% by weight where increased processability is desired.

In other words, the ethylene can comprise about 50 to 95.5% by weight of the ethylene vinyl acetate polymer, more preferably about 50 to 95% by weight, even more preferably about 60 to 95% by weight, even more preferably 70 to 95o by WO 97!37065 PCTILfS97104470 weight, and most preferably about 72 to 91% by weight, wit::
a preferred value being about 72% by weight. Again, where increased proces~;ability is desired higher amounts of ethylene in the ethylene vinyl acetate polymer is preferred, with a S preferred amount being about 91% by weight.
Still further, ethylene vinyl acetate polymer can comprise a melt.. index (MI> in r_he range of from about 0.1 to 500 grams per ten minutes, when measured in accordance with ASTM D-1238-86 at condition E. The manner of determining the melt index, and the relationship to melt flow are disclosed in U.S. Patent No. 4,803,117 to Daponte.
Exemplary ethylene vinyl acetate polymers that are utilizable in th.e present invention are those sold under the Trademark ELVA:X by Dupont, such as set forth in the ELVAX
Resins - Grade Selection Guide by Du Pont Company, October 1989. Ethylene/vinyl acetate copolymers include the High Vinyl Acetate Resins; the 200-, 300-, 400-, 500-, 600-, and 700-Series Resins and the corresponding packaging-grade 3100 Series Resins; and terpolymers include the ethylene/vinyl acetate/acid terpolymers indicated as Acid Terpolymers.
2S Preferred, copolymers are ELVAXm150, ELVAX~250, ELVAX~750, ELVAX~3124 and. ELVAXm3180 and a preferred acid terpolymer is ELVAX~4260. However, as stated above, the ethylene vinyl acetate polymer can comprise any ethylene vinyl acetate polymer, e.g.,, copolymer or terpolymer, that can 'be extruded under conditions to directly form a filament having a skin-core structure" such as by long spin, short spin or spunbond processes.
Additional. polymers can be contained in the polymer blend in addition to the polypropylene and the polymeric bond curve enhancing agents or mixture of. polymeric bond curve enhancing agents, as lone as the polymer blend remains spinnable and the resulting fibE~rs can be formed into nonwoven materials.
Polymers can be added to the blend depending upon desired properties of the fibers, such as desired properties in the production of nonwoven materials and in the nonwoven. In fact, the additional polymers may enhance the properties of the polymeric bond curve enhancing agent . For example, the polymer blend can include various polymers, in addition to polypropylene, whether or not the polymers are within the definition of polymeric bond curve enhancing agent, such as, polyamides, polyesters, polyethylenes and polybutenes. Thus, additional polymers can be added to the polymer blend, even though they are not polymeric bond curve enhancing agents.

In other words, and with exemplary reference to the situation wherein mixtures of polyolefins are contemplated in the polymer blend, the polymer blend can comprise 1000 polypropylene by weight of the polyolefin added to the polymer blend. However, varying amounts of other polyolefins can be added to the polypropylene. For example, various polyethylenes, even when these polyethylenes are not polymeric bond curve flattening agents, can be included with the polypropylene and polymeric bond curve enhancing agent in the polymer blend in amounts up to about 20o by weight of the polymer blend, more preferably up to about loo by weight of the polymer blend, still more preferably up to about 5o by weight of the polymer blend, and even more preferably up to about 3% by weight of the polymer blend, with a preferred range being about 0.5 to lo. Thus, for example, in embodiments of the present invention, various polymers can be added to the polymer blend in addition to polypropylene and polymeric bond curve enhancing agent, such as, polyethylenes that are or are not polymeric bond curve enhancing agents, or mixtures thereof.

Thus, continuing with respect to polyethylenes, any polyethylene can be added to the polymer blend that enables the polymer blend to be spun into a skin-core structure. The polyethylene can have a density of at least about 0.85 g/cc, with one preferred range being about 0.85 to 0.96 g/cc, and an even more preferred range being about 0.86 to 0.92 g/cc.

In particular, the polyethylenes can comprise low density polyethylenes, preferably those having a density in the range of about 0.86-0.935 g/cc; the high density polyethylenes, preferably those having a density in the range of about 0.94-0.98 g/cc; the linear polyethylenes, preferably those having a density in the range of about 0.85-0.96 g/cc, such as linear low density polyethylenes having a density of about 0.85 to 0.93 g/cc, and even more specifically about 0.86 to 0.93 g/cc, and including those prepared by copolymerizing ethylene with at least one C3 - C12 alpha-olefin, and higher density polyethylene copolymers with C3 - C1z alpha-olefins having densities of 0.94 g/cc or higher.
Thus, the polymer blend can comprise only two polymers, such as polypropylene and a single polymeric bond curve enhancing agent. Alternatively, the polymer blend can include three or more polymers, such as (a) polypropylene and a mixture of polymeric bond curve enhancing agents, or (b) polypropylene and one or more polymeric bond curve enhancing agents and an additional polymer which is not a polymeric bond curve enhancing agent.
Still further, the polymer blend can include various additives that are added to fibers, such as antioxidants, stabilizers, pigments, antacids and process aids.
The polymer blend of the instant invention can be made using any manner of mixing the at least two polymers. For example, the polymer blend can be obtained by tumble mixing the solid polymers, and then melting the mixture for extrusion into filaments.
Moreover, components of the polymer blend can be preblended prior to ultimate mixing to form the polymer blend.
For example, when at least one additional polymeric bond curve enhancing agent and/or additional polymer, such as polyethylene, is to be added to the polymer blend containing polypropylene as the preferred polymeric bond curved flattening agent ethylene vinyl acetate copolymer, the at least one additional polymeric bond curve enhancing agent and/or the at least one additional polymer can be preblended with the ethylene vinyl acetate copolymer. Any order of mixng can be used.
Thus, for example, a preblend of ethylene vinyl acetate copolymer and polyethylene can be prepared by mixing, as solid polymers, one part by weight of ethylene vinyl acetate copolymer with two parts by weight of polyethylene. This WO 97!37065 PCT/US97/04470 mixture can then be melt extruded at a temperature such as 180C, passed through a water bath, and cut into pellets.

The pellets can then be mixed, such as by tumble mixing, with polypropylene to form the polymer blend.

By practicing the process of the present invention, and by spinning polymer compositions using melt spin processes, such as a long spin or short spin process according to the present invention, fibers can be obtained which have excellent thermal bonding characteristics over a greater bonding window in combination with excellent softness, opacity, tenacity, tensile strength and toughness. Moreover, the fibers of the present invention are capable of providing nonwoven materials of exceptional cross-directional strength, toughness, elongation, uniformity, loftiness and softness even at lower basis weights than ordinarily practiced and using a variety of spinning processes.

The nonwoven material preferably has a basis weight of less than about 20 g/yd2 (gsy), more preferably less than about 18 gsy, mor preferably less than about 17 gsy, even more preferably less than about 15 gsy, even more preferably less than about 14 gsy, and even as low as about 10 gsy, or lower, with a preferred range being about 14 to 20 gsy.

For example, the fibers of the present invention can be processed on high speed machines for the making of various materials, in particular, nonwoven fabrics that can have diverse uses, including cover sheets, acquisition layers and back sheets in diapers. The fibers of the present invention enable the production of nonwoven materials at speeds as high as about 500 ft/min, more preferably as high as about 700 to 800 ft/min, and even as more preferably as high as about 980 ft/min (about 300 meters/min), at basis weights preferably less than about 20 g/ydz (gsy), as low as about 18 gsy, as low as about 17 gsy, as low as about 15 gsy, as low as about 14 gsy, and even as low as about 10 gsy, or lower, with a preferred range being about 14 to 20 gsy, and having cross-directional strengths on the order of at least about 200 to 400 g/in., more preferably 300 to 400 g/in, preferably greater than about 400 g/in, and more preferably as high as about 650 g/in, or higher. Further, the fabrics can have an elongation _ 22 -of about 50-200m, and a toughness of about 200 to lop g/in, preferably about 480-700 g/in for nonwoven fabrics at a basis S weight of about 20 g/ydz, more preferably less than about g/yd~, even mare preferably less than about 17 to 18 g/yd=, even more preferably less than about 15 g/yd=, and even more preferably less than about 14 g/ydz and most preferably as low as 10 g/ydz, or lower.

A number of procedures are used to analyze and define she composition and fiber of the present invention, and various 0 terms are used i_n defining characteristics of the composition and fiber. These will be described below.

As is disc:Losed in the above-noted European Application No. 0 630 996 t:o Takeuchi et al. , which is incroporated by S reference herein in its entirety, the substantially non-uniform morpho:Logical structure of the skin-core fibers according to th.e present invention can be characterized by transmission electron microscapy (TEM) of ruthenium tetroxide 0 (RuO,)-stained fiber thin sect.i.ons. In this regard, as taught by Trent et al.., in Macromola.~,1 c, Vol. 16, No. 4, 1983, "Ruthenium Tet:.roxide Staining of Polymers for Electron Microscopy". fit: is well known that the structure of: polymeric materials is dependent on their heat treatment, composition, and processing, and that, in turn, mechanical properties of 25 these materials such as toughness, impact strength, resilience, fatigue, and fracture strength can be highly sensitive to mo~.~-phology. Further, this article teaches that transmission electron microscapy is an established technique for the characterization of the structure of heterogeneous 30 polymer systems at a high level of resolution; however, it is often necessary to enhance image contrast for polymers by use of a staining agent. Useful staining agents for polymers are taught to inc:Lu.de osmium tetroxide and ruthenium tetroxide.

For the staining of the fibers of the present invention, 35 ruthenium tet:.-oxide is the preferred staining agent.

In' the morphological characterization of the present invention, samples of fibers are stained with aqueous Ru09, such as a 0.5a (by weight) aqueous solution of ruthenium tetroxide obtainable Erom Polysciences, Inc., overnight at room temperature. (While a liquid stain is utilized in this procedure, staining of the samples with a gaseous stain is also possible.) Stained fibers are embedded in Spurr epoxy resin and cured overnight at 60°C. The embedded stained fibers are then thin sectioned on an ultramicrotome using a diamond knife at room temperature to obtain microtomed sections approximately 80 nm thick, which can be examined on conventional apparatus, such as a Zeiss EM-10 TEM, at 100kV.
Energy dispersive x-ray analysis (EDX) was utilized to confirm that the Ru04 had penetrated completely to the center of the fiber.
Skin-core fibers according to the present invention show an enrichment of the ruthenium (Ru residue) at the outer surface region of the fiber cross-section to a depth of at least about 0.2 Vim, preferably to a depth of at least about 0.5 ~.m, more preferably to a depth of at least about 0.7 ~,m, more preferably to a depth of at least about 1 Vim, with the cores of the fibers showing a much lower ruthenium content.

Still further, the enrichment of ruthenium (Ru residue) at the outer surface region of the fiber cross-section can be greater than about 1.5 ~m thick.

Also, with fibers having a denier less than 2, another manner of stating the ruthenium enrichment is with respect to the equivalent diameter of the fiber, wherein the equivalent diameter is equal to the diameter of a circle with equivalent cross-section area of the fiber averaged over five samples.

More particularly, for fibers having a denier less than 2, the skin thickness can also be stated in terms of enrichment in staining of the equivalent diameter of the fiber. In such an instance, the enrichment in ruthenium staining can comprise at least about to and up to about 250 of the equivalent diameter of the fiber, preferably about 2o to l00 of the equivalent diameter of the fiber.

Another test procedure to illustrate the skin-core structure of the fibers of the pxesent invention, and especially useful in evaluating the ability of a fiber to thermally bond, consists of the microfusion analysis of residue using a hot stage test. This procedure is used to examine for the presence of a residue following axial shrinkage of a fiber during heating, with the presence of a higher amount of residue directly correlating with the ability of a fiber to provide good thermal bonding. In this hot stage procedure, a suitable hot stage, such as a Mettler FP82 HT low mass hot stage controlled via a Mettler FP90 control processor, is set to 145C. A drop of silicone oil is placed on a clean microscope slide. Approximately 10 to 100 fibers are cut into ;~ mm lengths from three random areas of filamentary sample, and stirred into the silicone oil with a probe. The randomly dispersed sample is covered with a cover glass and placed on the hot stage, so that both ends of the cut fibers will, for the most part, be in the field of view.

The temperature of the hot stage is then raised at a rate of 3C/minute. At some temperature, the fibers shrink axially, and the presence or absence of trailing residues is observed.

As the shrinkage is completed, the heating is stopped, and the temperature is reduced rapidly to 145C. The sample is then examined through a suitable microscope, such as a Nikon SK-E

trinocular polarizing microscope, and a photograph of a representative area is taken to obtain a still photo reproduction using, for example, a MTI-NC70 video camera equipped with a Pasecon videotube and a Sony Up-850 B/W

videographic printer. A rating of "good" is used when the maj ority of f fibers leaves residues . A rating of "poor" is used when only a few percent of the fibers leave residues.

Other comparative ratings are also available, and include a rating of "fair" which falls between "good" and "poor", and a rating of "none" which, of course, falls below "poor". A

rating of "none" indicates that a skin is not present, whereas ratings of "poor" to "good" indicate that a skin is present.

Size exclusion chromatography (SEC) is used to determine the molecular weight distribution. In particular, high performance size exclusion chromatography is performed at a temperature of 145C using a Waters 150-C ALC/GPC high temperature liquid chromatograph with differeritial refractive index (Waters) detection. To control temperature, the column compartment, detector, and injection system are thermostatted at 145C, and the pump is thermostatted at 55C. The mobile phase employed is 1,2,4-trichlorobenzene (TCB) stabilized with _ 25 -butylated hydroxytoluene (BHT) at 4 mg/L, with a flow rate cf 0.5 ml/min. The column set includes two Polymer Laboratories (Amherst, Mass.) PL Gel mixed-8 bed columns, 1.0 micron particle size, part no. 1110-6100, and a Polymer Laboratories PL-Gel 500 angstrom column, 10 micron particle size, part no.
'_110-6125. To perform the r_hromatographic analysis, the samples are diss~alved in stabilized Tc_B by heating to 175°C
for two hours followed by two additional hours of dissolution at 145°C. Moreover, the samples are nor_ filtered prior to the 1.0 analysis. All molecular weight data is based on a polypropylene calibration curve obtained from a universal transform of an experimental polystyrene calibration curve.
The universal transform employs empirically optimized Mark-Houwink coefficients of K and a of 0.0175 and 0.67 for 1.5 polystyrene, and 0.0152 and 0.72 for polypropylene, respectively.
The dynamic shear properties of the polymeric materials of the present invention are determined by subjecting a small polymeric sample to small amplitude oscillatory motion in the 20 manner described by Zeichner and Patel, Proceedings of Second World Congress of Chemir-a1 Eng~neersnq Mantrea~ Vol 6, pp.
333-337 (1981.)r Specifically, the? sample is held between two parallel plates of 25 millimeters in diameter at a gap of two millimeters.
25 The top plate is attached to a dynamic motor of the Rheometrics System IV rheometer (Piscataway, NJ) while the bottom plate is attached to a 2000 gm-cm torque transducer.
The test temperature is held at 200°C wherein the sample is in a molten state, and the temperature is maintained steady :30 throughout the test. While keeping the bottom plate stationary, a :small amplitude oscillatory motion is imposed on the top plate sweeping the frequency range from 0.1 to 400 radians/second. At each frequency, afr_er the transients have died out, the dynamic stress response is separable into in-35 phase and out-of-phase componenr_s of the shearing strain. The dynamic modulus, G', characterizes the in-phase component while the loss modulus, G", characterizes the out.-of-phase component of the dynamic stress. For high molecular weight polyolefins, such as polypropylenes, it is observed that these WO 97I370b5 PCT/US97/04470 moduli crossover or coincide at a point (a certain modules) when measured as a function of frequency. This crossover modules is characterized as Gc, and the crossover frequency is characterized by Wc.

The polydispersity index (PI) is defined by 106/crossover modules, and is found to correlate with the molecular weight distribution, Mw/Mn. At a constant polydispersity index, the crossover frequency correlates inversely with the weight average molecular weight, Mw, for polypropylenes.

Elaborating on the above for determining complex viscosity and dynamic modules, the sample is subjected to small amplitude oscillation of a frequency from 0.1 to 400 radians/second, and after the initial transients have died down, the transducer records an oscillatory stress output having a similar frequency as the strain input but showing a phase lag. This output stress function can be analyzed into an in-phase stress with a coefficient known as the storage (dynamic) modules, G', and an out-of-phase stress with a coefficient called the loss modules, G", which are only functions of the frequency.

The storage modules, G', is the measure of energy stored by the material during a small amplitude cyclic strain deformation, and is also known as the elastic modules of the sample. The loss modules, G", is the measure of energy lost after a small amplitude cyclic strain deformation.

The complex viscosity, which is a measure of the dynamic viscosity of the sample is obtainable from both of these modulii. More specifically, the complex viscosity is the geometric average of the elastic modules, G', and the loss modules, G", divided by the frequency. In the instant situation the frequency is taken at 100 radians/second. More specifically, the formula for the complex viscosity r~ is as follows (Gi)z+(Gn)z WO 97137065 PC'T/US97104470 -The ability of the fibers t.o hold together by measuring the force required to slide fibers in a direction parallel. ;.o their length is a measure of the cohesion of the fibers. The test utilized herE_in to measure the cohesion of the fibers .s ASTM D-4120-90. I:n this test, specific lengths of roving, sliver or top are drafted between two pairs of rollers, wit!
each pair moving at a different peripheral speed. The draft forces are recorded, test specimens are then weighed, and the linear density is calculated. Drafting tenacity, calculated as the draft re:;isting force per unit linear density, is considered to be a measure of the dynamic fiber cohesion.
More specifically, a sample of thirty (30) pounds of processed staple fiber is fed into a prefeeder where the fiber _~5 is opened to enable carding through a Hollingsworth cotton card ((Model CMC (EF38-5)). The fiber moves to an evenfeed system through th.e flats where the actual carding takes place.
The fiber then passes thraugh a doffmaster onto an apron moving at about 20 m/min. The fiber is then passed through a trumpet guide, then between two calender rolls. At this point, the carded fiber is converted from a web to a sliver.
The sliver is then passed through another trumpet guide into a rotating coiler~can. The sliver is made to 85 grains/yard.
From the c:oiler can, the sliver i.s fed into a Rothchild Dynamic Slivex: Cohesion Tester (Model #R-2020, Rothchild Corp., Zurich, Switzerland). An electronic tensiometer (Model #R-1191, Rothchild Corp.) is used to measure the draft forces.
The input speed is 5 m/min, the draft ratio is 1.25, and the sliver is measured over a 2 minute period. The overall force average divided by the average grain weight equals the sliver cohesion. Thus, the sliver cohesion is a measure of the resistance of the sliver to draft.
The term "c:rimps per inch" (CPI), as used herein , is the number of "kink," per inch of a given sample of bulked fiber under zero stress. It is determined by mounting thirty 1.5 inch fiber samples to a.. calibrated glass plate, in a zero stress state, the extremities of the fibers being 'held to the plate by double coated cellophane tape. The sample place is then covered with an uncalibrated glass plate and the kinks WO 97/370b5 PCT/US97/04470 present in a 0.625 inch length of each fiber are counted. The total number of kinks in each 0.625 inch length is then multiplied by 1.6 to obtain the crimps per inch for each fiber. Then, the average of 30 measurements is taken as CPI.

The skin-core structure of the instant fibers can be produced by any procedure that achieves an oxidation, degradation and/or lowering of molecular weight of the polymer blend at the surface of the fiber as compared to the polymer blend in an inner core of the fiber. Thus, the skin-core structure comprises modification of a blend of polymers to obtain the skin-core structure, and does not comprise separate components being joined along an axially extending interf ace, such as in sheath-core and side-by-side bicomponent fibers.

Of course, the skin-core structure can be utilized in a composite fiber, such as the skin-core structure being present in the sheath of a sheath-core fiber in the manner disclosed in U.S. Patent Nos. 5,281,378, 5,318,735 and 5,431,994.

Thus, for example, the skin-core fibers of the present invention can be prepared by providing and/or controlling conditions in any manner so that during extrusion of the polymer blend a skin-core structure is formed. For example, the temperature of a hot extrudate, such as an extrudate exiting a spinnerette, can be provided that is sufficiently elevated and for a sufficient amount of time within an oxidative atmosphere in order to obtain the skin-core structure. This elevated temperature can be achieved using a number of techniques, such as disclosed in the above discussed patents to Kozulla, and U.S.~ and foreign applications to Takeuchi et al.

More specifically, and as an example of the present invention, the temperature of the hot extrudate can be provided above at least about 250C in an oxidative atmosphere for a period of time sufficient to obtain the oxidative chain scission degradation of its surface. This providing of the temperature can be obtained by delaying cooling of the hot extrudate as it exits the spinnerette, such as by blocking the flow of a quench gas reaching the hot extrudate. Such blocking can be achieved by the use of a shroud or a recessed spinnerette that is constructed and arranged to provide the maintaining of temperature.

In another aspect, the skin-core structure can be obtained by heating the polymer blend in the vicinity of the spinnerette, either by directly heating the spinnerette or an area adjacent to the spinnerette. In other words, the polymer blend can be heated at a location at or adjacent to the at least one spinnerette, by directly heating the spinnerette or an element such as a heated plate positioned approximately 1 to 4 mm above the spinnerette, so as to heat the polymer composition to a sufficient temperature to obtain a skin-core fiber structure upon cooling, such as being immediately quenched, in an oxidative atmosphere.

For example, for a typical short spin process for the extrusion of the polymer blend, the extrusion temperature of the polymer is about 230C to 250C, and the spinnerette has a temperature at its lower surface of about 200C. This temperature of about 200C does not permit oxidative chain scission degradation at the exit of the spinnerette. In this regard, a temperature of most preferably at least about 250C

is desired across the exit of the spinnerette in order to obtain oxidative chain scission degradation of the molten filaments to thereby obtain filaments having a skin-core structure. Accordingly, even though the polymer blend is heated to a sufficient temperature for melt spinning in known melt spin systems, such as in the extruder or at another location prior to being extruded through the spinnerette, the polymer blend cannot maintain a high enough temperature in a short spin process upon extrusion from the spinnerette, under oxidative quench conditions, without the heating supplied at or at a location adjacent to the spinnerette.

While the above techniques for forming the skin-core structure have been described, the present invention is not limited to skin-core structure obtained by the above-described techniques, but any technique that provides a skin-core structure to the fiber is included in the scope of this invention. Thus, any fiber that includes a surface zone of lower molecular weight polymer, higher melt flow rate polymer, oxidized polymers and/or degraded polymer would be a skin-core fiber according to the present invention.

In order to determine whether a skin-core fiber is present, the above-referred to ruthenium staining test is utilized. According to the present invention, and in its preferred embodiment, the ruthenium staining test would be performed to determine whether a skin-core structure is present in a fiber. More specifically, a fiber can be subjected to ruthenium staining, and the enrichment of ruthenium (Ru residue) at the outer surface region of the fiber cross-section would be determined. If the fiber shows an enrichment in the ruthenium staining for a thickness of at least about 0.2 ~,m or at least about to of the equivalent diameter for fibers having a denier of less than 2, the fiber has a skin-core structure.

While the ruthenium staining test is an excellent test for determining skin-core structure, there may be certain instances wherein enrichment in ruthenium staining may not occur. For example, there may be certain components within the fiber that would interfere with or prevent the ruthenium from showing an enrichment at the skin of the fiber, when, in fact, the fiber comprises a skin-core structure. The description of the ruthenium staining test herein is in the absence of any materials and/or components that would prevent, interfere with, or reduce the staining, whether these materials are in the fiber as a normal component of the fiber, such as being included therein as a component of the processed fiber, or whether these materials are in the fiber to prevent, interfere with or reduce ruthenium staining.

Skin-core fibers according to the present invention can have, but do not necessarily have, an average melt flow rate which is about 20 to 300% higher than the melt flow rate of the non-degraded inner core of the fiber. For example, to determine the melt flow rate of the non-degraded inner core of the fiber, the polymer blend can be extruded into an inert environment (such as an inert atmosphere) and/or be rapidly quenched, so as to obtain a non-degraded or substantially non-degraded fiber. The average melt flow rate of this fiber not having a skin-core structure could then be determined. The percent increase in melt flow rate of the skin-core fiber can then be determined by subtracting the average melt flow rate of the non-degraded fiber (representing the melt flow rate of the core) from the average melt flow rate of the skin-core fiber, dividing this difference by the average melt flow rate of the non-degraded fiber, and multiplying by 100. In other words, Percent Increase in Melt Flow) Rate of Skin-Core Fiber to ) - (MFRS_~ - MFRS) /MFRS x 100 Melt Flow Rate of Core ) wherein:
MFRS_~ = average melt flow rate of the skin-core fiber, and MFRS = melt flow rate of the core Of course, the percent increase in the average melt flow rate of the skin-core-fiber as compared to the melt flow rate of the core would depend upon the characteristics of the skin-core structure. Thus, the skin-core structure can comprise an a gradient zone (e. g., of decreasing weight average molecular weight towards the external surface of the fiber) between the outer surface zone (e. g, of a high concentration of oxidative chain scission degraded polypropylene as compared to the inner core) and the inner core, as obtainable in the processes disclosed in the above-noted Kozulla patents, and in the above-noted European Patent Application No. 0 630 996 to Takeuchi et al. In the skin-core structure, the skin comprises the outer surface zone and the gradient zone.

Additionally, there can be distinct core and outer surface zone regions without a gradient, such as disclosed in European Patent Application No. 0 630 996 to Takeuchi et al. In other words, there can be a distinct step between the core and outer surface zone (e. g., of oxidative chain scission degraded polypropylene) of the skin-core structure forming two adjacent discrete portions of the fiber, or there can be a gradient between the inner core and the outer surface zone.

Thus, the skin-core fibers of the present invention can have different physical characteristics. For example, the average melt flow rate of the skin-core fibers having a discrete step between the outer surface zone and the core is only slightly greater than the melt flow rate of the polymer blend; whereas, the average melt flow rate of the skin-core fiber having a gradient between the outer surface zone and the inner core is significantly greater than the melt flow rate of the polymer composition. More specifically, for a melt flow rate of the polymer blend of about 10 dg/min, the average melt flow rate of the skin-core fiber without a gradient can be controlled to about 11 to 12 dg/min, which indicates that chain scission degradation has been limited to substantially the outer surface zone of the skin-core fiber. In contrast, the average melt flow rate for a skin-core fiber having a gradient is about 20 to 50 dg/min.

Still further, while not being wished to be bound to the relationship of the dominant phase of polypropylene to the polymeric bond curve enhancing agent, such as ethylene vinyl acetate copolymer, it is pointed out that the polymeric bond curve enhancing agent may be dispersed throughout the cross-section of the fiber in the form of fibrils. The dispersion can be in any manner, such as homogeneously or non-homogeneously, throughout the skin and core of the fiber, with the fibrils appearing to at least some degree in both the skin and core of the fiber.

More specifically, the polymeric bond curve enhancing agent, such as ethylene vinyl acetate copolymer, can be in the form of microdomains in the dominant phase, with these microdomains having an elongated appearance in the form of fibrils. These fibrils appear to have dimensions, which include a width of about 0.005 to 0.02 ~,m, and a length of about 0.1 ~,m or longer. However, while fibrils can be present, such as when the polymeric bond curve enhancing agent comprises ethylene vinyl acetate copolymer, fibrils need not be present. Accordingly, fibers according to the present invention may or may not have fibrils present therein.

The spun fiber obtained in accordance with the present invention can be continuous and/or staple fiber of a monocomponent or bicornponent type, and preferably falls within a denier per filament (dpf) range of about 0.5-30, or higher, more preferably is no greater than about 5, and preferably is about 0.5 and 3, more preferably about 1 to 2.5, with preferred dpf being about 1.5, 1.6, 1.7 and 1.9.

In the mufti-component fiber, e.g.,g the bicomponent type, such as a sheath-core structure, the sheath element would have a skin-core structure, while the core element would be of a conventional core element such as disclosed in the above-identified U.S. Patent Nos. 4,173,504, 4,234,655, 4323,626, 4,500,384, 4,738,895, 4,818,587 and 4,840,846.

Thus, the core element of the bicomponent fiber need not be degraded or even consist of the same polymeric material as the sheath component, although it should be generally compatible with, or wettable or adherent to the inner zone of the sheath component. Accordingly, the core can comprise the same polymeric materials as the sheath, such as including the same mixture of polypropylene and one or more polymeric bond curve enhancing agents, and possibly one or more additional polymers as included in the sheath, or can comprise other polymers or polymer mixtures. For example, both the core and the sheath can contain polypropylene or a mixture of polypropylenes, either alone or in combination with any other components including the polymeric bond curve enhancing agents, e.g., ethylene vinyl acetate polymer and/or additional polymers.

Further, the fibers of the present invention can have any cross-sectional configuration, such as illustrated in Figs.

1(a) - 1(g), such as oval (Fig. 1(a)), circular (Fig. 1(b)), diamond (Fig. 1(c)), delta (Fig. 1(d)), trilobal - "Y"-shaped (Fig. 1(e)), "X"-shaped (Fig. 1(f)) and concave delta (Fig.

1(g)) wherein the sides of the delta are slightly concave.

Preferably, the fibers comprise a circular or a concave delta cross-section configuration. The cross-sectional shapes are not limited to these examples, and can comprise other cross-sectional shapes. Additionally, the cross-sectional shapes can be different than those illustrated for the same cross-directional shapes. Also, the fibers can include hollow portions, such as a hollow fiber, which can be produced, for example, with a "C"cross-section spinnerette.

Still further, and so as to assist in visualization of the fibers of the present invention, Figs. 2-4 provide schematic illustrations thereof. Thus, Fig. 2 schematically illustrates a skin-core fiber composed of a polymer blend according to the present invention having a skin comprising outer zone 3 and an intermediate gradient zone 2, and a core 1. Fig. 3 schematically illustrates a skin-core fiber composed of a polymer blend according to the present invention having a discrete step between the skin 4 and core 5. Fig.

4 schematically illustrates a bicomponent sheath-core fiber comprising a sheath of a polymer blend according to the present invention having a skin-core structure. As illustrated the bicomponent fiber includes an inner bicomponent core component 6, which is different from the polymer blend of the sheath, and reference numerals 7, 8 and 9 are similar to reference numerals 1, 2 and 3 in Fig. 2.

According to the present invention, the starting composition preferably has a MFR of about 2 to 35 dg/minute, so that it is spinnable at temperatures within the range of about 250C to 325C, preferably 275C to 320C.

The oxidizing environment can comprise air, ozone, oxygen, or other conventional oxidizing environment, at a heated or ambient temperature, downstream of the spinnerette.

The temperature and oxidizing conditions at this location must be maintained to ensure that sufficient oxygen diffusion is achieved within the fiber so as to effect oxidative chain scission within at least a surface zone of the fiber to obtain an average melt flow rate of the fiber of at least about 15, 25, 30, 35 or 40 up to a maximum of about 70.

In making the fiber in accordance with the present invention, at least one melt stabilizer and/or antioxidant can be included with the extrudable composition. The melt stabilizer and/or antioxidant is preferably mixed in a total amount with the polymer blend to be made into a fiber in an amount ranging from about 0.005-2.0 weight % of the extrudable composition, preferably about 0.005-1.0 weight %, and more preferably about 0.0051 to 0.1 weight %. Such stabilizers and antioxidants are well known in fiber manufacture and include phenylphosphites, such as IRGAFOS~ 168 (available from Ciba Geigy Corp.), ULTRANOX 626 or ULTRANOX~ 641 (available from General Electric Co.), and SANDOSTAB~ P-EPQ (available from Sandoz Chemical Co.); and hindered phenolics, such as IRGANOX~

1076 (available from Ciba Geigy Corp.).

The stabilizer and/or antioxidant can be added to the extrudable composition in any manner to provide the desired concentration. In particular, it is noted that the materials may contain additives from the supplier. For example, the polypropylene, as supplied, can contain about 75 ppm of IRGANOX~1076, and the ELVAX resins, as supplied, can contain 0 to 1000 ppm of butylated hydroxytoluene (BHT) or other stabilizers.

Optionally, pigments, such as titanium dioxide, in amounts up to about 2 weight %, antacids such as calcium stearate, in amounts ranging from about 0.01-0.2 weight o, colorants, in amounts ranging from 0.01-2.0 weight %, and other well known additives can be included in the fiber of the present invention.

Additionally, the use of polymeric bond curve enhancing agents, such as ethylene vinyl acetate copolymers, in high temperature extrusion processes (greater than 220C) can result in pressure build-up situations on primary extruder filters and/or downstream spinnerette filters. To this end, processing aids designed to prevent "stick-slip" behavior of polyethylene in extrusion dies, mostly in film systems, can be used to prevent or reduce pressure build-up, such as with ethylene vinyl acetate copolymers ranging from 9 to 28% in vinyl acetate content. Such process aids are of the type that preferentially thinly coat the metal parts of the extrusion equipment, e.g., extruder, piping, filters and spinnerette capillaries, so that the polymeric bond curve enhancing agent (e.g., ethylene vinyl acetate copolymer) does not build up on the filters and/or capillaries, causing pressure build-ups.

For example, the process aids can comprise Viton~ Free FlowT""GB

(available from DuPont Dow Elastomers, Elkton, MD), DynamarT"' FX9613 and DynamarTM FX5920A (available from 3M, Specialty Fluoropolymers Dept., St. Paul, MN). Preferably, the process aid comprises DynamarTM FX5920A used in combination with PCT/US97/Od470 ethylene vinyl acetate copolymer as the polymeric bond cure=_ enhancing agent.
Various t.y~aes of finishes including spin finishes and over finishes can be applied to the fibers or incorporated into the polymer blend to affect the wettability and static properties of the fibers. For example, wetting agents, such as disclosed ire t.1,5. Patent No. 4,578,414 can be utilized with the fibers ofi the present invention. Still further, hydrophobic finishes, such as disclosed in U.S. Fatent No.
4,938,832 can also be utilized with the fibers of the present invention. AJ_so, the hydrophobic finishes can preferably comprise hydrophobic pentaeryt:hritol esters, as disclosed in 7.5 U.S. Patent Application Na. 08;728,490, as filed October 9th, 1996. Mixtures of these esters are available from Hercules Incorporated, 4~fi.lmi.ngton, Delaware, as HERCOLUBE~ and HERCOFLEX~ synt:he~tic esters, including HERCOLUBE~ J, HERCOLUBE~
F, HERCOLUBE~ 202, and HERCOFLEX~ 707A; and from George A.
Goulston Co., Monroe, North Carolina as LUROL~ PP6766, LUROL~
PP6767, LUROL~ P3?6768 and I~UROh'~ PP676g.
Additional components can be included in the polymer blend to effect properties of the fiber. For example, :'S components can bE~ included in the polymer blend which provide a repeat wettability to the fibers, such as an alkoxylated fatty amine opt:ieanally in combination with primary fatty acid amide, as disclc~e~ed by Harrington, U.S. Patent No. 5,033,172, a0 It is also preferred that the fiber of the present invention have a tenacity less than about 4 g/denier, and a fiber elongation of at least about 50%, and more preferably a tenacity less than about 2.5 g/denier, and a fiber elongation of at least about 200°x, and even more preferably 35 a tenacity of less than about 2 g/denier, and an elongation of at least about. 2500, as measured on individual fibers using a Fafegraph Instrument, Model T or Model M, from Textechno, Inc., which is designed to measure fiber tenacity and elongation, with 3 fiber gauge length of about 1.25 cm and an extension rate of about 200%/min (average of 10 fibers tested). Fiber tenacity is defined as the breaking force divided by the denier of the fiber, while fiber elongation is defined as the o elongation to break.

The fibers of the present invention can be drawn under various draw conditions, and preferably are drawn at ratios of about 1 to 4X, with preferred draw ratios comprising about 1 to 2.5X, more preferred draw ratios comprising about 1 to 2X, more preferred draw ratios comprising from about 1 to 1.6X, and still more preferred draw ratios comprising from about 1 to 1.4X, with specifically preferred draw ratios comprising about 1.15X to about 1.35X. The draw ratio is determined by measuring the speed of a first roller as compared to the speed of a second roller over which the filament is passing, and dividing the speed of the second roller by the speed of the first roller.

As discussed above, the present invention provides nonwoven materials including the fibers according to the present invention thermally bonded together. In particular, by incorporating the fibers of the present invention into nonwoven materials, the resulting nonwoven materials possess exceptional cross-directional strength and softness. These nonwoven materials can be used as at least one layer in various products, including hygienic products, such as sanitary napkins, incontinence products and diapers, comprising at least one liquid absorbent layer and at least one nonwoven material layer of the present invention and/or incorporating fibers of the present invention thermally bonded together. Further, the articles according to the present invention can include at least one liquid permeable or impermeable layer. For example, a diaper incorporating a nonwoven fabric of the present invention would include, as one embodiment, an outermost impermeable or permeable layer, an inner layer of the nonwoven material, and at least one intermediate absorbent layer. Thus, the nonwoven material of the invention can be used as the outer layer, which can be an outer impermeable layer but can also be permeable, and/or the inner nonwoven material. Of course, a plurality of nonwoven material layers and absorbent layers can be incorporated in the diaper (or other hygienic product) in various orientations, and a plurality of outer permeable and/or impermeable layers can be included for strength considerations.

Further, the nonwovens of the present invention can include a plurality of layers, with the layers being of the same fibers or different. Further, not all of the layers need include skin-core fibers of the polymer blend of the present invention. For example, the nonwovens of the present invention can used by themselves or in combination with other nonwovens, or in combination with other nonwovens or films.

Nonwovens according to the present invention can comprise 100% by weight of the skin-core fibers of the polymer blend of the present invention, or can comprise a combination of these fibers with other types of fibers. For example, the fibers in the nonwoven material can include fibers made from other polymers, such as polyolefins, polyesters, polyamides, polyvinyl acetates, polyvinyl alcohol and ethylene acrylic acid copolymers. These other fibers can be made by the same process or a different process, and can comprise the same or different size and/or cross-sectional shape. For example, the nonwovens can comprise a mixture of at least two different types of fibers, with one of the fibers comprising skin-core fibers formed from a polymeric bond curve enhancing agent, preferably, an ethylene vinyl acetate copolymer/polypropylene blend and the other fibers comprising skin-core polypropylene fibers and/or polymeric fibers not having a skin-core structure, such as polypropylene fibers or sheath-core fibers having different polymer materials in the sheath and core.

Thus, nonwovens of the present invention can comprise any combination of the fibers of the present invention, either alone or in combination with other fibers. As discussed above, the nonwovens of the present invention can be prepared at lighter basis weights while achieving structural properties that are at least equivalent to nonwovens having a heavier basis weight. Further, the bonding curve of cross-directional strength vs. temperature of the nonwovens is flatter whereby lower bonding temperatures can be used to achieve thermal bonding while achieving cross-directional strengths that usually require higher bonding temperatures. These lower bonding temperatures further contribute to the softness associated with the nonwovens using the polymer blend of the present invention.

The flattening of the bonding curve, raising of the bonding curve and/or the shifting of the bonding curve to the left can be evaluated for nonwovens produced from polymers containing a blend of polypropylene and polymeric bond curve enhancing agent, preferably ethylene vinyl acetate polymer, by determining bonding curve characteristics at set reference points along the bonding curve and/or by determining the area or reduced area under the bonding curve within the set reference points.

In particular, as can be seen in Figs. 5 and 6, the bonding curve of cross-directional strength (CDS) versus temperature has a generally parabolic function, with CDS

increasing with temperature until a maximum CDS is reached, and thereafter decreasing with temperature. Thus, as discussed above, if the bonding curve can be flattened, raised and/or shifted to the left, it would be possible to thermally bond the fibers at lower temperatures.

The set reference points according to the present invention are related to the maximum CDS and its associated temperature, the melting point of the fibers in the nonwoven and the CDS at the melting point, and the CDS measured at temperatures 10C lower than these temperatures. More specifically, values to be utilized for determining the flattening, raising and/or shifting to the left of peak of the bonding curve can be determined utilizing a second order regression quadratic fit to obtain a curve such as illustrated in Fig. 8. including lower and upper limits of regression A

and B, respectively.

The quadratic fit should be conducted over a temperature range which encompasses the melting point of the fiber, as determined by differential scanning, calorimetry (melting temperature or point D identified herein as Tm) for approximately 6C above the melting point to 15C below the melting point.

The quadratic fit is determined by the equation:
CDS = CzT2 + C1T + Co wherein:
T = Bonding Temperature (e.g., calendar roll, air temperature) CDS = Cross-Directional Strength of Nonwoven Material C2, C1 and Co = Coefficients of Regression In particular, the following points are illustrated in Fig. 8:
Tm = Temperature of differential scanning calorimetry endotherm maximum, which is believed to be the peak melting temperature of the fibers as determined by differential scanning calorimetry (illustrated as point D) TP = Temperature of regression maximum (-C1/2C2) , which is the temperature at which the bonding curve exhibits maximum cross-directional strength (illustrated as point C) Tm_lo = Temperature at ZOC to the left of Tm (illustrated as point H) Tp_lo = Temperature at 10C to the left of Tp (illustrated as point G) T1 Temperature at lower limit of regression Tu Temperature at upper limit of regression CDSm - Cross-directional strength at Tm (illustrated as point F) CDSP - Cross-directional strength at TP (illustrated as point E) CDSm_ lo = Cross-directional strength at Tm_lo (illustrated as point J) CDSP_ lo = Cross-directional strength at TP_lo (illustrated as point I) CDS1 = Lower limit of regression, which is the cross-directional strength at the lower limit of regression (illustrated as point A) CDS" = Upper limit of regression, which is the cross-directional strength at the upper limit of regression (illustrated as point B) CDS"~Y = Cross-directional strength of a line tangent to CDSP which is perpendicular to the CDS axis of the bonding curve (illustrated as the value at point K) O = Origin at CDS = 0 and T1 M = Point at CDS = 0 and T"

K = Point having coordinates of T1 and CDSP

L = Point having coordinates of Tm_,o and CDSp N = Point having coordinates of TP_lo and CDSP

P = Point having coordinates of T1 and CDSm Q = Point having coordinates of Tm and CDSP

The following values can be determined from the bonding curve for determining its flattening, raising and/or shifting to the left:

Cm = Percent of CDSP at Tm_lo = (CDSm_lo/CDSp) x 100 CP = Percent of CDSp at Tp_lo = (CDSP_lo/CDSP) x 100 C1 = Percent of CDSm at T1 = (CDS1/CDSm) x 100 ~Cm = Cm of invention - Cm of control = CP of invention - CP of control = C1 of invention - C1 of control A," - Area under curve from Tm to Tm_lo from CDS - 0, which is calculated as the integrated area of HJFD

AP - Area under curve from Tp to TP_lo from CDS - O, which is calculated as the integrated area of GIEC
A1 - Area under curve from Tm to T1 from CDS - 0, which is calculated as the integrated area of OAFD
%LIAm = .~~., of invention - A." of control) x 100 0 Am of control %~AP = f~, of invention - AF of control) x 100 0 Ap of control oDAl = ~$1 of invention - Al_ of control) x 100%
A1 of control WO 97!37065 Rm - Reduced area under curve from '=' T f to in ~,..
CDS = 0, which is calculated =om -as:
l t n x lCOo earared arAa o HJFD
integrated area of aLQD

Rp - Reduced area under curve from T
T -to o ., . , CDS = o, which is calculated t._~ f_om as:
i ntegrated area ~F rT~~ x 100a integrated area of GNEC

R~ - Reduced area under curve from T
LO T fr to m :
CDS = 0, which is calculated as: om ~nteQrated area of nnz~~ x 100a integrated area of OKQD

~Rm = Rm of invention - Rm of control ARP = Rp of invention - Rp of control ~R~ = R1 of invention - R1 of control In the examples of the present application, SigmaPlot~
Scientific Graphing Software - Version 4.1, (obtained from Jandel Scientific, Corte Madera,CA) was used to perform the quadratic (or curvilinear) regression and to obtain the ~'0 Coefficients of Regression. The SigmaPlot'~' Scientific Graphing Software User's Manual for IBM~PC and Compatibles, Version 4.0, December 1989, and the Supplement to the User's Manual Version 4.1, January 1991, describe the use of the 25 software. In particular, in the User's Manual for IBM~PC and Compatibles, at pages 4-164 to 4-166, information is provided about regression options. A regression order of 2 is used and data is regressed through data only from the minimum to the maximum values :Listed in Table 9. ' 30 The quadratic fit should be obtained for at least seven or more points aver the temperature range. The regression coefficient shou:Ld,be at least about 0.5, and is preferably above about 0.6. In the examples herein, the average is about 0.8.
The normal equations, by the method of least squares, can also be found ~n Fundamental Concepts in the Design of Experiments" by Tucks, CBS College Publishing, NY, 1982, at pages 130-136 fc>r linear regression and pages 137-139 for curvilinear regression. Th.e regression coefficient is ~:ne square root of the coefficient of~determination, which is the proportion of the total sum of squares that can be accounted for by the regression.

As indicated above, Tm is determined using differential scanning calorimetry (DSC). In particular, a Dupont DSC 2910 differential scanning calorimeter module with a Dupont Thermal Analyst TA 2000 was used to make the measurements. Also, the temperature was calibrated using an Indium standard. The instrument and its general operation are described in the DSC

2910 Operator's Manual, published 1993 by TA Instruments, 109 Lukens Drive, New Castle, DE 19720.

To obtain each Tm measurement, the fiber to be bonded, such as the staple fiber, is cut into 0.5 mm lengths and precisely weighed (to the nearest 0.01 mg) to about 3 mg in aluminum sample pans on a Perkin-Elmer AM-2 Autobalance. DSC

scans are made at heating rates of 20C per minute from room temperature (about 20C) to about 200C. Heat flow (in mcal/sec) is plotted vs. temperature. The melting points (Tm) of the fiber samples-are taken as the maximum values of the endothermic peaks. For example, where the scan includes a number of peaks, Tm would be determined using the highest temperature peak of the scan.

A representative DSC curve of Heat Flow (mcal/sec) vs.

Temperature (C) is illustrated in Fig. 9. More specifically, the DSC endotherm shows a peak at about 163C for a 3.24 mg.

sample of Example 45.

As illustrated in Fig. 8, Tm is to the left of TP because the DSC melting point is lower for this illustrative example than the temperature at the peak cross-directional strength.

However, this is for illustrative purposes only, and Tm can be to the right of Tp, or Tm can be equal to TP.

As will be discussed in the examples, Cz, Cl, Co, the minimum temperature of regression, the maximum temperature and the regression coefficient are set forth for the examples in Table 9. In most instances in the examples, Tm is approximately 163C, whereby approximately 6C above the DSC

melting point is about 169C, and approximately 15C below the DSC melting point is about 148C. Accordingly, the lower and upper limits of regression for the quadratic fit have been determined utilizing 148C and 169C, respectively, for most of the examples. However, as stated above, depending upon the DSC melting point of the fiber, other lower and upper limits of regression would be utilized.

The fiber according to the present invention can also be preferably characterized by various parameters utilizing the above-noted terminology.

Thus, for example, the present invention is also directed to skin-core fiber that preferably has a %0A1 which is greater than that of a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

Preferably, the %0A1 is increased by a member selected from the group consisting of at least about 3%, at least about 150, at least about 200, at least about 30%, at least about 40%, at least about 50% and at least about 60%.

Still more preferably, the fiber has a %~A1 and a ooAm which is greater than that of a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent. Even still more preferably, the fiber has a %~A1, a o~Am and a %~Ap which is greater than that of a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

The present invention is also directed to skin-core fiber containing polypropylene and polymeric bond curve enhancing agent which when processed into a nonwoven material by thermal bonding obtains for the nonwoven material at least one of a Cm of at least about 60a, more preferably at least about 750, and even more preferably at least about 900; a CP of at least about 75%, and preferably at least about 90%; a C1 of at least about 50%, more preferably at least about 70%, and even more preferably at least about 90%; a R1 of at least about 55%, preferably at least about 70%, more preferably at least about 80%, still more preferably at least about 850, still more preferably at least about 900, and even more preferably at least about 95%; and a Rm of at least about 900.

The present invention is also directed to a skin-core fiber containing polypropylene and polymeric bond curve WO 97/37065 PCT/US9?/04470 enhancing agent which when processed as a fiber into a nonwoven material by thermal bonding obtains for the nonwoven material at least one of an Am of at least about 3000, preferably at least about 5000, even more preferably at least about 6000 and even more preferably at least about 7000; an Ap of at least about 2500, preferably at least about 3500, even more preferably at least about 6000, and even more preferably at least about 6500; and an A1 of at least about 2500, preferably about 6000, even more preferably at least about 7500, even more preferably at least about 9000, and even more preferably at least about 10000.

The present invention is also directed to a skin-core fiber comprising polypropylene and a polymeric bond curve enhancing agent, preferably ethylene vinyl acetate polymers, the polypropylene and the polymeric bond curve enhancing agent being formed into the skin-core fiber under fiber processing conditions, and the skin-core fiber when processed into a thermally bonded nonwoven material under nonwoven processing conditions obtains, with respect to a nonwoven material produced under the same nonwoven processing conditions from fiber produced under the same fiber processing conditions but not containing the polymeric bond curve enhancing agent, at least one of a ~Cm of at least about 3%, preferably at least about 100, more preferably at least about 20%, still more preferably at least about 30%, still more preferably at least about 40%, still more preferably at least about 50%, and even more preferably at least about 60%; a OC1 of at least about 3%, preferably at least about 10%, more preferably at least about 20%, still more preferably at least about 30%, still more preferably at least about 40%, still more preferably at least about 500, and even more preferably at least about 60a;

a %DAm of at least about 3%, preferably at least about 100, more preferably at least about 20%, still more preferably at least about 300, and even more preferably at least about 40%;

a %~A1 as discussed above; a ~Rm of at least about 3%, preferably at least about 100, more preferably at least about 20%, still more preferably at least about 25%, and even more preferably at least about 300; and a ~R1 of at least about 30, preferably at least about 10%, more preferably at least about 20%, still more preferably at least about 30%, still more preferably at least about 35%, and even more preferably at least about 400.

As can be seen from the data presented in the examples below, thermally bonded nonwoven materials including fibers according to the present invention obtain absolute CDS values that are high. Additionally, the CDS values of the thermally bonded nonwoven materials produced including the fibers according to the present invention are relatively high as compared to nonwoven materials produced under the same conditions from fibers also produced under the same conditions but without the polymeric bond curve enhancing agent of the present invention. Thus, the nonwoven materials of the present invention can be defined using any one of the values described herein, or any combination of the values.

Expanding on the above, it is noted that fibers of the present invention which are thermally bonded into nonwoven materials provide resulting nonwoven materials that can have significantly higher strength properties than nonwoven materials produced under the same conditions but without the presence of polymeric bond curve enhancing agents. Thus, where all fiber production characteristics are the same, including each fiber forming step, and all nonwoven material production characteristics are the same, including all nonwoven material producing steps, the resulting nonwoven material which includes the fibers of the present invention has higher strength characteristics compared to the nonwoven material which does not include fibers according to the present invention.

For example, in a preferred embodiment of the invention wherein staple fibers are subjected to carding and bonding to form a thermally bonded nonwoven, all fiber forming, and carding and bonding operations for the fibers of the invention which include polypropylene and polymeric bond curve enhancing agent would be the same as that for the comparative fibers which contain polypropylene but not polymeric bond curve enhancing agent. In particular, the fiber processing would be conducted at the same spinning, crimping and cutting conditions to obtain staple fibers having the same or substantially the same denier, draw ratio and cross-sectional shape. The only difference would be in the composition of the polymer blend utilized in the spinning operation, and this composition would only be different in the inclusion of polymeric bond curve enhancing agent in the composition used to form the fiber according to the present invention; whereas, the composition for forming the comparative fiber would not contain polymeric bond curve enhancing agent. Then, as noted above, the formed staple fiber would be subjected to the same carding and bonding conditions.
While it is noted that the production of fibers and nonwovens under the same conditions is indicated, there will be occasions wherein the exact same conditions may not be exactly reproduceable, such as due to processing considerations. In such occasions, the conditions should be maintained as close as possible to achieve what is in effect the same conditions.
EXAMPLES
The invention is illustrated in the following non-limiting examples, which are provided for the purpose of representation, and are not to be construed as limiting the scope of the invention. All parts and percentages in the examples are by weight unless indicated otherwise.
Fibers and fabrics, including those of the present invention, were prepared using polymers identified as A-S in the following Table 1, and having the properties indicated therein. Polymers A-D are linear isotactic polypropylene homopolymers obtained from Montell USA Inc., Wilmington, Delaware, polymers E, F, K, M and P are ethylene vinyl acetate copolymers ELVAX~250, ELVAX~150, ELVAX~3180, ELVAX~750 and ELVAX°3124, respectively, and polymer G is an ethylene/vinylacetate/acid terpolymer ELVAX~4260, each of which is obtained from Dupont Company, Wilmington, Delaware, having weight percent of vinyl acetate in the polymers, as stated in Table 1. Polymers H-J are polyethylenes AspunT"'6835A, INSITET"'XU58200 . 03 (apparently now 8803 ) , and INSITET"'XU58200.02, respectively, obtained from Dow Chemical Company, Midland, Michigan. Polymer L is NUCREL°925 obtained from Dupont Company, Wilmington, Delaware. Polymer N is ELVALOY AM obtained from Dupont Company, Wilmington, Delaware.
Polymer O is KRATON°G1750 obtained from Shell Chemical Company, Houston, Texas. Polymers Q, R and S are Nylon 6, Nylon 66 and polyester obtained from North Sea Oil, Greenwood, South Carolina, and North Sea Oil obtaining these materials from Allied Signal, Morristown, N.J., or BASF, N.
Mount Olive, N.J., with the Nylon 6 having a relative viscosity of 60 {available from Allied Signal as 8200), the Nylon 66 having a relative viscosity of 45-60, and the polyester comprising a polyethylene terephthalate having an intrinsic viscosity of 0.7. The stabilizer used is the phosphate stabilizer IRGAFOS~168 obtained from Ciba-Geigy Corp., Tarrytown, New York, the antacid is calcium stearate from Witco Corporation, Greenswich, Connecticutt, and the pigment is Ti02 obtained from Ampacet Corporation, Tarrytown, New York.
In the Examples, the Montell polypropylenes may contain 75 ppm of IRGANOX~1076, the ELVAX resins may contain 50 to 1000 ppm of butylated hydroxytoluene (BHT), the Dow 6835 polyethylene may contain 1000 ppm of IRGAFOS°168, and the Dow XU58200.03 and XU58200.02 polyethylenes may contain 1000 ppm of SANDOTAB~P-EPQ, and are made with INSITET"' technology.
Fibers were individually prepared using a two step process. In the first step, polymer compositions were prepared by tumble mixing linear isotactic polypropylene flake identified as "A" to "D" in Table 1, with one or more of polymers "E" to "S" to form the polymer compositions listed in Table 2, except for the control examples wherein polymers "E" and "S" were not added.
In addition to containing the polypropylene, either alone or in combination with other polymers, as set forth in Table 2, the compositions also contained, in amounts denoted in the Table, from 0 to 500 ppm of a phosphate stabilizer, IRGAFOS~168, obtained from Ciba-Geigy, calcium stearate obtained from Witco as an antacid, and Ti02 obtained from Ampacet as a pigment. Primary antioxidants, such as IRGANOX°1076 and/or BHT are also included in the compositions, because the polymers include them as in-process shipping stabilizers.

After preparing the composition, the composition is then blanketed with nitrogen, heated to melt the composition, extruded and spun into circular or concave delta cross-section fibers at a melt temperature of about 280 to 315C, i.e., the highest temperature of the composition prior to extrusion through the spinnerette, using the process conditions and spinnerettes set forth in Tables 3 and 8. The melt is extruded through 675, 782, 1068 or 3125 hole spinnerettes at take-up rates of 762 to 1220 meters per minute to prepare spin yarn which is about 2.2 to 4.5 denier per filament, (2.4 to 5.0 dtex). The fiber threadlines in the quench box are exposed to normal ambient air quench (cross blow) with 10 to 25 millimeters of the quench nearest the spinnerette blocked off from the cross blow area to delay the quenching step, except for Example 72 which is not a skin-core fiber.

Standard winding equipment (available from Leesona and/or Bouligny) were used to wind the filaments onto bobbins.

The spinnerette descriptions are listed in Table 8, and one having ordinary skill in the art would be able to design such spinnerettes having the information including the number of holes, fiber shape, equivalent diameter (D) which in the case of a round cross-section would be the diameter, capillary length (L), entrance angle(6), counterbore diameter (B), holes per square inch, and length and width of the surface covered by the capillaries listed therein. However, to further assist in reviewing Table 8, Fig. 10 illustrating spinnerettes 1, 2, 6 and 7; Figs. lla-llc illustrating spinnerette 3; Figs. 12a and 12b illustrating spinnerette 4; and Figs. 13a and 13b illustrating spinnerette 5 are included. Dimensions illustrated in Figs. 11-13, unless otherwise stated, are in millimeters.

In the second step, the resulting continuous filaments were collectively drawn using a mechanical draw ratio of from 1.34 to 1.90X and quintet or septet roll temperature conditions of 40 to 75C and 100 to 120C, generally. The drawn tow is crimped at about 18 to 38 crimps per inch (70 to 149 crimps per 10 cm) using a stuffer box with steam or air.

During each step (the spinning, drawing and crimpi;
g) , , fiber is coated with a finish mixture (0.2 to 0.9 % b wei h y g :.

finish on fiber). Four different finish systems were d use .
(a) Finish "X" comprised an ethoxylated fatty acid est -d er a:
l an ethoxylated al~rohol phosphate (from George A. Goulston Co., Inc., Monroe, North Carolina, under the name Lurol PP 912);

(b) Finish "Y" Lurol PP5666/PP5667 (from George A. Goulston Co., Inc., Monroe, North Carolina) in the first and second steps as spin arid over finishes, respectively; (c) Finish "Z"

comprising a mixr_ure of 2 parts by weight of Nu Dry 90H from OS-i -8peci-allies,- I-nc : , Norcross; GA; -and-1 -part- by-we-fight--of---- --Lurol ASY from George A. Gaulston Co., Inc., Monroe, North Carolina in the first step as a spin finish and Lurol. ASY from George A. Goulston Co., Inc., Monroe, North Carolina in the second step as an over finish; or (d) Finish "W" comprising about 2 parts by weight of Lurol PP-6766 and 1 part by weight of Lurol ASY from George A. Goulston Co., Inc., Monroe, North Carolina (with about 97 parts by weight of water used to dilute these to a 3% concentration and including a minor percentage (1%) of Nuosept 95 from Nuodex Inc. division of HULS America Inc., Piscataway, N.J., as a biocide) in the first step as a spin finish, and Lurol ASY from George A.

Goulston Co., Inc., Monroe, North Carolina in the second step as an over finish. Finishes X and Y render the fiber :>.5 hydrophilic and wettable. Finish Z and W render the fiber hydrophobic and allow the fabric to repel water and aqueous liquids, The crimped fiber is cut to staple of about 1.5 inches (38 mm) length.

30 Fibers of each blend composition are then carded into conventional fiber webs at 250 feet per minute (76 m/min) using equipment and procedures as discussed in Legare, R. J., 1986 TAPPI Synthetic Fibers for Wet System and Thermal Bonding Applications, Boston Park Plaza Hotel & Towers, Boston Mass.

35 Oct 9-10, 1986, "Thermal Bonding of Polypropylene Fibers in Nonwovens", pages 1-13, 57-71 and attached Tables and Figures.

The Webmaster randomizers described in the TAPPI article were not used.

Specifically, two plies of the staple fibers are stacked in the machine direction, and bonded using a diamond design embossed calender roll and a smooth roll at roll temperatures ranging from about 145 to 172~C and roll pressures of 240 pounds per linear inch (420 Newtons per linear centimeter) to obtain nonwovens weighing nominally 20 1 or 17.5 1 grams per square yard (23.9 or 20.9 grams per square meter). The diamond pattern calender roll has a 15 0 land area, 379 spots/sq. in. with a depth of 0.030 inch. Further, the diamonds have a width of 0.040 inch, a height of 0.020 inch, and are spaced height-wise 0.088 inch on center, and width-wise 0.060 inch on center, and a pattern as illustrated in Fig. 7.

Test strips (six per sample) of each nonwoven, 1 inch x 7 inches (25 mm x 178 mm) are then tested, using a tensile tester Model 1122 from Instron Corporation, Canton, Mass. for cross-directional (CD) strength, elongation, and toughness (defined as energy to break fabric based on the area under the stress-strain curve values).

Specifically, the breaking load and elongation are determined in accordance with the "cut strip test" in ASTM D-1682-64 (Reapproved 1975), which is incorporated by reference in its entirety, using the Instron Tester set at constant rate of traverse testing mode. The gauge length is 5 inches, the crosshead speed is 5 inches/minute, and the extension rate is 100%/minute.

As noted above, the composition of each blend is shown in Table 2. Process conditions are shown in Table 3.

Characterizations of fiber spun from each composition and subjected to the listed process conditions are shown in Table 4. Tables 5, 6, and 7 show fabric cross directional properties obtained for each sample, with Table 5 showing cross-directional strength, Table 6 showing cross-directional elongation, and Table 7 showing cross-directional toughness.

The strength values (Table 5) and toughness values (Table 7) are normalized for a basis weight of 20 grams per square yard (23.9 grams per square meter), except where noted in Examples 44 and 45 where the values were normalized for a basis weight WO 97/37065 PCT/tJS97/04470 of 17.5 gsy (20.9 grams per square meter). The fabric elongation values are not normalized.

The control samples are those made from samples 16, 17, 25, 26, 34, 36, 38, 50, 58, 62 and 65, as well as sample 72 which is not a skin-core fiber.

Figure 5 illustrates a graph of a bonding curve of a nonwoven fabric containing fibers according to Examples 4, 7 and 10, as compared to control Example 25. As can been seen from this graph, the three uppermost curves (a), (b) and (c) of Examples 10, 4 and 7, respectively, have a flatter curve and enable bonding at lower temperatures as compared to curve (d) of Example 25. Thus, bonding can be achieved at lower temperatures using the fiber of the present invention, while preserving cross-directional strength and enabling the obtaining of a softer nonwoven fabric.

Figure 6 illustrates a graph of a bonding curve for a nonwoven fabric containing fibers according to Example 13 at a basis weight of 17.5 gsy instead of 20 gsy as compared to Example 25 at a basis weight of 20 gsy. This graph shows a flatter bonding curve for the fiber according to the present invention, and the ability to bond at lower temperatures while achieving a high cross-directional strength. Thus, high cross-directional strengths are achievable with the fibers of the present invention at lower bonding temperatures, whereby softer nonwoven fabrics can be obtained. It is noted that the data for Example 13 in the Tables is normalized to 20 gsy.

Representative data concerning bonding curve (cross-directional strength vs. bonding temperature relationship) characteristics for the examples according to the invention are set forth in Tables 9-11 and Tables 12-14 illustrate comparative data.

More specifically, C2, C1, Co, the minimum (lower) temperature of regression, the maximum (upper) temperature of regression and the regression coefficient, Tp and Tm are set forth for the examples in Table 9. As noted above, for most of the examples the minimum and maximum temperatures of regression are 148C and 169C, respectively. However, for certain comparative examples the data is determined by using other than 148C and 169C in view of the availability of data for these examples. In each of these instances, the lower point of regression is higher than 148C. However, once the bonding curve and regression coefficient have been determined, the calculated values of C1, Al, R1, CDS1 were determined using the definitions of C1, Al, Rl, CDS1 as set forth above.

Table 10 lists CDS1, CDSm, CDSp, CDSp_lo, CDSm_lo, Cp, Cm and C1 for the examples, with higher values of Cp, Cm and Cl indicating better performance at lower temperatures.

Table 11 lists Ap, A"" Al, Rm, RP and R1 for the examples .

Improvements in the area values Ap, Am and A1 represent either cross-directional strength improvements at all temperatures of the temperature interval, improvements at lower bonding temperatures, or both. Thus, either improvement could improve the integrated area value. However, the highest values result from flatter curves with high cross-directional strength values.

Rm, RP and R1 are values wherein the integrated areas under the bonding curves are subjected to a "double reduction"

to remove contributions of both the maximum cross-directional strength and the temperature interval. Thus, these reduced areas represent flatness of the bonding curve independent of the magnitude of the cross-directional strength. A value of 100% represents a completely flat cross-directional strength -temperature relationship.

Tables 12-14 show calculations obtained from Tables 10 and 11, wherein various values as denoted in Tables 10 and 11 are compared so as to denote flattening and/or shifting to the left of the bonding curve using a polymeric bond curve enhancing agent as compared to a bonding curve prepared under the same conditions (for fiber and nonwoven material production) except for the omission of polymeric bond curve enhancing agent. For example, improvements in the area under the bonding curve can be due to flattening of the bonding curve, to a cross-directional strength increase in the bonding curve, or both.

As can be discerned from the tables, the examples of the invention have been prepared with a range of properties and over a range of processing conditions, and with regard to a number of comparative examples of the same processing conditions but with the omission of polymeric bond curve enhancing agent. Thus, the performance of nonwovens containing fibers including polymeric bond curve enhancing agent can be compared to controls without polymeric bond curve enhancing agent. As noted above, Tables 12, 13, and 14 show these comparisons.

More specifically, Table 12 shows comparisons of CP, Cm and C1 between nonwovens of the invention obtained from fibers produced according to the invention wherein polymeric bond curve enhancing agent is included therein, and control nonwovens obtained from fibers produced under the same conditions but without polymeric bond curve enhancing agent therein. The comparisons are obtained by obtaining values of Cp, Cm and C~ for a nonwoven according to the invention, values of Cp, Cm and C lfor a control nonwoven, and respectively subtracting the control values from the values according to the invention to obtain oCp, ~Cm and ~C1, respectively.

Table 13 shows comparisons of Ap, Am and A 1 between nonwovens of the invention obtained from fibers produced according to the invention wherein polymeric bond curve enhancing agent is included therein, and control nonwovens obtained from fibers produced under the same conditions but without polymeric bond curve enhancing agent therein. The comparisons are obtained by obtaining values of AP, Am and A1 for a nonwoven according to the invention, and values of Ap, Am and A1 for a control nonwoven. The respective control values are then subtracted from the values according to the invention, the result is divided by the control value, and multiplied by 1000 to obtain %~, aDAa, and oDAi, respectively.

Table 14 shows comparisons of Rp, Rm and R1 between nonwovens of the invention obtained from fibers produced according to the invention wherein polymeric bond curve enhancing agent is included therein, and control nonwovens obtained from fibers produced under the same conditions but without polymeric bond curve enhancing agent therein. The comparisons are obtained by obtaining values of Rp, Rm and R1 for a nonwoven according to the invention, the values of RP, Rm and R1 for a control nonwoven, and respectively subtracting the control values from the values according to the invention to obtain ~Rp, ORm and OR1, respectively.
Table 15 illustrates rheological data for elastic (storage) modulus and complex viscosity for various polymer additives, and compares this data to that of polypropylene in the columns which list the ratio of the polymer additive to the polypropylene. As can be seen in Table 15, preferred polymeric additives have a lower elastic modulus and complex viscosity than polypropylene. Table 15 also lists the DSC
melting temperature of the polymers.
Comparison 1 Examples 3, 7 and 12 may be compared to control example 16. All examples were made to 2.2 dpf (nominally) by using a 1.55X draw ratio with polymer B. All were of round cross-section. Examples 3 and 7 contain 5o EVA; example 12 contains 3% EVA; and the control 16 has no EVA.

Although the control shows a good CDSp, it occurs at a high temperature and the bonding curve is steep. Thus, no improvement is realized for ~Cp, with CP being 89.10 for the control, and 75.50, 81.9%, and 86o for the nonwoven according to the invention. However, at Tm_lo and at temperatures as low 15C below the melting point of the fibers, improvements are made. Thus, Cm is 45.30 for the control, and 89%, 95.30, and 86.40 for the nonwoven according to the invention, thereby providing a ~Cm of about 41 to 500. Further, C1 is 21.8% for the control, and 68.4%, 85.2%, and 69.1% for the nonwoven according to the invention, thereby providing a ~C1 of about 47 to 630.

The control shows a good Ap due to the high temperature at which CDSP occurs. Thus, no improvement is realized for %~AP, with Ap being 6114 for the control, and 4716, 4435 and 5032 for the nonwoven according to the invention. However, at Tm_lo and to temperatures as low as 15C below the melting point of the fibers, improvements are made. Thus, Am is 4191 for the control, and 4995, 4649 and 5042 for the nonwoven according to the invention, thereby providing a o~A", of about 11 to 20%. Further, A1 is 5212 for the control, and 7018, 6752 and 7109 for the nonwoven according to the invention, thereby providing a oDAi of about 30 to 36%.

The control shows a good Rp due to the high temperature at which CDSp occurs. Thus, no improvement is realized for ~Rp, with Rp being 96.40 for the control, and 91.8%, 94o and 95.3% for the nonwoven according to the invention. However, at Tm_lo and at temperatures to as low as 15C below the melting point of the fibers, improvements are made. Thus, Rm is 66.10 for the control, and 97.30, 98.5% and 95.5% for the nonwoven according to the invention, thereby providing a significant ~Rm of about 30%. Further, R1 is 54.8% for the control, and 91.1%, 95.40 and 89.80 for the nonwoven according to the invention, thereby providing a ~R1 of about 35 to 40%.

The above comparative examples, as well as the comparative examples below are interesting in that they establish that nonwovens according to the present invention retain higher cross-directional strengths at lower temperatures than those of the controls. In other words, as compared to the controls, the nonwovens according to the present invention show higher retained cross-directional strengths as the comparisons are made at lower and lower temperatures. Thus, the nonwovens according to the present invention obtain ~C1 values which are generally higher than oCm values which are generally higher than MCP values; %~A1 values which are generally higher than %DAm values which are generally higher than %DAp values; and OR1 values which are generally higher than ~Rm values which are generally higher than ORP values .

Further comparisons are set forth below wherein data may be compared as described in Comparison-- 1, using the information provided in the Tables.
Comparison 2 Examples 13, 18, 40, 41 and 42 may be compared to control example 17. All were made to 1.9 dpf (nominally) by using a 1.35X draw ratio with polymer B. All were of round cross section. Examples 13, 18, 40, 41 and 42 contain 3o EVA. The - 57 _ control 17 has no EVA. Improvements may be noted in each range and type of comparison as denoted in Tables 12-14.
Comparison 3 Groupings 3a, 3b and 3c represent samples prepared on a larger extruder at higher rates as noted in Table 3. Results may be once again be noted in Tables 12-14.

(a) Example 35 may be compared to control example 34.

Each was made to 1.9 dpf (nominally) by using a 1.35X draw ratio with polymer B. Each was of concave delta cross-section. Example 35 contains 3% EVA. The control 34 has no EVA. Improvements may be noted in each range and type of comparison.

(b) Example 37 may be compared to control example 36.

Each was made to 1.9 dpf (nominally) by using a 1.35X draw ratio with polymer B. Each was of concave delta cross-section. Tables 3 and 8 shows the difference in spinnerette and amount of cross air blocked between examples 34, 35 and examples 36,37. Example 37 contains 3% EVA. The control 36 has no EVA. In this comparison, the flatness of the bond curve as indicated by the reduced area is not generally improved, but the values of Ap, Am, and A1 are higher by about 21 to 24% indicating cross-directional strength increases over the entire temperature range.

(c) Example 39 may be compared to control example 38.

Each was made to 1.9 dpf (nominally) by using a 1.35X draw ratio with polymer B. Each was of round cross-section.

Example 39 contains 3% EVA. The control 38 has no EVA. In this comparison, the flatness of the bond curve is not generally improved but the values of Ap, A"" and A1 are higher by about 42 to 37o indicating cross-directional strength increases over the entire temperature range.

Comparison 4 Examples 19, 20, 21 and 22 may be compared to control example 16. All were made to 2.2 dpf (nominally) by using a 1.55X draw ratio with polymer B. All were of round cross section. Examples 19, 20, 21 and 22 contain a combined 3 to 7% amount of EVA and PE (see Table 2 for specific amounts).

The control 16 has no EVA. Performance at lower ranges of temperature is improved as can be seen from reviewing the results in Tables 12-14.
Comparison 5 Example 24 may be compared to control example 26. Each was made to 1.8 dpf (nominally) by using a 1.85X draw ratio with polymer B. Each was of round cross-section. Both were made with hydrophobic finish system "Z". Example 24 contains 3o EVA. The control 26 has no EVA. Improvements may be noted in each range and type of comparison as denoted in Tables 12-14 .
Comparison 6 Examples 28, 29 and 30 may be compared to control example 25. All were made to 2.2 dpf (nominally) by using a 1.55X or 1.60X draw ratio with polymer B. All were of round cross section. Examples 2$, 29 and 30 contain 3% EVA. The control has no EVA. These samples were made on larger equipment at higher rates. Improvements may be noted in each range and type of comparison as denoted in Tables 12-14. Enhancement 20 of properties at lower bonding temperatures is evident.
CQm~arison 7 Examples 44 and 45 may be compared to control example 38.
Each was made at similar rates into, nominally, 17.5 gsy fabrics. Example 38 is of round cross-section and contains 25 no EVA bond curve flattening agent. The data are normalized to 20 gsy, similarly to all the other examples. Examples 44 and 45, however, are normalized to 17.5 gsy and represent fabrics of fibers according to the present invention made to a lower basis weight. Examples 44 and 45 each contain 30 of ELVAX~3180 and are concave delta cross-section. Even though basis weight differences of 2.5 gsy typically account for about 50 to 125 g/in differences in cross-directional strength under these bonding conditions (about 14%), examples 44 and 45 still exceed the control example 38 in all of the comparative values (DC, DA and DR), as indicated by the values in Tables 12, 13 and 14. This indicates that cross-directional strength is improved over the entire temperature range and that the bond curves are "flatter" also. Example 46 shows the values when the data of example 45 is normalized to 20 gsy. A 14% increase in each CDS value (in Table 5) is realized.
Comparison 8 Examples 51, 52, 53, 54, 59, 60 and 61 may be compared with control example 58. All were made at similar rates to nominally 1.9 denier using a 1.35X draw ratio. The control l0 contains no polymeric band curve enhancing agent. The invention examples contain 3% of various ethylene copolymers, as denoted in Tables 1 and 2. Although DC and DR values actually are negative, all the DA values are positive by 14 to 48%, indicating CD strength improvement over the entire temperature range, as seen from the cross-directianal strength values in Tables 5, 9 and 10.
Comparison 9 Examples 56 and 57 may be compared to control example 62.
Each was made at similar rates into, nominally, 1.9 dpf using a 1.35X draw ratio. Each was of concave delta cross-sectional shape. Examples 56 and 57 were made into about 17.5 gsy fabrics and the cross-directional strength values normalized to 20 gsy basis weight. The control, example 62, was bonded into 19.7 gsy fabrics and normalized to 20 gsy basis weight.
Example 56 contains 3a Elvax~3180 and 1,000 ppm of a fluorocarbon processing aid, DynamarTr' FX5920A. Example 57 contains 3a Elvax~ 3124 and 500 ppm of DynamarTM FX5920A. The control, example 62, contains no ethylene vinyl acetate copolymer bond curve enhancing agent nor any processing aid.
The DC and OR values are negative. The DA values are positive by 3 to 240, indicating cross-directional strength improvement over the entire temperature range.
Comparison 10 Example 71 may be compared to control example 50. Each was made on similar equipment into, nominally, 1.9 dpf using a 1.35X draw ratio. Each was made with a round cross sectional shape. The main difference is in the type of finish used and that Example 71 contains 3% ELVAX~3124 and control Example 50 does not contain any polymeric bond curve flattening agent. The fabric tensile values for Example 71 are high, especially for nonwoven fabric from hydrophobic fiber. Example 71 used finish "W", control 50 used finish "X". The values of AP, Am and A1 are higher by about 31 to 35%
indicating cross-directional strength increase over the entire temperature range.
Comparison 11 Examples 66, 67, 68, and 69, may be compared with control example 65. All were made at similar rates using a 675 hole spinnerette (round cross-section) to nominally 2.2 to 2.5 denier using a 1.35X draw ratio. The control contains no additives. The invention examples contain 30 of various additives (note Tables 1 and 2). The DA values are positive by 4 to 18o when the additive is Nylon 6 indicating CDS
improvement over the entire temperature range. The DA values are negative when the additive is either polyethylene terephthalate or Nylon 66 indicating that not all polymeric additives function as polymeric bond curve enhancing agents.
Comparison 12 Example 70 may be compared to control example 17. Each was made at similar rates into, nominally, 1.9 dpf using a 1.35X draw ratio. Each was made suing a 1068 hole (round cross-section) spinnerette. Example 70 contains 3% Elvax~3124 and 3o Nylon 6. The control 17 contains no polymeric additives. Each DC, DA, and DR value is positive, indicating bond curve enhancement by CDS improvement over the entire temperature range by shifting of the peak temperature maximum and by flattening the curve in general. The DA values are shown in Table 13 to increase by 21 to 44%.
C'om~arison 13 The DA values of examples 27, 40, 43, 46, 47, 70, and 71 exceed the best complete set of DA values of all the controls.
For DAP, the best control value is 6114 from control sample 16. For ~Am and ~A1, the best values are 5453 and 7716 from control sample 50. Examples 27, 40, 43, 46, 47 contain 30 ELVAX~3180 or ELVAX~250. Example 71 contains 3% ELVAX~3124 and Example 70 contains 3% ELVAXp3124 and 3o Nylon 6. The values are shown in Table 13.
A much larger group of examples show improvement over the best control when only °s~Am and o~A1 are examined. In addition to the examples listed above, examples 13, 18, 21, 22, 27, 37, 39, 41, 45, 52, 53, 55, 56, 59, 60, and 66 also exhibit improved %~Am and %~A1 values.
Although the invention has been described with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to the particulars disclosed and extends to all equivalents within the scope of the claims.

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SUBSTITUTE SHEET (RULE 26) WO 97!37065 PCT/US97/04470 TABLE 2 - COMPOSITIONS (BY WEIGHT) EX. PP Wt. °/ AGENT Wt. % AGENT WT. % STABILIZER ANTACID PIGMENT
pP 1 AGENT1 2 AGENT2 1 C 89.8 E 10 - - 0.05 0.050 0.063 2 C 94.9 E 5 - - 0.05 0.025 0.063 3 B 94.9 E 5 - - 0.05 0.025 0.063 4 A 94.9 E 5 - - 0.00 0.025 0.063 A 94.9 E 5 - - 0.00 0.025 0.063 6 A/D 72.9/20 E 7 - - 0.00 0.025 0.063 7 B 94.9 E 5 - - 0.05 0.025 0.063 g B 94.9 F 5 - - 0.05 0.025 0.063 g B 94.9 E 5 - - 0.05 0.025 0.063 B 96.9 E 3 - - 0.05 0.025 0.063 11 B 94.9 E 5 - - 0.05 0.025 0.063 12 B 96.9 E 3 - - 0.05 0.025 0.063 13 B 96.9 E 3 - - 0.05 0.025 0.063 14 B 96.8 E 3 - - 0.05 0.050 0.063 B 94.9 G 5 - - 0.05 0.025 0.063 C-16 B 99.9 - - - - 0.05 0.025 0.063 C-17 B 99.9 - _ - - 0.05 0.025 0.063 18 B 96.9 E 3 - - 0.05 0.025 0.063 19 B 96.9 E 1 I 2 0.05 0.025 0.063 B 92.9 E 2.3 I 4.7 0.05 0.025 0.063 21 B 93.9 E 2 J 4 0.05 0.025 0.063 22 B 92.9 E 2.3 H 4.7 0.05 0.025 0.063 23 B 96.9 E 3 - - 0.05 0.025 0.063 24 B 96.9 E 3 - - 0.05 0.025 0.063 C-25 B 99.8 - - - - 0.05 0.100 0.075 C-26 B 99.8 - - - - 0.05 0.100 0.075 27 B 96.9 E 3 - - 0.05 0.025 0.063 28 B 96.9 E 3 - - 0.05 0.025 0.063 29 B 96.9 E 3 - - 0.05 0.025 0.063 B 96.9 E 3 - - 0.05 0.025 0.063 31 B 96.9 E 3 - - 0.00 0.025 0.063 32 B 96.9 E 3 - - 0.00 0.025 0.063 33 B 96.9 E 3 - - 0.00 0.025 0.063 C-34 B 99.8 - - - - 0.05 0.100 0.100 B 96.8 E 3 - - 0.05 0.100 0.100 C-36 B 99.8 - - - - 0.05 0.100 0.100 37 B 96.8 E 3 - - 0.05 0.100 0.100 C-38 B 99.8 - - - - 0.05 0.100 0.100 39 B 96.8 E 3 - - 0.05 0.100 0.100 B 96.9 K 3 - - 0.05 0.00 0.063 41 B 96.9 K 3 - - 0.05 0.30 0.063 42 B 96.9 K 3 - - 0.05 0.30 0.063 43 B 96.9 K 3 - - 0.01 0.05 0.075 44 B 96.9 K 3 - - 0.01 0.05 0.075 B 96.9 K 3 - - 0.01 0.05 0.075 46 B 96.9 K 3 0.01 0.05 0.075 SUBSTITUTE SHEET (RULE 26) WO 97137065 PCTlUS97104470 TABLE 2 - COMPOSITIONS (BY WEIGHT) EX PP Wt. °/ AGENT wf, % AGENT WT'. % STABILIZER ANTACID PIGMENT

47 B 96.9 K 3 - - 0.01 0.05 0.075 48 B 96.9 K 3 - - 0.01 0.05 0.075 49 B 96.9 K 3 - - 0.01 0.05 0.075 C-50 B 99.8 - - - - 0.05 0.10 0.100 51 B 96.9 M 3 - - 0.05 0.05 0.06 52 B 96.9 L 3 - - 0.05 0.05 0.06 53 B 96.9 N 3 - - 0.05 0.05 0.06 54 B 96.9 O 3 - - 0.05 0.05 0.06 55' B 99.8 - - - - 0.05 0.05 0.06 56~ B 96.9 E 3 - - 0.01 0.05 0.05 5T B 96.9 P 3 - - 0.00 0.02 0.05 C-58 B 99.9 - - - - 0.01 0.05 0.075 59 8 96.9 H 3 - - 0.01 0.05 0.075 60 B 96.9 E 3 - - 0.01 0.05 0.075 61 B 96.9 1 3 - - 0.01 0.05 0.075 C-62 B 99.9 - - - - 0.01 0.05 0.075 63 B 89.7 J 10 - - 0.05 0.10 0.10 64 B 89.7 J 10 - - 0.05 0.10 0.10 C-65 B 99.9 - - - - 0.05 0.05 0.065 66 B 96.9 Q 3 - - 0.05 0.05 0.065 67 B 96.9 R 3 - - 0.05 0.05 0.065 68 B 96.9 S 3 - - 0.05 0.05 0.065 69 B 96.9 Q 3 - - 0.05 0.05 0.065 70 B 93.9 P 3 Q 3 0.05 0.05 0.065 71 B 96.9 P 3 - - 0.0 0.02 0.05 C-72 C 89.9 E 10 - - 0.2 0.00 0.00 1 Example 55 includes 0.5 wt. % Hydrobrite 550 PO oil (available from Witco Corporation, Greenswich, Connecticutt) 2 Example 56 includes 0.10 wt. % Dynamar"'' FX5920A (available from 3M, Specialty Fluoropolymers Dept.,St. Paul, MN) 3 Example 57 includes 0.05 wt. % Dynamar"" FX5920A (available from 3M, Specialty Fluoropolymers Dept.. ST. Paul, MN) SUBSTITUTE SHEET (RULE 26) TABLE - PROCESS S - ENIERS

EX. THROUGHPUT' D STAPLE
SPIN TAKE- SPIN DENIER
SPIN (glmin/hole) DPF RATIO
CROSS UP (g19000m)DPF
TEMP RATE DRAW
ID' (m/min) (g19000m) BLOW RATIOz (C) BLOCKED
(mm) 1 303 1 25 0.31 770 3.6 1.52 3.0 1.20 2 315 1 25 0.27 900 2.7 1.54 2.3 1.20 3 315 1 25 0.27 900 2.7 t .53 2.1 1.29 4 315 1 25 0.27 900 2.7 1.55 2.1 1.28 315 1 25 0.27 900 2.7 1.53 2.2 1.25 6 315 1 25 0.27 900 2.7 1.53 2.2 1.24 7 296 2 25 0.23 765 2.7 1.55 2.1 1.27 B 310 2 25 0.26 850 2.7 1.53 2.2 1.21 9 295 3 25 0.26 850 2.8 1.54 2.4 1.15 295 3 25 0.26 850 2.8 1.55 2.3 1.21 11 300 2 25 0.27 900 2.7 1.56 2.2 1.23 12 300 2 25 0.27 900 2.7 1.54 2.3 1.21 13 295 4 25 0.23 900 2.3 1.35 2.1 1.08 14 300 2 25 0.26 850 2.7 1.53 2.4 1.15 300 2 25 0.31 900 3.1 1.54 2.4 1.27 C-16 295 2 25 0.27 900 2.7 1.55 2.2 1.21 C-17 295 2 25 0.23 900 2.3 1.36 2.0 1.15 18 295 2 25 0.23 900 2.2 1.34 2.0 1.12 19 295 2 25 0.27 900 2.7 1.55 2.4 1.17 295 2 25 0.27 900 2.7 1.55 2.3 1.17 21 295 2 25 0.27 900 2.7 1.56 1.9 1.42 22 295 2 25 0.27 900 2.7 1.55 1.9 1.42 23 305 2 20 0.31 1130 2.5 1.35 2.2 1.14 24 305 2 20 0.31 1130 2.5 1.85 1.8 1.39 C-25 297 7 25 0.35 1100 2.9 1.55 2.2 1.32 C-26 305 2 25 0.32 1100 2.6 1.90 1.8 1.44 27 305 2 20 0.34 1130 2.7 1.40 2.2 1.23 28 305 2 20 0.34 1130 2.7 1.40 2.2 1.23 29 305 2 20 0.34 1130 2.7 1.40 ' 2.2 1.23 305 2 20 0.34 1130 2.7 1.40 2.2 1.23 31 300 2 20 0.32 949 3.0 1.60 2.3 1.30 32 300 2 20 0.32 949 3.0 1.60 2.3 1.30 33 300 2 20 0.32 949 3.0 1.60 2.3 1.30 C-34 300 4 20 0.30 1220 2.2 1.40 2.1 1.05 300 4 20 0.30 1220 2.2 1.40 2.2 1.00 C-36 300 5 10 0.30 1220 2.2 1.40 2.1 1.05 37 300 5 10 0.30 1220 2.2 1.40 1.9 1.16 C-38 300 2 20 0.30 1220 2.2 1.40 1.9 1.16 39 300 2 20 0.30 1220 2.2 1.40 2.1 1.05 295 2 25 0.22 900 2.2 1.35 1.9 1.16 41 295 2 25 0.22 900 2.2 1.35 1.9 1.16 42 310 2 25 0.22 900 2.2 1.35 1.9 1.16 43 300 5 16 0.31 1220 2.3 1.35 2.0 1.15 44 300 5 16 0.31 1220 2.3 1.35 2.0 1.15 SUBSTITUTE SHEET (RULE 26) TABLE S -- DENIERS
PROCESS SPIN
CONDITION DRAW
EX. STAPLE
SPIN DENIER
SPIN DPF
CROSS RATIO
THROUGHPUT' DPF
TAKE- DRAW
TEMP (gI9000m) ID' (gf9000m) BLOW RATIO' (glminlhole) UP
(C) BLOCKED
RATE
(mm) (mlmin) 45 295 5 16 0.31 1226 2.3 1.35 2.0 1.17 46 295 5 16 0.31 1226 2.3 1.35 2.0 1.17 47 295 5 16 0.31 1226 2.3 1.35 2.0 1.17 48 295 5 16 0.31 1226 2.3 1.35 2.1 1.12 49 300 2 20 0.31 1226 2.3 1.35 2.2 1.06 C-50 300 2 20 0.31 1226 2.3 1.35 2.0 1.15 51 305 2 25 0.22 900 2.2 1.35 1.9 1.16 52 300 2 25 0.27 900 2.7 1.55 2.0 1.35 53 300 2 25 0.22 900 2.2 1.35 1.9 1.16 54 300 2 25 0.22 900 2.2 1.35 1.9 1.16 55 300 2 25 0.22 900 2.2 1.35 1.9 1.16 56 300 5 13 0.22 850 2.3 1.35 2.2 1.05 II 300 5 13 0.22 850 2.3 1.35 1.9 1.21 C-58 300 2 18 0.22 900 2.2 1.35 1.9 1.15 59 300 2 18 0.22 900 2.2 1.35 2.0 1.10 60 300 2 18 0.22 900 2.2 1.35 2.1 1.04 61 300 2 18 0.22 900 2.2 1.35 2.1 1.04 C-62 300 4 18 0.22 900 2.2 1.35 2.1 1.04 63 305 2 25 0.22 800 2.5 1.25 2.3 1.07 64 310 2 25 0.22 800 2.5 1.25 2.3 1.10 C-65 295 6 25 0.27 900 2.7 1.35 2.5 1.09 66 280 6 25 0.27 900 2.7 1.35 2.5 1.08 67 280 6 25 0.27 900 2.7 1.35 2.5 1.06 68 306 6 25 0.26 900 2.6 1.35 2.2 1.20 69 300 6 25 0.28 900 2.8 1.35 2.6 1.07 70 300 2 25 0.23 900 2.3 1.35 2.1 1.10 71 305 2 20 0.24 943 2.3 1.35 2.0 1.15 C-72 280 6 0 0.38 762 4.5 1.65 3.4 1.32 1 See Table 8 2 Denier Draw Ratio = Spin DPF/Stapfe DPF
3 Throughput = (dof x no. of holes in soinnerette) x Take uo rate (Take up rate = Speed of godet roll in m/min) SUBSTITUTE SHEET (RULE 26) z O~ M ~Q M t17 ~ N 07 O a0 O~ O 07 M O ~f (O Wf'1 00 h ~ M ~ tD t0 W
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SUBSTtTUT~ SHEET (RULE 26) WO 97/37065 PCTlUS97/04470 z O , , . . . ~ sf ~ V O~ .- tD ~ ~ M M , O7 ~ u') <o mci o v ri v M ~ cp ~ v co v w z n (D n O ~ m O (D (D O (D 47 O N M O M
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SUBSTITUTE SHEET (RULE 26) TABLE 5 - NORMALIZED CROSS-DIRECTIONAL STRENGTH (CDS) (g/in) ~~I EX. ACTUAL CDS CDS CDS CDS CDS CDS CDS CDS CDS
AVERAGE @ @ @ @ @ @ @ @ @
FABRIC 148°C 151°C 154°C 157°C 160°C
163°C 166°C 169°C 172°C
WEIGHT (glin) (glin) (glin) (glin) (g/in) (glin) (glin) (glin) (glin) (9IYdz) 1 20.0 95 116 207 259 354 307 293 288 293 2 19.8 388 398 416 418 339 266 249 258 229 3 20.0 305 463 496 484 506 497 438 426 404 4 19.9 365 515 515 542 503 483 400 456 415 20.4 342 416 423 472 541 549 489 480 442 6 20.3 369 409 512 520 505 453 540 539 506 7 19.9 358 481 467 418 482 464 418 371 404 8 20.4 319 352 324 3t9 370 393 320 314 247 9 20.0 385 470 427 484 506 482 468 437 448 19.9 466 514 541 531 533 536 544 535 472 12 20.7 353 461 519 510 544 451 516 517 405 13 20.1 416 464 518 580 542 562 551 541 525 14 19.6 297 398 488 486 468 427 446 435 -C16 20.1 145 173 354 347 504 525 612 578 517 C17 20.7 203 349 451 530 562 603 547 563 530 18 20.1 402 504 577 642 608 600 659 549 574 19 20.6 268 293 402 480 466 511 492 464 -20.1 272 360 470 484 493 451 465 420 402 21 20.1 459 516 573 556 629 493 508 411 449 22 20.9 356 426 527 560 578 520 531 482 465 23 20.9 246 272 356 409 440 409 428 375 342 24 20.1 177 208 259 330 372 430 354 357 367 C25 20.9 285 346 304 450 467 423 344 299 C26 19.7 172 260 249 290 267 238 27 20.4 386 569 594 680 677 757 542 561 -28 20.8 404 389 503 471 561 542 554 470 -29 21.4 293 475 476 405 480 435 409 463 -20.2 365 394 506 502 535 498 492 , 423 -C34 16.9 276 320 474 518 515 570 471 492 -16.7 386 492 510 540 560 471 502 449 -C36 16.7 357 473 418 534 517 439 519 440 37 18.1 463 584 535 600 629 615 594 573 -C38 16.7 303 379 443 472 462 4t5 412 450 -39 17.3 442 532 601 597 585 604 564 625 -20.2 363 536 602 646 690 633 651 692 41 20.1 300 445 548 572 680 610 618 613 42 20.2 427 532 434 572 509 574 530 550 481 43 18.2 509 612 641 682 552 672 631 539 512 44" 15.6 452 482 520 534 467 456 488 464 414 4 ~ 17 4 ~ 5 5 ~ 534 I 654 I 6~5 I 638 I 586 I 9y1 I 546 I I
SUBSTITUTE SHEET (RULE 2fi) TABLE 5 - NORMALIZED CROSS-DIRECTIONAL STRENGTH (CDS) (g/in) EX. ACTUAL CDS CDS CDS CDS CDS CDS CDS CDS CDS
AVERAGE @ @ @ @
FABRIC 148°C 151°C 154°C 157°C 160°C
163°C 166°C 169°C 172°C
WEIGHT (glin) (g/in) (glin) (glin) (glin) (glin) (glin) (g/in) (g/in) (91Yd2) ~~, 46 17.4 600 610 748 726 729 669 682 624 47 19.5 567 734 702 722 721 767 765 698 48 20.3 430 407 458 485 531 492 454 491 -49 21.0 296 439 495 515 509 475 446 466 -C50 19.0 362 395 541 573 532 542 505 477 -51 20.1 - 424 469 509 527 560 495 484 -52 20.4 - 514 542 624 632 636 645 566 -53 20.1 - 501 562 539 598 564 524 554 -54 20.2 - 431 438 476 535 551 469 436 -55 19.9 - 473 469 602 608 613 626 613 -56 17.3 408 48t 589 553 575 611 526 468 -57 17.7 410 313 532 558 534 454 442 450 C58 20.5 348 396 418 442 43B 383 393 416 -59 20.7 453 525 523 590 647 573 521 446 -60 21.3 529 534 588 661 629 599 542 486 -61 19.9 444 489 537 529 540 446 452 463 -C62 19.7 501 413 507 44t 444 438 485 446 -63 21.2 495 504 506 513 507 470 432 380 -64 20.4 310 362 461 492 424 442 366 335 C65 20.3 438 421 479 548 523 478 395 478 -66 20.4 488 543 591 580 587 558 591 524 -67 20.3 - 439 464 472 474 469 476 484 -68 20.3 205 424 417 449 463 439 414 432 -69 20.2 443 455 537 539 505 504 499 495 -70 19.9 456 535 637 692 644 699 668 629 71 17.2 565 637 757 648 746 694 649 451 -C72 20.4 - - - 167 214 254 298 271 283 " Examples 44 and 45 nortnaiized to basis weight of 17.5 gsy.
SUBSTITUTE SHEET (RULE 26) ' IONALLONGATION ) TABLE E (CDE (%) -CROSS-DIRECT

EX. ACTUAL CDE CDE CDE CDE CDE CDE CDE CDE CDE

AVERAGE @ @ @ @ @ @ @

WEIGHT (%) (%) (%) (%) (%) (%) (%) (%) (%) (9~Yd2) 1 20.0 49 57 76 84 97 86 80 76 72 2 19.8 109 108 112 101 85 77 66 68 56 3 20.0 84 108 106 100 104 92 78 76 73 4 19.9 81 106 101 107 93 89 73 83 73 'I 20.4 89 97 101 105 112 112 98 96 90 6 20.3 95 99 105 103 102 87 99 94 78 7 19.9 103 121 125 1t2 122 111 89 76 82 8 20.4 108 108 102 96 111 108 89 78 67 9 20.0 104 112 101 108 112 100 88 82 81 19.9 109 117 117 115 104 96 99 89 70 12 20.7 100 119 131 117 123 103 106 99 79 13 20.1 127 124 133 144 120 120 108 104 98 14 19.6 94 101 130 124 121 98 98 96 -C16 20.1 54 49 80 76 103 96 105 91 85 C17 20.7 59 87 105 112 121 128 103 105 98 18 20.1 93 120 129 137 117 107 116 97 88 19 20.6 75 83 100 123 112 113 106 95 93 20.1 79 100 119 111 104 93 103 89 87 21 20.1 121 121 136 123 132 109 109 82 89 22 20.9 90 109 119 128 128 114 102 89 86 23 20.9 100 102 129 124 142 121 114 101 88 24 20.1 94 92 98 114 118 109 87 83 80 C25 20.9 77 85 78 94 100 75 69 61 C26 19.7 76 83 89 95 81 73 27 20.4 83 93 102 99 99 97 70 69 28 20.8 99 99 110 101 112 103 100 81 29 21.4 82 111 109 85 102 91 82 81 20.2 96 94 111 108 110 94 91 73 C34 16.9 77 85 104 98 103 95 85 81 16.7 94 112 114 109 109 B7 84 78 C36 16.7 89 96 94 110 95 84 87 75 37 18.1 92 100 103 102 105 90 84 74 C38 16.7 77 85 100 106 87 83 80 83 39 17.3 97 99 99 118 92 102 94 85 20.2 98 129 128 122 124 119 112 109 84 41 20.1 77 102 112 114 129 106 110 97 92 42 20.2 96 107 94 109 97 106 88 89 79 I

43 18.2 86 99 98 100 95 102 88 69 60 SUBSTITUTE SHEET (RULE 26) _ 7 TABLE IONAL LONGATION E) 6 E (CD (%) -CROSS-DIRECT

EX. ACTUAL CDE CDE CDE CDE CDE CDE CDE CDE CDE

AVERAGE@ @ @ @ @ @ @ @ @

WEIGHT (%) (%) (%) (%) (%) (%) (%) (%) (%) (9~Yd') 44 15.6 97 93 100 94 83 81 72 76 64 45 17.4 106 109 118 111 95 89 78 66 -46 17.4 106 109 118 111 95 89 78 66 -47 19.5 84 98 91 93 90 88 87 75 -48 20.3 85 77 91 84 91 82 72 74 -49 21.0 88 121 130 115 107 103 88 98 C50 19.0 77 80 100 97 87 90 83 73 -51 20.1 - 97 103 103 95 102 87 79 -52 20.4 - 97 92 104 96 101 99 83 -53 20.1 - 102 115 108 108 99 84 87 -54 20.2 - 100 97 97 107 95 86 77 55 19.9 - 93 90 104 101 95 93 95 -56 17.3 85 94 100 110 114 117 83 72 -57 17.7 97 97 116 121 98 67 85 87 -C58 20.5 124 132 114 134 129 101 99 98 -59 20.7 116 129 118 131 134 108 96 77 -60 21.3 111 103 114 121 115 95 87 75 -61 19.9 104 113 113 98 100 85 85 85 -C62 19.7 100 91 102 88 82 84 73 83 -63 21.2 135 143 134 137 118 103 85 73 -64 20.4 103 88 123 119 74 99 84 69 -C65 20.3 132 132 118 127 127 120 89 104 -66 20.4 93 85 105 103 103 96 99 82 67 20.3 - 110 121 121 106 97 92 93 -68 20.3 66 88 85 87 91 87 73 79 69 20.2 123 116 127 131 117 108 96 98 -70 19.9 90 101 120 116 102 104 103 97 -71 17.2 80 89 102 84 93 78 79 53 -C72 20.4 56 71 69 71 65 60 SUBSTITUTE 5HE~T (RULE 26) (CD TEA) (g/in per inch) EX. ACTUAL CD CD CD CD CD CD CD CD CD
AVERAGE TEA TEA TEA TEA TEA TEA TEA TEA TEA
FABRIC @ @ @ @ @ @ @ @ @
WEIGHT 148°C 151°C 154°C 157°C 160°C
163°C 166°C 169°C 172°C
(9~Y~z) 1 20.0 25 35 81 113 179 141 122 115 112 2 19.8 223 222 243 216 154 106 88 90 67 3 20.0 133 257 274 255 270 235 176 168 153 4 19.9 154 285 273 302 244 224 157 197 158 20.4 167 210 226 254 309 319 246 240 207 6 20.3 185 217 284 278 272 205 279 262 198 7 19.9 194 302 301 245 306 288 196 149 176 8 20.4 182 198 177 162 214 220 155 128 87 9 20.0 214 278 225 272 295 249 219 191 188 19.9 265 311 333 321 298 269 282 251 179 12 20.7 188 293 359 326 358 246 285 276 165 13 20.1 272 297 354 432 345 352 312 298 280 14 19.6 150 213 327 318 297 216 230 220 -C16 20.1 42 44 145 138 272 261 331 274 189 C17 20.7 63 156 249 303 346 401 289 309 269 18 20.1 200 314 383 448 373 340 391 277 263 19 20.6 105 125 209 308 276 296 270 230 214 20.1 113 185 290 279 271 196 250 266 180 21 20.1 293 331 401 358 428 287 284 177 210 22 20.9 171 245 330 374 383 311 276 218 204 23 20.9 131 147 241 264 328 255 252 198 155 24 20.1 86 100 132 t96 231 240 163 153 151 C25 20.9 122 154 125 220 245 168 125 97 C26 19.7 70 86 114 142 92 76 27 20.4 172 278 326 362 357 386 206 209 -28 20.8 211 202 289 255 330 293 294 203 29 21.4 132 280 272 184 256 207 178 201 -20.2 127 188 195 292 285 311 245 234 165 C34 16.9 112 144 256 271 274 285 214 210 16.7 194 289 310 311 322 231 227 200 C36 16.7 168 240 207 307 262 199 246 181 37 18.1 229 319 296 326 351 291 266 224 C38 16.7 122 168 228 262 212 180 174 200 39 17.3 229 283 315 372 289 331 293 284 20.2 184 355 400 412 452 385 382 394 258 41 20.1 122 234 319 339 458 343 354 315 299 42 20.2 215 292 215 324 255 314 242 250 195 SUBSTITUTE SHEET (RULE 26) _ 77 _ (CD TEA) (glin per inch) EX. ACTUAL CD CD CD CD CO CD CD CD CD
AVERAGE TEA TEA TEA TEA TEA TEA TEA TEA TEA
FABRIC @ @ @ @ @ @ @ @
WEIGHT 148°C 151°C 154°C 157°C 160°C
163°C 166°C 169°C 172°C
(glyd~) 44" 15.6 229 238 270 267 208 198 187 183 144 45" 17.4 286 307 397 362 314 268 251 196 -46 17.4 327 351 454 413 359 306 287 224 -I 47 19.5 251 381 337 358 347 361 355 276 -48 20.3 194 168 224 216 252 216 173 197 -49 21.0 145 275 332 306 281 252 205 241 -C50 19.0 145 166 281 285 242 252 222 178 51 20.1 - 215 256 276 206 303 231 207 -52 20.4 - 266 267 350 327 346 346 251 -53 20.1 - 263 342 298 336 288 228 249 -54 20.2 - 227 217 242 296 275 207 177 -55 19.9 - 228 221 327 321 303 300 301 -56 17.3 181 250 314 315 342 367 234 186 -57 17.7 210 158 323 350 278 170 194 202 -C58 20.5 222 274 247 307 289 199 201 209 -59 20.7 280 350 318 396 450 322 264 181 -60 21.3 365 291 366 420 384 301 253 198 -61 19.9 245 286 320 270 284 200 204 210 -C62 19.7 258 195 271 204 195 196 185 196 -63 21.2 345 369 360 363 311 265 193 147 -64 20.4 201 172 302 311 214 242 167 127 -C65 20.3 295 288 292 357 344 305 188 258 66 20.4 247 239 329 314 320 293 305 23t -67 20.3 - 256 289 304 262 250 233 239 -68 20.3 73 197 194 211 223 212 167 185 -69 20.2 281 271 353 374 304 283 250 250 -70 19.9 210 279 392 414 337 372 356 311 -71 17.2 243 300 399 293 367 287 272 136 -C72 20.4 50 80 94 112 1 100 90 '* Examples 44 and 45 normalized for basis weight of 17.5 gsy.
SUBSTITUTE SH~~T (RULE 26) _ 78 _ C N N N N N O O
I~ f~ 1~ I~ I~ M t!7 N N N N N N M
C 47 ~ ~ ~ O ~ O
J n r n ~ ~ ~ O
C
OD M M M M O (O
M O ~(7 47 ~ C N
J
Z .
L
U
O O O
O O O O O O O
O O O O O O O
w w w w w w U ~ C7 p p p O p p p t~ r z W Z Q M M c°o ~ c°o c°n v D w W

~ z ~
J Z C O O O O O O O
O G O O O O O
U J
c~
J Z ~
J F- ~ _'vt _~ 1n N ~_t ~_t _~
f- j ~ U O O O O O O O
C
O O O O O O O
a o w u~ w w a z° °z Q ~ a ~ Q ~ z °z m z O O z w z w z w u- cn ~ ~ O p O p O p w J
C7 O m W ~l7 O O O O ~ N
Z
i W
m ~ N M et ~ t0 t~
Z
SUBSTITUTE SHEET (RULE 26~

WO 97/37065 PCT/US97l04470 REGRESSfON
i RANGE
i MIN MAX REGRESS
EX. TEMP TEMP Co C, CZ COEFF Tp (°C) Tm (°C) 1 148 169 -26604.33 328.863 -1.0044 0.953 163.7 162 2 148 169 -9215.49 129.522 -0.4359 0.903 148.6 163 3 148 169 -31622.39 402.497 -1.2603 0.907 159.7 163 4 148 169 -25329.55 326.457 -1.0307 158.4 163 148 169 -22499.91 283.217 -0.8711 0.942 162.6 163 6 148 169 -12288.51 154.851 -0.4678 0.824 165.5 162 7 148 169 -20914.25 270.525 -0.8555 0.777 158.1 163 8 148 169 -14117.75 185.660 -0.5951 0.784 15fi.0 162 9 148 169 -14762.18 190.633 -0.5957 0.825 160.0 164 148 169 -7842.43 103.283 -0.3180 0.903 162.4 163 12 148 169 -18806.13 238.885 -0.7379 0.798 161.9 162 13 148 169 -19136.45 242.940 -0.7488 0.958 162.2 163 14 148 169 -222fi1.16 282.649 -0.8808 0.868 160.4 163 C-16 148 169 -20630.10 242.453 -0.6911 0.975 175.4 163 C-17 148 169 -41183.17 510.728 -1.5611 0.993 163.6 162 18 148 169 -33065.08 417.883 -1.2953 0.942 161.3 163 19 148 169 -27189.34 338.401 -1.0340 0.972 163.6 162 148 169 -33343.66 420.862 -1.3086 0.960 160.8 164 21 148 169 -32387.87 418.145 -1.3258 0.890 157.7 164 22 148 169 -33679.97 426.504 -1.3279 0.966 160.6 164 23 148 169 -2551fi.43 319.750 -0.9852 0.968 162.3 164 24 148 169 -22399.42 276.977 -0.8419 0.950 164.5 163 C-25 151 172 -34262.00 427.745 -1.3186 0.828 162.2 162 C-26 157 172 -28878.05 348.624 -1.0424 0.955 167.2 163 27 148 169 -51883.10 657.188 -2.0535 0.902 160.0 163 28 148 169 -20911.63 264.578 -0.8160 0.857 162.1 163 29 148 169 -16471.30 210.436 -O.fi537 0.593 161.0 164 148 169 -29873.29 379.916 -1.1871 0.952 160.0 163 C-34 148 169 -36379.04 455.499 -1.4050 0.949 162.1 163 148 169 -26371.92 338.007 -1.0613 0.884 159.2 162 C-36 148 i69 -20889.29 266.513 -0.8300 0.734 160.5 163 37 148 169 -19430.69 248.565 -0.7705 0.876 161.3 162 C-38 148 169 -19876.65 252.172 -0.7817 0.854 161.3 162 39 148 169 -16255.93 206.971 -0.6349 0.862 163.0 163 148 169 -31419.95 392.814 -1.2014 0.944 163.5 163 41 148 169 -39390.86 491.564 -1.5087 0.974 162.9 162 I 421 148 I 16~ I -906131 I 116 iCl I -u.,s~~a i u_ocu i ino.s i ins i SUBSTITUTE SHEET (RULE 26) REGRESSION
RANGE
MIN MAX REGRESS
I EX. TEMP TEMP Co C, Cz COEFF Tp (°C) Tm (°C) 43 148 169 -24805.54 320.173 -1.0067 0.705 159.0 163 44 148 169 -8525.74 114.436 -0.3627 0.552 157.8 163 45 148 169 -23726.93 306.358 -0.9631 0.854 159 163 46 148 169 -27116.49 350.120 -1.1007 0.854 159 163 47 148 169 -21080.32 270.44 -0.8374 0.829 161.5 163 48 148 169 -10375.85 133.874 -0.4122 0.156 162.4 163 49 148 169 -30269.12 383.810 -1.1963 0.895 160.4 164 C-50 148 169 -33648.98 426.340 -1.3284 0.928 160.5 164 51 151 169 -26197.51 330.758 -1.0231 0.944 161.6 164 52 151 169 -30827.88 388.854 -1.2012 0.945 161.9 164 53 151 169 -14060.67 181.620 -0.5636 0.660 161.1 162 54 151 169 -29792.20 377.092 -1.1728 0.846 160.8 163 55 151 169 -22651.77 281.806 -0.8529 0.926 165.2 163 56 148 169 -34699.61 442.366 -1.3862 0.935 159.6 163 57 148 169 -27202.65 347.082 -1.0865 0.646 159.7 163 C-58 148 169 -10921.94 141.792 -0.4429 0.714 160.1 163 59 148 169 -35003.59 448.708 -1.4137 0.921 158.7 163 60 148 169 -29577.24 382.166 -1.2088 0.925 158.1 163 61 148 169 -16159.64 211.697 -0.6717 0.730 157.6 163 C-62 145 169 -5978.25 80.683 -0.2525 0.412 159.8 163 63 148 169 -14798.83 198.218 -0.6414 0.991 154.5 164 64 148 169 -33583.39 429.356 -1.3536 0.921 158.6 163 C-65 148 169 -16144.94 209.591 -0.6597 0.576 158.9 164 66 148 169 -17412.26 225.585 -0.7066 0.887 159.6 164 67 151 169 -3353.05 45.952 -0.1377 0.900 166.9 165 68 148 169 -30872.62 388.971 -1.2068 0.863 161.2 164 69 148 169 -13334.29 173.652 -0.5402 0.800 160.2 164 70 148 169 -32172.35 406.497 -1.257 0.965 161.7 163 71 148 169 -47237.48 608.607 -1.9302 0.891 157.7 164 C-72 157 175 -20065.25 239.322 -0.7035 0.974 170.1 163 SUBSTiTLJTE SHEET (RULE 26) TABLE

~
EX.
CDSP
CDSP.,o CDS,~,o Cp Cm C, CDSm CDS, 1 314.9 214.5 177.1 68.1 56.3 11.0 312.0 34.4 2 406.0 362.4 397.5 89.3 97.9 128.8 315.2 405.9 3 513.6 387.5 457.3 75.5 89.0 68.4 499.7 341.6 4 520.4 417.3 490.7 80.2 94.3 82.2 498.3 409.6 520.4 433.3 440.7 83.3 84.7 64.5 520.2 335.6 6 526.2 479.4 440.8 91.1 83.8 70.3 520.4 365.9 7 472.0 386.5 449.7 81.9 95.3 85.2 451.5 384.6 8 362.9 303.3 353.4 83.6 97.4 92.2 341.4 314.8 9 489.2 429.6 467.7 87.8 95.6 86.9 479.7 417.0 543.9 512.1 515.8 94.2 94.8 87.9 543.8 478.0 12 527.8 454.0 455.9 86.0 86.4 69.1 527.8 364.7 13 568.3 493.4 504.6 86.8 88.8 73.4 567.8 416.9 14 414.3 326.2 365.4 78.7 88.2 68.0 408.6 277.8 C-16 634.4 565.3 287.3 89.1 45.3 21.8 527.9 115.1 C-17 589.2 433.1 379.9 73.5 64.5 27.4 585.3 180.1 18 638.8 509.3 549.4 79.7 86.0 64.5 635.1 409.4 19 498.1 394.7 358.1 79.2 71.9 42.8 495.3 211.9 495.0 364.1 434.3 73.6 87.8 64.9 481.6 312.6 21 581.9 449.3 563.8 77.2 96.9 91.0 529.2 481.6 22 566.9 434.2 509.2 76.6 89.8 70.4 551.5 388.5 23 427.5 329.0 361.6 77.0 84.6 60.5 424.2 256.5 24 381.3 297.1 270.1 77.9 70.8 40.1 379.5 152.3 C-25 427.3 295.5 287.5 69.1 67.3 27.8 427.2 118.8 C-26 270.7 166.5 44.8 61.5 16.5 -54.4 247.5 -134.7 27 697.4 492.1 607.5 70.6 87.1 62.4 673.9 420.3 28 534.9 453.3 471.5 84.7 88.1 71.0 533.8 379.1 29 464.3 398.9 427.9 85.9 92.2 78.9 460.1 362.8 523.5 404.8 469.9 77.3 89.8 70.6 510.7 360.4 C-34 539.0 398.5 432.6 73.9 80.3 51.3 536.6 275.3 540.6 434.4 490.2 80.4 90.7 73.6 530.3 390.5 C-36 505.0 422.0 461.2 83.6 91.3 76.2 498.7 380.2 37 616.1 539.1 551.9 87.5 89.6 75.1 615.6 462.3 C-38 460.7 382.5 398.1 83.0 86.4 67.1 459.8 308.7 '~

39 611.7 548.2 549.9 89.6 89.9 77.1 611.7 471.4 688.9 568.8 563.2 82.6 81.7 59.5 688.9 410.2 41 649.5 498.6 479.6 76.8 73.9 43.4 648.9 281.8 SUBSTITUTE SHEET (RULE 26) CDSp CDSP.,o CDS,~,o CP Cm C, CDSm CDS, 42 547.8 512.7 495.3 93.6 90.4 81.2 546.1 443.6 43 651.8 550.9 608.8 84.6 93.4 81.0 639.4 518.0 44 500.8 464.5 490.8 92.8 98.0 93.9 492.8 462.6 45 635.9 539.fi 597.8 84.9 94.0 82.4 622.7 513.2 46 725.8 615.7 682.3 84.8 94.0 82.4 710.6 585.6 47 755.3 671.5 691.6 88.9 91.6 79.3 753.9 597.7 48 494.0 452.8 456.2 91.7 92.3 82.3 494.0 408.4 49 515.4 395.8 461.9 76.8 89.6 70.1 502.3 352.1 C-50 558.7 425.8 505.6 76.2 90.5 71.8 540.7 388.4 51 535.2 432.9 480.4 80.9 89.8 72.0 527.8 380.0 52 642.2 522.1 569.3 81.3 88.6 70.0 636.3 445.7 53 571.1 514.7 525.0 90.1 91.9 80.6 570.6 459.9 54 519.5 402.2 447.7 77.4 86.2 63.5 514.0 326.6 55 626.1 540.8 499.0 86.4 79.7 60.1 621.9 373.6 56 592.5 453.9 523.4 76.6 88.3 67.3 580.5 390.9 57 516.1 407.4 459.8 78.9 89.1 69.8 507.5 354.5 C-58 426.5 382.3 404.4 89.6 94.8 85.6 422.7 362.0 59 601.4 460.0 555.4 76.5 92.4 76.4 575.2 439.5 60 628.5 507.6 597.4 80.8 95.0 84.4 599.2 505.8 61 520.3 453.1 506.2 87.1 97.3 91.6 500.6 458.6 C-62 467.0 441.8 455.5 94.6 97.5 93.0 464.4 432.1 63 515.5 451.3 515.3 87.6 100.0 108.3 457.8 495.9 64 464.1 328.7 421.7 70.8 90.9 71.3 437.8 312.0 C-fi5 502.2 436.2 486.6 86.9 9fi.9 90.4 484.7 438.1 66 592.5 521.8 570.1 88.1 96.2 88.6 579.0 512.7 67 480.6 466.9 461.3 97.1 96.0 92.0 480.1 441.5 68 470.3 349.6 408.4 74.3 86.9 63.4 460.5 291.9 69 524.9 470.9 504.3 89.7 96.1 88.5 517.0 457.5 70 691.6 565.9 596.6 81.8 86.3 66.1 689.4 455.9 71 737.1 544.1 695.3 73.8 94.3 81.7 fi82.0 557.3 C-72 288.4 218.0 82.8 75.6 28.7 - 253.0 -SUBSTITUTE SHEET (RULE 26) TABLE

EX.
Am AD
A, Rm Rp 1 2613 2814 3163 83.0 89.4 67.0 2 3636 3915 5653 89.6 96.4 92.8 3 4995 4716 7018 97.3 91.8 91.1 4 5117 4860 7389 98.3 93.4 94.7 4950 4913 6909 95.1 94.4 88.5 fi 4884 5106 6910 92.8 97.0 87.6 7 4649 4435 6752 98.5 94.0 95.4 8 3573 3430 5256 98.5 94.5 96.6 9 4836 4693 7060 98.9 95.9 96.2 5351 5333 7842 98.4 98.1 96.1 12 5042 5032 7109 95.5 95.3 89.8 13 5487 5433 7807 96.6 95.6 91.6 14 4017 3850 5643 97.0 92.9 90.8 C-16 4191 6114 5212 66.1 96.4 54.8 C-17 5086 5372 6469 86.3 91.2 73.2 18 6138 5956 8562 96.1 93.2 89.4 19 4439 4636 5885 89.1 93.1 78.8 4798 4513 6692 96.9 91.2 90.1 21 5686 5377 8327 97.7 92.4 95.4 22 5525 5227 7797 97.5 92.2 91.7 23 4094 3947 5659 95.8 92.3 88.3 24 3388 3533 4461 88.8 92.6 78.0 C-25 3793 3834 4837 88.8 89.7 75.5 C-26 1635 2360 1432 60.4 87.2 35.3 27 675D 6290 9362 96.8 90.2 89.5 28 5162 5077 7306 96.5 94.9 91.0 29 4549 4425 6540 98.0 95.3 93.9 5101 4839 7201 97.4 92.4 91.7 C-34 5080 4921 6879 94.3 91.3 85.1 5279 5052 7503 97.7 93.5 92.5 C-36 4938 4773 7059 97.8 94.5 93.2 37 5966 5905 8517 96.8 95.8 92.2 C-38 4420 4347 6203 95.9 94.3 89.8 39 5914 5905 8480 96.7 96.5 92.4 6460 6489 8919 93.8 94.2 86.3 SUeSTITL1TE SHEET (RULE 26) EX. Am AP A, Rm Rp R, 41 5894 5992 7829 90.8 92.3 80.4 42 5266 5361 7620 96.1 97.9 92.7 43 6409 6181 9247 98.4 94.9 94.6 44 4977 4887 7369 99.4 97.6 98.1 45 6263 6038 9061 98.5 95.0 95.0 46 7148 6891 10341 98.5 94.9 95.0 47 7367 7274 10608 97.5 96.3 93.6 48 4819 4803 6985 97.6 97.2 94.3 49 5020 4755 7080 97.4 92.3 91.6 C-50 5453 5144 7716 97.6 92.1 92.1 51 5212 5011 7384 97.4 93.6 92.0 52 6228 6022 8791 97.0 93.8 91.3 53 5572 5523 8046 97.6 96.7 93.9 54 5004 4804 6964 96.3 92.5 89.4 55 5747 5976 7946 91.8 95.5 84.6 56 5751 5463 8065 97.1 92.2 90.7 57 5018 4799 7076 97.2 93.0 91.4 C-58 4210 4118 6135 98.7 96.5 95.9 59 5889 5542 8406 97.9 92.2 93.2 60 6184 5882 8967 98.4 93.6 95.1 61 5146 4979 7572 98.9 95.7 97.0 C-62 4641 4586 6866 99.4 98.2 98.0 63 4973 4941 7514 96.5 95.9 97.2 64 4523 4190 6386 97.5 90.3 91.7 C-65 4967 4802 7292 98.9 95.6 96.8 66 5863 5689 8585 99.0 96.0 96.6 67 4730 4760 6990 98.4 99.0 97.0 68 4546 4301 6322 96.7 91.4 89.6 69 5197 5069 7613 99.0 96.6 96.7 70 6640 6497 9297 96.0 93.9 89.6 71 7208 6728 10380 97.8 91.3 93.9 I

SUBSTj'fUTE SHEET (RULE 26) _ 85 _ Comparison Ex. Cm LICm C~ 0C C, DC.
I C-16 45.3 89.1 21.8 I
1 3 89.0 43.7 75.5 -13.6 68.4 46.6 7 95.3 50.0 81.9 -7.2 85.2 63.4 C-17 64.5 73.5 27.4 13 88.8 24.3 86.8 13.3 73.4 46.0 2 18 86.0 21.5 79.7 6.2 64.5 37.1 40 81.7 17.3 B2.6 9.1 59.5 32.1 41 73.9 9.4 76.8 3.3 43.4 16.0 C-34 80.3 73.9 51.3 35 90.7 10.4 80.4 6.4 73.6 22.3 3 C-36 91.3 83.6 76.2 37 89.6 -1.8 87.5 3.9 75.1 -1.1 C-38 86.4 83.0 67.1 C-16 45.3 89.1 21.8 19 71.9 26.6 79.2 -9.9 42.8 21 4 20 87.8 42.5 73.6 -15.5 64.9 43.1 21 96.9 51.6 77.2 -11.9 91.0 69.2 C-26 16.5 61.5 -54.40 C-25 67.3 69.1 27.8 6 28 88.1 20.8 84.7 15.6 71.0 43.2 29 92.2 24.9 85.9 16.8 78.9 51.1 C-38' 86.4 83.0 67.1 7 44" 98.0 11.6 92.8 9.7 93.9 26.8 45" 94.0 7.6 84.9 1.8 82.4 15.3 SUBSTITUTE SHEET (RULE 26) Comparison ~ Cm ACm ~ DC
C-58 94.8 89.6 85.6 51 89.8 -5.0 80.9 -8.7 72.0 -13.6 52 88.6 -6.2 81.3 -8.3 70.0 -15.6 8 53 91.9 -2.9 90.1 0.5 80.6 -5.0 54 86.2 -8.6 77.4 -12.2 63.5 -22.1 59 92.4 -2.4 76.5 -13.1 76.4 -9.2 60 95.0 0.2 80.8 -8.8 84.4 -1.2 61 97.3 2.5 87.1 -2.5 91.6 6.0 C-62 97.5 94.6 93.0 9 56 88.3 -9.2 76.6 -i 8.0 67.3 -25.7 57 89.1 -8.4 78.9 -15.6 69.8 -23.2 C-50 90.5 76.2 71.8 71 94.3 3.8 73.8 -2.4 81.7 9.9 'Normalized to 20 gsy "Normalized to 17.5 gsy SUBSTITUTE SHEET (RULE 26) _ 87 _ Comparison Ex. Am %AAm Q %~A° A~ °/=

C-38' 4420 4347 6203 7 44'~ 4977 13 4887 12 7369 19 45'~ 6263 42 6038 39 9061 46 SUBST1TUT~ SHEET (RULE 26) _ 88 Comparison Ex. Am %AAm ~ %AA A, %AA, 11 fi7 4730 -5 4760 -1 6890 -4 6g 5197 5 5069 6 7613 4 SUBST1TUT~ SHEET (RULE 26) Comparison Ex. Am %~
~=

Highest 5453 6114 7716 I
Control Example' 70 fi640 22 6497 6 9297 20 I

'Normalized to 20 gsy "Normalized to 17.5 gsy 1 Values for Highest Control Example A"" Ap and A, are taken from control Examples 16, 17, 25, 26, 34, 36, 38, 50, 58, 62 and 65.
A", and A, are taken from control Example 50 and AP is taken from control Example 16.
SUBSTITUTE SHEET (RULE 26) Comparison Ex. R ARo Rm ARm R, AR, C-16 96.4 68.1 54.8 1 3 91.8 -4.6 97.3 31.2 91.1 3fi.3 7 94.0 -2.4 98.5 32.4 95.4 40.6 C-17 91.2 86.3 73.2 13 95.6 4.4 96.6 10.3 91.6 18.4 2 18 93.2 2.0 96.1 9.8 89.4 16.2 40 94.2 3.0 93.8 7.5 86.3 13.1 41 92.3 1.1 90.8 4.5 80.4 7.2 C-34 91.3 94.3 85.1 35 93.5 2.2 97.7 3.4 92.5 7.4 3 C-36 94.5 97.8 93.2 37 95.8 1.3 96.8 -1.0 92.2 -1.0 C-38 94.3 95.9 89.8 C-16 96.4 68.1 54.8 19 93.1 -3.3 89.1 23.0 78.8 24.0 4 20 91.2 -5.2 96.9 30.8 90.1 35.4 21 92.4 -4.0 97.7 31.6 95.4 40.6 C-26 87.2 60.4 35.3 C-25 89.7 88.8 75.5 6 28 94.9 5.2 96.5 7.7 91.0 15.6 29 95.3 5.6 98.0 9.2 93.9 18.4 SUBSTITUTE SHEET (RULE 26) Comparison Ex. Rp OR Rm ~Rm R, DR.
C_ 94.3 95.9 89.8 38' 7 44" 97.6 3.3 99.4 3.5 98.1 8.3 45'* 95.0 0.7 98.5 2.6 95.0 5.2 C-58 96.5 98.7 95.9 51 93.6 -2.9 97.4 -1.3 92.0 -3.9 52 93.8 -2.8 97.0 -1.7 91.3 -4.6 8 53 96.7 0.2 97.6 -1.1 93.9 -2.0 54 92.5 -4.0 96.3 -2.4 89.4 -6.5 59 92.2 -4.4 97.9 -0.8 93.2 -2.7 60 93.6 -2.9 98.4 -0.3 95.1 -0.8 61 95.7 -0.8 98.9 0.2 97.0 1.1 C-62 98.2 99.4 98.0 9 56 92.2 -6.0 97.1 -2.3 90.7 -7.3 57 93.0 -5.2 97.2 -2.1 91.4 -6.6 C-50 92.1 97.6 92.1 71 91.3 -0.8 97.8 0.2 93.9 1.8 'Normalized to 20 gsy "Normalized to 17.5 gsy SUBSTITUTE SHEET (RULE 26) RHEOLOGICAL
DATA OF POLYMERS
RUN AT 200C' ELASTIC COMPLEX
MODULUS VISCOSITY
(DYNESISO. (DYNESISQ.
CM) CM) POLYMERS FREQUENCYELASTIC RATIO COMPLEX RATIO DSC
(radianslsec)MODULUS PA/PPZ VISCOSITYPA/PP MP(C) ELVAX~750 100 202900 0.572 307.9 0.659 97.3 ELVAX~3180 100 84300 0.238 167.7 0.359 63 NUCREL~925 100 68980 0.195 145.5 0.312 92.4 KRATON~1750 100 793200 2.238 1178.0 2.520 NONE

ELVALOY~AM 100 141200 0.398 231.3 0.496 71.5 ELVALOY~HP661 100 129000 0.364 205.0 0.439 62 ELVALOY~HP662 100 147600 0.416 241.1 0.517 60 BYNEL~2002 100 147600 0.416 241.1 0.517 90 BYNEL~2022 100 55240 0.156 115.5 0.248 90.4 SURLYN~RX9-1 100 79200 0.223 147.5 0.316 72 PE 6835A 100 110000 0.310 312.1 0.669 131.3 PE XU58200.03 100 48180 0.136 198.2 0.425 109.2 PE XU58200.02 100 48300 0.136 175.8 0.377 66 PROFAX 165 100 354500 1.000 466.6 1.000 163 1 The scan was conducted at 10°C/min in contrast to 20°Clmin as set forth in the procedure for determining Differential Scanning Calorimetry Melting Point (DSC MP).
2 PA = Polymer Additive, and PP = Polypropylene

Claims (155)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure;
wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains flattening of a bond curve of cross-directional strength vs. temperature as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

2. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure;
wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains raising of at least some points of cross-directional strength of a bond curve of cross-directional strength vs. temperature as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

3. The process according to claim 2, wherein said raising of at least some points of cross-directional strength includes raising of peak cross-directional strength.

4. The process according to claim 2, wherein the skin-core fiber when processed into a thermally bonded nonwoven material additionally obtains shifting to lower temperatures of the bond curve of cross-directional strength vs. temperature as compared to the nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

5. The process according to claim 4, wherein said raising of at least some points of cross-directional strength includes raising of peak cross-directional strength.

6. The process according to claim 4, wherein the skin-core fiber when processed into a thermally bonded nonwoven material additionally obtains flattening of the bond curve of cross-directional strength vs. temperature as compared to the nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

7. The process according to claim 6, wherein said raising of at least some points of cross-directional strength includes raising of peak cross-directional strength.

8. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure;
wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains am increase in area over a defined temperature range under a bond curve of cross-directional strength vs. temperature as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

9. The process according to claim 8, wherein said increase in area is provided by the bond curve being flatter and having the same or substantially the same peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

10. The process according to claim 8, wherein said increase in area is provided by the bond curve being of the same or substantially the same shape and having higher cross-directional strengths over at least some points on the bond curve over the defined temperature range as compared. to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

11. The process according to claim 10, wherein said at least some points include a higher peak cross-directional strength.

12. The process according to claim 9, wherein said increase in area is provided by the bond curve being shifted to lower temperatures with the area under the bond curve in the defined temperature range being increased as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

13. The process according to claim 8, wherein said polymeric bond curve enhancing agent has (a) a DSC melting point of below about 230°C and (b) at least one of an elastic modulus and a complex viscosity below that of the polypropylene in the polymer blend.

14 . The process according to claim 13 , wherein said polymeric bond curve enhancing agent has a DSC melting point of below about 200°C.

15. The process according to claim 13 , wherein said polymeric bond curve enhancing agent has a DSC melting point below that of the polypropylene in the polymer blend.

16. The process according to claim 13, wherein said polymeric bond curve enhancing agent has a DSC melting point of about 15 to 100°C
below that of the polypropylene in the polymer blend.

17. The process according to claim 15, wherein both of said elastic modulus and said complex viscosity are below that of the polypropylene in the polymer blend.

18. The process according to claim 17, wherein the elastic modulus of the polymeric bond curve enhancing agent is about 5 to 1000 below that of the polypropylene in the polymer blend.

19. The process according to claim 17, wherein the complex viscosity of the polymeric bond curve enhancing agent is about 10 to 80% below that of the polypropylene in the polymer blend.

20. The process according to claim 17, wherein the elastic modulus of the polymeric band curve enhancing agent is about 5 to 100%
below that of the polypropylene in the polymer blend, and the complex viscosity of the polymeric bond curve enhancing agent is about 10 to 80% below that of the polypropylene in the polymer blend.

21. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate, the polymeric bond curve enhancing agent being present in an amount less than 20% by weight of the polymer blend; and providing condition=: so that the hot extrudate forms a fiber having a skin-core structure.

22. The process according to claim 21, wherein the polymeric bond curve enhancing agent is present in an <amount less than about 10%
by weight of the polymer blend.

23. The process according to claim 22, wherein the polymeric bond curve enhancing agent is present in an amount less than about 10%
by weight of the polymer blend.

24. The process according to claim 21, wherein the polymeric bond curve enhancing agent is present in an amount of about 0.5 to 7% by weight of the polymer blend.

25. The process according to claim 24, wherein polymeric bond curve enhancing agent is present in an amount of about 1 to 5% by weight of the polymer blend.

26. The process according to claim 21, wherein the polymeric bond curve enhancing agent is present in an amount of about 1.5 to 4% by weight of the polymer blend.

27. The process according to claim 12, wherein the polymer blend includes copolymer containing propylene and ethylene units.

28. The process according to claim 12, wherein the polymer blend includes copolymer containing propylene units and up to about 20 weight percent of ethylene units.

29. The process according to claim 12, wherein the polymer blend includes copolymer containing propylene units and up to about 10 weight percent of ethylene units.

30. The process according to claim 21, wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains an increase in area over a defined temperature range under a bond curve of cross-directional strength vs. temperature as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

31. The process according to claim 30, wherein said increase in area is provided by the bond curve being flatter and having the same or substantially the same peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

32. The process according to claim 30, wherein said increase in area is provided by the bond curve being of the same or substantially the same shape and having higher cross-directional strengths over at least some points on the bond curve over the defined temperature range as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

33. The process according to claim 32, wherein said at least some points include a higher peak cross-directional strength.

34. The process according to claim 30, wherein said increase in area is provided by the band curve being shifted to lower temperatures with the area under the bond curve in the defined temperature range being increased as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

35. The process according to claim 22, wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains an increase in area over a defined temperature range under a bond curve of cross-directional strength vs. temperature as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

36. The process according to claim 35, wherein said increase in area is provided by the bond curve being flatter and having the same or substantially the same peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

37. The process according to claim 35, wherein said increase in area is provided by the bond curve being of the same or substantially the same shape and having higher cross-directional strengths over at least ;some points on the bond curve over the defined temperature range as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

38. The process according to claim 37, wherein said at least some points include a higher peak cross-directional strength.

39. The process according to claim 35, wherein said increase in area is provided by the bond curve being shifted to lower temperatures with the area under the bond curve in the defined temperature range being increased as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

40. The process according to claim 12, wherein the polymeric bond curve enhancing agent comprises at least one polymer selected from the group consisting of alkene vinyl carboxylate polymers, polyethylenes, alkene acrylic acids or esters, alkene co-acrylates, acid modified alkene acrylates, alkene acrylate acrylic acid polymers, and polyamides.

41. The process according to claim 40, wherein the polymeric bond curve enhancing agent comprises at least one polymer selected from the group consisting of ethylene vinyl acetate polymers, polyethylenes, ethylene methacrylic acids, ethylene N-butyl acrylate glycidyl methacrylate, alkene co-acrylate co-carbon monoxide polymers, acid modified ethylene acrylates, ethylene acrylate methacrylic acid terpolymers, and nylon.

42. The process according to claim 44, wherein the ethylene vinyl acetate polymers comprise at least one of ethylene vinyl acetate copolymer and ethylene vinyl acetate terpolymer; the alkene co-acrylate co-carbon monoxide polymers comprise ethylene N-butyl acrylate carbon oxides; and the acid modified ethylene acrylates comprise at least one of ethylene isobutyl acrylate-methyl acrylic acid and ethylene N-butyl acrylic methylacrylic acid.

43. A process for preparing a skirl-core fiber, comprising:
extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure;
wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains a % .DELTA.A1 which is greater than that of a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond, curve enhancing agent.

44. The process according to claim 43, wherein said % .DELTA.A1 is increased by a member selected from the group consisting of at least about 3%, at least about 15%, at least about 20%, at least about 30%, at least about. 40%, at least about 50% and at least about 60%.

45. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure;
wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains a % .DELTA.A1 and a % .DELTA.Am which is greater than that of a nonwoven material produced under same conditions from, fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

46. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate;
and providing conditions so that the hot extrudate forms a fiber having a skin-core structure;
wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains a % .DELTA.A1 a % .DELTA.A m and a % .DELTA.A
p which is greater than that of a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

47. A process for preparinq a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and polymeric bond curve enhancing agent as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure;
wherein said polymeric bond curve enhancing agent comprises a plurality of polymeric bond curve enhancing agents.

48. The process according to claim 47, wherein said plurality of bond curve enhancing agents comprising at least one ethylene vinyl acetate polymer and at least one polyamide.

49. The process according to claim 47, wherein said plurality of bond curve enhancing agents comprising at least one ethylene vinyl acetate polymer and at least one polyethylene.

50. The process according to claim 12, wherein said polymer blend further comprises an additional polymer.

51. The process according to claim 12, wherein the polymer blend is extruded in an oxidative atmosphere under conditions to form the fiber having a skin-core structure.

52. The process according to claim 12, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 0.2 µm.

53. The process according to claim 52, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 0.5 µm.

54. The process according to claim 53, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 0.7 µm.

55. The process according to claim 54, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 1 µm.

56. The process according t:o claim 55, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 1.5 µm.

57. The process according too claim 12, wherein said fiber comprises a denier of less than 2, and said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 1% of the equivalent diameter of the fiber.

58. The process according to claim 57, wherein, said skin-core structure comprises a skin showing a ruthenium staining enrichment of up to about 25% of the equivalent diameter of the fiber.

59. The process according to claim 57, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of up to about 2% to 10% of the equivalent diameter of the fiber.

60. The process according to claim 12, wherein said polymer blend further comprises at least one member selected from the group consisting of stabilizers, antioxidants and antacids.

61. The process according to claim 12, wherein said fiber comprises a hydrophobic or a hydrophilic finish.

62. The process according to claim 12, further including a component included in the polymer blend for modifying the surface properties of the fiber.

63. The process according to claim 12, wherein said fiber comprises a circular, diamond, delta, concave delta, trilobal, oval, or "X"-shaped cross-sectional configuration.

64. The process according to claim 63, wherein said cross-sectional configuration comprises a concave delta cross-sectional configuration.

65. The process according to claim 12, wherein said fiber comprises a denier of less than about 5.

66. The process according too claim 65, wherein said fiber comprises a denier of between about 0.5 and 3.

67. The process according to claim 12, wherein said fiber is a monocomponent fiber.

68. The process according t:o claim 67, wherein said monocomponent fiber comprises a staple fiber.

69. The process according to claim 12, wherein said fiber comprises a staple fiber.

70. The process according to claim 12, wherein said fiber is a bicomponent fiber.

71. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and ethylene vinyl acetate polymer as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure.

72. The process according to claim 71, wherein the polymer blend is extruded in an oxidative atmosphere under conditions to form the fiber having a skin-core structure.

73. The process according to claim 72, wherein the polymer blend comprises at least about 80 percent by weight of polypropylene.

74. The process according to claim 73, wherein the polymer blend comprises at least about 90 percent by weight of polypropylene.

75. The process according to claim 73, wherein said polymer blend comprises less than 10 percent by weight of said ethylene vinyl acetate polymer.

76. The process according to claim 75, wherein said polymer blend is prepared by tumble mixing.

77. The process according to claim 75, wherein said polymer blend comprises about 0.5 to 7 weight percent of said ethylene vinyl acetate polymer.

78. The process according to claim 77, wherein said polymer blend comprises about 1 to 5 weight percent of said ethylene vinyl acetate polymer.

79. The process according to claim 78, wherein said polymer blend comprises about 1.5 to 4 weight percent of said ethylene vinyl acetate polymer.

80. The process according to claim 79, wherein said polymer blend comprises about 3 weight percent of said ethylene vinyl acetate polymer.

81. The process according to claim 71, wherein an additional polymer is added to said polymer blend.

82. The process according to claim 75, wherein polyethylene is preblended with said ethylene vinyl acetate polymer to form a preblend, and said preblend is mixed with said polypropylene.

83. The process according to claim 75, wherein polyethylene is added to said polymer blend.

84. The process according to claim 83, wherein said polyethylene comprises polyethylene having a density of at least about 0.85 g/cc.

85. The process according t:o claim 84, wherein said polyethylene has a density of at least about 0.85 to 0.93 g/cc.

86. The process according to claim 85, wherein said polyethylene has a density of at least about 0.86 to 0.93 g/cc.

87. The process according to claim 75, wherein said ethylene vinyl acetate polymer contains about 0.5 to 50 weight percent vinyl acetate units.

88. The process according to claim 87, wherein said ethylene vinyl acetate polymer contains about 5 to 50 weight percent vinyl acetate units.

89. The process according to claim 88, wherein said ethylene vinyl acetate polymer contains about 10 to 50 weight percent vinyl acetate units.

90. The process according to claim 89, wherein said ethylene vinyl acetate polymer contains about 20 to 40 weight percent vinyl acetate units.

91. The process according to claim 90, wherein said ethylene vinyl acetate polymer contains about 25 to 35 weight percent vinyl acetate units.

92. The process according to claim 75, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 0.2 µm.

93. The process according t:o claim 92, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 0.5 µm.

94. The process according to claim 93, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 0.7 µm.

95. The process according to claim 94, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 1 µm.

96. The process according to claim 95, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 1.5 µm.

97. The process according to claim 75, wherein said fiber comprises a denier of less than 2, and said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 1% of the equivalent diameter of the fiber.

98. The process according to claim 97, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of up to about 25% of the equivalent diameter of the fiber.

99. The process according to claim 97, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of up to about 2% to 10% of the equivalent diameter of the fiber.

100. The process according to claim 75, wherein said skin-core fiber shows a residue trail in a hot stage test.

101. The process according to claim 71, wherein said ethylene vinyl acetate polymer consists of ethylene and vinyl acetate units.

102. The process according to claim 75, wherein said polymer blend further comprises at least one member selected from the group consisting of stabilizers, antioxidants and antacids.

103. The process according to claim 75, wherein said fiber comprises a hydrophobic or a hydrophilic finish.

104. The process according too claim 75, further including a component included in the polymer blend for modifying the surface properties of the fiber.

105. The process according to claim 75, comprising:
feeding said polymer blend comprising said polypropylene and said ethylene vinyl acetate polymer to at least one spinnerette;
and said extruding comprises extruding said polymer blend through the at least one spinnerette.

106. The process according to claim 75, wherein said ethylene vinyl acetate polymer comprises an ethylene vinyl acetate polymer containing about 20 to 40 weight percent vinyl acetate units.

107. The process according to claim 75, wherein said ethylene vinyl acetate polymer comprises an ethylene/vinyl. acetate/acid terpolymer.

108. The process according to claim 75, wherein said ethylene vinyl acetate polymer comprises an ethylene vinyl acetate copolymer.

109. The process according to claim 75, wherein said fiber comprises a circular, diamond, delta, concave delta, trilobal, oval, or "X"-shaped cross-sectional configuration.

110. The process according to claim 109, wherein said cross-sectional configuration comprises a concave delta cross-sectional configuration.

111. The process according too claim 75, wherein said fiber comprises a denier of less than about 5.

112. The process according to claim 111, wherein said fiber comprises a denier of between about O.5 and 3.

113. The process according to claim 112, wherein said fiber comprises a denier of about 1.5.

114. The process according to claim 112, wherein said fiber comprises a denier of about 1.6.

115. The process according too claim 112, wherein said fiber comprises a denier of about 1.7.

116. The process according too claim 112, wherein said fiber comprises a denier of about 1.9.

117. The process according to claim 75, wherein said fiber comprises a staple fiber having a length of about 1 to 3 inches, and a denier of about 0.5 to 3.

118. The process according to claim 117, wherein said fiber comprises a staple fiber having a length of about 1.25 to 2 inches.

119. The process according to claim 75, wherein said fiber is a monocomponent fiber.

120. The process according to claim 119, wherein said monocomponent fiber comprises a staple fiber having a length of about 1 to 3 inches, and a denier of about 0.5 to 3.

121. The process according to claim 75, wherein said fiber is a bicomponent fiber.

122. The process according to claim 121, wherein said bicomponent fiber comprises a staple fiber having a length of about 1 to 3 inches, and a denier of about 0.5 to 3.

123. The process according to claim 111, wherein said fiber comprises a staple fiber.

124. The process according to claim 112, wherein said fiber comprises a staple fiber.

125. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and an ethylene vinyl acetate polymer as a hot extrudate into an oxidative atmosphere, said polymer blend comprising at least about 90 percent by weight polypropylene, less than 10 percent by weight ethylene vinyl acetate polymer, and said ethylene vinyl acetate polymer contains about 20 to 40 weight percent vinyl acetate units; and providing conditions of the hot: extrudate in the oxidative atmosphere to form a fiber having a skin-core structure, said skin-core structure comprising a skin showing a ruthenium staining enrichment of at least about 0.2 µm.

126. The process according to claim 125, wherein said polymer blend comprises about 0.5 to 7 weight percent of said ethylene vinyl acetate polymer.

127. The process according to claim 126, wherein said polymer blend comprises about 1 to 5 weight percent of said ethylene vinyl acetate polymer.

128. The process according to claim 127, wherein said polymer blend comprises about 1.5 to 4 weight percent of said ethylene vinyl acetate polymer.

129. The process according to claim 128, wherein said polymer blend comprises about 3 weight percent of said ethylene vinyl acetate polymer.
.

130. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend consisting essentially of polypropylene and ethylene vinyl acetate polymer as a hot extrudate; and providing conditions so that the hot extrudate forms a fiber having a skin-core structure.

131. A process for preparing a skin-core fiber, comprising:
extruding a polymer blend comprising polypropylene and a polymeric bond curve enhancing agent as a hot extrudate; and controlling conditions so that the hot extrudate forms a fiber having a skin-core structure; wherein the skin-core fiber when processed into a thermally bonded nonwoven material obtains an increase in area over a defined temperature range under a bond curve of cross-directional strength vs. temperature as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent, and said increase in area is provided by the bond curve being shifted to lower temperatures with the area under the bond curve in the defined temperature range being increased as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

132. The process according to claim 131, wherein said polymeric bond curve enhancing agent comprises ethylene vinyl acetate polymer.

133. The process according to claim 131, wherein said polymeric bond curve enhancing agent comprises a plurality of polymeric bond curve enhancing agents.

134. The process according to claim 117, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 0.2µm.

135. The process according to claim 119, wherein said skin-core structure comprises a skin showing a ruthenium staining enrichment of at least about 0.2µm.

136. The process according to claim 130, wherein said ethylene vinyl acetate polymer consists of ethylene and vinyl acetate units.

137. The process according to claim 8, wherein said increase in area is provided by the bond curve being flatter and having the same peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

138. The process according to claim 8, wherein said increase in area is provided by the bond curve being flatter and having the same peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

139. The process according to claim 8, wherein said increase in area is provided by the bond curve being flatter and having cross-directional strength points at temperatures lower than peak cross-directional strength raised as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

140. The process according to claim 8, wherein said increase in area is provided by the bond curve being flatter and being shifted to lower temperatures as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

141. The process according to claim 8, wherein said increase in area is provided by the bond curve being flatter, being shifted to lower temperatures and having cross-directional strength points at temperatures lower than peak cross-directional strength raised as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

142. The process according to claim 2, wherein said raising of at least Nome points of cross-directional strength includes raising at least some points at temperatures lower than peak cross-directional strength.

143. The process according to claim 4, wherein said raising of at least come points of cross-directional strength includes raising at least some anoints at temperatures lower than peak cross-directional strength.

144. The process according to claim 6, wherein said raising of at least some points of cross-directional strength includes raising at least some points at temperatures lower than peak cross-directional strength.

145. The process according to claim 30, wherein said increase in area is provided by the bond curve being flatter and having the same peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

146. The process according to claim 30, wherein said increase in area is provided by the bond curve being flatter and having a lower peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

147. The process according to claim 30, wherein said increase in area is provided by the bond curve being flatter and having cross-directional strength-points at temperatures lower than peak cross-directional strength raised as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

148. The process according to claim 30, wherein said increase in area is provided by the bond curve being flatter and being shifted to lower temperatures as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

149. The process according to claim 30, wherein said increase in area is provided by the bond curve being flatter, being shifted to lower temperatures and having cross-directional strength points at temperatures lower than peak cross-directional strength raised as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

150. The process according to claim 35, wherein said increase in area is provided by the bond curve being flatter and having the same peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

151. The process according to claim 35, wherein said increase in area is provided by the bond curve being flatter and having a lower peak cross-directional strength as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

152. The process according to claim 35, wherein said increase in area is provided by the bond curve being flatter and having cross-directional strength points at temperatures lower than peak cross-directional strength raised as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

153. The process according to claim 35, wherein said increase in area is provided by the bond curve being flatter and being shifted to lower temperatures as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

154. The process according to claim 35, wherein said increase in area is provided by the bond curve being flatter, being shifted to lower temperatures and having cross-directional strength points at temperatures lower than peak cross-directional strength raised as compared to a nonwoven material produced under same conditions from fibers produced under same conditions except for absence of the polymeric bond curve enhancing agent.

155. The process according to claim 12, wherein the fiber comprises at least one hollow portion.