Highly crimpable spunbond conjugate fibers and nonwoven webs made therefrom

DETAILED DESCRIPTION The present invention provides a highly crimpable conjugate spunbond fiber comprising a propylene polymer component and an ethylene polymer component, wherein each of the components occupies a distinct section for substantially the entire length of the spunbond fiber.
The propylene polymer component contains a propylene polymer having a melt flow rate between about 50 g/10 min.
and 200 g/10 min.
as measured in accordance with ASTM D1238, Testing Condition 230/2.
16 and is selected from homopolymers and copolymers of propylene and blends thereof, and the ethylene polymer component contains an ethylene polymer which is selected from homopolymers and copolymers of ethylene.
Additionally provided is a nonwoven web containing the conjugate spunbond fibers.
The present conjugate fibers are highly crimpable even at fine deniers, providing a soft, high loft nonwoven web.
As such, the nonwoven webs produced from the conjugate fibers are highly useful as various parts for disposable articles, including diapers, sanitary napkins, incontinence products, wipes, cover materials, garment materials, filters and the like.
The term "conjugate fibers" refers to fibers containing at least two polymeric components which are arranged to occupy distinct sections for substantially the entire length of the fibers.
The conjugate fibers are formed by simultaneously extruding at least two molten polymeric component compositions as a plurality of unitary multicomponent filaments or fibers from a plurality of capillaries of a spinneret.
The term "fine denier fibers" refers to fibers having a weight-per-unit length of less than about 2.
5 denier (2.
8 dtex).
The term "webs" as used herein refers to fibrous webs and fabrics.