Absorbent articles and methods of making

专利摘要:
An absorbent article comprising an absorbent core secured between a liquid permeable topsheet and a liquid impermeable backsheet, and an acquisition distribution layer disposed between the topsheet and backsheet, the absorbent core comprising absorbent material selected from the group consisting of cellulose fibers, superabsorbent polymers and combinations thereof, wherein the absorbent core includes at least one coupled channel that is free of the absorbent material, the channel having a length extending along a longitudinal axis and the absorbent core having a length extending along the longitudinal axis and wherein the length of the channel is from 10% to 95% of the length of the absorbent core, the acquisition distribution layer comprising a spunbond and / or carded fleece layer comprising synthetic fibers, the synthetic fibers being present at a level greater than 80 weight% of the far acquisition distribution layer, and wherein the acquisition distribution layer has a basis weight of 10 to 50 g / m2.
公开号:BE1026999B1
申请号:E20200018
申请日:2020-02-11
公开日:2020-08-20
发明作者:Christina Lambertz；Ainas Weber；Toon Coppejans；Gezime Dzaferi；Björn Ingenfeld；Jochen F Schneider
申请人:Ontex；Ontex Group Nv；
IPC主号:

专利说明:

M lcd le -1- BE2020 / 0018 Absorbent articles and methods of making
TECHNICAL FIELD The disclosure belongs to the technical field of absorbent hygiene products. In particular, the present disclosure relates to an absorbent core that can be used in an article for absorbing bodily fluids and secretions, such as urine and fecal matter, or blood, menstruation, and vaginal fluids. More specifically, the present disclosure relates to absorbent garments, such as disposable diapers or diaper pants, disposable incontinence pads or pants, and which are configured to collect and contain fecal material and prevent leakage, or sanitary napkins or pantyliners, which are configured to contain blood, collect and contain menstrual periods, urine and vaginal fluids and avoid leakage.
BACKGROUND The disclosure relates to an absorbent core for an absorbent article, particularly for sanitary articles, absorbent articles comprising the absorbent core, and methods for providing the absorbent core. In particular, cores with one or more channels therethrough. Absorbent cores have been subject to significant improvement and innovation over time to address needs such as improved fluid absorption and distribution, as well as comfort, and there is a need for continuous improvement. Such needs are always present in today's demanding consumer environment. The following sections explain some of the relevant disclosures pertaining to this topic.
EP 1077052 A1 and EP 1078617 A2 disclose a sanitary napkin that allows controlled deformation in response to lateral compression when in use. The sanitary napkin has preferred bending zones extending along a longitudinal axis formed by a perforating, cutting, cutting or embossing process.
EP 1959903 B1 discloses an incontinence pad comprising a pair of fold lines dividing the absorbent core material into a central portion and a pair of longitudinal side portions to better conform to the user's body. The fold lines are formed by compression of the absorbent material.
EP2211808 B1 discloses an absorbent core comprising an upper absorbent core and a lower absorbent core. The upper absorbent core includes fold indicia that enable the absorbent core to assume a predetermined three-dimensional shape when subjected to width direction pressure. The fold indications are cuts or lines of compression that may or may not extend completely through the top core. EP 1349524 B1 discloses a pantiliner comprising at least one fold line defining a central region and two side regions that allow for adjusting the size of the pantiliner by folding the pantiliner along the fold line. The folding lines are embossing lines.
EP 1267775 B1 discloses a sanitary napkin that conforms to body shapes. The sanitary napkin includes a forwardly protruding wide portion and a rear narrow portion and at least two fold lines pre-formed on the top or bottom surface of the narrow portion. The fold lines can be selected from mechanically pressed lines, chemically bonded components forming the lines, heat generated lines, laser generated lines, adhesive generated lines and / or mechanical vibration generated lines.
EP1088536 A2 discloses a sanitary napkin provided with pleats that allow the sanitary napkin to be adapted to the user's underpants.
US 5,756,039 A discloses an absorbent core comprising separate segments that can be moved independently of each other by means of a lifting member.
The lifting part ensures that the topsheet conforms to the body of the wearer.
US 2006/0184150 A1 discloses an absorbent core of varying flexibility that acts as a shaping element for improved body fit.
The absorbent core may have lines of reduced flexural resistance formed by removal of material, for example, in the form of openings or grooves.
US 6,503,233 B1 discloses an absorbent article comprising a combination of pleating lines that deflect downward and a shaping line that deflect upward to achieve an improved body fit geometry.
The pleating lines are formed by embossing the absorbent material.
The forming line is formed by perforation or cut.
US 2015/0088084 A1 discloses a method of manufacturing an absorbent structure having a three-dimensional topography that includes placing at least a portion of the absorbent structure between opposed mold surfaces.
At least one of the mold surfaces has a three-dimensional topography.
The three-dimensional topography of the mold surface is imparted to the absorbent structure so that the absorbent structure has a three-dimensional topography that matches the three-dimensional topography of the mold surface.
EP3342386A1 discloses an absorbent core comprising substantially continuous zones of one or more high fluid distribution structures and discontinuous zones of fluid absorption structures surrounding the one or more high fluid distribution structures, the one or more high fluid distribution structures being arranged to distribute fluid through the absorbent speed that is higher than the speed of
BE2020 / 0018 fluid distribution through the absorbent core by means of the discontinuous fluid absorption structures, and wherein the continuous zones extend along a path that is substantially parallel to at least a portion of the outer edge of the core, the portion of the outer edge of the core comprises at least a portion of the sides of the core and one of the ends of the core. While channels such as described in EP3342386A1 are beneficial in terms of fluid handling, there still remains a need to further improve dryness while maintaining acquisition rate.
The present disclosure seeks to provide a novel absorbent article utilizing a synergistic combination of a channeled core and a selected acquisition distribution layer that is particularly designed to provide excellent acquisition rate performance as well as exceptionally low rewet, adding to an even greater consumer perceived dryness. the product.
RESUME ; In one aspect, the disclosure relates to an absorbent article comprising an absorbent core sandwiched between a liquid pervious topsheet and a liquid impervious backsheet, and an acquisition distribution layer disposed between the topsheet and the absorbent core, the absorbent core comprising absorbent material selected from the group consisting of cellulose fibers, superabsorbent polymers and combinations thereof, wherein the absorbent core comprises at least one coupled channel that is free of the absorbent material, the channel having a length extending along a longitudinal axis and the absorbent core having a length extending along the longitudinal axis and wherein the length of the channel is from 10% to 95% of the length of the absorbent core, the acquisition distribution layer comprising a spunbond and / or carded fleece layer comprising synthetic fibers, the synthetic fibers in a content e is greater than 80% by weight of the acquisition distribution layer, and where the
° ° BE2020 / 0018 acquisition distribution layer has a basis weight of 10 to 50 g / m2. Preferably, the length of the channel is from 30% to 90%, more preferably from 40% to 85%, most preferably from 50% to 80%, of the length of the absorbent core.
In one aspect, the disclosure concerns the use of a web having a relative porosity of less than 9000 L / m2 / s as an acquisition distribution layer for an absorbent article comprising an absorbent core sandwiched between a liquid-pervious topsheet and a liquid-impervious backsheet, wherein the acquisition distribution layer disposed between the topsheet and the absorbent core, the absorbent core comprising absorbent material selected from the group consisting of cellulose fibers, superabsorbent polymers, and combinations thereof, the absorbent core comprising at least one interlocked channel free of the absorbent material, wherein the channel has a length that extends along a longitudinal axis and the absorbent core has a length that extends along the longitudinal axis and the length of the channel is from 10% to 95% of the length of the absorbent core is.
In one aspect, the disclosure concerns an absorbent core comprising a front portion; a rear part; a middle portion disposed between the front portion and the rear portion; a longitudinal axis extending along a length of the core and intersecting the front, middle and rear portions, the absorbent core having a width extending perpendicular to its length and having an outer edge comprising at least two opposite ends and at least two opposed sides interposed between the ends, the core being a multilayer core comprising at least a first and a second separate core layers superimposed on each other, a first core layer having a first concentration of superabsorbent polymer therein and a second core layer comprises a second concentration of superabsorbent polymer therein, wherein the first and / or second core layers comprise one or more channels, and the second core layer comprises a first region of superabsorbent polymer particles on a surface thereof that is opposite the first core layer , the first region being patterned in substantially follows the shape of the channel (s), at least along a plane formed by the core length and width, so that the shape of the channel (s) is substantially the same to that of the cartridge.
In one aspect, the disclosure concerns an absorbent core comprising a front portion; a rear part; a middle portion disposed between the front portion and the rear portion; and a longitudinal axis extending along a length of the core and intersecting the front, middle and rear portions, the absorbent core having a width extending perpendicular to its length and having an outer edge including at least two opposite ends and at least two opposite sides disposed between the two ends, the core being a multilayer core comprising at least two separate core layers, a first core layer comprising a first concentration of superabsorbent polymer therein and a second core layer having a second concentration of superabsorbent polymer therein, wherein the first and second concentrations are different, wherein at least the first core layer comprises one or more channels, the channel (s) being continuous and coupled at least along its length and the width of the core such that at least two channel portions extending along its length in fluid communication are n via a connecting channel portion disposed proximal to the rear portion. In one aspect, the disclosure concerns an absorbent core comprising a front portion; a rear part; a middle portion disposed between the front portion and the rear portion; and a longitudinal axis extending along a length of the core and intersecting the front, center and rear portions, the absorbent core having a width extending perpendicular to its length and having an outer edge comprising at least two opposed ends and at least two opposite sides interposed between the ends, the absorbent core comprising one or more channels having a first shape when the absorbent core is in a dry state and a second shape when the absorbent core is in a wet state and wherein the first and second shapes are different.
ie BE2020 / 0018 In one aspect, the disclosure concerns an absorbent core comprising substantially continuous zones of one or more high fluid distribution structures and discontinuous zones of fluid absorption structures surrounding the one or more high fluid distribution structures, the one or more high fluid distribution structures being arranged around fluid distribute the absorbent core at a rate in excess of the rate of fluid distribution through the absorbent core by the discontinuous fluid absorption structures, and wherein the continuous zones extend along a path substantially parallel to at least a portion of the outer edge of the core, wherein the portion of the outer edge of the core comprises at least a portion of the sides of the core and one of the ends of the core.
In a further aspect, the disclosure relates to an absorbent core comprising: a front portion ,; a rear part; a crotch portion position between the front portion and the rear portion, and a longitudinal axis extending a length of the core and intersecting the front, crotch, and rear portions, the absorbent core having a width extending perpendicular to the length and a outer rim comprising at least two opposite ends and at least two opposite sides interposed between the ends, the absorbent core comprising one or more substantially coupled channels extending through at least a portion of the crotch portion along the length of the core and along at least a portion of the width of the core extends from one side of the core to the other, preferably the one or more substantially coupled channels being symmetrical or asymmetrical about the longitudinal axis.
In a preferred aspect, the absorbent core has at least one of the coupled channels, preferably each of the channels, forming a shape with a closed end in the form of a U-bend, and preferably an open end in the shape of two divergent ends or a funnel shape, preferably with the closed end disposed proximal to the rear portion of the absorbent core and the open end disposed proximal to the front portion of the absorbent core and distal to the closed end.
In a further aspect, the disclosure relates to an absorbent article comprising the core, preferably the article is selected from disposable diapers or diaper pants; disposable incontinence pads or diaper pants; sanitary napkin; or pantyliners; and typically wherein the channels in the core remain visible both before and after use of the article, preferably wherein the channels are more visible after use than before use of the article.
In yet a further aspect, the disclosure concerns the use of an absorbent core according to the disclosure in an absorbent article for improved liquid distribution compared to the same absorbent article comprising a core free of substantially interlocked channels.
In yet a further aspect, the disclosure involves the use of an absorbent core according to the disclosure in an absorbent article, to provide a three-phase fluid distribution comprising a first fluid distribution at a first rate, a second fluid distribution at a second rate, and a third fluid distribution. at a third speed, wherein the first speed is greater than or equal to the second speed and the third speed is less than the first speed and less than or equal to the second speed, preferably wherein the first fluid distribution is driven by the in substantially coupled channels, the second fluid distribution is driven by a three-dimensional absorbent material contained within the core, and the third fluid distribution is driven by an amount of superabsorbent polymer dispersed within the three-dimensional absorbent material.
In yet a further aspect, the disclosure relates to a method of manufacturing an absorbent core comprising the steps of: providing a mold including a 3D insert therein, the 3D insert having the inverted shape of the desired channels, wherein substantially all of the mold surface is in fluid communication with a negative pressure source except for the 3D insert; applying a first nonwoven web to the mold; applying a three-dimensional absorbent material over at least a portion of the web; applying a second nonwoven web directly or indirectly over the three-dimensional absorbent material; optionally applying a bonding step to form a laminate comprising the first web, the second web and the three-dimensional absorbent material therebetween; optionally removing the laminate from the mold to form an absorbent core comprising channels with the inverted shape of the 3D insert; and wherein at least for the duration of the step of applying a three-dimensional absorbent material, the vacuum source is arranged to provide a vacuum force that forces the three-dimensional material around the 3D insert to substantially clear its surface of three-dimensional absorbent material. and to form channels that are substantially free of three-dimensional absorbent material.
BRIEF DESCRIPTION OF THE FIGURES Fig. 1 shows a schematic top view of an absorbent core according to an embodiment herein. FIG. 2 shows a schematic top view of an absorbent core according to an embodiment herein. FIG. 3 shows a schematic top view of an absorbent core according to an embodiment herein.
FIG. 4 shows a schematic top view of an absorbent core according to one embodiment thereof and with various geometric shapes formed by interlocking channels.
FIG. 5 shows a perspective view of an absorbent article according to an embodiment herein.
FIG. 6 shows a perspective view of a product according to an embodiment herein.
FIG. 7 shows a top view of an absorbent article according to an embodiment herein.
-10- BE2020 / 0018 Fig. 8 shows a top view of an absorbent article according to an embodiment herein. FIG. 9 shows a perspective view of an absorbent article according to an embodiment herein. FIG. 10 shows a perspective view of a product according to an embodiment herein. FIG. 11 shows a top view of an absorbent article according to an embodiment herein. FIG. 12 shows a top view of an absorbent article according to an embodiment herein. FIG. 13 shows a schematic view of an absorbent article according to an embodiment herein. FIG. 14 shows a schematic view of an absorbent article according to an embodiment herein.
FIG. 15A and FIG. 15B show images of molds comprising a 3D insert according to an aspect of the present disclosure. FIG. 16 illustrates coupled channels where the width of the channels varies. FIG. 17A to D illustrate embodiments of the present disclosure in which the absorbent core is combined with an acquisition and distribution layer. FIG. 18A to B illustrate the visual appearance of a channel in the dry state (Fig. 18A) and wet state (Fig. 18B), respectively. FIG. 19A to B shows images of samples and test bench for the hang-crack value test method.
FIG. 20A illustrates a cross-section of a core according to an embodiment of the present disclosure, such as that of FIG. 1. FIG. 20B illustrates a cross-section of an absorbent article according to an embodiment of the present disclosure showing the core of FIG. 20A.
FIG. 21A illustrates a cross-section of a core according to an embodiment of the present disclosure, such as that of FIG. 3.
FIG. 21B illustrates a cross-section of an absorbent article according to one embodiment of the present disclosure showing the core of FIG. 21A. FIG. 22 illustrates an absorbent article according to an embodiment of the present disclosure that includes protruding channels (namely, when wet). FIG. 23 is a photograph of two identical diapers comprising channels according to Example 9, the only difference being that the one designated as “D” includes an ADL according to sample A / A 'and the one designated as “E” sample B / B '. Where the respective residual wetness difference is visually shown.
DETAILED DESCRIPTION Unless otherwise defined, all terms used in the disclosure of features of the disclosure, including technical and scientific terms, have the meaning commonly understood by one of ordinary skill in the art to which this disclosure belongs. Through further guidance, term definitions have been included to better appreciate the teaching of the present disclosure.
As used herein, the following terms have the following meanings: "A" and "the" / "the" as used herein refer to both single and multiple referents unless the context clearly dictates otherwise. For example, “a compartment” refers to one or more than one compartment. "About" as used herein, referring to a measurable value, such as a parameter, an amount, a time duration, and the like, is intended to mean variations of +/- 20% or less, preferably +/- 10% or less, with more preferably +/- 5% or less, even more preferably +/- 1% or less, and even more preferably to include +/- 0.1% or less of and from the specified value, insofar as such variation suitable to perform in the published disclosure. However, it must be understood that the value
-12- BE2020 / 0018 to which the modifier “approximately” refers is itself also specifically disclosed.
"Include", "comprising", and "includes" and "consisting of" as used herein are synonymous with "containing", "including", "including", "contains", "containing", and are inclusive or open terms that specify the presence of what follows, e.g., component, and that do not exclude or prevent the presence of additional, unnamed components, features, elements, parts, steps known in the art or disclosed therein.
The term "weight%" (weight percent), here and throughout the specification, refers to the relative weight of the particular component, based on the total weight of the formulation, unless otherwise defined.
Endpoint naming of numerical ranges includes all numbers and fractions included in the range, as well as the named endpoints. "Absorbent article" refers to devices that absorb and contain liquid, and more specifically, refers to devices placed against or near the wearer's body to absorb and contain the various secretions released from the body. Absorbent articles include, but are not limited to, diapers, adult incontinence pants, training pants, diaper holders and liners, sanitary napkins and the like, as well as surgical dressings and sponges. Absorbent articles preferably include a longitudinal axis and a transverse axis perpendicular to the longitudinal axis. The longitudinal axis is hereby conventionally selected in the front-to-back direction of the object when referring to the object being worn, and the transverse axis is conventionally selected in the left-to-right direction of the object when referring to the object that is worn. Disposable absorbent articles can include a liquid permeable topsheet, a backsheet bonded to the topsheet, and an absorbent core disposed and retained between the topsheet and the backsheet. The topsheet is permeable to the operation
-13- BE2020 / 0018 liquids intended to be held or stored by the absorbent article, and the backsheet may or may not be substantially impermeable or otherwise impermeable in operation to the intended liquids. The absorbent article may also include other components, such as liquid wicking layers, liquid receiving layers, liquid distribution layers, transfer layers, barrier layers, wrap layers, and the like, as well as combinations thereof. Disposable absorbent articles and their components can function to provide a body-facing surface and a garment-facing surface.
An absorbent article, such as a diaper, includes a front waistband area, a rear waistband area, an intermediate crotch area connecting the front and rear waistband areas. When used herein, reference to a "front" portion refers to that portion of the absorbent article that is generally in front of a subject, such as a child or adult, when in use. Reference to the "back" portion refers to the portion of the absorbent article that is generally at the rear of the subject, such as a child or adult, when in use, and reference to the "crotch" portion refers to that portion that is generally located between the legs of a subject, such as a child or adult, when in use. The crotch region is an area where repetitive fluid flow typically occurs, within the assembly of the absorbent article.
"Front", "back or back" and "crotch" portions of the absorbent core as used herein typically refer to portions of the absorbent core that are proximal to the respective portions of the absorbent article. For example, the "front" portion of the core is that which is most proximal to the front of the subject when worn, the "back or back" portion of the core is that which is most proximal to the back or back of the body. subject is when worn, and the "crotch" portion of the core is the mid-portion of the absorbent core between the "front" and "back or back" portions.
-14- BE2020 / 0018 Preferably, a diaper comprises a liquid pervious topsheet ”, a liquid impermeable“ backsheet ”, and an“ absorbent medium ”disposed between the topsheet and the backsheet.
The topsheet, backsheet and absorbent medium may be made of any suitable material known to those of skill in the art.
The topsheet is generally at or near the body side surface of the article, while the backsheet is generally at or near the garment side surface of the article.
Optionally, the article may comprise one or more separate layers that are in addition to the backsheet and that are interposed between the backsheet and the absorbent medium.
Topsheet and backsheet are connected or otherwise functionally associated with each other.
The "absorbent medium" or "absorbent core" or "absorbent body" is the absorbent structure disposed between the topsheet and the backsheet of the absorbent article in at least the crotch region of the absorbent article and is capable of absorbing liquid body exudates. absorb and hold.
The size and absorbent capacity of the absorbent medium should be compatible with the size of the intended wearer and the liquid loading given by the intended use of the absorbent article.
In addition, the size and absorbent capacity of the absorbent medium can be varied to accommodate wearers ranging from children to adults.
It can be made in a wide variety of shapes (e.g., rectangular, trapezoidal shape, T shape, I shape, hourglass shape, etc.) and of a wide variety of materials.
Examples of commonly occurring absorbent materials are cellulose fluff pulp, fabric layers, highly absorbent polymers (so-called superabsorbent polymer particles, SAP), absorbent foam materials, absorbent fleece materials or the like.
It is common to combine cellulose fluff pulp with superabsorbent polymers in an absorbent material.
-15- BE2020 / 0018 “Acquisition and Distribution Layer”, “ADL”, or “Flow Management Section” refers to a sub-layer which is preferably a fleece-like discharge layer beneath the topsheet of an absorbent product that accelerates the transport and distribution of fluids through the absorbent core improves.
The flow management portion is typically less hydrophilic than the retention portion, and has the ability to rapidly collect and temporarily retain fluid streams, and to transport the fluid from the initial entry point to other parts of the absorbent structure, particularly the retention portion.
This configuration can help prevent the liquid from accumulating and collecting on the portion of the absorbent garment placed against the wearer's skin, thereby reducing the wearer's feeling of wetness.
Preferably, the flow management portion is disposed between the topsheet and the retention portion.
The term "bulk density" as used herein refers to the weight of a material per unit volume.
Bulk density is generally expressed in units of weight / volume (e.g., grams per cubic centimeter). The bulk density of flat, generally planar materials such as fibrous fleece webs, for example, can be derived from measurements of thickness and basis weight of a sample.
The thickness of the samples is determined using a Model 49-70 thickness tester available from TMI (Testing Machines Incorporated) of Amityville, New York (alternatively, a portable thickness gauge J 100 / A can be used). The thickness is measured with a 6.45 cm (2 inch) diameter circular base at an applied pressure of about 1.38-10 ° Pa (about 0.2 pounds per square inch (psi)). The basis weight of the sample is determined essentially according to ASTM D-3776-9 with the following changes: 1) sample size is cut to 10.16 cm X 10.16 cm (4 inches X 4 inches) square and 2); a total of 9 samples are weighed.
The term "specific volume" as used herein refers to the inverse bulk density of material that is measured in volume per unit weight and may be expressed in units of cubic centimeters per gram.
-16- BE2020 / 0018 The term “mean flow pore size” as used herein refers to a measure of mean pore diameter as determined by a fluid displacement technique using a Coulter Porometer and Coulter POROFIL® test fluid available from Coulter Electronics Limited, Luton, England.
The average flow pore size is determined by wetting a test sample with a liquid with a very low surface tension (namely Coulter POROFIL®). Air pressure is applied to one side of the sample.
Finally, as the air pressure is increased, the capillary attraction of the fluid in the largest pores is overcome, forcing the fluid out and allowing air to pass through the sample.
A flow versus pressure relationship can be established for the wet sample and compared to the results for the dry sample.
The average flow pore size is measured at the point where the curve representing 50% of the flow versus pressure of the dry sample intersects the curve representing flow versus pressure of the wet sample.
The diameter of the pore that opens at that specific pressure (namely the mean flow pore size) can be determined from the following expression: Pore diameter (um) = (40t) / pressure where T is the surface tension of the liquid expressed in units of mN / M; the pressure is the applied pressure expressed in millibars (mbar); and the very low surface tension of the liquid used to wet the sample permits the assumption that the contact angle of the liquid on the sample is approximately zero.
The term "adhesive" as used herein is intended to refer to any suitable hot melt, water or solvent borne adhesive that can be applied to a surface of a film layer in the required pattern or network of adhesive regions to form the nonwoven laminate of the present disclosure. form.
Accordingly, suitable adhesives include conventional hot melt adhesives, pressure sensitive adhesives and reactive adhesives (namely polyurethane).
-17- BE2020 / 0018 As used herein, the term "bonding" means a bonding process that forms a bond by applying an adhesive. Such application of an adhesive can be by various processes such as groove coating, spray coating and other topical applications. Furthermore, such an adhesive can be applied within a product component and then subjected to pressure so that contact of a second product component with the product component containing the adhesive forms an adhesive bond between the two components.
As used herein, an "air-formed web" refers to a material comprising cellulose fibers, such as those from fluff pulp, that have been separated, such as by a hammer milling process, and then deposited on a porous surface without a significant amount of binding fibers present. For example, air-felted materials that have been used as the absorbent core in many diapers are typical of air-formed material. As used herein, an "airlaid" web is a fibrous structure formed primarily by a process involving deposition of air-entrained fibers on a mat, typically with binder fibers being present, and typically followed. is produced by compaction and heat binding. In addition to traditional heat-bonded air-laid structures (those formed with non-tacky binder material present and substantially heat-bonded), the scope of the term "air-laid" according to the present disclosure may also include coform, which is made by combining of air-entrained, dry, dispersed cellulose fiber is with meltblown synthetic polymer fibers while the polymer fibers are still tacky. Furthermore, an air-formed web to which binder material has subsequently been added can be considered to be within the scope of the term "laid in air" according to the present disclosure. Binder can be added in liquid form (for example an aqueous solution or melt) to an air-formed web by means of nozzles, directional injection or impregnation,
-18- BE2020 / 0018 vacuum drawing, foam impregnation, and so on. Solid binder particles can also be added by mechanical or pneumatic means.
As used herein, an "air-through-bonded" web is a web structure formed primarily by a method comprising applying heated air to the surface of the web. During the permeable air bonding process, heated air flows through cavities in a compressed air filled space above the fleece material. Unlike hot ovens, which push air through the material, the permeable air process uses negative suction pressure to draw the air through an open transport baffle that retains fleece as it is drawn through the oven. Drawing air through the material allows the rapid and even transfer of heat to minimize deformation of the nonwoven material. The binders used in the permeable air bonding process include crystalline binder fibers and powders, which melt to form molten droplets across the cross-section of the web. When the material is cooled, binding takes place at these drip points. As used herein, the term "associated" includes configurations in which the topsheet is bonded directly to the backsheet by bonding the topsheet directly to the backsheet, and configurations in which the topsheet is bonded to the backsheet by bonding topsheet to intermediate elements that are on their own. are in turn attached to backsheet. Topsheet and backsheet can be bonded directly together by an attachment means such as an adhesive, sonic bonds, heat bonds, or any other attachment means known in the art. For example, a uniform continuous layer of adhesive, a layer of patterned adhesive, a sprayed pattern of adhesive, or a series of separated lines, swirls, or dots of construction adhesive can be used to adhere topsheet to backsheet. It should be readily appreciated that the fasteners described above may also be used to connect and assemble the various other component parts of the article described herein.
-19- BE2020 / 0018 The terms "rear portion" and "rear back portion" are used synonymously herein and refer to the area of the absorbent article that is in contact with the wearer's back when the absorbent article is worn.
The term "backsheet" refers to a material that forms the outer covering of the absorbent article. The backsheet prevents the exudates present in the absorbent structure from wetting articles such as bed sheets and overgarments in contact with the disposable absorbent article.
The backsheet may be a unitary layer of material or may be a composite layer composed of multiple components assembled or laminated side-by-side. The backsheet can be the same or different in different parts of the absorbent article. At least in the region of the absorbent medium, the backsheet comprises a liquid impermeable material in the form of a thin plastic film, for example a polyethylene or polypropylene film, a nonwoven material covered with a liquid impermeable material, a hydrophobic nonwoven material that resists liquid penetration, or a non-woven material. laminate of a plastic film and a nonwoven material. The backsheet material can be breathable to allow vapor to escape from the absorbent material while still preventing liquids from passing through it. Examples of breathable backsheet materials are porous polymeric films, nonwoven laminates of spunbond and meltblown layers, and laminates of porous polymeric films and nonwoven materials.
The term "belly portion" and "anterior belly portion" are used synonymously herein and refer to the area of the absorbent article that is in contact with the wearer's abdomen when the absorbent article is worn.
The term "blend" means a blend of two or more polymers while the term "alloy" means a subclass of blends in which the components are immiscible but are compatibilized.
- 20 - BE2020 / 0018 As used herein, "skin-facing", "body-facing" or "body-side" surface means the surface of the article or component that is intended to be applied facing or placed adjacent to the wearer's body during normal use, while the “outer”, “outward-facing” or “garment side” surface is on the opposite side, and is intended to be applied to face away from the body of the wearer. the carrier during normal use. Such an outer surface may be arranged to face or be disposed adjacent to the wearer's underwear when the absorbent article is worn.
"Bound" refers to the joining, sticking, joining, securing, or the like, of at least two elements. Two elements will be considered to be bound together when they are directly or indirectly bound together, such as when each is directly bound to intermediate elements. The term “breathable” refers to films with a water vapor transmission rate (WVTR) of at least 300 grams / m ° up to 24 hours. “Carded web (or layer (s) or fleece)” refers to webs made from base fibers that are sent through a comb or carding unit, which opens and aligns the base fibers in the machine direction to a generally machine direction. - form oriented fibrous nonwoven web. The web is then bonded by one or more of several known bonding methods. Fleece web bonding can be accomplished by a number of methods; powder bonding, in which a powdered adhesive or binder is distributed throughout the web and subsequently activated, usually by heating the web and adhesive with warm air; pattern bonding, using heated calender rolls or ultrasonic bonding equipment to bond the fibers together, usually in a localized bonding pattern, although the web can be bonded over its entire surface if desired; permeable air bond, wherein air sufficiently warm to soften at least one component is passed through the web; chemical bonding with uses of, for example
-21- BE2020 / 0018 latex adhesives that are deposited on the web by, for example, spraying; and consolidation by mechanical methods such as sewing and hydroentanglement. Carded heat-bonded fleece thus refers to a carded fleece in which the bonding is achieved through the use of heat.
As used herein, the term "cellulosic" is intended to include any material having cellulose as a major constituent, and specifically including at least 50 weight percent cellulose or a cellulose derivative. Thus, the term includes cotton, typical wood pulp, non-woody cellulose fibers, cellulose acetate, cellulose triacetate, rayon, thermomechanical wood pulp, chemical wood pulp, decomposed chemical wood pulp, milk plant, or bacterial cellulose.
“Chassis” refers to a basic component of an absorbent article on which the rest of the structure of the article is built up or overlaid, for example, in a diaper, the structural elements that give the diaper the shape of underpants or trousers when configured for wear, such as a backsheet, a topsheet, or a combination of a topsheet and a backsheet.
"Covorm" as used herein is intended to describe a mixture of meltblown fibers and cellulose fibers that is formed by air forming a meltblown polymer material while simultaneously blowing air suspended cellulose fibers into the flow of meltblown fibers. The coform material can also include other materials such as superabsorbent particles. The meltblown fibers include wood fibers collected on a shaping surface, such as provided by a perforated belt. The forming surface may include a gas permeable material, such as spunbond fabric material, disposed on the forming surface.
“Compression” refers to the process or the result of pressing by applying force to an object, thereby increasing the density of the object.
“22 - BE2020 / 0018 The term“ consists essentially of ”does not exclude the presence of additional materials that do not significantly affect the desired properties of a given composition or product. Exemplary materials of this kind would include, without limitation, pigments, antioxidants, stabilizers, surfactants, waxes, flow promoters, solvents, particles, and materials added to improve the processability of the composition. The diaper may include "containment flaps" or "barrier cuffs". It is generally believed that the containment flaps are particularly well suited for containment of fecal matter and to prevent the lateral flow of liquid waste in the time it takes for the liquid waste to be absorbed by the absorbent article. Many containment flap constructions are known. Such containment flaps generally include a proximal edge, which is intended to be attached to the absorbent article, and an opposite distal edge which is generally not attached to the absorbent article along at least a portion of its length. An elastic member is generally located adjacent to the distal edge to aid in maintaining the containment flap in an upright position and in maintaining a sealing relationship between the distal edge of the containment flap and a wearer's body during use. The elastic element is generally located between two material layers so that the elastic does not come into contact with the body of a wearer. The containment flaps can be made from a wide variety of materials such as polypropylene, polyester, rayon, nylon, foams, plastic films, molded films, and elastic foams. A number of manufacturing techniques can be used to make the containment flaps. For example, the containment flaps can be woven, non-woven, spunbond, carded, molded, blown or the like.
The diaper may include leg containment packings. Leg “containment packings” help prevent leakage of bodily secretions when the wearer applies compressive forces to the absorbent article. In particular
-23-
BE2020 / 0018 the stiffness of the leg containment gaskets prevents twisting and crumpling of the leg openings of the absorbent article which can lead to leakage.
In addition, the elasticity and conformability of the leg containment gaskets ensures that the body-facing surface of the leg containment gaskets provides an adequate seal against the body of the wearer.
The physical properties of the leg containment packings, such as thickness and stiffness, also function to locate the body side liner, outer cover and absorbent core away from the wearer's body when in use.
In this way, void volume is created between the wearer's body and the body side liner and absorbent core of the absorbent article to help contain body secretions.
A "continuous waistband" can be an elastomeric cloth-like non-woven fibrous material such as an elastomer stretch bonded laminate web or an elastomeric meltblown web.
By means of an adequate selection of materials, the continuous waistband can be temporarily made elastic with brakes, such as by compression.
Once temporarily elastically inhibited, the elastic material composing the waistband can be activated, such as by heat treatment, to regain a state of elasticity. "Conventional Hot Melt Adhesive" means a formulation that generally includes several components.
These components typically include one or more polymers to provide cohesive strength (e.g., aliphatic polyolefins such as poly (ethylene-co-propylene) copolymer; ethylene-vinyl acetate copolymers; styrene-butadiene or styrene-isoprene block copolymers; etc.); a resin or analog material (sometimes referred to as a tackifier) to provide adhesive strength (e.g., hydrocarbons distilled from petroleum distillates; resins and / or resin esters; terpenes derived from e.g. wood or citrus, etc.) ; perhaps waxes, plasticizers or other materials to modify viscosity (namely, flowability) (examples of such materials include, but are not limited to, mineral oil, polybutylene, paraffin oils, ester oils, and the like); and / or
24 - BE2020 / 0018 other additives including, but not limited to, antioxidants or other stabilizers. A typical hot melt adhesive formulation can include from about 15 to about 35 weight percent cohesive strength polymer or polymers; from about 50 to about 65 weight percent of resin or other tackifier or tackifiers; from more than zero to about 30 weight percent plasticizer or other viscosity modifier; and optionally less than about 1 weight percent stabilizer or other additive. It should be understood that other adhesive formulations comprising different weight percentages of these components are possible.
The term "density" or "concentration", when referring to the absorbent material, refers to the amount of the absorbent material divided by the surface area of the layer over which the absorbent material is spread.
As used herein, the term "diaper" refers to an absorbent article that is generally worn around the lower body by children. The term "disposable" is used herein to describe absorbent articles that are generally not intended to be washed or otherwise repaired or reused as an absorbent article (namely, they are intended to be disposed of after a single use and, preferably, , to be recycled, composted or otherwise disposed of in an environmentally sound manner).
As used herein, the term "elastic resistance" describes an elastic force that tends to withstand an applied tensile force so that a material supplied therewith tends to contract to an unstressed configuration in response to a tensile force.
As used herein, the terms "elastic", "elastomeric", "elasticity" or derivatives thereof are used to describe the ability of various materials and objects made up of them to reversibly deformation under stress.
-25- BE2020 / 0018 undergo, for example, stretched or elongated, in at least one direction when a force is applied to the material, and to substantially regain their original dimensions after relaxation, namely when the force is released, without tearing or fracture. Preferably, this term refers to a material or composite that can be elongated in at least one direction by at least 50% of its relaxed length, namely extended to at least 150% of its relaxed length, after releasing the applied tension regains at least 40% of its extension. Accordingly, upon release of the applied tension at 50% elongation, the material or composite contracts to a relaxed length of no more than 130% of its original length. Examples of suitable elastomeric materials include polyether polyamide block copolymers, polyurethanes, synthetic linear ABA and AB block copolymers, chlorinated rubber / EVA (ethylene vinyl acetate) blends, EPDM (ethylene propylene diene monomer) rubbers, EPM (ethylene propylene monomer) rubbers, blends of EPDM / EPDM / EVA, and the like. The term "elasticized" refers to a material, layer or substrate that is naturally non-elastic, but which has been made elastic by, for example, adequately bonding an elastic material, layer, or substrate thereto. “Elongation” means the ratio of the stretch of a material to the length of the material prior to stretching (expressed in percent), as represented by the following: “Stretch” means the change in length of a material due to stretching ( expressed in units of length). As used herein, the term "stretchable" means extensible in at least one direction, but not necessarily recoverable.
The term “fabrics” is used to refer to all woven, knitted and nonwoven webs.
- 26 - BE2020 / 0018 "Closure", such as an adhesive tape lip closure, is typically applied to the rear waistband area of the diaper to provide a mechanism for retaining the diaper on the wearer. Closure means, such as tape tab closures, snaps, pins, straps, hooks, buckles, hook and loop fasteners (e.g., VELCRO® type closures) and the like, may be used and are typically disposed on the lateral side ends of the rear waistband area of the diaper to provide a mechanism for retaining the diaper around the waist of the wearer in a conventional manner. Adhesive tape lip closures can be any of those known in the art, and are typically disposed on the corners of the diaper. For example, adhesive closures, mechanical closures, hook and loop fasteners, snaps, pins or buckles can be used alone or in combination. For example, the closures may be adhesive closures constructed to releasably adhere to a catchment zone attachment zone piece attached to the front waistband region of the diaper to provide a reclosable adhesive attachment system. The term “final” or “ultimate”, when used with reference to a product, means that the product is adequately manufactured for its intended purpose. The term "flexible" refers to materials that are pliable and that will conform readily to the general shape and contours of the wearer's body.
As used herein, the term "garment" means any type of clothing that can be worn. This includes diapers, training pants, incontinence products, surgical gowns, industrial work clothes and coveralls, undergarments, pants, shirts, coats and the like.
Many of the known superabsorbent polymer particles exhibit gel blocking. “Gel blocking” occurs when superabsorbent polymer particles are wetted and the particles swell to prevent fluid transfer to other
“27 - BE2020 / 0018 to inhibit areas of the absorbent structure. Wetting of these other areas of the absorbent element therefore takes place via a very slow diffusion process. In practical terms, this means that fluid acquisition through the absorbent structure is much slower than the rate at which fluids are released, especially in gouging situations. Leakage from the absorbent article can occur well before the particles of SAP in the absorbent element are even nearly completely saturated or before the fluid can diffuse or drain past the "blocking" particles into the remainder of the absorbent element. Gel blocking can be a particularly acute problem if the superabsorbent polymer particles do not have the adequate gel strength and deform or disperse under stress once the particles swell with absorbed fluid.
The term "image" includes, but is not limited to, any type of design, image, sign, figure, codes, words, patterns, or the like. For a product such as training pants, images will generally include objects associated with little boys and little girls, such as multi-colored trucks, planes, balls, dolls, bows, or the like.
"Hydro-entanglement process" refers to the manufacture of fleece webs. The process involves directing a series of jets of water at a fibrous web carried on a moving porous belt. The water jets go down through the fiber mass and when they make contact with the surface of the belt they bounce back and disintegrate: the energy released causes the fiber mass to entangle.
The term "high absorption material" refers to materials that are able to absorb at least 10 times their own weight in liquid. The high absorption material may include absorbent gelling materials, such as super absorbent polymers. Superabsorbent polymers are water-swellable, water-insoluble organic or inorganic materials capable of absorbing at least about 20 times their own weight of an aqueous solution containing 0.9 weight percent sodium chloride. Absorbent gelling
-28-
BE2020 / 0018 materials can be natural, synthetic and modified natural polymers and materials.
In addition, the absorbent gelling materials can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers.
The term "crosslinked" refers to any means for effectively rendering normally water-insoluble materials substantially water-insoluble but swellable.
Such an agent may include, for example, physical entanglement, crystalline domains, covalent bonds, ionic complexes and associations, hydrophilic associations, such as hydrogen bonding, and hydrophobic associations or van der Waals forces.
Examples of synthetic polymers for absorbent gelling material include the alkali metal and ammonium salts of polyacrylic acid and polymethacrylic acid, polyacrylamides, polyvinyl ethers, maleic anhydride copolymers with vinyl ethers and alpha olefins, polyvinylpyrrolidone, polyvinylmorpholinone, and polyvinylmorpholinone, copolymers thereof.
Additional polymers suitable for use in the absorbent structure include natural and modified natural polymers such as hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, methyl cellulose, carboxymethyl cellulose, hydroxypropyl cellulose, and the natural gums such as alginates, xanthan gum, locust bean gum gum and the like.
Mixtures of natural and fully or partially synthetic absorbent polymers can also be used.
Synthetic absorbent gelling materials are typically xerogels that form hydrogels when wetted.
However, the term "hydrogel" has commonly been used to also refer to both the wetted and non-wetted forms of the material.
The high absorption material can be in any of a wide variety of geometric shapes.
As a general rule, it is preferred that the high absorption material be in the form of discrete particles.
However, the high absorption material may also be in the form of fibers, flakes, rods, spheres, needles, spiral or semi-spiral, cubic, rod-like, polyhedral, or the like.
Conglomerates of particles of the high absorption material can also be used.
The high absorbency material may be present in the absorbent core in an amount from about 5 to about 100 weight percent, and desirably from about 30 to about 100 weight percent, based on the total weight of the absorbent core.
The distribution of the
-29-; BE2020 / 0018 high absorption material within the different portions of the absorbent core may vary depending on the intended end use of the absorbent core. The high absorbency material can be arranged in a generally discrete layer within the matrix of hydrophilic fibers. Alternatively, the absorbent core may comprise a laminate of fibrous webs and high absorbency material or other suitable means for retaining a high absorbency material in a localized area.
A "hook and loop closure" refers to a complementary closure device having a "hook" portion and a "loop" portion and which is reclosable. The term "hook" as used herein refers to any element that is capable of engaging another element, the so-called "loop" portion. The term "hook" is not limited to just "hooks" in the normal sense, but rather includes any form of engaging elements, whether unidirectional or bidirectional. The term "loop" is also not limited to "loops" in the normal sense, but includes any structure capable of engaging a "hook" closure. Examples of "loop" materials are fibrous structures, such as nonwoven materials. The term "hydrophilic" describes fibers or the surfaces of fibers that are wetted by the aqueous liquids that come into contact with the fibers. The degree of wetting of the materials can, in turn, be described in terms of the contact angles and the surface tensions of the liquids and materials involved. The term "wettable" is intended to refer to a fiber that exhibits a liquid, such as water, synthetic urine, or a 0.9 weight percent aqueous saline solution, in air contact angle less than 90 °, while "hydrophobic" or "non- wettable ”describes fibers with contact angles equal to or greater than 90 °. As used herein, the term "impermeable" generally refers to articles and / or elements that are substantially not penetrated by aqueous fluid throughout their thickness under a pressure of 1.0 kPa or less. Preferably, the impermeable article or element is not penetrated by aqueous fluid at pressures of 3.4 kPa or less. With more
BE2020 / 0018 Preferably, the impermeable article or element is not penetrated by fluid under pressures of 6.8 kPa or less. An object or element that is not impermeable is permeable.
"Integral" is used to refer to various portions of a single unitary element rather than separate structures that are connected, placed or placed in close proximity to each other. "Connecting", "connecting", "connecting", or variations thereof, when used in describing the relationship between two or more elements, means that the elements can be bonded together in any suitable manner, such as by heat sealing, ultrasonic bonding, heat bonding, by adhesives, stitching, or the like. Furthermore, the elements can be directly connected to each other, or the elements can have one or more elements interposed between them, all of which are bound together.
The term "laid-flat state" is intended to refer to the article when it is flattened in a plane or substantially flattened in a plane and is used as opposed to when the object is placed in some other way, such as when it is article is folded or shaped or for use by a wearer.
"Laminate" refers to elements that are joined together in a layered arrangement.
The use of the term "sheet" may refer to, but is not limited to any type of substrate, such as woven web, nonwoven web, films, laminates, composites, elastomeric materials, or the like. A layer can be liquid and air permeable, permeable to air but impermeable to liquids, impermeable to both air and liquid, or the like. When used in the singular, it can have the dual meaning of a single element or multiple elements.
-31- BE2020 / 0018 The crotch portion of the absorbent article preferably includes opposed longitudinal side portions that include a pair of elasticized, longitudinally extending "leg cuffs". The leg cuffs are generally adapted to fit around a wearer's legs when in use and to act as a mechanical barrier to the lateral flow of body secretions. Leg cuffs are elastic made with leg elastics. The diaper may further include a front waist elastic and a back waist elastic. Materials suitable for use in forming leg elastics are known to those of skill in the art. Exemplary of such materials are strands or ribbons of a polymer, elastomeric material that are bonded to the diaper at the leg cuff while it is in a stretched position, or that are bonded to the diaper while the diaper is pleated, so that elastic constrictive forces apply to the leg cuff. leg cuff are included. Examples of suitable elastomeric materials that can be used include polyether polyamide block copolymers, polyurethanes, synthetic linear ABA and AB block copolymers, chlorinated rubber / EVA (ethylene vinyl acetate) blends, EPDM (ethylene propylene diene monomer) rubbers, EPM (ethylene propylene monomer) rubbers, blends of EPDM / EPM / EVA, and the like.
“Liquid” means a non-gaseous substance and / or material that flows and can take the interior shape of a container into which it is poured or placed.
"Longitudinal" is a direction that is parallel to the maximum linear dimension of the object.
The term "meltblown fibers" means fibers formed by extruding a molten thermoplastic material through multiple fine, usually circular, die capillaries as molten wires or filaments in a high velocity gas flow (e.g., air) that weaken the filaments or molten thermoplastic material for their diameter, which can be down to a microfiber diameter. In general, meltblown fibers have an average fiber diameter of up to about 10 microns. After the fibers are formed
-32- BE2020 / 0018, the meltblown fibers are carried by the high velocity gas stream and deposited on a collection surface to form a web of randomly dispensed meltblown fibers.
The term "inelastic" refers to any material that does not fall within the definition of "elastic" above. The term "nonwoven fabric or web" means a sheet of material with a structure of individual fibers or threads that are interlaced, but not in a regular manner as happens with knitting or weaving processes. Nonwoven fabrics or webs are formed by many processes, such as, for example, meltblown processes, spin bonding processes, and bonded carded web processes. "Trouser body" refers to a garment that has a waist opening and a pair of leg openings, similar to shorts, swimwear, or the like. The garment described may or may not have a manually tearable side seam. By the terms "particle", "particles", "dust particle", "dust particles" and the like is meant that the material is generally in the form of discrete units. The units can include granules, powders, spheres, comminuted materials or the like, as well as combinations thereof. The particles can be any desired shape such as, for example, cubic, rod-like, polyhedral, spherical or semi-spherical, round or semi-circular, angular, irregular, and so on. Forms with a large largest dimension / smallest dimension ratio, such as needles, flakes and fibers, are also contemplated for inclusion herein. The terms "particle" or "dust particle" can also include an agglomeration comprising more than one individual particle, dust particle or the like. In addition, a particle, dust particle or any desired agglomeration thereof can be composed of more than one type of material. The term "polymer" generally includes, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random and
- 33 - BE2020 / 0018 alternate copolymers, terpolymers, etc., and blends and modifications thereof. In addition, the term "polymer" will include all possible geometric configurations of the material, unless specifically limited otherwise. These configurations include, but are not limited to, isotactic, syndiotactic, and random symmetries. By the term "prepacked" as used herein, it is meant that one or more absorbent article is / are packed into a single unit before stacking.
"Pulp pulp" or "pulp pulp" refers to a material made from cellulose fibers. The fibers can be either natural or synthetic or a combination thereof. The material is typically lightweight and has absorbent properties.
"Resealable" refers to the property of two elements that are capable of releasable attachment, separation, and subsequent releasable reattachment without significant permanent deformation or tearing.
The "retention portion" or "liquid absorption layer" is part of the absorbent medium. This portion may comprise a matrix of hydrophilic fibers, such as a web of cellulosic fluff, mixed with particles of high absorbency material. In particular, the retention portion may comprise a mixture of superabsorbent hydrogel-forming particles and synthetic polymeric meltblown fibers, or a mixture of superabsorbent particles with a fibrous coform material comprising a mixture of natural fibers and / or synthetic polymer fibers. The superabsorbent particles may be substantially homogeneously mixed with the hydrophilic fibers, or may be non-uniformly mixed. For example, the concentrations of superabsorbent particles may be arranged in a non-step gradient through a substantial portion of the thickness of the absorbent structure, with lower concentration towards the body side of the absorbent structure and relatively higher concentrations towards the outside of the absorbent structure. The super absorbent particles
234- - BE2020 / 0018 may also be arranged in a generally discrete layer within the matrix of hydrophilic fibers. In addition, two or more different types of superabsorbers can be selectively located at different locations within or along the fiber matrix.
As used herein, the term "sheet" or "sheet material" refers to woven materials, nonwoven webs, polymeric films, polymeric loosely woven materials, and polymeric foam coating.
The absorbent article can also include side panels. The "side panels" can be of any shape, including but not limited to square, rectangular, triangular, round and trapezoidal shape. They can be bonded to respective opposite portions of the back section by any known method such as heat sealing or bonding. The side panels may also be integrally formed with the back section by allowing the respective topsheet and / or backsheet and / or absorbent medium to protrude outwardly in lips having the shape of the side panel panels. Preferably, the side panels are formed by laminating a layer of nonwoven fabric, a layer of thermoplastic film and a layer of elastic material. The layer of elastic material can be secured between the nonwoven fabric layer and the thermoplastic film by means of adhesive layers. The nonwoven fabric layer can be made of natural fibers, synthetic fibers or a mixture of natural fibers and synthetic fibers. The thermoplastic film layer can be made of polyethylene or polypropylene.
The term "spunbond fibers (or la (s) or webs)" refers to fibers formed by extruding molten thermoplastic polymers as filaments or fibers from a plurality of relatively fine, usually circular, capillaries of a spinneret, and then rapidly drawing the extruded filaments by an eductive or other known drawing mechanism to impart molecular orientation and physical strength to the filaments. The average diameter of the spunbond fibers is typically in the range of 15 to 60 µm or greater. The spinneret can either be a large spinneret with several thousand holes
-35- BE2020 / 0018 per meter of width or banks of smaller spinnerets containing, for example, only 40 holes. The term "spunbond meltblown spunbond" (SMS) nonwoven fabric as used herein refers to a multilayer composite sheet comprising a web of meltblown fibers secured between and bonded to two spunbond layers. An SMS nonwoven fabric may be formed in-line by sequentially depositing a first layer of spunbond fibers, a layer of meltblown fibers, and a second layer of spunbond fibers on a moving porous collection surface. The composite layers can be bonded by passing them through a nip formed between two rollers which can be heated or unheated and smooth or patterned. Alternatively, the individual spunbond and meltblown layers may be preformed and optionally individually bonded and collected, such as by winding the fabrics on take-up rolls. The individual layers can be assembled by layering at a later time and bonded together to form an SMS nonwoven fabric. Additional spunbond and / or meltblown layers may be incorporated into the SMS fabric, e.g., spunbond-meltblown-meltblown-spunbond (SMMS), and so on.
"Base fibers" refers to commercially available fibers with diameters ranging from less than about 0.001 mm to more than about 0.2 mm; they come in various different shapes, such as short fibers ranging in length from about 10 to 50 mm and long fibers greater than 50 mm in length, preferably up to 100 mm. By "stretch" it is meant that the material has the ability to stretch in at least one dimension beyond its original dimension when subjected to a tensile force (namely tensile) applied in the direction of that dimension, without breaking the material . For example, an elongation of 50% means that the material with an initial length of 100mm has reached a length of 150mm. Stretch can be unidirectional, bidirectional, or multi-directional. The specific stretch properties of a material can vary along each of the
- 36 - BE2020 / 0018 rack vectors. The term can include elastic materials, as well as webs that can be inherently stretchable, but not necessarily in an elastic manner. Such webs can be made to behave in an elastic manner by binding them to elastic films.
By "channels" is meant that the structure referred to (e.g., the absorbent core) includes recessed areas that form visible conduits or passages that typically extend along a longitudinal axis of the core and that have a depth in a direction perpendicular to the core. longitudinal axis. By "visible" herein is meant clearly visible to the naked eye and typically that the channels have a width generally greater than 1mm, preferably from Smm to 50mm, more preferably from 8mm to 40mm, more preferably from 10mm. up to 30mm, even more preferably from greater than 10mm to less than 25mm.
By "coupled" it is meant that the structure referred to (e.g., the channels) form a substantially continuous path such as from a first end of a channel to a second end of the same channel.
By "substantially" is meant at least most of the structure referred to. For example, with reference to coupled channels, "substantially coupled" means that the majority of the channel is coupled and in general a direct and continuous path can be followed starting at one end of the channel to another end of the channel. channel, wherein the ends (also referred to herein as end positions) are distal to each other in a width direction of the core and proximal to a portion of the outer edge of the core, preferably the sides thereof. By "directly over" is meant that the referenced feature is placed over the referenced structure such that the two are in direct contact with each other over a substantial portion of the structure.
-37- BE2020 / 0018 By “indirectly over” is meant that the referenced feature is placed over the referenced structure but such that the two are not in direct contact with each other over at least a substantial portion of the structure.
For example, a nonwoven web that is indirectly disposed over a three-dimensional absorbent material includes a further layer of material between the nonwoven web and the three-dimensional absorbent material.
Use of the term "substrate" includes, but is not limited to, woven or nonwoven webs, porous films, ink permeable films, composite structures, or the like.
Superabsorbent materials suitable for use in the present disclosure are known to those of skill in the art, and can be in any functional form, such as in particulate form, fibers, and mixtures thereof.
Generally speaking, the "superabsorbent material" may be a water-swellable, generally water-insoluble, hydrogel-forming polymeric absorbent material capable of at least 15, appropriately about 30, and possibly about 60 times or more of its weight physiologically. saline solution (e.g., saline solution containing 0.9% NaCl).
The superabsorbent material can be biodegradable or bipolar.
The hydrogel-forming polymeric absorbent material may be formed from organic hydrogel-forming polymeric material, which may include: natural material such as agar, pectin, and guar gum; modified natural materials such as carboxymethyl cellulose, carboxyethyl cellulose, and hydroxypropyl cellulose; and synthetic hydrogel-forming polymers.
Synthetic hydrogel-forming polymers include, for example, alkali metal salts of polyacrylic acid, polyacrylamides, polycinyl alcohol, ethylene maleic anhydride copolymers, polyvinyl ethers, polyvinyl morpholinone, polymers and copolymers of vinyl sulfonic acid, polyacrylates, polacrylamides, polyvinyl pyridine, and the like.
Other suitable hydrogel-forming polymers include hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, and isobutylene maleic anhydride copolymers and mixtures thereof.
The hydrogel-forming polymers can be light sells around the material
-38- BE2020 / 0018 essentially water insoluble. Crosslinking can be, for example, by irradiation or by covalent, ionic, Van der Waals or hydrogen bonding. The superabsorbent material may be suitably contained in an allocated storage or retention portion of the absorbent system, and may optionally be used in other components or portions of the absorbent article. The superabsorbent material may be included in the absorbent layer or other fluid storage layer of the absorbent article of the present disclosure in an amount of up to about 60% by weight. Typically, the superabsorbent material, when present, will be comprised in an amount of about 5% to 40% by weight, based on the total weight of the absorbent layer. "Superabsorbent polymer particles" or "SAPs" refers to water-swellable, water-insoluble organic or inorganic materials that are capable, under the most favorable conditions, of absorbing at least 10 times their weight, or at least about 15 times their weight, or at least about 25 times their weight in an aqueous solution containing 0.9 weight percent sodium chloride. In absorbent articles such as diapers, incontinence pads, etc., the particle size typically ranges between 100 to 800 µm, preferably between 300 to 600 µm, more preferably between 400 to 500 µm. The term "target zone" refers to an area of an absorbent core where it is particularly desirable for the majority of fluid flow, such as urine, menstruation, or stool, to make initial contact. In particular, the inflow target zone for an absorbent core having one or more fluid entry points in use refers to the region of the absorbent core extending a distance equal to 15% of the total length of the composite from each inflow point in either direction.
"Pull" includes a uniaxial force that tends to cause the stretching of a body or the balancing force within that body that resists extension.
-39- BE2020 / 0018 As used herein, the term "thermoplastic" is intended to describe a material that softens when exposed to heat and returns substantially to its original condition when cooled to room temperature.
The term "topsheet" refers to a sheet of liquid-permeable material that forms the inner cover of the absorbent article and which, in use, is placed in direct contact with the wearer's skin. The topsheet is typically used to help isolate the wearer's skin from the liquids that are trapped in the absorbent structure. The topsheet may comprise a nonwoven material, for example, spunbond, meltblown, carded, hydroentangled, wetlaid, and so on. Suitable nonwoven materials can be composed of artificial fibers, such as polyester, polyethylene, polypropylene, viscose, rayon, etc., or natural fibers, such as wood pulp or cotton fibers, or a mixture of natural and artificial fibers. The topsheet material may further be composed of two fibers, which may be joined together in a bonding pattern. Further examples of topsheet materials are porous foams, plastic films with openings, laminates of nonwoven materials and plastic films with openings, and so on. The materials suitable as topsheet material should be soft and non-irritating to the skin and should be readily penetrated by body fluid, e.g., urine or menstrual fluid. The inner cover sheet may further be different in the different portions of the absorbent article. The topsheet fabrics may be composed of a substantially hydrophobic material, and the hydrophobic material may optionally be treated with a surfactant or otherwise processed to impart a desired level of wettability and hydrophilicity. "Training Pants" are available for use by children in the potty training phase, and are popular with mothers and caregivers. Training pants typically include a topsheet, a backsheet, an absorbent medium between the topsheet and the backsheet, and side seams that bind portions of the side edges of the pants together to form waist and leg openings.
- 40 - BE2020 / 0018 As used herein, the term "transverse" or "lateral" refers to a line, axis, or direction that lies within the plane of the absorbent article and is generally perpendicular to the longitudinal direction.
"Ultrasonic welding" refers to a technology that binds two materials by melting them with heat generated from ultrasonic oscillations and then laminating them together so that the molten materials flow respectively and fill the gap between the two unaffected portions of the two materials.
After cooling and molding, the two materials are bonded together.
"Dry state" refers to the condition in which an absorbent article is not yet saturated with secretions and / or liquid.
"Wet state" refers to the condition in which an absorbent article is saturated with secretions and / or liquid. Typically wherein at least 30ml, preferably at least 40ml, even more preferably at least 50ml, most preferably from 60ml to 800ml, of exudate and / or liquid is present in the absorbent article.
| As used herein, the term "water-swellable, water-insoluble" is intended to refer to a material that, when exposed to an excess of water, swells to its equilibrium volume but does not dissolve in solution. As such, a water-swellable, water-insoluble material generally retains its original identity or physical structure, but in a highly expanded state, during the absorption of the water, and therefore must have sufficient physical integrity to resist flow and fusion with adjacent particles.
By the term "wrapping material" as used herein, it is meant a flexible material, preferably a sheet material whose thickness is less, more preferably much less than its width or length, such as a sheet, a film or a foil. In a particularly preferred embodiment, the wrapping material is capable of being rolled up.
- 41 - BE2020 / 0018 The term “concentration” of (e.g. superabsorbent polymer) as used herein means the amount of the material referred to divided by the surface area of the layers referred to (typically the area in the plane of the length and width of the core) over which or within which the referenced material is present. It can be determined by standard weighing and dimensional measurement methods known in the art and expressed in g / mm °.
By the term "substantially U-shaped" as used herein is meant any shape that visually approximates the shape of a "U", such as a "V-shape", a semicircle, and the like.
By the term "separate cellulosic fibers" as used herein, it is meant cellulosic fibers that are not part of a substrate (e.g., a fleece layer) and are instead separate therefrom and / or physically separate therefrom, and are typically in the form of cellulosic fibers that contained but kept separate from the substrate. For clarity, cellulose fibers present in a substrate (e.g., a fleece layer) are not included in this sense.
By the term “substantially follows the shape of the channel (s)” as used herein, it is meant that the feature referred to has an overlapping shape that is visually the same as the channel (s). l (s).
By the term "superabsorbent polymer fibers" as used herein is meant fibers made from superabsorbent polymers (as opposed to particles made from them). Examples of suitable fibers for use herein are selected from those of Example 1, Example 2, Example 3, and / or Example 4 (page 5, lines 1-46) of EP3190216A1, which is incorporated herein by reference. The fibers have typically been used to form nonwoven webs or substrates of the same referenced application.
42 - BE2020 / 0018 Embodiments of the articles and methods of the disclosure will now be described. It is understood that technical features described in one or more embodiments can be combined with one or more other embodiments without departing from the intent of the disclosure and without generalization thereof.
ABSORBENT CORE Absorbent cores 101, 501, 601 according to the present disclosure may include: a front portion 122; a rear portion 124; a middle portion 126 disposed between the front portion 122 and the rear portion 124; and a longitudinal axis extending along a length of the core 101, 501, 601 and intersecting the front, center and rear portions 122, 126, 124, the absorbent core 101, 501, 601 having a width that extends perpendicularly. extends longitudinally, and has an outer edge, comprising at least two opposite ends 102, 103 and at least two opposite sides 104, 105 disposed between the two ends 102, 103, the core 101, 501 , 601 is a multilayer core comprising at least two distinct core layers 502, 503, 602, 603, with a first core layer 502, 602 therein comprising a first concentration of superabsorbent polymer 504, 604 and a second core layer 503, 603 having a second concentration therein of superabsorbent polymer 504, 604, wherein the first and second concentrations are different, wherein at least the first core layer 502, 602 comprises one or more channels 106, wherein the channel (s) 106 is / are continuous and at least min is / are coupled along the length and width of the core 101, 501, 601 so that at least two channel portions 107, 108 extending along the length are in fluid communication via a connecting channel portion 109 disposed proximal to the rear portion 124 . An advantage of this arrangement is that a synergistic and efficient fluid distribution and absorption is achieved within the core, with the channel shape providing immediate fluid redistribution along the length and width of the core, especially from the front to the back of the article, and the multilayer core arrangement with differential concentration of superabsorbent polymer allows for the fluids
-43- BE2020 / 0018 more efficiently absorbent and reduce the risk of gel blocking.
Preferably, the channel (s) 106 herein do not extend to any of the edges formed by the outer edge of the absorbent core 101, 501, 601. Preferably forms the connecting channel portion 109 has a generally U-shaped bend, preferably wherein the first core layer 502, 602 comprises a single channel 106. Such a shape optimizes the fluid distribution properties of the core. Preferably, the channel (s) 106 comprises a single connecting channel portion 109 such that a continuous region of superabsorbent polymer (typically in the core length / width plane) around the channel (a) 1 ( and) is formed and generally no region of superabsorbent polymer is completely enclosed by portions of the channel (s) 106. This arrangement allows optimum fluid distribution with limited risk of forming supersaturated and undersaturated regions in the core, as well as reducing the risk of delamination of bound layers forming the channel (s). Preferably, at least one of the coupled channels 106, preferably each of the channel 106, forms an open end shape in the form of two diverging ends or a funnel shape and an opposite closed end formed by the connecting channel portion 109 , preferably wherein the open end is located proximal to the front portion 122 of the absorbent core 101 and distal to the closed end. Advantages include stimulated fluid distribution from the front to the back of the article. Preferably, the first core layer 502, 602 comprises at least one core wrap substrate 505, 506, 605, 606 enclosing the superabsorbent polymer therebetween, and wherein a top layer 505, 605 of the core wrap is bonded to a bottom layer 506, 606 of the core wrap in regions of the core containing the channel (s) 106
- 44 - BE2020 / 0018, preferably so that substantially none (i.e. less than 1% by weight, preferably less than 0.5% by weight, more preferably less than 0.1% by weight, even more preferably less than 0.05% by weight, most preferably about 0% by weight, based on the weight of the core wrap substrate) of superabsorbent polymer 504, 604 is present in the channel (s) 106. This ensures that fluids can flow rapidly along the channel direction without swelling / absorption slowing their path.
Preferably, the first core layer 502, 602 further comprises separate cellulose fibers 507, 607 blended with the superabsorbent polymer 504, 604 and wherein the second core layer 503, 603 is free of the separate cellulose fibers 507, 607. This arrangement allows for added "localized" fluid distribution. possibly provided by the discrete cellulose fibers that direct fluid to the superabsorbent polymer dispersed thereby to be subsequently absorbed and trapped by the latter. Preferably, the second core layer 503, 603 is typically lint-free and comprises a nonwoven backing having an upper support layer 508, 608, and a lower support layer 509, 609 and superabsorbent polymer therebetween, wherein the superabsorbent polymer is in the form of particles contained in the support. immobilized, and wherein the top support layer 508, 608 is a carded web made of base fibers or is a spunbond meltblown spunbond web, and the bottom support layer 509, 609 is a carded web made from base fibers or a spunbond meltblown spunbond web. (preferably wherein the top and bottom support layers are different), preferably wherein the top and bottom support layers are mechanically bonded together, preferably via hydroentanglement, preferably wherein the top support layer 508, 608 consists of base fibers penetrable by the superabsorbent polymer particles , and the lower support layer 509, 609 of a vl It exists that is hydro-entangled to the top support layer 508, 608. This arrangement makes it possible to form a lint-free core layer comprising immobilized superabsorbent particles that maintain their position, allowing the
BE2020 / 0018 size of the product is limited and the absorption and fluid containment properties of the layer are maximized.
Preferably, the second core layer 503, 603 is core-wrap-free and includes a first nonwoven support layer having superabsorbent polymer immobilized thereon or therein, the nonwoven support layer being porous and the superabsorbent polymer being in the form of particles and immobilized by mechanical action such as ultrasound ; one or more adhesives; and combinations thereof. This arrangement has been found to be beneficial to further reduce core bulk and raw materials. In particular by entrapping particles in the substrate, for example by ultrasound, such immobilization can be achieved without chemical adhesive treatments and thereby also reduces the risk of chemical contamination and / or the need for multiple / additional layers to contain the particles. is going to be.
Preferably, the second concentration of superabsorbent polymer 504, 604 is higher than the first concentration of superabsorbent polymer 504, 604, preferably wherein the second concentration is at least 1.5, preferably 2 times higher than the first concentration. This provides benefits such as a reduced risk of gel blockage. Preferably, the second core layer 503, 603 is disposed below the first core layer 502, 602 and wherein the second core layer 503, 603 includes a first region of superabsorbent polymer particles 504 on a surface thereof that is opposite the first core layer 502, 602, the first region is arranged in a pattern that substantially follows the shape of the channel (s) 106, at least along a plane formed by the core length and width, so that the shape of the channel (s) 106 (a) l (s) is substantially the same as that of the pattern. Typically where the first region of superabsorbent polymer particles is the only region of the second core layer 503, 603 that contains superabsorbent particles, preferably wherein the second core layer 503, 603 comprises superabsorbent polymer fibers other than in the first region, wherein the first region is free of the super-absorbent polymer fibers. This ranking makes the
- 46 - BE2020 / 0018 dual characteristic of maximizing absorption effects by the core surface, as well as providing a multisensory (e.g. visual and tactile) signal that the core is saturated.
Typically, the second core layer 503, 603 is free of cellulose fibers and preferably consists of superabsorbent fibers or a mixture of superabsorbent fibers (as described herein) and synthetic fibers.
Preferably, the second core layer 503, 603 has a smaller size, in a plane corresponding to the core length and width, than the first core layer 502, 602. This allows an optimization between performance needs and raw material utilization and cost. Absorbent cores 101 according to the present disclosure may include: a front portion 122; a rear portion 124; a middle portion 126 disposed between the front portion 122 and the rear portion 124; and a longitudinal axis extending along a length of the core 101 and intersecting the front, crotch, and rear portions 122, 126, 124, the absorbent core 101 having a width that extends perpendicular to the length and having an outer edge. comprising at least two opposite ends 102, 103 and at least two opposite sides 103, 105 interposed between the ends 102, 103, the absorbent core 101 comprising one or more, optionally substantially coupled, channels 106 , having a first shape when the absorbent core 101 is in a dry state and a second shape when the absorbent core is in a wet state and wherein the first and second shapes are different. The inventors have found that this arrangement makes it possible to provide a more effective alternative to standard visual wetness indicators that use a simple change in color to provide such an indication. Indeed, the change in channel shape in dry / wet conditions provides not only an immediate visual indication but also a tactile one, combining both senses to provide a unique warning to the caregiver that the absorbent article needs to be replaced.
47 - BE2020 / 0018 In one embodiment, the first and second shapes are visually discernible and arranged to provide a visual and / or tactile indication that the core is saturated with secretions.
Preferably, the absorbent core comprises a single substantially coupled dry channel 106, and more preferably a plurality (typically two) discrete channels 206 when wet.
In one embodiment, the coupled channel 106 includes a U-turn proximal to a rear end of the absorbent article and first / second end ends 110, 111 proximal to the front of the absorbent article, generally when in a dry state, and when in a wet state. (namely, when saturated with secretions and / or liquid) the channel is separated into multiple (preferably two) separate channels 206 and typically with the separate channels 206 clear of the U-bend. In a preferred embodiment as shown in FIG. 18A, the coupled channel 106 in dry condition includes the first / second end ends 110, 111 arranged in divergent relationship to form an open and / or funnel-shaped end disposed opposite a closed end formed by the U-bend. An advantage of this form is to increase the speed of especially liquid distribution and the early stages of the release. When wet, the channel described above is arranged to change shape as shown in Fig. 18B, wherein the single coupled channel becomes a plurality (preferably two) disconnected channels substantially clear of the U-turn. Preferably, the wet state shape of the channels is the same as the dry state shape except that the U-turn is absent, so that one channel (in the dry state) becomes two channels (in the wet state). Typically, this is formed by breaking the bond that forms the U-bend channel portion as the absorbent material expands when liquid is absorbed.
- 48 - BE2020 / 0018 Such a change in shape may be accomplished in a number of ways, which will be described herein below as preferred embodiments, although not limiting.
In one embodiment, the core comprises at least one core wrap substrate enclosing one or more absorbent materials therein, preferably the absorbent materials are selected from the group consisting of superabsorbent polymers, cellulose fibers, and combinations thereof, and wherein a top layer of the core wrap adheres to a core wrap. bottom layer of the core wrap is bonded to form a coupled absorbent material-free channel (s) (106) (generally in a dry state). Typically, areas where top and bottom layers are unbound include absorbent material therebetween (which generally separates the top and bottom layers from the bottom layer) and areas where the top and bottom layers are bound together are substantially free of absorbent material to form channels within the absorbent material of the to form the core. Preferably, the bonded top and bottom layers of the core wrap have a first bond in at least two separate regions of the channel (s) 106 and a second bond in at least one other region of the channel (s) 106 ( a) 1 (and) 106 connecting the at least two separate regions, and wherein the second bond is arranged to break upon liquid saturation and / or expansion of the absorbent material while the first bond is arranged to break upon liquid saturation and / or expansion of the absorbent material. the absorbent material to remain intact, preferably with the other area being the U-bend of the channel (s). More preferably, the channel is arranged such that when in a dry state one or more, preferably a single, coupled channel 106 is visible and when it is in a wet condition multiple, preferably two, separate channels 206 are visible. However, it is understood that a core wrap (although preferred) is not necessary to achieve this effect, and instead other means could be devised, such as by directly or indirectly bonding a top sheet to a top sheet in a similar manner. backsheet without the need for a core wrap (thus, the same features as those described above may be present / replaced with a topsheet / backsheet instead of a core wrap).
49 - BE2020 / 0018 The first and second bonds may comprise a first and second adhesive, respectively.
The first and second adhesives may be different, for example the second adhesive is selected to be soluble when in contact with liquid at room temperature (about 37 ° C), such as low melting pressure sensitive adhesives (i.e. a melting point of about 40 ° C). ) such as 3798LM sold by 3M Company.
The first adhesive can be selected from hot melt adhesives which also retain adhesive strength upon contact with liquid at room temperature (namely, a melting point greater than 60 ° C, preferably greater than 70 ° C, even more preferably greater than 90 ° C), such as Technomelt DM Cool 110 Dispomelt (also known as Dispomelt Cool 110) sold by Henkel AG & Co.
KGaA; or VV290F sold by Savare's Specialty adhesives.
In the above arrangement, the second adhesive may be disposed in the U-bend section while the first adhesive may be disposed in all other areas of the channel.
In an alternative embodiment of the above, the same adhesive may be used throughout the channel, but in areas to be released when wet, a lower pressure is applied between substrates to provide a bonding force.
For example, the pressure applied to the U-bend may be less (preferably less than half) than the pressure applied to all other areas of the channel.
While the two examples above are examples of how to achieve different channel shapes in the Dry / Wet state, other means of achieving the inventive arrangement can be envisaged and therefore the application should not be limited thereto, for example the first and second bonds can be respectively provide first and second bond strength, wherein the first bond strength is greater than the second bond strength.
The bond strength as used herein is preferably defined herein as the "peel strength".
- 50 - BE2020 / 0018 Typically the first bond has a peel strength of greater than 5g / mm, preferably more than 6g / mm, even more preferably of 7g / mm, and the second bond has a peel strength of less than 5g / mm , preferably from 0.1g / mm to 4g / mm, more preferably from 0.2g / mm to 3.5g / mm, even more preferably from 0.3g / mm to 3g / mm, the peel strength in the generally determined according to ASTM Designation: D1876-72, "Standard Test Methods for Peel Resistance of Adhesives (T-Peel test)," which is incorporated herein by reference.
In a preferred embodiment, the first bond has a first hang tear value and the second bond has a second hang tear value, the first hang tear value being greater than the second hang tear value, the hang tear value being determined by the hang tear test described herein.
Preferably, the first hang tear value is greater than 14 minutes (min), preferably from 15 min to 40 min, more preferably from 20 min to 35 min, even more preferably from 22 min to 29 min.
Preferably, the second hanging tear value is less than 14 min, preferably from 0.5 min to 10 min, more preferably from 1 min to 5 min.
Absorbent cores 101 according to the present disclosure may include: a front portion 122; a rear portion 124; a crotch portion (also referred to herein as "center portion") 126, positioned between the front portion 122 and the rear portion 124; and a longitudinal axis extending along a length of the core 101 and intersecting the front, crotch and rear portions 122, 126, 124, the absorbent core 101 having a width extending perpendicular to its length and having an outer edge that is at least two opposed ends 102, 103 and at least two opposed sides 103, 105 interposed between ends 102, 103, wherein the absorbent core 101 comprises one or more substantially interlocked channels 106 extending through at least one extend at least a portion of the crotch portion 126 (preferably which is at least 60%, more preferably at least 70%, even more preferably at least 80%, of a crotch portion length that is substantially parallel to the longitudinal axis) along the length of the core and along at least a portion of the width of the core, typically along and substantially parallel to the
-51- BE2020 / 0018 longitudinal axis, and from one side of the core [e.g. a first side 104] to the other [e.g. a second side 105], preferably with the one or more substantially coupled channels 106 symmetrically or asymmetrically round. be the longitudinal axis. An advantage of such a coupled channel arrangement is that faster instantaneous distribution of fluid is achieved through the core versus a core that is free of such coupled channels or cores comprising only interrupted channels. This helps limit core supersaturation in the fluid delivery portion. Without wishing to be bound by theory, it is believed that the fact that the fluid is distributed through the core and immediately away from the fluid delivery position provides the subject with a perception of dryness and skin comfort, as well as an impression of prolonged dryness by the user. . The longitudinal axis of the core referred to herein may be substantially parallel to the longitudinal direction 48 and may be used interchangeably herein (as illustrated, for example, in Fig. 11 and Fig. 12), and the width of the core or width axis of the core. core referred to herein may be substantially parallel to the lateral direction 49 and may be used interchangeably herein (as illustrated, for example, in Fig. 11 and Fig. 12).
In one embodiment, the one or more coupled channels are configured to effectively direct fluid away from the delivery area, typically by forming a shape that has a spacing gradient between opposed surfaces of the coupled channels, preferably forming a funnel-shaped profile. . In one embodiment, the channels form a geometric shape through the absorbent core and along a plane extending parallel to the longitudinal axis of the core, the geometric shape being selected from the group consisting of semi-sand-runner, v-shaped, u-shaped , cake-shaped, and combinations thereof. Where “by semi-sandglass shape” is meant an hourglass shape with only a single end, example shapes are shown in Fig. 4.
-52- BE2020 / 0018 In one embodiment the channels comprise, preferably those consisting of, a first nonwoven web bonded to a second nonwoven web by one or more adhesives. Preferably, the adhesive is applied in zones across the width of the channels to form zones, preferably alternating zones, of different bond strength between the nonwoven web laminate. For example, the first fleece web may be bonded to the second fleece web at least three zones along the width of the channel. Such an arrangement may include a first adhesive zone, a second adhesive zone, and a third adhesive zone, wherein the second adhesive zone is disposed between the first and third adhesive zones along the width of the channel (e.g., on an axis parallel to the core width and perpendicular to the longitudinal axis of the core) wherein the bond strength of the second adhesive zone is greater than the bond strength of the first and third adhesive zones. Examples of ways to achieve such stronger bond strength in the second zone include using greater amounts of adhesive in this zone, applying greater mechanical pressure to this zone, or using a different adhesive type, other ways are also contemplated provided that stronger adhesion between fleece webs occurs in such an area.
In one embodiment, the bond strength in the first and third zones is less than the tensile force generated by the absorbent material located proximal to the channel upon wetting, so that the first and second fleece webs can separate in the zones; and wherein the bond strength in the second zone is greater than the tensile force generated by the absorbent material located proximal to the channel when wet, so that the first and second fleece webs in the zone cannot separate when wet, and typically swelling of the absorbent material, and instead may remain rigidly bonded. An advantage of this arrangement is that in dry conditions, a discernible channel is visible from the topsheet side of the article and / or core that provides wide channels that are further useful for channeling more fluid, especially in initial / early release. This arrangement then further enables that
-53- BE2020 / 0018 the binding at the first and third portions fails, for example, upon swelling of the SAP, so as to leave more volume available for expansion thereof (and prevent early saturation or non-optimal absorption), typically with the second zone resists such expansion and thus provides channel integrity even when wet.
In a preferred embodiment, the first nonwoven web and / or the second nonwoven web, preferably the second nonwoven web, are elastic fleeces (for example those containing an elastic material such as Vistamaxx resin from ExxonMobil, or other suitable polymers capable of imparting elasticity to a nonwoven web. to contain). An advantage of this embodiment is that the nonwoven web wraps better and more easily around the 3D insert upon application of a vacuum and allows subsequent bonding to the first nonwoven web at a location corresponding to a position on the base of the 3D insert (opposite an excellent top of it). This has an advantage of limiting the formation of fluid collection basins or pools within the channels.
The cores herein may have a substantially rectilinear outer edge, as illustrated in FIG. 1 and FIG. 2, or may include symmetrical concave portions in the center portion thereof, as illustrated in FIG. 3. In the latter embodiment, the concave portions may be aligned and / or disposed in a crotch portion of the absorbent article so as to provide better ergonomics and fit along a wearer's leg.
In any of these core shape embodiments, it is preferred that the cores are symmetrical at least about their longitudinal axis.
Regardless of core geometry, it is understood herein that the same or similar channels as described herein may be used interchangeably.
In one embodiment, referring to FIG. 1 to FIG. 3, at least one and preferably each substantially coupled channel 106 includes: a first channel portion 107 extending substantially along the longitudinal axis proximal to the first side 104 of core 101; a second channel portion 108 extending substantially along the longitudinal axis proximal to a second side 105 of core 101
-54- BE2020 / 0018 extends; and at least one, preferably only one, connecting channel portion 109 in fluid communication with the first and second channel portions 107, 108. An advantage of this arrangement is rapid liquid distribution along more than one axis of the absorbent core, typically both the longitudinal axis and the width axis thereof, so as to maximize the absorption capacities of the absorbent core over its entire surface area. In addition, such geometry improves core folding and thus allows for a better and snug fit to the subject's skin (with or without the addition of additional elastics proximal to the channel portions).
Hereby forms connecting channel portion (109) of at least one of the coupled channels, wherein the connecting channel portion is in fluid communication with the first and second channel portions (107, 108), preferably the closed end in the form of a U-turn, at preferred wherein the first and second channel portions (107, 108) extend away from the longitudinal axis at least along a portion of the coupling channel (106) that typically departs from the U-bend, leaving at least partially a funnel-shaped coupled channel near the closed end. is formed.
The first and second channel portions can be substantially linear; or have a substantially curved profile, preferably selected from concave or convex; or may include a combination of the linear and curved profiles. In a preferred embodiment, the first and second channel portions are concave in shape and generally symmetrical about at least the longitudinal axis.
The first and second channel portions may extend through at least a major portion, preferably all, of the length of the crotch portion along the longitudinal axis and are typically substantially parallel to the sides of the core forming the outer edge thereof.
In a highly preferred embodiment, each coupled channel herein includes only a single interconnecting channel portion 109, which typically forms a top of the coupled channel. An advantage of this embodiment is fast
BE2020 / 0018 fluid distribution throughout the core while limiting the risk of blockages that might otherwise occur if pockets of wetted areas are formed instead.
Preferably, the connecting channel portion 109 extends substantially along the width of the core 101, which preferably forms a closed end within a surface of the core 101 along a plane parallel to the longitudinal axis, and which is preferably disposed opposite a open end formed by unconnected first and second end positions 110, 111 of the coupled channel 106, preferably of the first and second channel portions 107, 108, respectively, with typically the unconnected first and second end positions 110, 111 distal to each other and proximal of the first and second sides 104, 105, respectively, of the core 101, even more preferably with the end positions 110, 111 facing away from each other, so as to form a funnel-shaped geometric opening therebetween. Without wishing to be bound by theory, it is believed that such geometry helps to "funnel" and collect more fluid where it is needed and quickly and effectively distribute it away from the collection area.
In one embodiment, and preferably in combination with the foregoing embodiment, the coupled channel includes unconnected first (110) and second (111) end positions, with the first end position (110) extending to a first side (104) of the core and / or the second end position (111) extends to a second side (105) of the core, as illustrated, for example, in Fig. 3.
This allows the entire width of the absorbent core to be covered by the channel, which ensures better fluid distribution.
In one embodiment, the closed end is substantially curvilinear in shape, which preferably forms a convex shape between the first and second channel portions 107, 108, or is substantially linear in shape, which is preferably a straight or triangular shape between the first and second channel portions 107, 108. The closed end can be formed by the connecting channel portion 109. An advantage of such a shape is the raising of the
- 56 - BE2020 / 0018 surface area of contact with adjacent areas of three-dimensional absorbent material, so as to promote better absorption of the distributed liquid when released from areas of typically high saturation.
In one embodiment, a first distance (d) between the first channel portion 107 and the second channel portion 108, a second distance (da) between the first channel portion 107 and the second channel portion 108, the first distance (di) being proximal of the front portion 122 of the core 101 and the second distance (d ») is proximal to the rear portion 124 of the absorbent core 101, and wherein the first distance (di) is greater than the second distance (d>), preferably wherein the first distance ( di) at least 1.5d2, more preferably from 1.8d2 to 3d is. An advantage of this is the rapid and effective fluid distribution from areas of typically high saturation to areas of typically lower saturation.
In one embodiment, the core includes a first nonwoven web, typically in the form of a backsheet; a second nonwoven web, typically in the form of a top sheet; and a three-dimensional absorbent material disposed between the first and second nonwoven webs to form an absorbent core laminate, typically wherein the three-dimensional absorbent material comprises a fibrous web typically comprising airlaid fibers, and preferably comprising a predetermined amount of superabsorbent polymer dispersed therethrough. .
In a highly preferred embodiment, the coupled channel 106 is substantially free of the three-dimensional absorbent material, and preferably also free of superabsorbent polymer. Without wishing to be bound by theory, it is believed that absorbent materials retard fluid distribution as compared to the effectiveness of such channels, indeed as fluid absorbed by the absorbent materials swell and / or saturate, effectively increasing the amount of fluid that could pass through them. decreases. Eliminating such materials from the channels allows to maintain a highly efficient fluid distribution system that operates essentially independent of the fluid acquisition / absorption mechanism of the adjacent regions.
-57- BE2020 / 0018 In a preferred embodiment, the core comprises a plurality of substantially coupled channels, which are preferably arranged in a substantially concentric manner, an example of which is shown in FIG. 4E.
An advantage is the exponential effectiveness in fluid distribution and channel formation, especially when neighboring areas become more saturated or swell.
In one embodiment, as shown in FIG. 4C and 4D, the core further includes one or more severed channels, preferably at least a portion thereof being arranged concentrically about the substantially coupled channel.
An advantage is effective added local uniform fluid distribution.
In addition, it is believed that as the adjacent regions of the channels swell, upon saturation, visual patterns may be formed that more clearly convey the perception of effectiveness of the entire core surface for fluid absorption.
Preferably, the substantially coupled channels 106 have a regular or irregular depth, with the depth measured on an axis perpendicular to both the longitudinal axis and the axis along the width of the core 101, preferably with the cross-section of the channels 106 is selected from the group consisting of curved, polygonal, or combinations thereof.
In a preferred embodiment, as illustrated in Figure 16, the width of the coupled channel (106) may vary along the channel.
Preferably, the width of the channel decreases from the end positions (110, 111) to the connecting channel portion (109). This is illustrated in Fig. 16, where the width (21023) of the channel (106) near the first end position (110) and the width (210b) of the channel (106) near the second end position (111) are greater than the width (21123) of the channel (106) in the first channel portion (107) and the width (211b) of the channel (106) in the second channel portion (108), which are greater than the width (212) of the channel ( 106) in the connecting channel portion (109). Such variance in the width of the channel sections results in a faster distribution.
Without wishing to be bound by theory, the inventors believe that the varying
-58- BE2020 / 0018 utilizes width capillary effects that better promote fluid transport from the front to the back of the absorbent article.
It is understood that a number of alternative shapes may be used for channels described herein, examples of which are shown in FIG. 4 and Fig. 16 without departing from the disclosure embodiments described herein. The present disclosure further relates to an absorbent core 101, which comprises substantially continuous zones of one or more high fluid distribution structures 112 and continuous or discontinuous zones of fluid absorption structures 113, 114 around the one or more high fluid distribution structures 112, wherein the one or more more high fluid distribution structures 112 are arranged to distribute fluid across the absorbent core 101 at a rate greater than the rate of fluid distribution through the absorbent core through the discontinuous fluid absorption structures 113, 114, and the continuous zones extending along a path which is substantially parallel to at least a portion of the outer edge of the core 101, the portion of the outer edge of the core being at least a portion of the sides 104, 105, preferably at least a portion of both sides 104, 105 , of the core 101 and one of the ends 102, 103 of the core 101 (at front may comprise only one end 103), preferably the end 103 proximal to the rear portion 124. Advantages of this embodiment include separating absorbent regions of the core with fluid distribution regions that effectively uniformly distribute fluid throughout the core surface by a mechanism as described above as well as providing a visual perception of effectiveness. In one embodiment, the fluid distribution structures are configured to effectively divert fluid away from an area of delivery, typically by forming a shape that has a spacing gradient between opposite surfaces of the structures, preferably forming a funnel-shaped profile that is is substantially limited by one or more fluid absorption structures.
- 59 - BE2020 / 0018 In one embodiment, the high fluid distribution structures form a geometric shape across the absorbent core and along a plane extending parallel to the longitudinal axis of the core, the geometric shape being selected from the group consisting of semi-hourglass-shaped, v-shaped, u-shaped, pie-shaped, and combinations thereof. Where “by semi-hourglass-shaped” and hourglass-shaped with only one end is meant, as shown for example in Fig. 4B.
In a preferred embodiment, the one or more high fluid distribution structures comprise, preferably they consist of, at least two nonwoven webs bonded together (e.g., with an adhesive); and the zones of fluid absorption structures comprise a three-dimensional absorbent material (such as cellulosic fluff and / or fibrous web typically comprising airlaid fibers, typically of the cellulose type) and / or a superabsorbent polymer (typically in the form of a plurality of discrete particles that may be distributed within the three-dimensional absorbent material or may be directly agglomerated in one or more pockets between at least two nonwoven webs).
Preferably, the fluid distribution structures comprise substantially coupled channels as described in the previous embodiments, and the fluid absorption structures comprise a three-dimensional absorbent material and / or superabsorbent polymer as described in the previous embodiments.
ABSORBENT ARTICLES Absorbent articles 10, 20, 300, 500, 600 according to the present disclosure include a core 101, 501, 601 interposed between a liquid permeable topsheet 520, 620 and a liquid impervious backsheet 521, 621, and an acquisition distribution layer 522, 622, as described herein, which is interposed between the topsheet 520, 620 and the core 101, 501, 601. Preferably wherein the backsheet comprises a print or image visible from the garment-facing side of the article which is substantially
- 60 - BE2020 / 0018 corresponds to the shape and / or contour of the channel (s) 106. The latter having the advantage of reducing the visual perception of the presence of such a channel and its location. further accentuate the absorbent article.
Preferably, a first region of the second core layer 503, 603 swells when saturated with secretions to form one or more protrusions 525 visible from a garment-facing side of the article, the protrusions having a shape substantially corresponding to the shape of the one or more channels 106, typically so as to provide an indication to the caregiver that the absorbent article is saturated and needs to be replaced. An advantage is that a truly multisensory warning is provided that the object must be replaced.
Preferably, the print or image comprises multiple shades with the darkest hue positioned such that when the article 10, 20, 300, 500, 600 is in a wet state, the darkest hue on a top of each of the one or more protrusions 525 is. An advantage is that a gradual warning is provided as the protrusions increase in size during swelling, with the darker hue becoming more pronounced (visually) to the fully saturated / expanded state.
In one aspect of the disclosure, an absorbent article may include a core 101 as described above, the article preferably being selected from disposable diapers or diaper pants; disposable incontinence pads or diaper pants; sanitary napkin; or pantyliners; and typically wherein the channel (s) in the core remain visible both before and after use of the article and have a first shape when the absorbent core 101 is in a dry state and has a second shape / have when the absorbent core is in a wet state, the first and second shapes being different. Preferably wherein the channel (s) is / are visible when viewed from a garment side and / or a skin-facing side of the article, preferably is / are visible when looking at a backsheet of the article object is viewed from its garment side. Preferably the channels remain
- 61 - BE2020 / 0018 visible in the core both before and after use of the object, preferably whereby the channels are more visible after use than before use of the object. In one embodiment, the absorbent article comprises a topsheet and a backsheet that directly or indirectly encloses the core, wherein at least one of the backsheet or topsheet comprises a color that is different from the color of the core, preferably wherein the backsheet is a color which is different from the color of the topsheet and core, so that the channels are visually visible from the topsheet side of the article.
ACQUISITION AND DISTRIBUTION LAYER One particular component used in absorbent articles herein is an acquisition and distribution layer (ADL). The ADL may be placed on a body-facing side of the absorbent core, between the topsheet and the absorbent core of the absorbent article, and more preferably in close proximity or even in good contact with the body-facing side of the absorbent article. absorbent core. The use of an ADL in combination with the fluid distribution structures and / or coupled channels of the present invention results in extremely good distribution of fluids from a delivery area to the entire absorbent core while achieving excellent perceived dry performance. In one embodiment, the acquisition distribution layer 522, 622 comprises, for use herein, a spunbond and / or carded, preferably a heatbond card. fleece layer comprising synthetic fibers, wherein the synthetic fibers are present at a level greater than 80 weight percent of the acquisition distribution layer 522, 622, and wherein the acquisition distribution layer 522, 622 has a basis weight of 10 to 50 g / m2, preferably of 15 to 40 g / m2, more preferably from 18 to 35 g / m2, even more preferably from 20 to 30 g / m2, most preferably from 21 to 25 g / m2.
62 - BE2020 / 0018 Preferably, the acquisition distribution layer 522, 622 has a specific volume of less than 11.4 cm * / g, preferably less than 11.3 cm * / g, more preferably of 5.5 cm * / g. up to 11.2 cm * / g, even more preferably from 8.5 cm * / g to 11.17 cm * / g. Advantageously, a specific volume within these ranges allows to minimize spongy rewet drawbacks while still ensuring high acquisition rates when combined with channeled cores as described herein. Preferably, the synthetic fibers are present at a level greater than 90 weight percent, preferably from 95 weight percent to 100 weight percent, of the acquisition distribution layer 522, 622.
Preferably, the acquisition distribution layer 522, 622 is composed of synthetic fibers and is preferably free of cellulose fibers, more preferably with the acquisition distribution layer 522, 622 being treated, such as with a surfactant, to render the layer 522, 622 hydrophilic. Preferably, the synthetic fibers comprise, preferably they consist of, polypropylene fibers. Advantageously, the observed dryness is improved by further eliminating cellulose fibers from the ADL.
In one embodiment, the acquisition distribution layer 522, 622 is comprised of a, preferably single, spunbond or carded layer and is free of air-through bonded, airlaid and / or meltblown fleece layers.
Preferably, the acquisition distribution layer 522, 622 has an average flow pore size from 15 µm to 200 µm, preferably from 30 µm to 150 µm, more preferably from 45 µm to 130 µm, even more preferably from 55 µm to 110 µm, with even more preferably from 60 µm to less than 100 µm, even more preferably from 65 µm to 95 µm, even more preferably from 70 µm to 90 µm.
Without wishing to be bound by theory, if the pore size is too small the web will retain more liquid therein and have reduced liquid wash-out performance, on the other hand, if the pore size is too large the web will not have the
- 63 - BE2020 / 0018 have desirable discharge characteristics to still provide acceptable liquid distribution through the core.
Preferably, the acquisition distribution layer 522, 622 includes a first center position Can. and the absorbent core 101, 501, 601 includes a second center position Cc, and wherein the acquisition distribution layer 522, 622 is disposed asymmetrically over the absorbent core 101, 501, 601 so that the first center position Cap. and second center position Cc are offset at least along the longitudinal axis 48, preferably with the acquisition distribution layer 522, 622 positioned so as not to overlap with a portion of the channel 106 extending in the width direction along an axis substantially perpendicular to the longitudinal axis 48 extends. This arrangement has the advantage of saving raw materials costs by ensuring that the ADL is in a position where it is needed most, as well as ensuring that part of the channel remains exposed (particularly the U-bend of the channel) and speed of the fluid flow through the channel from front to back is not compromised. Preferably, the acquisition distribution layer (522, 622) has a relative porosity of less than 9000 L / m2 / s, preferably from 1000 L / m2 / s to 8000 L / m2 / s, preferably from 2000 L / m2 / s to 7000 L / m2 / s, more preferably from 3000 L / m2 / s to 5000 L / m2 / s, most preferably from 3500 L / m2 / s to 4500 L / m2 / s s. Advantageously, webs with relative porosity within these ranges allow for reduced spongy behavior while providing good liquid distribution performance. The inventors have found that fluid distribution in embodiments of the absorbent article of the present invention that include an ADL may depend on the relative size and positioning of the ADL with respect to the fluid distribution structure, and in particular the interconnected channels, of the absorbent core .
- 64 - BE2020 / 0018 Figures 17A-D illustrate embodiments having an ADL (201) and its relative size and position with respect to the coupled channels (106). FIG. 17A shows an embodiment where the ADL (201) covers the entire channel (106). Such an arrangement is already improving over prior art arrangements because the combined effects of the ADL and coupled channels lead to a significant improvement in the distribution of fluids across the entire absorbent core. Nevertheless, the inventors have found that certain arrangements provide even better improvements in the distribution of fluids, these arrangements being illustrated in Figs. 17B-D and discussed further below.
FIG. 17B illustrates a preferred embodiment where the ADL (201) is narrower than the coupled channel (106), and positioned so that the first (110) and second (111) end positions extend beyond the side edges (202, 203) of the ADL.
FIG. 17C illustrates a preferred embodiment where the ADL (201) is positioned such that the connecting channel portion (109) extends beyond a rear edge (204) of the ADL. The connecting channel portion (109) is preferably in the shape of or U-bend.
FIG. 17D illustrates a preferred embodiment where the ADL (201) is narrower than the coupled channel (106), and positioned so that the first (110) and second (111) end positions extend beyond the side edges (202, 203) of the ADL, and wherein the ADL (201) is positioned such that the connecting channel portion (109) extends beyond a rear edge (204) of the ADL. The connecting channel portion (109) is preferably in the shape of or U-bend.
These arrangements, illustrated in Figs. 17B-D have in common that certain extremities of the coupled channel (106), in particular the end positions (110, 111) and / or the connecting channel portion (109), are not covered by the ADL and are therefore more intimately exposed to the wearer. . Without on
BE2020 / 0018 theory, the inventors believe that these extremities are very beneficial in the action of the coupled channel (106) in distributing fluids from the delivery area to the areas of the absorbent core that are typically not exposed. are, or at least not directly exposed, to fluid delivery.
By ensuring that the ADL does not cover some or all of these extremities, it is believed that fluid inflow and / or fluid outflow for the coupled channel is maximized. In addition, these embodiments make it possible to use a smaller ADL, and hence less raw material, in the absorbent article.
METHODS OF MANUFACTURE AND USE The disclosure further relates to a method of manufacturing an absorbent core 101 which may include the steps of: i. providing a mold including a 3D insert therein, the 3D insert having the inverted shape of the desired channels, wherein substantially all of the surface of the mold is in fluid communication with a depression source, except for the 3D insert; ii. applying a first nonwoven web to the mold; ili. applying a three-dimensional absorbent material over at least a portion of the web; iv. applying a second nonwoven web directly or indirectly over the three-dimensional absorbent material; v. optionally applying a bonding step to form a laminate comprising the first web, with the second web and the three-dimensional absorbent material therebetween; vi. optionally removing the laminate from the mold to form an absorbent core comprising channels with the inverse shape of the 3D insert; and wherein at least for the duration of step iii, the vacuum source is arranged to provide a vacuum force that forces the three-dimensional material around the 3D insert, so as to substantially expose the surface thereof of three-dimensional absorbent material and form channels that in substantially free of three-dimensional absorbent material. Such a method has proven effective in creating channels that are essentially free of three dimensional
- 66 - BE2020 / 0018 absorbent material compared to methods that use embossing (namely, creating channels of highly dense / packed three-dimensional absorbent material) or material removal methods that involve removing three-dimensional absorbent material from a pre-formed core structure, which inevitably results in the presence of any three-dimensional absorbent material that can affect effective / uniform fluid distribution when it is saturated.
FIG. 15A and FIG. 15B illustrate an example of a mold that includes a 3D insert as described herein.
In one embodiment, the mold includes a plurality of perforations or openings over its surface that typically form channels arranged in fluid (preferably air) communication with the negative pressure source. Preferably, the 3D insert is located above and / or over the mold surface comprising the plurality of perforations or openings and wherein the 3D insert is free from the perforations or openings and is a solid component that is not in fluid communication with the negative pressure source. {Preferably, the 3D insert has a transverse shape selected from the group consisting of square, rectangle, oval, semi-circular, and combinations thereof.
More preferably, the 3D insert has the same or varying depth throughout its outer edge.
In one embodiment, the 3D insert is 3D printed, preferably it is made of a material selected from alumide, or made of metal and formed by milling or casting.
In a preferred embodiment, the bonding step comprises applying an adhesive to a surface of the second nonwoven web and bonding the web to the first nonwoven and / or three dimensional absorbent material, wherein
- 67 - BE2020 / 0018 Preferably the adhesive is applied in continuous or discontinuous spaced stripes aligned with the channels so that the resulting core laminate comprises adhesive rich and adhesive poor areas, the adhesive rich areas being substantially along the channels and the adhesive poor regions are in regions of the core other than the channels. An advantage of this embodiment is to limit the risk of absorbent material adhering within the channels and instead to directly bond the topsheet and backsheet fleece together at these channel locations.
In one embodiment, the adhesive is applied in zones across the width of the channels so as to form zones, preferably alternating zones, of different bond strength between the laminate. For example, the first fleece web may be bonded to the second fleece web in at least three zones along the width of the channel. Such an arrangement may include a first adhesive zone, a second adhesive zone and a third adhesive zone, the second adhesive zone being disposed between the first and third adhesive zones along the width of the channel (for example, on an axis parallel to the core width and perpendicular to the longitudinal axis of the core), wherein the bond strength of the second adhesive zone is greater than the bond strength of the first and third adhesive zones. Examples of ways to achieve such stronger bond strength in the second zone include using greater amounts of adhesive in this zone, applying greater mechanical pressure to this zone, or using a different adhesive type, other ways are also contemplated provided that stronger adhesion between fleece webs occurs in such an area.
In one embodiment, the bond strength in the first and third zones is less than the tensile force generated by the absorbent material located proximal to the channel after wetting, so that the first and second fleece webs in the zones can separate after wetting. ; and wherein the bond strength in the second zone is greater than the tensile force generated by the absorbent material located proximal to the channel after wetting, so that the first and second fleece webs in the zone cannot separate
- 68 - BE2020 / 0018 after swelling of the absorbent material and can instead remain firmly connected. An advantage of this arrangement is that in dry conditions, a discernible channel is visible from the topsheet side of the article and / or core that provides wide channels that are further useful for channeling more fluid, especially in initial / early release. This arrangement then further allows the binding at the first and third portions to fail, for example, upon swelling of the SAP, so as to leave more volume available for expansion thereof (and prevent early saturation or non-optimal absorption), typically with the second zone resists such expansion, thus providing channel integrity even when wet. In a preferred embodiment, the first nonwoven web and / or the second nonwoven web, preferably the second nonwoven web, are elastic nonwoven (e.g., containing an elastic material such as Vistamaxx resin from ExxonMobil). An advantage of this embodiment is that the nonwoven web wraps better and more easily around the 3D insert upon application of a vacuum and allows subsequent bonding to the first nonwoven web at a location corresponding to a position on the base of the 3D insert (opposite an excellent top of it). This has an advantage of limiting the formation of fluid collection basins or pools within the channels. More preferably, the channels are formed substantially only by the vacuum force and not by additional mechanical action such as embossing.
In one embodiment, the adhesive is applied such that, when laminated, the bonded first and second nonwoven webs in the channel locations are substantially flush with the non-bonded portions of the second nonwoven web, so as to form fluid retention pockets in the resulting laminated | 30 core limit. An advantage of this embodiment is to prevent the formation of pockets of fluid that can reduce comfort to the subject.
-69- BE2020 / 0018 The mold as described above may be contained within the periphery of a rotary drum device, the drum device typically comprising a plurality of molds along its periphery. The drum device can be integrated within existing devices for forming absorbent core laminates. An advantage of such a simple arrangement is that it allows the formation of such new absorbent cores in a simple and effective manner, without significant capital investment to materially alter important parts of existing core-forming equipment.
The disclosure also concerns the use of an absorbent core as described in the foregoing sections in an absorbent article described above, for improved liquid distribution compared to the same absorbent article comprising a core free of substantially interlocked channels.
The disclosure further relates to the use of an absorbent core as described in the foregoing sections in an absorbent article described above, to provide a three-phase fluid acquisition typically comprising a first fluid distribution at a first rate, a second fluid distribution at a second rate, and a second fluid distribution at a second rate. third fluid distribution having a third speed, wherein the first speed is greater than or equal to the second speed and the third speed is less than the first speed and less than or equal to the second speed, preferably with the first fluid distribution driven is driven through the substantially coupled channels, the second fluid distribution is driven by a three-dimensional absorbent material contained in the core, and the third fluid distribution is driven by an amount of superabsorbent polymer dispersed within the three-dimensional absorbent material. Without wishing to be bound by theory, it is believed that the novel cores disclosed herein incorporating the disclosed novel interconnection channel arrangement enables a distinct fluid distribution and absorption system to be achieved that is unique and first of its kind, wherein first the channels allow for rapid fluid distribution / discharge into / out of the areas for delivery, followed by further distribution from neighboring
- 70 -
BE2020 / 0018 surfaces from the channels to other portions of the core through the three-dimensional absorbent material, and finally the superabsorbent polymer dispersed in the three-dimensional absorbent material begins an absorption of the fluid when confronted with fluid as it swells, so as to allow the three-dimensional material to distribute and transfer more of the fluid to the superabsorbent polymer.
Hang tear test method:
A core (unused, namely in a dry state) comprising a channel as described herein is in multiple samples of approximately 5cm x 10cm as shown in Fig. 19A (as shown in the figure, sample 3 represents the U-bend portion of the channel and samples 1 and 2 other portions of the channel). Each sample is then conditioned to room conditions (generally in an oven at a temperature of 25 ° C and 40% RH for at least 12 hours). For each sample, its top and bottom substrates are peeled / separated up to (and not including) the position of the channel (location where both top and bottom substrates are bonded together) and the bottom substrate is secured in a stationary clamp and the top substrate is placed in attached a second clip to which weights totaling 109g are hooked to each sample (as shown in Fig. 19B). ; The time is then recorded from the moment the weights are applied to the moment when complete tearing occurs between top / bottom substrates (i.e. the weights fall to the ground). Lately, the hanging represents crack value.
The disclosure is further described by the following non-limiting examples which further illustrate the disclosure, and which are not intended, nor should be construed, to limit the scope of the disclosure.
The examples herein provide further embodiments and structural technical features that may be present
-71- BE2020 / 0018 (in isolation or combination) in absorbent articles according to the present disclosure. However, it is understood that alternative structural features of the absorbent article may be utilized without departing from the inventive scope of the present disclosure.
Acquisition Time Test Method: The following test is performed to determine the acquisition time of a diaper. The diaper core is loaded with a weight of 8 kg. A certain amount of NaCl solution is poured onto the diaper using a special kind of funnel and the absorption time is measured. This procedure is repeated a total of four times, waiting 5 minutes after each injection. Solutions to be used: demineralized water (conductivity <5 uS / em); colored NaCl solution (0.9%) [9g sodium chloride, NaCl AR must be dissolved in 991g demineralized water and colored with food coloring that is free from common salt]. Equipment to be used: foam plastic mat covered with hook material; weight of 8 kg with a funnel on it (base area 100 mm x 300 mm; about 0.4 psi); electronic timer (accuracy 1 s per 20 min); balance (accuracy + 0.01 g); filter paper according to Hy-Tec (100 mm x 300 mm; Schleicher & Schuell type 604); beaker. Sample preparation: At least four unused diapers are tested. The weight of each sample is determined and recorded. Weighted filter papers (10 pcs) for backsheet leakage are placed on the foam plastic mats before attaching the samples to them. The feeding point is marked on the diaper according to the gender-specific position, namely in the center of the total diaper for girl, 2.5 cm to the front for unisex and 5 cm to the front for boy. After this, the filter paper is placed with its center on the feeding point.
-72- BE2020 / 0018 Procedure: The diaper is mounted on the foam plastic mat above the filter paper for leakage through the backsheet. The 8 kg weight is placed on the absorbent core so that the mark on the side lines up with the mark on the diaper. The NaCl solution (4x70ml) is poured onto the diaper through the funnel. The time it takes for the liquid to penetrate the top layer is measured and recorded. When the liquid has been absorbed by the diaper, a timer is started to measure a waiting period. After a waiting period of 5 minutes, the same amount of liquid is poured onto the diaper a second time and the absorption time is measured and recorded again. This procedure is repeated a total of four times. After the fourth 5 minute wait period, the diaper is removed from weight and any residual liquid on the base plate is wiped away. For the products tested, the mean and standard deviation of the absorption time (in seconds) after the fourth liquid addition is recorded as the mean acquisition time.
Surface dryness evaluation (rewet) test method: The following test is performed to determine the Surface dryness of a diaper surface. .
A defined amount of NaCl solution is poured on the diaper in one shot with a measuring cylinder. When the liquid is absorbed, the time is recorded.
Two minutes after injection, rewet under a weight of 580 g should be determined using filter paper weighed before and after testing and the values recorded.
Solutions to be used: demineralized water (conductivity <5 uS / em); colored NaCl solution (0.9%) [9g sodium chloride, NaCl AR must be dissolved in 991g demineralized water and colored with food coloring that is free from common salt].
- 73 - BE2020 / 0018 Equipment to be used: plastic box (37 cm x 26 cm x 17 cm); metal sign and magnets; plexiglass plate (25 (+1) cm); 580 + 2g); electronic timer (accuracy 1 s per 20 min); balance (accuracy + 0.01 g); filter paper according to Hytec (14 cm x 19 cm; Schleicher & Schuell type 604); measuring cylinder (capacity> 100 ml). Preparation of the samples: Diapers (at least 5 samples of each) are placed in a transparent box in a curved shape, fastened with metal clips on the sides / edges of the box.
The core is assumed to be completely within the box, with the sides of the core not being turned over the walls of the box.
Procedure: The measuring cylinder is filled with 100 mL of the NaCl solution and placed in front of the center of the diaper.
The liquid is poured onto the diaper in one shot and the clock is started.
One minute after pouring the liquid, the diaper is placed flat on a metal plate with the help of four magnets on the corners of the diaper.
After two minutes in total, the filter paper, which has been pre-weighed, and the Plexiglas plate are placed centered on the diaper.
The stack of filter paper is weighed again.
The difference in weight of the filter paper before and after testing equals the rewet in grams.
The rewet is calculated according to the following formula: Rewet [ge] = -WA-WB Where W B = weight of filter paper before testing, and W A = weight of filter paper after testing.
The average rewet is then reported as the average of all samples tested (values in g). Air Permeability Test Method: The following test method is performed to determine the air permeability (or "relative porosity" as referred to herein) of nonwoven substrates.
-74- BE2020 / 0018 Equipment to be used: Air permeability tester model FX 3300 LABOTESTER III (from Textest AG) equipped with a test head with part number FX 3300-20 (from Textest AG).
Procedure: Each fleece sample is placed as an obstacle in an air flow (using the respective clamp holder in the equipment). A pressure difference Ap (between both top and bottom sides of the fleece sample) develops as a result of hydraulic losses. The differential pressure is recorded by means of a manometer. Standard evaluation (according to EN ISO 9237: 1995) is included under the conditions: clamping area 20 cm, differential pressure 200 Pa. The measured value can be reported as a velocity of air in liters per square meter per second (L / m2 / s).
EXAMPLES Example 1: Fig. 5-8 representatively illustrate an example of a disposable diaper, as indicated generally at 20, according to the present disclosure.
As representatively illustrated in Fig. 5-7, the diaper 20 defines a front waist region 22, a rear waist region 24, a crotch region 26 extending between and connecting the front and rear waist regions 22 and 24, a pair of laterally opposed sides 28, an inner surface 30 and an outer surface 32. The front waist region 22 includes the portion of the diaper 20 which, when worn, is placed on the front of the wearer, while the rear waist region 24 comprises the portion of the diaper 20 that, when worn, placed on the jerk side of the carrier. The crotch region 26 of the diaper 20 includes the portion of the diaper 20 which, when worn, is placed between the legs of the wearer and covers the wearer's lower body.
The diaper 20 includes an outer cover 34, an absorbent chassis 36 and a fastening system 50. The absorbent chassis 36 is configured to hold any
- 75 - BE2020 / 0018 body secretions that are released by containing and / or absorbing the wearer. While the outer cover 34 and fastening system 50 are configured to retain the diaper 20 around the waist of the wearer, hide the absorbent chassis 36 from view, and provide a garment-like appearance. The diaper 20 may further include leg elastics 96 and 98 and containment flaps 100 and 102. It should be recognized that individual components of the diaper 20 may be optional depending on the intended use of the diaper 20.
As representatively illustrated in Fig. 5-8, the laterally opposed sides 28 of the diaper 20 are generally defined by the sides of the outer cover 34 that further define leg openings that may be curvilinear. The waist edges of the outer cover 34 also define a waist opening configured to surround the waist of the wearer when worn.
As representatively illustrated in Fig. 5-8, the absorbent chassis 36 of the diaper 20 is adequately connected to the outer cover 34 to provide the disposable diaper 20. The absorbent chassis 36 may be coupled to the outer cover 34 in ways well known to those of skill in the art. For example, the absorbent chassis 36 may be bonded to the outer cover 34 using adhesive, heat or ultrasonic bonding techniques known to those of skill in the art. Alternatively, the absorbent chassis 36 may be bonded to the outer cover 34 using conventional closures such as buttons, hook and loop closures, adhesive tape closures, and the like. The other components of the diaper 20 may be adequately coupled together using similar means. Desirably, the absorbent chassis 36 is coupled to the outer cover 34 only at or adjacent the waist sides of the outer cover 34, creating a front fastened portion, a rear fastened portion, and an unattached portion. The unattached portion of the absorbent chassis 36 remains substantially unattached to the outer cover 34 and is in
- 76 - BE2020 / 0018 generally configured to fit between the legs of the wearer and at least partially cover the wearer's lower body when in use. As a result, the unsecured portion is generally the portion of the absorbent chassis 36 that is configured to initially receive the wearer's body exudates when in use. In this way, the absorbent chassis 36 is connected to the outer cover 34 in such a way as to secure the chassis 36 in place while not impeding the movement of the outer cover 34 when in use. Alternatively, the absorbent chassis 36 may be attached to the outer cover 34 along the full longitudinal length of the absorbent chassis 36 or any portion thereof or along the outer edge of the absorbent chassis 36.
As representatively illustrated in FIG. 5-8, the absorbent chassis 36 of the present disclosure may include a backsheet 38, a topsheet 40 bonded to the backsheet 38 in stacked relationship, and an absorbent core 42 interposed between the topsheet 40 and the backsheet 38.
The absorbent chassis 36 is generally conformable and capable of absorbing and retaining body secretions. The absorbent chassis 36 can be in any number of shapes and sizes. For example, as representatively illustrated in Fig. 5-8, the absorbent chassis 36 can be rectangular, I-shaped or T-shaped. The size and absorbent capacity of the absorbent chassis 36 must be compatible with the size of the intended wearer and the fluid load imparted by the intended use of the diaper 20.
The topsheet 40 of the absorbent chassis 36, as representatively illustrated in FIG. 5-8, adequately presents a body-facing surface, which is intended to be worn adjacent to the wearer's body and is compliant, soft feeling and non-irritating to the wearer's skin.
Furthermore, the topsheet 40 may be less hydrophilic than the absorbent core 42, to present a relatively dry surface to the wearer, and may be porous enough to be liquid permeable, allowing liquid to easily penetrate through its thickness. . A suitable topsheet 40 can be made from a wide selection of web materials, such as porous foams, reticulate foams, apertured plastic films, natural fibers (e.g. wood or cotton fibers), synthetic fibers (e.g. polyester or polypropylene fibers), or a combination of natural and synthetic fibers. The topsheet 40 is adequately used to help insulate the wearer's skin from fluids contained in the absorbent core 42 of the absorbent chassis 36.
The topsheet 40 and backsheet 38 are generally bonded together to form a pocket in which the absorbent core is located to provide the absorbent chassis 36. The topsheet 40 and the backsheet 38 may be bonded directly together around the outer periphery of the absorbent chassis 36 by any means known to those of skill in the art, such as adhesive bonds, sonic bonds, or thermal bonds. For example, a uniform continuous layer of adhesive, a patterned adhesive layer, a sprayed or meltblown adhesive pattern, or a series of lines, swirls, or dots of adhesive can be used to adhere the topsheet 40 to the backsheet 38. It should be noted that both the topsheet 40 and the backsheet 38 need not extend fully to the outer periphery of the absorbent chassis 36. For example, the backsheet 38 may extend to the outer periphery of the absorbent chassis 36, while the topsheet 40 may be attached to the backsheet within the outer periphery of the absorbent chassis 36, or more toward the longitudinal centerline of the diaper 20.
Absorbent core 42, as representatively illustrated in FIG. 5-8, is interposed between the topsheet 40 and the backsheet 38 to form the absorbent chassis 36. The absorbent core 42 is desirably conformable and capable of absorbing and retaining body secretions. The absorbent core 42
78 -
BE2020 / 0018 can be in any of a number of shapes and generally have a discrete layer within the matrix of hydrophilic fibers.
Alternatively, the absorbent core 42 may comprise a laminate of fibrous webs and high absorbent material or other suitable means for retaining a high absorbent material in a localized area.
As representatively illustrated in Fig. 5-8, the absorbent chassis 36 of the disposable diaper 20 may include a pair of containment flaps 100 and 102 configured to provide a barrier to the lateral flow of bodily exudates.
The containment flaps 100 and 102 may be located along the laterally opposed sides of the absorbent chassis 36.
Each containment flap defines an attached side 104 and an unattached side 106. Each of the containment flaps 100 and 102 may also include at least one extended elastic member 108 bonded and configured to the unattached side 106 of the containment flaps 100 and 102 is to receive the unattached side 106 and form a seal against the wearer's body when in use.
The containment flaps 100 and 102 can extend longitudinally along the full length of the absorbent chassis 36 or can extend only partially along the length of the absorbent chassis 36.
When the containment flaps 100 and 102 are shorter in length than the absorbent chassis 36, the containment flaps 100 and 102 may be selectively located anywhere along the sides 38 of the absorbent chassis 36.
In a particular aspect of the disclosure, containment flaps 100 and 102 extend along the full length of absorbent chassis 36 to better contain body secretions.
Each containment flap 100 and 102 is attached to the sides 38 of the absorbent chassis 36 such that the containment flaps 100 and 102 provide a barrier to the lateral flow of body exudates.
The attached side 104 of each of the containment flaps 100 and 102 is attached to the sides 38 of the absorbent chassis 36, while the unattached side 106 remains unattached from the absorbent chassis 36 in at least the crotch region 26 of the diaper 20. The fastened side 104 of the containment flaps
79 - BE2020 / 0018 100 and 102 may be attached to the absorbent chassis 36 in any of several ways well known to those of skill in the art. For example, the fastened side 104 of the flaps 100 and 102 may be ultrasonically bonded, heat bonded, or adhesive bonded to the absorbent chassis 36. In one particular aspect, the unsecured side 106 of each of the containment flaps 100 and 102 remains unattached from the sides 38 of the absorbent chassis 36 along substantially the full length of the fastened side 106, to provide improved performance.
Alternatively, as representatively illustrated in Figs. 4-7, containment flaps 100 and 102 may be integral with the backsheet 38 or topsheet 40 of the absorbent chassis 36.
Each containment flap 100 and 102 is also configured such that the unsecured side 106 of containment flaps 100 and 102 tends to position itself in spaced relationship away from the absorbent chassis 36 to a generally upright and perpendicular configuration. , especially in the crotch region 26 when in use. As representatively illustrated in Fig. 5-8, the unsecured side 106 of each containment flaps 100 and 102 is desirably positioned away from the absorbent chassis 36 when in use, thereby providing a barrier to the lateral flow of bodily exudates. Desirably, the unsecured side 106 of each containment flaps 100 and 102 maintains a contacting relationship with the wearer's body, while the absorbent chassis 36 may be positioned away from the wearer's body when in use. Typically, an elastic member 108 is attached to the unsecured side 106 of each containment flap 100 and 102 to maintain the road-facing relationship between the unsecured side 106 and the absorbent chassis 36. For example, the elastic member 108 may be attached to the unattached side 106 in an elastically contractible condition such that the contraction of the elastic member 108 receives or contracts and shortens the unattached side 106 of the containment flaps 100 and 102.
- 80 - BE2020 / 0018 The disposable diaper 20 of the various aspects of the present disclosure may further include elastics on the waist edges and side 28 of the diaper 20 to further prevent the leakage of bodily exudates and support the absorbent chassis 36.
For example, as representatively illustrated in FIG. 5 - 8, the diaper of the present disclosure may comprise a pair of leg elastic members 96 and 98 connected to the laterally opposed sides 28 in the crotch region 26 of the diaper 20. The leg elastics 96 and 98 are generally adapted to fit around the legs of the wearer in use to maintain a positive contacting relationship with the wearer to effectively reduce or eliminate the leakage of body secretions from the diaper 20.
The absorbent article illustrated in FIG. 9 - FIG. 12 generally represents training pants.
The absorbent article 10. The longitudinal direction 48 generally extends from the front of the absorbent article to the back of the absorbent article.
Opposite the longitudinal direction 48 is a lateral direction 49. The absorbent article 10 includes a chassis 12 that includes a front portion 22, a rear portion 24, and a crotch portion 26.
An absorbent core 28 is disposed within the crotch portion 26 and extends from the front portion 22 to the rear portion 24.
The absorbent article 10 defines an inner surface that is configured to be placed next to the body when worn.
The absorbent article 10 also includes an outer surface opposite the inner surface.
The front and rear portions 22 and 24 are those portions of the article that, when worn, partially cover or surround the waist or lower mid-body of the wearer.
The crotch portion 26, on the other hand, is generally disposed between the legs of the wearer when the absorbent article is put on.
As shown in Fig. 9, the absorbent article further includes a first side region 30 and a second side region 34. The side regions 30 and 34 engage the
- 81 - BE2020 / 0018 front portion 22 with the rear portion 24. The side regions 30 and 34 can also help to define the leg openings and the waist opening.
Side regions 30 and 34, in one embodiment, may be made of a stretchable or extensible material. For example, in one embodiment, the side regions 30 and 34 are made of an elastic material. The side areas serve to form a snug yet comfortable fit around the wearer's body. The side regions 30 and 34 may also allow accommodating different body contours.
As shown, each of the side regions 30 and 34 can be made of multiple stretchable panels. For example, in the embodiment shown in FIG. 9 the side areas 30 and 34 made of two buildings. For example, as shown, the side area 30 includes a first panel 31 and a second panel 33. Likewise, the second side area 34 includes a first panel 35 attached to a second panel 37. The panels 31 and 33 of the first side area 30 are secured together to form a first vertical fastening region 41 while the panels 35 and 37 of the second side region 34 are fastened together along a second vertical fastening region 43. The fastening between the panels may be permanent or may be releasable and reclosable. For example, when the panels are releasably attached to each other, any suitable mechanical closure can be used. For example, in one embodiment, the panels may be releasably bonded together using any suitable adhesive closure, binding closure, mechanical closure, or the like. Suitable mechanical fastening elements can be provided by interlocking geometrically shaped materials such as hooks, loops, spheres, mushrooms, arrowheads, balls on stems, male and female components, buckles, snaps, and the like.
In the embodiment as illustrated in Figures 9-12, panels 31 and 33 comprising the first side region 30 and panels 35 and 37 comprising the second side region 34 are joined together using a fastening system 80 comprising laterally opposed first fastening components. 82 that are modified
82 - BE2020 / 0018 for reclosable engagement with corresponding second fastening components
84. For example, in one embodiment, a front or outer surface of each of the fastening components 82, 84 includes a plurality of engagement elements. The engagement members of the first fastening components 82 are adapted to repeatedly engage and release corresponding engagement members of the second fastening components 84 to releasably secure the absorbent article in its three-dimensional configuration.
For example, in one embodiment, the first fastening components 82 include loop closures and the second fastening components 84 include complementary hook closures. Alternatively, the first fastening components 82 may include hook closures and the second fastening components 84 may be complementary loop closures. In another aspect, the fastening components 82 and 84 may be interlocking closures having a similar surface, or adhesive or adhesive fastening elements such as an adhesive fastener and an adhesive receptive receiving zone or material.
As described above, in an alternative embodiment, the panels comprising the side regions may be permanently bonded together. For example, referring to Figs. 10, an alternative embodiment of an absorbent article 10 is shown. The same reference numbers are used to designate the same or similar elements. As shown, the absorbent article 10 in FIG. 10 a first side area 30 with panels 31 and 33 and a second side area 34 with panels 35 and 37. The first side panel 30 defines a first vertical fastening area 41 where panels 31 and 33 are permanently bonded together. Likewise, the second side region 34 defines a second vertical securing region 43 where the panels 35 and 37 are permanently bonded together. In this embodiment, the vertical fastening areas include seams. For example, the seams can be constructed in any suitable manner. For example, the vertical seam may include an overlapping seam, a butt seam, or any other suitable configuration. The seams can be formed by securing the panels together, using any suitable one
- 83 - BE2020 / 0018 method or technique. For example, the panels may be permanently bonded together using ultrasonic bonding, heat bonding, adhesive bonding, and / or pressure bonding. In yet another alternative embodiment, the separated panels can be sewn together.
As shown in Fig. 9 and 10, when the side regions 30 and 34 are in a locked position, the front and rear portions 22 and 24 are joined together to form a three-dimensional trouser configuration having a waist opening 50 and a pair of leg openings 52. Thus, the side regions 30 and 34 comprise when wearing the absorbent article 10, the portions of the article placed on the hips of the wearer and, in one embodiment, define the top of the leg openings 52. As described above, the chassis 12 may, in one embodiment, have an outer cover 40 and a topsheet 42 as shown specifically in FIG. 11 and 12. Depending on the embodiment, the outer cover 40 and the topsheet 42 may comprise a unitary one piece material or comprise multiple pieces of material bonded together. The topsheet 42 may be bonded to the outer cover 40 in a superimposed relationship using, for example, adhesives, ultrasonic bonding, heat bonding, compression bonding, or other conventional techniques. The topsheet 42 may be adequately bonded to the outer cover 40 along the outer edge of the chassis 12 to form a front waist seam 62 and a back waist seam 64. The topsheet 42 may also be joined to the outer cover 40 to form a pair of side seams 61. The topsheet 42 is generally adaptable, namely, it can be positioned relative to the other components of the absorbent article 10 to be applied to the wearer's skin when donned. As described above, the chassis 12 also includes the absorbent core 28 disposed between the outer cover 40 and the topsheet 42 to absorb liquid body exudates exuded by the wearer.
84 - BE2020 / 0018 In accordance with the present disclosure, the absorbent article 10 further comprises one or more extended waistbands that are intended to enhance product appearance, improve fit and / or make the product feel more like real underwear. For example, as shown in the figures, the absorbent article 10 may include a rear waistband 56, a front waistband 54, or may include both a front waistband and a rear waistband. For example, as shown, the rear waistband 56 extends throughout the rear portion 24 of the chassis 12 and terminates at each end of the side regions 30 and 34.
It is believed that the present disclosure is not limited to any form of realization as previously described and that some modifications can be added to the presented example of manufacture without reconsideration of the appended claims. While the example above refers to the embodiment of FIG. 5 to FIG. 8, for example, similar structures can be found in other embodiments such as those illustrated in FIG. 9 to FIG. 12, and further female care products such as those of FIG. 13 and FIG. 14. In addition, although the example and figures relate to baby diapers and pants, the same remains applicable to adult incontinence diapers and pants, albeit with some structural modifications that are apparent to one of skill in the art. Example 2: Referring to FIG. 13 and FIG. 14, the absorbent articles can be of the sanitary napkin or pantiliner type. The structure of the sanitary napkin or pantiliner can vary in construction as long as a core is used as described herein. In general, such a sanitary napkin or pantiliner comprises a laminate comprising a backsheet, an absorbent core (with or without a three-dimensional absorbent material) and optionally a liquid distribution layer (ADL) placed between the topsheet and the absorbent core.
- 85 - BE2020 / 0018 As shown in Fig. 14, the coupled channel 106 may be multiples and be substantially concentric with respect to each other and may be inverted in shape about an axis parallel to the width of the core. While such a pattern is illustrated as an example for use in a sanitary napkin core or panty liner 300, such a shape may likewise be applied to and included in the teaching of the cores for diapers and pants (whether those for infants or incontinence). for adults) herein. Example 3: Reference - Commercially available baby diapers (Junior size) with core, free of channels, comprising a mixture of fluff and SAP (sold by Ontex bvba, under the FlexFit name), are prepared according to the method described above for "Acquisition time" method tested. A total of 5 diaper samples each having an acquisition distribution layer (ADL) corresponding to Sample A - C below are tested. Mean acquisition time and standard deviation (STD) are reported in Table 1 below.
Sample A - Air-through bonded fleece layer with basis weight of 50 g / m (commercially available from TWE Meulebeke bvba, and sold as DryWeb T28) Sample B - Spunbonded fleece layer with 100% polypropylene (PP) fibers and basis weight of 21 g / m (commercially available from Fitesa Italy Srl, and sold under item code ISEW-100 021 FA-S) Sample C - Carded heat bonded fleece layer with 100% polypropylene (PP) fibers and basis weight of 30 g / m (commercially available from Union Industries SpA, and sold under item code T3000PIWT) Table 1: Example 3 Average STD Acquisition Time (s) CT (eme TT
- 86 - BE2020 / 0018 The results in Table 1 show that the mean acquisition time in traditional non-channeled diapers is very long when using ADLs according to Samples B and C. Levels above 200s are considered unacceptable in industry (e.g. Hy-tec- target values for baby diapers 01-2019) while levels below 200s are considered acceptable (especially for size Junior-Junior +, Maxi / Maxi +, XL / XL +). The latter has discouraged the use of such ADLs in modern-performance diapers.
Example 4: Baby diapers (Junior size) with core, having a single U-shaped channel free of absorbent material therein, comprising a mixture of fluff and SAP, are tested according to the method described above for “Acquisition Time” method . A total of 5 diaper samples each having an acquisition distribution layer (ADL) corresponding to Sample A "C" below are tested. Mean acquisition time and standard deviation (STD) are reported in Table 2 below.
Sample A '- Air-through bonded fleece layer with basis weight of 50 g / m (commercially available from TWE Meulebeke bvba, and sold as DryWeb T28) Sample B "- Spunbonded fleece layer with 100% polypropylene (PP) fibers and basis weight of 21 g / m (commercially available from Fitesa Italy Srl, and sold under item code ISEW-100 021 FA-S) Sample C '- Carded heat bonded fleece layer with 100% polypropylene (PP) fibers and basis weight of 30 g / m (commercially available from Union Industries SpA, and sold under item code T3000PIWT) Table 2:
- 87 - BE2020 / 0018 Example 4 Mean STD Acquisition Time (s) eee ET Ke The results in Table 2 show that introducing a channelized core allows to significantly reduce the acquisition time, with ADLs according to Samples B 'and C' now provide a very acceptable performance (particularly according to Hy-Tec thresholds discussed in Example 3).
Example 5: Reference - Commercially available baby diapers (Junior size) with core, free of channels, comprising a mixture of fluff and SAP (sold by Ontex bvba, under the FlexFit name) are prepared according to the method described above for “ Surface Dryness (Rewet) ”method tested. A total of 6 diaper samples each having an acquisition distribution layer (ADL) corresponding to Samples A to C below are tested. Mean acquisition time and standard deviation (STD) are reported in Table 3 below.
Sample A - Air-through bonded fleece layer with basis weight of 50 g / m (commercially available from TWE Meulebeke bvba, and sold as DryWeb T28) Sample B - Spunbonded fleece layer with 100% polypropylene (PP) fibers and basis weight of 21 g / m (commercially available from Fitesa Italy Srl, and sold under article code ISEW-100 021 FA-S) Sample C - Carded thermobonded fleece layer with 100% polypropylene (PP) fibers and basis weight of 30 g / m (commercially available from Union Industries SpA, and sold under item code T3000PIWT) Table 3:
- 88 - BE2020 / 0018 Example 5 Average STD rewet (g) CT (mme (EEE) Results in Table 3 show poorer rewet performance of diapers comprising Sample A ADLs Example 6: Baby diapers (Junior size) with core, with a single U -shaped channel free of absorbent material therein, comprising a mixture of fluff and SAP, are tested according to the method described above for “Surface Dry (Rewet)” method. A total of 6 diaper samples each having an acquisition distribution layer (ADL ) corresponding to Sample A'-C ° below is tested Mean acquisition time and standard deviation (STD) are reported in Table 4 below.
Sample A '- Air-through bonded fleece layer with basis weight of 50 g / m (commercially available from TWE Meulebeke bvba, and sold as DryWeb T28) Sample B "- Spunbonded fleece layer with 100% polypropylene (PP) fibers and basis weight of 21 g / m (commercially available from Fitesa Italy Srl, and sold under item code ISEW-100 021 FA-S) Sample C "- Carded thermobonded fleece layer with 100% polypropylene (PP) fibers and basis weight of 30 g / m (commercially available from Union Industries SpA, and sold under item code T3000PIWT) Table 4: Example 6 Average STD rewet (g) CT names EEE
-89- BE2020 / 0018 The results show that by introducing ADLs according to Samples B / B 'and C / C' into channeled core diapers, surprisingly an optimal balance of acquisition time (Example 4) and rewet (Example 6) is achieved .
The compromise in acquisition time performance in channeled diapers (Example 4) when Samples B / B 'and C / C' are chosen is much smaller compared to non-channeled diapers (Example 3), this tradeoff being significantly offset by the significant rewet improvement to maintain excellent perceived drought. This leads to an ideal point in terms of overall diaper performance in a cost effective manner.
Example 7: The ADLs according to Samples A / A ", B / B", C / C "of Examples 3 - 6 are further tested according to the bulk density test described herein and results are reported in Table 5.
Table 5: Example 8: The ADLs according to Samples A / A ", B / B", C / C "or Examples 3 to 6 have been further tested for fluid retention. The test includes the following steps: cutting each sample to a size of 245mm x 80mm; measuring and recording the weight of the sample in the dry state; immersing each sample in a saline bath (same as described / used in Examples 3 to 6) and leaving it in the solution for 2 minutes; taking the sample out of the bath and allowing excess to drip by clamping one end of the sample to a cantilever mold and allowing it to hang by gravity at
- 90 - BE2020 / 0018 room conditions for 3 minutes; then measure the weight again.
The difference in weight of dry state compared to after the immersion test gives the liquid retention weight.
The remainder is repeated for at least 3 samples for each of Samples A / A ", B / B", C / C "of Examples 3 to 6.
Results are reported in Table 6. Table 6: The results in Table 6 show that ADLs according to Sample A / A "retain a significantly greater amount of fluid therein compared to Samples B / B" and C / C ". Without wishing to be bound by theory, it is believed that one of the reasons for higher perceived wetness is because of such spongy behavior of the ADL.
Example 9: Diapers according to Examples 3 to 6 with ADLs according to Samples A / A "and B / B" are tested for visual inspection of residual wetness.
This is measured by following the following procedure: 150 mL of tap water is poured into one shot on the diaper that is in a bowl shape on a table; timing a wait period, and allowing the liquid to be absorbed into the diaper for the duration of the 90 second wait period; applying a softshell cloth (water-repellent hydrophobic cloth, 100% polyester) to the topsheet on the skin-facing side of the diaper and applying a 4kg weight for 5 seconds; remove the softshell cloth and visually inspect for signs of moisture thereon.
FIG. 23 shows the difference in visual appearance of moisture, with the diaper containing the Monster A / A "ADL showing a significantly higher degree of residual wetness compared to the same diaper using the Monster B / B" ADL.
-91- BE2020 / 0018 Example 10: ADLs according to Samples A / A ", B / B", C / C "are tested for relative porosity according to the air permeability test method described herein.
3 replicas of each of Monster A / A ", B / B", C / C "are cut and sized to fit the 20cm clamping area as described in the test method described herein (and according to ISO 9237: 1995), the mean relative porosity and corresponding standard deviation (STD) are calculated and results are reported in Table 7.
Table 7: Sample Relative Porosity | STD (L / m / S) ls TETE The results in Table 7 show significantly higher values of Relative Porosity of Sample A / A ° compared to Samples B / B "and C / C". Without wishing to be bound by theory, the higher Relative Porosity stimulates capillary action to an extent that results in a spongy behavior in use, affecting the perceived wetness following secretion events in use.
|

权利要求:
Claims (16)
[1]
An absorbent article (10, 20, 300, 500, 600) comprising an absorbent core (101, 501, 601) secured between a liquid pervious topsheet (520, 620) and a liquid impervious backsheet (521, 621), and a acquisition distribution layer (522, 622) disposed between the topsheet (520, 620) and the absorbent core (101, 501, 601) and placed on a body-facing side of the absorbent core in contact with the body-facing side of the absorbent core, wherein the absorbent core (101, 501, 601) comprises absorbent material selected from the group consisting of cellulose fibers, superabsorbent polymers and combinations thereof, wherein the absorbent core (101, 501, 601) is at least one coupled channel that is free of the absorbent material, the channel having a length extending along a longitudinal axis (48) and the absorbent core (101, 501, 601) having a length extending along the longitudinal the axis (48) extends and wherein the length of the channel is from 10% to 95% of the length of the absorbent core (101, 501, 601), characterized in that the acquisition distribution layer (522, 622) comprises synthetic fibers, wherein the synthetic fibers are present at a level greater than 80% by weight of the acquisition distribution layer (522, 622), and wherein the acquisition distribution layer (522, 622) has a basis weight of 10 to 50 g / m2, wherein the acquisition distribution layer ( 522, 622) consists of a spunbond or carded heatbond fleece.
[2]
The absorbent article of claim 1, wherein the absorbent core (101, 501, 601) comprises a single coupled channel.
[3]
An absorbent article according to any one of the preceding claims, wherein the coupled channel extends both along the longitudinal axis (48) and along an axis perpendicular to the longitudinal axis (48), such that a shape is formed that is substantially U -shaped.
[4]
The absorbent article of any preceding claim, wherein the acquisition distribution layer (522, 622) has a specific volume of less
03. BE2020 / 0018 than 11.4 cm2 / g, preferably less than 11.3 cm2 / g, more preferably from 5.5 cm2 / g to 11.2 cm2 / g, even more preferably from 8.5 cm2 / g to 11.17 cm2 / g.
[5]
An absorbent article according to any one of the preceding claims, wherein the synthetic fibers are present at a level of greater than 90% by weight, preferably from 95% to 100% by weight, of the acquisition distribution layer (522, 622).
[6]
The absorbent article of any preceding claim, wherein the acquisition distribution layer (522, 622) is composed of synthetic fibers and is preferably free of cellulose fibers, more preferably wherein the acquisition distribution layer (522, 622) has been treated, such as with a surface coating. active agent, to render the layer (522, 622) hydrophilic.
[7]
Absorbent article according to any of the preceding claims, wherein the synthetic fibers comprise, preferably consist of, polypropylene fibers.
[8]
The absorbent article of any one of the preceding claims, wherein the acquisition distribution layer (522, 622) consists of a single, spunbond or carded fleece layer and is free of air-through-bonded, air-laid (“Airlaid”) and / or melt-blown fleece layers.
[9]
The absorbent article of any preceding claim, wherein the acquisition distribution layer (522, 622) has a basis weight of 15 to 40 g / m2, preferably from 18 to 35 g / m2, more preferably from 20 to 30 g / m2, most preferably from 21 to 25 g / m2.
[10]
The absorbent article of any one of the preceding claims, wherein the acquisition distribution layer (522, 622) has an average flow pore size from 15 µm to 200 µm, preferably from 30 µm to 150 µm, more preferably from 45 µm to 130 µm, with even more preferably from 55 µm to 110 µm, even more preferably from 60 µm to less than 100 µm, even more preferably from 65 µm to 95 µm, even more preferably from 70 µm to 90 µm.
'94 - BE2020 / 0018
[11]
The absorbent article of any preceding claim, wherein the acquisition distribution layer (522, 622) comprises a first center position (Cap) and the absorbent core (101, 501, 601) comprises a second center position (Cc), and wherein the acquisition distribution layer ( 522, 622) is disposed asymmetrically over the absorbent core (101, 501, 601) such that the first center position (Cap) and second center position (Cc) are offset at least along the longitudinal axis (48), preferably with the acquisition distribution layer (522, 622) is positioned so that it does not overlap with a portion of the channel that extends in the width direction along an axis substantially perpendicular to the longitudinal axis (48).
[12]
An absorbent article according to any one of the preceding claims, wherein the acquisition distribution layer (522, 622) has a relative porosity of less than 9000 L / m2 / s, preferably from 1000 L / m2 / s to 8000 L / m2. / s, preferably from 2000 L / m2 / s to 7000 L / m2 / s, more preferably from 3000 L / m2 / s to 5000 L / m2 / s, most preferably from 3500 L / m2 / s m / s to 4500 L / m / s.
[13]
13. Use of an acquisition distribution layer (522, 622) with a relative porosity of less than 9000 L / m 2 / s placed between a topsheet (520, 620) and an absorbent core (101, 501, 601) of an absorbent article. and which is disposed on a body-facing side of the absorbent core (101, 501, 601) in contact with the body-facing side of the absorbent core (101, 501, 601), the absorbent core (101 , 501, 601) comprises absorbent material selected from the group consisting of cellulose fibers, superabsorbent polymers and combinations thereof, wherein the absorbent core (101, 501, 601) comprises at least one interconnected channel that is free of the absorbent material, wherein the channel has a length that extends along a longitudinal axis (48) and the absorbent core (101, 501, 601) has a length that extends along the longitudinal axis (48) and the length of the channel is 10% up to 95% of the length of the absorbent core (101, 501, 601).
_95. BE2020 / 0018
[14]
Use according to claim 13, wherein the relative porosity is from 1000 L / m2 / s to 8000 L / m2 / s, preferably from 2000 L / m2 / s to 7000 L / m2 / s, more preferably from 3000 L / m2 / s to 5000 L / m2 / s, most preferably from 3500 L / m2 / s to 4500 L / m2 / s, and the absorbent article preferably according to any one of the preceding claims 1 to 12.
[15]
The absorbent article of claims 1 to 12, wherein the core comprises a plurality of the channels.
[16]
An absorbent article according to claims 1 to 12 or 15, wherein the length of the channel is from 30% to 90%, more preferably from 40% to 85%, most preferably from 50% to 80%, of the length of the absorbent core.

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法律状态:
2020-10-12| FG| Patent granted|Effective date: 20200820 |

优先权:

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申请号 | 申请日 | 专利标题

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EP19164452.5A|EP3711729B1|2019-03-21|2019-03-21|Absorbent articles|EP21162901.9A| EP3881813A1|2019-03-21|2020-02-19|Process and apparatus for making channeled absorbent articles|

---

EP20158150.1A| EP3711726B1|2019-03-21|2020-02-19|Process and apparatus for making channeled absorbent articles|

---

EP20158571.8A| EP3711731A1|2019-03-21|2020-02-20|Process and apparatus for making channeled absorbent articles|

---

PCT/EP2020/057684| WO2020188056A1|2019-03-21|2020-03-19|Absorbent articles and methods of making|

---

PCT/EP2020/057659| WO2020188047A1|2019-03-21|2020-03-19|Absorbent articles and methods of making|

---

EP20164374.9A| EP3711732B1|2019-03-21|2020-03-19|Absorbent articles and methods of making|

---

DE202020102457.4U| DE202020102457U1|2019-03-21|2020-03-19|Absorbent articles|

---

EP20711195.6A| EP3941405A1|2019-03-21|2020-03-19|Absorbent articles and methods of making|

---

AU2020244212A| AU2020244212A1|2019-03-21|2020-03-19|Absorbent articles and methods of making|

---

AU2020243062A| AU2020243062A1|2019-03-21|2020-03-19|Absorbent articles and methods of making|

---

EP20711196.4A| EP3941406A1|2019-03-21|2020-03-19|Absorbent articles and methods of making|

---

PCT/EP2020/057817| WO2020188094A1|2019-03-21|2020-03-20|Absorbent articles and methods of making|

---

PCT/EP2020/057824| WO2020188098A1|2019-03-21|2020-03-20|Process and apparatus for making channeled absorbent articles|

---

EP20713581.5A| EP3941403A1|2019-03-21|2020-03-20|Process and apparatus for making channeled absorbent articles|

---

EP20713276.2A| EP3941407A1|2019-03-21|2020-03-20|Absorbent articles and methods of making|