Carded staple fiber nonwovens
A carded staple fiber nonwoven having a basis weight of between about 45 grams per square meter (gsm) and about 150 gsm, includes a blend of absorbing fibers, stiffening fibers and filler fibers. The carded staple fiber nonwoven is non-heat stiffened, has an air permeability of between about 100 m 3 /m 2 /min and about 500 m 3 /m 2 /min, and a pore radius mode of between about 60 μm and about 120 μm.
1. A carded staple fiber nonwoven having a basis weight of between about 40 grams per square meter (gsm) and about 150 gsm, the carded staple fiber nonwoven comprising a blend of absorbing fibers, stiffening fibers and filler fibers, wherein the carded staple fiber nonwoven is non-heat stiffened, has an air permeability of between about 100 m 3 /m 2 /min and about 500 m 3 /m 2 /min, and a pore volume radius mode of between about 60 μm and about 120 μm, wherein the stiffening fibers form about 10% to about 50%, by weight, of the carded staple fiber nonwoven, wherein the absorbing fibers form about 10% to about 50%, by weight, of the carded staple fiber nonwoven, and wherein the filler fibers form about 60% or less, by weight, of the carded staple fiber nonwoven.
2. The carded staple fiber nonwoven of claim 1 , wherein the carded staple fiber nonwoven has a caliper of between about 0.08 mm and about 0.20 mm per 10 gsm of basis weight.
3. The carded staple fiber nonwoven of claim 1 , wherein the carded staple fiber nonwoven has a caliper of between about 0.5 mm to about 3 mm.
4. The carded staple fiber nonwoven of claim 1 , wherein the carded staple fiber nonwoven has a basis weight of between about 45 gsm to about 85 gsm.
5. The carded staple fiber nonwoven of claim 1 , wherein the carded staple fiber nonwoven has an MD flexural rigidity of less than about 4.8 mNcm.
6. The carded staple fiber nonwoven of claim 1 , wherein the carded staple fiber nonwoven has a pore volume ratio of greater than about 8.
7. The carded staple fiber nonwoven of claim 1 , wherein the stiffening fibers comprise hollow, spiral fibers formed from polyethylene terephthalate (PET), wherein the stiffening fibers have a linear density of between about 6 dtex and about 15 dtex.
8. The carded staple fiber nonwoven of claim 1 , wherein the absorbing fibers comprise tri-lobal fibers formed from rayon, wherein the absorbing fibers have a linear density of between about 2 dtex and about 6 dtex.
9. The carded staple fiber nonwoven of claim 1 , wherein the filler fibers comprise solid, round fibers formed from polypropylene (PP), wherein the filler fibers have a linear density of about 3 dtex or greater.
10. A carded staple fiber nonwoven, comprising:
a) about 10% to about 50%, by weight, of stiffening fibers comprising hollow, spiral fibers formed from polyethylene terephthalate (PET), wherein the stiffening fibers have a linear density of between about 6 dtex and about 15 dtex;
b) about 10% to about 50%, by weight, of absorbing fibers comprising tri-lobal fibers formed from rayon, wherein the absorbing fibers have a linear density of between about 2 dtex and about 6 dtex; and
c) about 1% to about 60%, by weight, of filler fibers comprising solid, round fibers formed from polypropylene (PP), wherein the filler fibers have a linear density of about 3 dtex or greater;
wherein the carded staple fiber nonwoven has a basis weight of between about 40 grams per square meter (gsm) and about 150 gsm, is non-heat stiffened, has an air permeability of between about 100 m 3 /m 2 /min and about 500 m 3 /m 2 /min, and a pore radius mode of between about 60 μm and about 120 μm.
11. The carded staple fiber nonwoven of claim 10 , comprising:
about 20% to about 30%, by weight, of the stiffening fibers;
about 30% to about 40%, by weight, of the absorbing fibers; and
about 1% to about 50%, by weight, of the filler fibers.
12. The carded staple fiber nonwoven of claim 11 , comprising:
about 25%, by weight, of the stiffening fibers;
about 35%, by weight, of the absorbing fibers; and
about 40%, by weight, of the filler fibers.
13. The carded staple fiber nonwoven of claim 10 , wherein the carded staple fiber nonwoven has a caliper of between about 0.9 mm and about 1.2 mm, a basis weight of between about 45 gsm and about 85 gsm, and a density of between about 0.065 g/cc and about 0.094 g/cc.
14. An absorbent article, comprising:
a topsheet;
an absorbent core; and
a secondary topsheet positioned between the topsheet and the absorbent core,
wherein the secondary topsheet comprises the carded staple fiber nonwoven of claim 10 .
15. The absorbent article of claim 14 , wherein the secondary topsheet is bonded to the topsheet.
16. The carded staple fiber nonwoven of claim 1 , wherein the carded staple fiber nonwoven web has a pore volume factor greater than 500.
17. A carded staple fiber nonwoven, comprising:
a) about 15% to about 35%, by weight, of stiffening fibers comprising hollow, spiral fibers formed from polyethylene terephthalate (PET), wherein the stiffening fibers have a linear density of between about 6 dtex and about 15 dtex;
b) about 10% to about 50%, by weight, of absorbing fibers comprising tri-lobal fibers formed from rayon, wherein the absorbing fibers have a linear density of between about 2 dtex and about 6 dtex; and
c) about 1% to about 60%, by weight, of filler fibers comprising solid, round fibers formed from polypropylene (PP), wherein the filler fibers have a linear density of about 3 dtex or greater;
wherein the carded staple fiber nonwoven has a basis weight of between about 40 grams per square meter (gsm) and about 150 gsm, is non-heat stiffened, has an air permeability of between about 100 m 3 /m 2 /min and about 500 m 3 /m 2 /min, and a pore volume radius mode of between about 60 μm and about 120 μm.