IP Library › Granted Patent US 12,331,465
Granted Patent B2
US 12,331,465 · App. 16/608,471 · Granted Jun 17, 2025

Foam-formed fibrous sheets with crimped staple fibers

Inventors: Jian Qin (Appleton, WI); Deborah J. Calewarts (Winneconne, WI); Charles W. Colman (Marietta, GA); Donald E. Waldroup (Roswell, GA); Cathleen M. Uttecht (Menasha, WI); Peter Wallace (Penzance, GB)
Assignee: Kimberly-Clark Worldwide, Inc.
D21H15/10D01D5/22D21F11/002D21H13/10D21H15/04D21H27/005
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Quick Facts
Patent No.
US 12,331,465
App. No.
16/608,471
Granted
Jun 17, 2025
Kind
B2
Abstract

A method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 1% by weight crimped synthetic fibers and at least 1% by weight binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate. A substrate includes an aqueous-based polymer foam including at least 1% by weight crimped synthetic fiber and at least 1% by weight binder fiber, wherein the substrate is free of superabsorbent material. A method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 2% by weight crimped binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate, wherein the foam-formed substrate is free of superabsorbent material, and wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

Claims (18)

1. A method for producing a foam-formed substrate, the method comprising:

producing an aqueous-based foam including at least 1% by weight crimped synthetic fibers and at least 1% by weight binder fibers; wherein the crimped synthetic fibers include a polymer having a Tg greater than or equal to 0° C., have a length from 5 mm to 60 mm, and have a diameter of at least 3 dtex;

forming a wet sheet from the aqueous-based foam; and

drying the wet sheet to obtain the foam-formed substrate;

wherein the foam-formed substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

2. The method of claim 1 , wherein the crimped synthetic fibers have a length from 5 mm to 30 mm.

3. The method of claim 1 , wherein the crimped synthetic fibers have a diameter of at least 4 dtex.

4. The method of claim 1 , wherein the crimped synthetic fibers have a three-dimensional kinked or curly structure.

5. The method of claim 1 , wherein the foam-formed substrate exhibits at least a 30% reduction in density compared to the same foam-formed substrate with non-crimped fiber replacing the crimped synthetic fibers.

6. The method of claim 1 , wherein producing includes at least 2% by weight crimped synthetic fibers and at least 2% by weight binder fibers.

7. The method of claim 1 , wherein producing includes at least 5% by weight crimped synthetic fibers and at least 5% by weight binder fibers.

8. The method of claim 1 , wherein the foam-formed substrate is free of superabsorbent material.

9. The method of claim 1 , wherein the crimped synthetic fibers have a fiber length from 5 to 30 mm and a fiber diameter of at least 4 dtex.

10. A substrate comprising an aqueous-based polymer foam including at least 1% by weight crimped synthetic fibers and at least 1% by weight binder fibers, wherein the substrate is free of superabsorbent material; wherein the crimped synthetic fibers include a polymer having a Tg greater than or equal to 0° C., have a length from 5 mm to 60 mm, and have a diameter of at least 3 dtex; and wherein the foam-formed substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

11. The substrate of claim 10 , wherein the crimped synthetic fibers have a length from 5 mm to 30 mm.

12. The substrate of claim 10 , wherein the crimped synthetic fibers have a diameter of at least 4 dtex.

13. The substrate of claim 10 , wherein the crimped synthetic fibers have a fiber length from 5 to 30 mm and a fiber diameter of at least 4 dtex.

14. The substrate of claim 10 , wherein producing includes at least 2% by weight crimped synthetic fibers and at least 2% by weight binder fibers.

Continuity (1)
Related Publication 20200190739A1 · Jun 18, 2020
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