专利摘要:
absorbent core with high content of superabsorbent material. The invention relates to an absorbent core (28) and an absorbent article (20) as a diaper comprising the core. the absorbent core comprises a core shell (16, 16') surrounding an absorbent material (60), wherein the absorbent material comprises at least 80% of the superabsorbent polymers ("sap"), by weight, of the absorbent material. the absorbent core has a relative wet gauge increase (rwci) after compaction of less than 10% as measured by the wet gauge and compaction force (wcacf) test as described here, and in which the shell to core (16, 16') is at least partially sealed so that substantially no absorbent material leaks from the core shell when performing the wcacf test.
公开号:BR112015013519B1
申请号:R112015013519-6
申请日:2013-12-10
公开日:2021-07-27
发明作者:Blanca Arizti;Ernesto Bianchi;Bruno Johannes Ehrnsperger;Hans Adolf Jackels;Carsten Heinrich Kreuzer;Rodrigo Rosati
申请人:The Procter & Gamble Company;
IPC主号:
专利说明:

FIELD OF THE INVENTION
[001] The invention relates to an absorbent core for absorbent personal care products such as, but not limited to, baby diapers, training diapers, feminine pads or adult incontinence products. BACKGROUND OF THE INVENTION
[002] Absorbent personal care items such as disposable diapers for babies, training diapers for toddlers or adult incontinence underwear are designed to absorb and contain body exudates, in particular, a large amount of urine. Such absorbent articles comprise several layers that provide different functions, for example, a topsheet, a backsheet and, in the middle, an absorbent core, among other layers.
[003] The function of the absorbent core is to absorb and retain exudates for a prolonged period of time, for example, overnight for a diaper, minimize wetness or keep the user dry, and avoid soiling clothes or sheets. Most absorbent articles currently marketed comprise, as absorbent material, a blend of ground wood pulp with superabsorbent polymers (SAP - superabsorbent polymers) in the form of particulates, also called absorbent gelling materials (MGA), see, for example, US 5,151,092 (Buell). Absorbent articles with a core consisting essentially of SAP as absorbent material (called "aerated felt-free" cores) have also been proposed, but are less common than traditional mixed cores (see, for example, WO2008/155699 (Hundorf), WO95/11652 (Tanzer) and WO2012/052172 (Van Malderen)).
[004] Absorbent articles comprising an absorbent core with slits or grooves have also been proposed, typically to enhance the fluid-capturing properties of the core or to act as a fold guide. WO95/11652 (Tanzer) discloses absorbent articles which include superabsorbent material situated in distinct pockets with water sensitive and water insensitive containment structure. WO2009/047596 (Wright) discloses an absorbent article with a slotted absorbent core.
[005] Absorbent products that are flexible in the region between the thighs provide the benefits of greater freedom of movement for the user, specifically when the user's legs compress the region between the thighs of the article laterally. However, the inventors have found that highly flexible products can, in general, have poor resilience to wetting and thus tend to lose their shape when they are compressed by the movement of the user's legs. As the absorbent core is deformed, the product may fail to perform its function properly, and this increases the chance of failures such as fluid leaks. The inventors have now discovered a new absorbent core structure that can provide the benefit of good flexibility combined with good resilience when loaded with fluid. SUMMARY OF THE INVENTION
[006] The invention relates to an absorbent core, as defined in the claims, and an absorbent article comprising such an absorbent core. The absorbent core comprises a core wrap surrounding an absorbent material, wherein the absorbent material comprises at least 80% superabsorbent polymer ("SAP"), by weight, of the absorbent material. The absorbent core comprises a leading edge, a trailing edge and two longitudinal edges, and has a longitudinal axis oriented in a longitudinal direction. The absorbent material comprises at least one channel, in particular at least one pair of channels at least partially oriented in the longitudinal direction. The absorbent core has a Relative Wet Gauge Enhancement (RWCI) value of less than 10.0%, as measured by the Wet Gauge and Compaction Force Test (WCACF) as described herein, and the core shell is at least partially sealed so that substantially no absorbent material leaks from the core shell when performing the WCACF test. The absorbent core may further have a Wet Compaction Strength below 5.00 N, in particular 1.00 to 3.00 N, as measured by the WCACF test. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a top view of an absorbent article in the form of a diaper comprising an exemplary absorbent core in accordance with the invention; Figure 2 is a cross-section of the diaper illustrated in Figure 1; Figure 3 is a top view of the exemplary absorbent diaper core of Figure 1, alone; Figure 4 is a cross-section of the core of Figure 3; Figure 5 is a longitudinal cross-section of the core of Figure 3; Figure 6 shows a view Figure 7 is a schematic description of an apparatus used to perform the Wet Gauge and Compaction Force Test, further detailed below. DETAILED DESCRIPTION OF THE INVENTION Introduction
[007] As used herein, the term "absorbent article" refers to disposable products, such as diapers for children or adults, training diapers and the like, that are placed against or close to the user's body to absorb and retain the various exudates released from the body. Typically, such articles comprise a topsheet, a backsheet, an absorbent core, and optionally a capture layer and/or a distribution layer, and typically other components with the absorbent core normally placed between the backsheet and the system. capture or the top layer.
[008] As used herein, the term "absorbent core" refers to an individual component which is placed or is intended to be placed within an absorbent article and which comprises an absorbent material enclosed in a core shell. The term "absorbent core" does not encompass a capture or delivery layer, or any other component of an absorbent article that is not an integral part of the core shell or placed within the core shell. The absorbent core is typically the component of an absorbent article which comprises all, or at least the majority of superabsorbent particles (SAP) and which has the greatest absorbent capacity of all the components of the absorbent article.
[009] A "non-woven mat" as used herein means a sheet, thin mat (web) or mat (batt) manufactured from directionally or randomly oriented fibers, bonded by friction and/or cohesion and/or adhesion , excluding paper and products that are woven, knitted, tufted, needled or stitch-bonded incorporating connecting yarns or filaments, or felted by wet milling, whether or not additionally stitched. The fibers can be of natural or synthetic origin and can be textile fibers or continuous filaments or can be formed locally. Commercially available fibers have diameters in the range of less than about 0.001 mm to more than about 0.2 mm and have many different shapes, such as short fibers (known as staples, or cut), single continuous fibers (filaments or monofilaments) , untwisted sets of continuous filaments (untwisted yarn), and twisted sets of continuous filaments (twisted yarn). Non-woven mats can be formed through many processes such as blow spinning, continuous spinning, solvent spinning, electrospinning, carding and air deposition. The basis weight of non-woven mats is generally expressed in grams per square meter (g/m2 or g/m2).
[0010] Comprises" "comprises" and "comprises" are terms that are not limited, each specifying the presence of the feature that follows, for example, a component, but does not exclude the presence of other features, by example, of elements, steps, components known in the art or disclosed in the present invention. These terms, based on the verb "comprise" should be read as encompassing the more restricted terms "consisting essentially of", which excludes any element, step or unnamed ingredient that substantially affects the way the resource performs its function, and the term "consisting of", which excludes any unspecified element, step, or ingredient. Any exemplary or preferred embodiments described below are not limited in scope of the claims, unless specifically indicated. The words "typically", "usually", "advantageously" and the like also qualify the characteristics which are not intended to limit the scope of the claims, except as specifically indicated.
[0011] Except where otherwise indicated, the description refers to the absorbent core and the absorbent article before use (i.e., dry and not loaded with a fluid) and conditioned for at least 24 hours at 21°C +/- 2 °C and at 50 +/- 20% relative humidity (RH). Overview of the absorbent article 20
[0012] An example of an absorbent article 20 in which the absorbent core 28 of the invention may be used is a baby tape diaper 20, as shown in Figure 1. Figure 1 is a top plan view of the example diaper. 20, in a flat state, portions of the frame being cut away to more clearly show the construction of the diaper 20. This diaper 20 is shown for illustrative purposes only as the invention can be used to produce a wide variety of diapers or the like. absorbent articles.
[0013] The absorbent article 20 comprises a liquid permeable topsheet 24, a liquid impervious backsheet 25, an absorbent core 28 between the topsheet 24 and the backsheet 25. The absorbent article may also comprise other typical components, such as a capture layer 52 and/or a distribution layer 54 (collectively called the "ADS" capture and distribution system, designated as 50 in Figure 2), and elasticized sealing clamps 32 present between the upper layer and the lower layer, and clamps for the integral barrier legs 34, which will be further detailed below. Figures 1 to 2 also show other typical tape diaper components, such as a fastening system comprising fastening tabs 42 fastened towards the trailing edge 12 of the article, and cooperating with a contact zone 44 towards the edge previous article. The absorbent article may also comprise other typical components, which are not shown in the figures, such as an elastic back waist detail, an elastic front waist detail, transverse barrier clamp(s), a lotion application, etc.
[0014] The absorbent article 20 comprises a leading edge 10, a trailing edge 12 and two longitudinal edges. Lead edge 10 is the edge of the article intended to be placed facing the front of the wearer when dressed, and trailing edge 12 is the opposite edge. The absorbent article can theoretically be divided by a longitudinal axis 80 extending from the leading edge to the trailing edge of the article, and dividing the article into two halves substantially symmetrical about that axis, when viewing the article from the side. facing the user in a flat outward configuration, as shown by way of example in Figure 1. If any part of the article is under tension due to elasticized components, the article can typically be flattened using staples along the periphery of the article and/or a tacky surface, so that the top layer and the bottom layer can be snugly pulled so that they are substantially flat. The absorbent article 20 could also theoretically be divided by a transverse axis 90 into an anterior region and a posterior region of equal length, measured on the longitudinal axis when the article is in such a flat state. This transverse axis of the article 90 is perpendicular to the longitudinal axis 80 and is placed halfway along the length of the article. The length of the article can be measured along the longitudinal axis 80 from the leading edge 10 to the trailing edge 12.
[0015] The topsheet 24, the backsheet 25, the absorbent core 28 and the other components of the article can be assembled in a variety of well-known configurations, in particular by hot gluing or embossing. Exemplary diaper assemblies are, for example, generally described in documents US3,860,003, US5,221,274, US5,554,145, US5,569,234, US5,580,411, and US6,004,306. The absorbent article is preferably thin. The article may advantageously be thin at the intersection of the longitudinal and transverse axes, for example, with a gauge of 1.0 mm to 8.0 mm, in particular 1.5 mm to 6.0 mm, as measured with wear. of the Absorbent Article Gauge Test described below.
[0016] These and other components of the articles will now be discussed in more detail. Absorbent core 28
[0017] The absorbent core of the invention comprises absorbent material with a high amount of superabsorbent polymers (hereinafter abbreviated as "SAP") enclosed in the core shell. The SAP content represents at least 80% by weight of the absorbent material contained in the core shell. The core wrap is not considered an absorbent material for purposes of assessing the percentage of SAP in the absorbent core. The absorbent material defines an absorbent material deposition area 8 as seen when the core is placed substantially flat. As used herein, the term "absorbent core" does not include the topsheet, the backsheet and (if present) a capture and delivery system or layer that is not an integral part of the absorbent core, in particular, that is not placed within. of casing for core. The core may consist essentially or consist of the core shell, absorbent material and optionally glue. The term "absorbent core" and the term "core" are used interchangeably in the present invention.
[0018] The absorbent core example 28 of the absorbent article of Figure 1 is shown in isolation in Figures 3 to 5. The absorbent core of the invention comprises a leading edge 280, a trailing edge 282 and two longitudinal edges 284, 286 joining the Leading edge 280 and trailing edge 282. Leading edge 280 of the core is the core edge intended to be placed toward leading edge 10 of the absorbent article. Typically, the absorbent material will advantageously be distributed in a greater amount towards the leading edge than towards the trailing edge, as greater absorbency is required at the front. Typically, the anterior and posterior edges of the core 280, 282 are shorter than the longitudinal edges 284, 286 of the core. The absorbent core may also comprise an upper side and a lower side. The upper side 288 of the core is the side intended to be placed towards the top layer, and the lower side 290 is the side intended to be placed towards the lower layer in the finished article 20. The upper side 288 of the core is typically , more hydrophilic than the underside 290. The core width at hook height, as measured between the two longitudinal edges 284, 286, must be sufficient for the WCACF test to be performed, ie, it must be at least equal to 40 mm. The core width at hook height can in particular be from 45 mm to 200 mm, or from 50 mm to 150 mm.
[0019] The absorbent article can theoretically be divided by a longitudinal axis 80' extending from the leading edge to the trailing edge of the core, and dividing the core into two halves substantially symmetrical with respect to that axis, see the upper side core in a flat outward configuration as shown, by way of example, in Figure 3. Typically the longitudinal axis 80' of the core and the longitudinal axis 80 of the article in which the core is intended to be placed will be contiguous when viewed from the top, as in Figure 1. The transverse axis of the core (hereafter also called the "line between the legs") is perpendicular to the longitudinal axis and passes through the hook height C of the core. The hook height C is the point of the absorbent core placed at a distance of 0.45 of L from the leading edge of the absorbent core, where L is the length of the core measured from its leading edge to its trailing edge on the longitudinal axis 80' as illustrated in Figure 3. The total length L of the core is measured from the leading edge 280 to the trailing edge 282 of the core, along its longitudinal axis 80' and also includes the core shell region, which it does not enclose the absorbent material, in particular at the front and rear end seals, where present. The core length L is at least 320 mm, for example from 320 mm to 600 mm.
[0020] The region between the thighs 81 is defined, in the present invention, as the region of the core extending from the line between the legs, that is, at the level of the hook height C, towards the posterior edge and towards the front edge of the core for a distance of a quarter of L (L/4), in both directions for a total length equal to L/2. The anterior region 82 and posterior region 83 of the nucleus are the remaining regions of the deposition area towards, respectively, the anterior and posterior edges of the nucleus.
[0021] The core shell can be formed of two non-woven materials 16, 16' which can be at least partially sealed along the edges of the absorbent core. The core wrap may be at least partially sealed along the leading edge, trailing edge and two longitudinal edges of the core so that substantially no absorbent material leaks from the absorbent core wrap when performing the compaction step of the test. WCACF described below. It is not excluded that the core wrap may be sealed with a sealing line even closer to the center than the edge of the core, for example, as in a wrapping paper if the core wrap comprises a single substrate. The absorbent core can also advantageously achieve a SAP loss of at most about 70%, 60%, 50%, 40%, 30%, 20% or 10%, according to the Wet Immobilization Test described in WO2010 document /0051166A1. Other aspects of the absorbent core will now be described in more detail.
[0022] The absorbent core of the invention can be relatively thin, and thinner than conventional aerated felt cores. In particular, the core gauge (before use), as measured at hook height (C) according to the Core Gauge Test as described here, may be from about 0.25mm to 5.0mm , in particular, from 0.5 mm to 4.0 mm.
[0023] By "absorbent material" is meant a material that has at least some degree of absorbency and/or liquid-retaining properties, such as SAP, cellulosic fibers and some hydrophilically treated synthetic fibers. Typically, the glues used in making the absorbent cores do not have absorbent properties, and are not considered to be absorbent material. The SAP content may be greater than 80%, for example at least 85%, at least 90%, at least 95% and even 100% inclusive of the weight of the absorbent material contained in the core wrap. This high SAP content can provide a relatively thin core compared to a conventional core, typically comprising between 40 and 60% SAP, and the remainder cellulose fibers. The absorbent material of the invention may in particular comprise less than 10% percent by weight, or less than 5% percent by weight, or even be substantially free of natural and/or synthetic fibres. The absorbent material may advantageously comprise little or no aerated felt (cellulosic) fiber, in particular, the absorbent core may comprise less than 15%, 10% or 5% of aerated felt (cellulose) fibers by weight of the absorbent core, or even be substantially free of cellulose fibers.
[0024] The absorbent core of the invention may further comprise an adhesive, for example to help immobilize the SAPs within the core shell and/or to ensure the integrity of the core shell, in particular when the core shell is produced from of two or more substrates. The core wrap will typically extend to a larger area than is strictly necessary to contain the absorbent material therein.
[0025] Cores comprising a relatively high amount of SAP with multiple core designs have been proposed earlier; see, for example, US5,599,335 (Goldman), EP1,447,066 (Busam), WO95/11652 (Tanzer), US2008/0312622A1 (Hundorf) and WO2012/052172 (Van Malderen). In some embodiments, the absorbent material can be continuously present within the core shell. In that case, the absorbent material can be, for example, obtained by applying a single continuous layer of absorbent material. In other embodiments, the absorbent material may be comprised of individual pockets or strips of absorbent material, enclosed in the core shell and separated by joint areas.
[0026] The continuous layer of absorbent material, in particular SAP, can also be obtained by combining two "halves" of absorbent layers with a discontinuous absorbent material application pattern, wherein the resulting layer is distributed substantially continuously by the area of the absorbent particulate polymeric material, as shown, for example, in US2008/0312622A1 (Hundorf). The absorbent core 28 may comprise, for example, as illustrated in Figure 5, a first absorbent layer and a second absorbent layer, the first absorbent layer comprising a first substrate 16 and a first layer 61 of absorbent material, which may be of 100% SAP, and a second absorbent layer comprising a second substrate and a second layer of absorbent material, which may also be 100% SAP, and a fibrous thermoplastic adhesive material 51 that at least partially bonds each layer of the absorbent material 61, 62 to its respective substrate. The first substrate 16 and the second substrate 16' form the core shell. The first and second absorbent layers can be deposited onto their respective substrates in a deposition pattern comprising flat areas, which comprise absorbent material, and adjoining areas between the flat areas, which are free of absorbent material. The flat areas, as exemplified in Figure 5, for example, may be transversely oriented and span the width of the deposition area of the absorbent material 8. The fibrous thermoplastic adhesive material 51 may be at least partially in contact with the absorbent material 61, 62 in the flat areas, and at least partially in contact with the substrate layer in the joint areas. This imparts an essentially three-dimensional structure to the fibrous layer of the thermoplastic adhesive material 51, which itself is essentially a two-dimensional structure of relatively small thickness, compared to dimension in the length and width directions. Thus, the fibrous thermoplastic adhesive material can provide cavities to cover the absorbent material in the flat area and thus immobilize such absorbent material which, as already indicated, may be 100% SAP.
[0027] The thermoplastic adhesive material may comprise, in its entirety, a single thermoplastic polymer or a blend of thermoplastic polymers, having a softening point, as determined by the ASTM D-36-95 "Ring and Ball" method, in the range between 50°C and 300°C, and/or the thermoplastic adhesive material may be a thermofused adhesive comprising at least one thermoplastic polymer in combination with other thermoplastic diluents such as tackifying resins, plasticizers and additives such as antioxidants.
[0028] The thermoplastic polymer typically has a molecular weight (MW) greater than 10,000 and a glass transition temperature (Tg) typically below room temperature, or -6 °C < Tg < 16 °C. Typical concentrations of polymer in a hotmelt are in the range of about 20 to about 40% by weight. Thermoplastic polymers can be insensitive to water. Exemplary polymers are (styrenic) block copolymers including ABA triblock structures, AB diblock structures and radial block copolymer structures (A-B)n where the A blocks are non-elastomeric polymer blocks typically comprising polystyrene and the B blocks are unsaturated conjugated diene or (partially) hydrogenated versions thereof. Block B is typically isoprene, butadiene, ethylene/butylene (hydrogenated butadiene), ethylene/propylene (hydrogenated isoprene), and mixtures thereof. Other suitable thermoplastic polymers that may be employed are metallocene polyolefins, which are ethylene polymers prepared using single-site or metallocene catalysts. In that case, at least one comonomer can be polymerized with ethylene to produce a higher order copolymer, terpolymer, or other polymer. Also applicable are amorphous polyolefins or amorphous polyalphaolefins (APAO), which are homopolymers, copolymers or terpolymers of alpha-olefins C2 to C8.
[0029] The tackifier resin may, by way of example, have a molecular weight below 5,000 and a Tg typically above room temperature, typical resin concentrations in a hot-melt are in the range of about 30 to about 60% and the plasticizer has a low molecular weight typically less than 1,000 and a Tg below room temperature, with a typical concentration of about 0 to about 15%.
The thermoplastic adhesive 51 used for the fibrous layer preferably has elastomeric properties so that the mat formed by the fibers on the SAP layer can be extended as the SAP swells. Elastomeric hot melt adhesives include thermoplastic elastomers such as ethylene-vinyl acetates, polyurethanes, polyolefin blends of a hard component (generally a crystalline polyolefin such as polypropylene or polyethylene) and a soft component (such as ethylene-propylene rubber); copolyesters such as poly(ethylene terephthalate-ethylene co-azelate); and thermoplastic elastomeric block copolymers having thermoplastic end blocks and rubbery intermediate blocks referred to as A-B-A block copolymers: mixtures of structurally different homopolymers or copolymers, for example, a mixture of polyethylene or polystyrene with an A-B-A block copolymer; blends of a thermoplastic elastomer and a low molecular weight resin modifier, for example, a blend of a styrene-isoprene styrene block copolymer with polystyrene; and the elastomeric hot-melt pressure sensitive adhesives described herein. Elastomeric hot melt adhesives of these types are described in more detail in US Patent No. 4,731,066 issued to Korpman on March 15, 1988.
[0031] The thermoplastic adhesive material is advantageously applied as fibers. The fibers may, by way of example, have an average thickness of from about 1 to about 50 micrometers or about 1 to about 35 micrometers and an average length from about 5 mm to about 50 mm or about 5 mm to about 30 mm. To optimize the adhesion of the thermoplastic adhesive material to the substrate or to any other layer, in particular to any other non-woven layer, such layers can be pretreated with an auxiliary adhesive. The fibers adhere to each other to form a fibrous layer, which can also be described as a mesh.
[0032] In certain embodiments, the thermoplastic adhesive material will satisfy at least one or more or all of the following parameters. An exemplary thermoplastic adhesive material may have a storage modulus G' measured at 20°C of at least 30,000 Pa and less than 300,000 Pa or less than 200,000 Pa, or between 140,000 Pa and 200,000 Pa, or less than 100,000 Pa. In one Future aspect, storage module G' measured at 35°C may be greater than 80,000 Pa. In another aspect, storage module G' measured at 60°C may be less than 300,000 Pa and greater than 18,000 Pa, or greater than 24,000 Pa, or greater than 30,000 Pa, or greater than 90,000 Pa. In another aspect, the storage modulus G' measured at 90°C may be less than 200,000 Pa and greater than 10,000 Pa, or greater than 20,000 Pa or greater than 30,000 Pa. The storage modulus measured at 60°C and 90°C can be a measure of how stable thermoplastic adhesive material is at elevated ambient temperatures. This value is particularly important if the absorbent product is used in a hot climate where the thermoplastic adhesive material loses its integrity if the storage modulus G' at 60 °C and 90 °C is not high enough.
[0033] G' can be measured using a rheometer as indicated in WO2010/27719. The rheometer is capable of applying a shear stress to the adhesive and measuring the resulting elongation response (shear strain) at a constant temperature. The adhesive is placed between a Peltier element, which acts as a lower fixed plate, and an upper plate with a radius R of, for example, 10 mm, which is connected to the drive shaft of a motor to generate the shear stress . The gap between both plates has a height H of, for example, 1500 microns. The Peltier element enables material temperature control (+0.5°C). The effort rate and frequency should be chosen so that all measurements are made in the linear viscoelastic region. Absorbent material deposition area 8
[0034] The absorbent core may comprise a deposition area of the absorbent material 8 defined by the periphery of the layer formed by the absorbent material 60 within the core shell, as seen from above when the absorbent core is arranged flat, as illustrated in the figure 3. The absorbent material 60 can be applied continuously or discontinuously in the absorbent material deposition area 8. If channels without absorbent material or junction areas between pockets or strips of the absorbent material are present, these are considered to be part of the absorbent material deposition area 8, for example, for the purpose of measuring the width or length L of the absorbent material deposition area.
[0035] The shape of the deposition area of the absorbent material 8 can vary, in particular it can be rectangular, as shown in Figure 3, or in a shape called "dog bone" or "hourglass", which presents a taper to the along its width, at least in the region between the thighs 81 of the absorbent material deposition area, as shown in Figure 6. When molded (non-rectangular), the absorbent material deposition area 8 may have a relatively narrow width in the region. between the thighs 81 of the core, as it can provide, for example, better wearing comfort in the finished article incorporating the core. The deposition area of the absorbent material 8 may thus have a width (as measured in the transverse direction perpendicular to the longitudinal axis 80') at its narrowest point which is less than about 100 mm, 90 mm, 80 mm, 70 mm, 60 mm or even less than about 50 mm. This narrower width may typically be in the region between the thighs and may additionally have, for example, a width at least 5 mm, at least 10 mm or at least 20 mm smaller than the maximum width of the material deposition area. absorbent 8 at its greatest point in the anterior region 82 and/or in the posterior region 83 of the absorbent core.
[0036] The basis weight (amount deposited per unit area) of the absorbent material may also vary along the deposition area of the absorbent material 8 to create a profiled distribution of the absorbent material in the longitudinal direction, in the transverse direction, or in both Core directions. Therefore, the basis weight of the absorbent material can vary along the longitudinal axis of the core 80', as well as along the transverse axis, or any axis parallel to any of these axes. The basis weight of the absorbent material in the relatively high basis weight area, such as the hook height, can thus be, for example, at least 10%, 20%, 30%, 40% or 50% greater in a relatively low basis weight area. In particular, the absorbent material present in the absorbent material deposition area 8 at the level of the hook height C may have more SAP per unit deposited area compared to any other area of the anterior region 82 or the posterior region 83 of the deposition area 8 . The basis weight of the SAPs may be equal to at least 10%, 20%, 30%, 40% or 50% greater at the height of the hook (C) of the core than elsewhere in the area of deposition of the absorbent material on the shaft longitudinally, in particular, in the anterior or posterior region of the nucleus.
[0037] The absorbent material 60 can be deposited using known techniques, which can allow relatively accurate deposition of SAP at a relatively high rate. In particular, SAP printing technology, as disclosed, for example, in US 2006/24433 (Blessing), US 2008/0312617 and US 2010/0051166A1 (both to Hundorf et al.) can be used. This technique uses a print cylinder to deposit SAPs onto a substrate disposed on a grid of a support which may include a plurality of crossbars extending substantially parallel and spaced apart from one another to form channels extending between a plurality of crossbars. This technology allows for accurate and high-speed deposition of SAP onto a substrate. The channels of the absorbent core can be formed, for example, by modifying the pattern of the grid and receiving cylinders so that no SAP is applied in the areas corresponding to the channels. EP application number 11169396.6, for example, discloses this modification in more detail. Super absorbent polymer (SAP)
[0038] "Superabsorbent polymers" ("SAP"), as used herein, refers to absorbent materials that are cross-linked polymeric materials that can absorb at least 10 times their weight of a 0.9% aqueous saline solution, such as measured using the Centrifugal Retention Capacity (CRC) test (EDANA Method WSP 241,2-05E). The SAPs of the invention may in particular have a CRC value of more than 20 g/g or more than 24 g/g or 20 to 50 g/g or 20 to 40 g/g or 24 to 30 g/g. SAPs useful in the present invention include a variety of water-insoluble but water-swellable polymers capable of absorbing large amounts of fluid.
[0039] The superabsorbent polymer may be in particulate form so as to be flowable when in a dry state. Typical particulate absorbent polymeric materials are made from poly(meth)acrylic acid polymers. However, for example, starch-based particulate absorbent polymeric material can also be used, as well as polyacrylamide copolymer, ethylene maleic anhydride copolymer, crosslinked carboxymethylcellulose, polyvinyl alcohol copolymers, crosslinked poly(ethylene oxide) and grafted polyacrylonitrile copolymer with starch. The superabsorbent polymer can be polymers of polyacrylates and polyacrylic acid, which are internally and/or surface crosslinked. Suitable materials are described in PCT patent application WO07/047598 or, for example, WO07/046052 or, for example, WO2009/155265 and WO2009/155264. In some embodiments, suitable superabsorbent polymer particles can be obtained by current and modern production processes, as is more particularly described in WO 2006/083584. The superabsorbent polymers are preferably internally crosslinked, i.e. the polymerization is carried out in the presence of compounds having two or more polymerizable groups which can be free radically copolymerized in the polymer network. Useful crosslinkers include, for example, ethylene glycol dimethacrylate, diethylene glycol diacrylate, allyl methacrylate, trimethylol propane triacrylate, triallylamine, tetraallyloxyethane as described in EP-A 530 438, di- and triacrylates as described in EP- A 547 847, EP-A 559 476, EP-A 632 068, WO 93/21237, WO 03/104299, WO 03/104300, WO 03/104301 and DE-A 103 31 450, mixed acrylates which as well as acrylate groups, additionally include ethylenically unsaturated groups as described in DE-A 103 31 456 and DE-A 103 55 401, or crosslinker mixtures as described, for example, in DE-A 195 43 368, DE-A 196 46 484 , WO 90/15830 and WO02/32962 as well as crosslinkers described in WO2009/155265. The superabsorbent polymer particles can be externally cross-linked at the surface, or: post-cross-linked). Useful post-crosslinkers include compounds including two or more groups capable of forming covalent bonds with the carboxylate groups of the polymers. Useful compounds include, for example, alkoxysilyl compounds, polyaziridines, polyamines, polyamidoamines, di or polyglycidyl compounds as described in EP-A 083 022, EP-A 543 303 and EP-A 937 736, polyhydric alcohols as described in DE -C 33 14 019, cyclic carbonates as described in DE-A 40 20 780, 2-oxazolidone and its derivatives, such as N-(2-hydroxyethyl)-2-oxazolidone, as described in DE-A 198 07 502, bis and poly-2-oxazolidones as described in DE-A 198 07 992, 2-oxotetrahydro-1,3-oxazine and its derivatives as described in DE-A 198 54 573, N-acyl-2-oxazolidones as described in DE-A 198 54 574, cyclic ureas as described in DE-A 102 04 937, bicyclic starch acetals as described in DE-A 103 34 584, oxetane and cyclic ureas as described in EP1199,327 and morpholine -2,3-dione and its derivatives as described in WO03/031482.
[0040] In some embodiments, SAPs are formed by polyacrylic acid polymers/polyacrylate polymers, for example, having a degree of neutralization of 60% to 90%, or about 75%, having, for example, sodium counterions .
The SAPs useful for the present invention can be of numerous formats. The term "particles" refers to granules, fibers, flakes, spheres, powders, platelets and other shapes and forms known to those skilled in the art of superabsorbent polymer particles. In some embodiments, the SAP particles can be in the form of fibers, i.e., elongated, acicular superabsorbent polymer particles. In such embodiments, the fibers of the superabsorbent polymer particles have a smaller dimension (i.e. fiber diameter) of less than about 1 mm, typically less than about 500 µm, and preferably less than 250 µm to 50 µm. The length of the fibers is preferably from about 3 mm to about 100 mm. The fibers can also be in the form of a long filament, which can be woven.
[0042] Typically, SAPs are sphere-like particles. In contrast to fibers, "sphere-like particles" have a longer and smaller dimension with a particle ratio of the longest to the shortest particle size in the range of 1 to 5, where a value of 1 would equate to a particle. perfectly spherical and 5 would allow a deflection of such a spherical particle. The superabsorbent polymer particles may have a particle size of less than 850 µm, or 50 to 850 µm, preferably 100 to 710 µm, more preferably 150 to 650 µm, as measured according to EDANA method WSP 220.2-05 . SAPs that have a relatively small particle size help to increase the surface area of the absorbent material that is in contact with the liquid exudates and therefore support the rapid absorption of liquid exudates.
[0043] SAPs can have particle sizes in the range of 45 µm to 4000 µm, more specifically a particle size distribution within the range of 45 µm to about 2000 µm or from about 100 µm to about 1000, 850 or 600 µm. The particle size distribution of a material in particulate form can be determined, as is known in the art, for example, by means of dry sieving analysis (EDANA 420.02 "Particle Size Distribution).
[0044] In some embodiments of the present invention, the superabsorbent material is in the form of particles with a mass average particle size of up to 2 mm or between 50 microns and 2 mm or up to 1 mm or preferably of 100 or 200 or 300 or 400 or 500 µm, or up to 1000 or up to 800 or up to 700 µm; as can, for example, be measured by the method set out, for example, in EP-A-0.691,133. In some embodiments of the invention, the superabsorbent polymer material is in the form of particles wherein at least 80% by weight are particles of a size between 50 µm and 1200 µm, and which have a mass average particle size between any of the above range combinations. Furthermore, or in another embodiment of the invention, said particles are essentially spherical. In yet another embodiment or further embodiment of the invention, the superabsorbent polymer material has a relatively narrow range of particle sizes, e.g., at least 80%, or preferably at least 90%, or even at least 95% by weight) of the particles having a particle size between 50 µm and 1000 µm, preferably between 100 µm and 800 µm, and more preferably between 200 µm and 600 µm.
[0045] Suitable SAPs can, for example, be obtained from reversed-phase suspension polymerizations as described in US 4,340,706 and US 5,849,816 or from spray or other gas phase dispersion polymerizations as described in the applications US Patent Nos. 2009/0192035, 2009/0258994 and 2010/0068520. In some embodiments, suitable SAPs can be obtained by the current state of the art production processes as is more particularly described from page 12, line 23 to page 20, line 27 of WO 2006/083584.
[0046] The surface of SAP can be coated, for example, with a cationic polymer. Preferred cationic polymers can include polyamine or polyimine materials. In some embodiments, SAPs can be coated with chitosan-based materials such as those disclosed in US 7,537,832. In some other embodiments, the SAPs may comprise mixed bed ion exchange absorbent polymers such as those disclosed in WO 99/34841 and WO 99/34842.
[0047] The absorbent core will typically comprise only one type of SAP, but it is not excluded that a blend of SAPs may be used. The fluid permeability of a superabsorbent polymer can be quantified using its Urine Permeability Measurement (UPM) value as measured in the test disclosed in European patent application disclosed under number EP12174117.7. The UPM of SAPs can, for example, be at least 10 x10-7 cm3s/g, or at least 30 x10-7 cm3.sec/g, or at least 50 x10-7 cm3.sec/g, or more, for example, at least 80 or 100 x10-7 cm3.sec/g. Flow characteristics can also be adjusted by varying the amount and distribution of SAPs used in the second absorbent layer.
[0048] For most absorbent articles, liquid discharge occurs predominantly in the front half of the article, in particular for diapers. The absorbent core can thereby be placed in the absorbent article so that the front half of the absorbent article comprises most of the absorbent capacity of the core. Thus, at least: 60%, 65%, 70%, 75% or 80% of the SAPs, by weight, can be present in the front half of the absorbent article, with the remaining SAPs being placed in the back half of the absorbent article. The region of the front half of the absorbent article may be defined as the region between the leading edge 10 of the absorbent article and the transverse axis 90 of the absorbent article. The transverse axis 90 is perpendicular to the longitudinal axis 80, and is placed at a distance of half the length of the article, as measured on the longitudinal axis of the article, from the leading or trailing edge of the article.
[0049] The total amount of SAP present in the absorbent core may also vary according to the expected user. Newborn diapers may require less PAS than baby or adult incontinence diapers. The amount of SAP in the core can be, for example, comprised from about 5 to 60 g, in particular from 5 to 50 g. The average basis weight of SAP within (or "at least one", if several are present) deposition area 8 of the SAPs can be, for example, at least 50, 100, 200, 300, 400, 500 or more g/m2. The areas of the channels present in the absorbent material deposition area 8 are deducted from the absorbent material deposition area to calculate this average basis weight. Shell for Core (16, 16’)
[0050] The core casing may be produced from a single substrate folded around the absorbent material, or may advantageously comprise two (or more) substrates, which are bonded together. Typical attachments are so-called C-shaped casings and/or sandwich casings. In a C-shaped casing, as exemplarily shown in Figures 2 and 4, the longitudinal and/or transverse edges of one of the substrates are folded over the other substrate to form flaps. These tabs are then bonded to the outer surface of the other substrate, typically by bonding.
[0051] The core shell may be formed of any materials suitable for receiving and containing the absorbent material. Typical substrate materials used in the production of conventional cores can be used, in particular paper, fabrics, films, woven or non-woven materials or laminates of any of them. The core shell may, in particular, be formed of a non-woven mat, such as carded non-woven, continuous-spun non-woven ("S") or meltblown non-woven ("M") and laminated from any of them. For example, spunmelt polypropylene nonwovens are suitable, in particular those having an SMS or SMMS or SSMMS laminated mat, structure, and having a basis weight range of about 5 g/m2 to 15 g/m2. Suitable materials are, for example, disclosed in US 7,744,576, US 2011/0268932A1, US 2011/0319848A1 or US 2011/0250413A1. Non-woven materials supplied from synthetic fibers can be used, such as PE, PET and in particular PP.
[0052] If the casing for core comprises a first substrate 16 and a second substrate 16', these can be produced from the same type of material or can be produced from different materials, or one of the substrates can be treated differently from the another to endow it with different properties. As polymers used for the production of nonwovens are inherently hydrophobic, they are preferably treated with hydrophilic coatings if placed on the fluid receiving side of the absorbent core. It is advantageous that the upper side of the core wrap, i.e. the side placed closest to the wearer on the absorbent article, is more hydrophilic than the underside of the core wrap. One possible way to produce nonwovens with permanently hydrophilic coatings is by applying a hydrophilic monomer and a radical polymerization initiator to the nonwoven and conducting an activated polymerization through UV light resulting in the monomer chemically bonded to the surface of the nonwoven. An alternative possible way to produce nonwovens with permanently hydrophilic coatings is to coat the nonwoven with hydrophilic nanoparticles, for example as described in WO 02/064877.
[0053] Permanently hydrophilic nonwovens are also useful in some modalities. Surface tension, as described in US 7744576 (Busam et al.), can be used to measure how permanently a hydrophilically certain level is achieved. Liquid leakage as described in US 7744576 can be used to measure the level of hydrophilic capacity. The first and/or the second substrate may, in particular, have a surface tension of at least 55, preferably at least 60 and most preferably at least 65 mN or greater when wetted with saline. The substrate may also have a liquid pour time of less than 5 s for a fifth jet of liquid. These values can be measured using the test methods described in document US 7,744,576B2: "Determination of surface tension" and "Leakage determination" respectively.
[0054] Hydrophilic capacity and wettability are typically defined in terms of contact angle and time for fluid penetration, for example through a non-woven material. This is discussed in detail in the American Chemical Society publication entitled "Contact angle, wettability and adhesion", edited by Robert F. Gould (copyright 1964). A substrate that has a lower contact angle between the water and the substrate surface can be said to be more hydrophilic than the other.
[0055] Substrates can also be permeable to air. Films useful in the present invention may therefore comprise micropores. The substrate may have, for example, an air permeability of 40 or 50, at 300 or at 200 m3/(m2x min), as determined by the EDANA method 140-1-99 (125 Pa, 38.3 cm2). The core shell material may alternatively have a lower air permeability, for example, being non-permeable to air, for example, to facilitate handling on a moving surface that comprises a vacuum.
[0056] In the present invention, the core wrap may be at least partially sealed along all sides of the absorbent core or otherwise such that substantially no absorbent material leaks from the core wrap when performing the test of WCACF indicated below. By "substantially no absorbent material" is meant that less than 5%, advantageously less than 2% or less than 1% or 0% by weight of the absorbent material escapes from the core shell. In particular, the core casing must not, in any significant way, burst during testing.
[0057] The term "seal" is to be understood in a broad sense. The seal need not be continuous along the entire periphery of the core shell, but may be discontinuous along part or all of it, such as formed by a series of closely spaced seal points in a line. Although the seal may be on the periphery of the core, it is not excluded that a seal may also be at other locations on the core, for example, near the longitudinal centerline 80’. Typically, a seal can be formed by gluing and/or heat welding.
[0058] If the core wrap is formed of two substrates 16, 16', a core edge seal can typically be used to enclose the absorbent material 60 in the core wrap. This is exemplified in Figures 4 and 5. As shown in Figure 4, for example, the first substrate 16 can be placed on one side of the core (the top side, as shown there) and extends around the longitudinal edges of the core until at least partially envelops the opposite (lower) side of the core. The second substrate 16' may be present between the wrapped flaps of the first substrate 16 and the core absorbent material 60. The flaps of the first substrate 16 can be glued to the second substrate 16' to provide a strong seal. This so-called C-shaped casing construction can provide benefits such as greater tear strength in a wet loaded state compared to a sandwich seal. The leading edge and trailing edge of the core wrap may then also be sealed, for example, by gluing the first substrate and second substrate flat to each other to provide a more complete wrapping of the absorbent material throughout the periphery of the core. It may be advantageous to use the C-shaped casing at least over the longitudinal edges of the core, which are longer than the front and end edges. In the so-called sandwich construction, the first and second substrates may also extend outwardly over all edges of the core and be flat-sealed along all or parts of the core periphery typically by gluing and/or heat/pressure bonding . Typically neither the first nor the second substrates need to be shaped so that they can be cut rectangularly for ease of production, but of course other shapes are possible.
[0059] The core shell can also be formed of a single substrate, which can enclose, as in a package shell, the absorbent material and be, for example, sealed along the leading edge and trailing edge of the core and a longitudinal seal. Channels 26, 26’
[0060] The absorbent core comprises at least one channel, which is at least partially oriented in the longitudinal direction of the core. Next, the plural form "channels" will be used to mean "at least one channel". Channels can be formed in a variety of ways. For example, the channels can be formed by zones within the area of deposition of the absorbent material, which can be substantially or completely free of absorbent material, in particular SAPs. Additionally or alternatively, the channel(s) may also be formed by continuous or discontinuous connection of the material forming the upper side of the core housing to the material forming the underside of the core housing through the deposition area of the core. absorbent material. Channels can be advantageously continuous, but without excluding that the channels are intermittent. The capture and delivery system, or any sublayer between the topsheet and the absorbent core, or another layer of the article, may also comprise channels, which may or may not correspond to the channels of the absorbent core. The channels can be, in particular, completely surrounded in the area of deposition of the absorbent material 8.
[0061] The channel or channels may, in particular, be present in the region between the thighs (81) of the core, in particular, at least at the same longitudinal level as the hook height C, as shown in Figure 3 by the two channels extending longitudinally 26, 26'. Some channels may also extend from the region between the thighs 81 into the posterior region 82 and/or the anterior region 83 of the nucleus, or they may be uniquely present in the anterior region and/or the posterior region of the nucleus, as shown in figure 6 by smaller channels 27, 27'.
[0062] The absorbent core 28 may also comprise more than two channels, for example at least 3, at least 4, at least 5 or at least 6. Shorter channels may also be present, for example in the posterior region or in the anterior region of the core, as represented by the pair of channels 27, 27' in Figure 6 towards the front of the core. The channels may comprise one or more pairs of channels symmetrically disposed with respect to the longitudinal axis 80'.
[0063] The channels can be particularly useful in the absorbent core when the deposition area of the absorbent material is rectangular, as the channels can optimize the flexibility of the core as there is less advantage in using a non-rectangular (shaped) core . Of course, channels can also be present in a SAP layer that has a shaped deposition area.
[0064] The channels may extend substantially longitudinally, which typically means that each channel extends more in the longitudinal direction than the transverse direction, and typically at least twice as much in the longitudinal direction as the transverse direction (such as measured after projection onto the respective axis). The channels may have a length L' projecting about the longitudinal axis 80' of the core, which corresponds to at least 10% of the length L of the deposition area of the absorbent material 8. It may be advantageous that at least some or all of the channels do not are completely or substantially completely transversely oriented channels in the core.
[0065] The channels can be completely oriented longitudinally and parallel to the longitudinal axis, but they can also be curved. In particular, some or all of the channels, in particular the channels present in the region between the thighs, can be concave towards the longitudinal axis 80', as is, for example, represented in figures 3 and 7 for the pair of channels 26 ,26'. The radius of curvature may typically be at least equal (and preferably at least 1.5 or at least 2.0 times that mean transverse dimension) to the mean transverse dimension of the absorbent material deposition area 8; and also straight, but under an angle of (eg 5°) to 30° or, for example, up to 20° or up to 10° with a line parallel to the longitudinal axis. The radius of curvature can be constant for a gutter, or it can vary along its length. This may also include channels having an angle therebetween, provided that said angle between two parts of a channel is at least 120°, preferably at least 150°; and, in any of these cases, as long as the longitudinal extension of the channel is greater than the transverse extension. The channels may also be branched, for example a central channel superimposed with the longitudinal axis in the region between the thighs which branches towards the back and/or towards the front of the article.
[0066] In some embodiments, there is no channel that coincides with the longitudinal axis 80’ of the core. When present as symmetrical pairs in relation to the longitudinal axis, the channels can be spaced in relation to each other along their entire longitudinal dimension. The smallest spacing distance can be, for example, equal to at least 5 mm, or at least 10 mm or at least 16 mm.
[0067] In addition, to reduce the risk of fluid leakage, the main longitudinal channels typically do not extend to any of the edges of the absorbent material deposition area 8, and are therefore completely surrounded in the material deposition area core absorbent. Typically, the shortest distance between a trough and the edge closest to the deposition area of the absorbent material is at least 5 mm.
[0068] The channels may have a width Wc along at least part of their length, which is equal to at least 2 mm, at least 3 mm or at least 4 mm, up to, for example, 20 mm, 16 mm or 12 mm. The width of the channel can be constant throughout substantially the entire channel, or it can vary along its length.
[0069] At least some or all of the gutters are advantageously permanent gutters, which means that their integrity is at least partially maintained in both the dry and wet state. Permanent channels can be obtained by providing one or more adhesive materials, for example, the fibrous layer of adhesive material or a construction glue that aids in the adhesion, for example, of a substrate with an absorbent material within the walls of the channel. The permanent channels may also be particularly formed by connecting the upper side and the lower side of the core shell (e.g., the first substrate 16 and the second substrate 16') to each other through the channels. Typically, an adhesive can be used to bond both sides of the core shell through the channels, but it is possible to bond through other known means, such as by pressure bonding, ultrasonic bonding or hot bonding, or combinations thereof. The core housing may be continuously connected, or intermittently connected, along the channels. The channels may advantageously remain or become visible through at least the topsheet and/or the backsheet when the absorbent article is fully loaded with a fluid, as disclosed in the Wet Channel Integrity Test below. This can be achieved by making the channels substantially free of SAP, so that they do not swell, and large enough so that they do not close when wet. Furthermore, the connection of the core shell to itself through the channels can be advantageous. The Wet Gutter Integrity Test described below can be used to test whether gutters are permanent and visible after wet saturation, and to what extent. Advantageously, a permanent channel according to the invention has an integrity percentage of at least: 20%, 30%, 40%, 50%, 60, 70%, 80% or 90%, according to the Integrity Test of Wet Channel described below. Top layer 24
[0070] The topsheet 24 is the part of the absorbent article that is directly in contact with the wearer's skin. Topsheet 24 may be joined to backsheet 25, core 28 and/or any other layers as is known in the art (as used herein, the term "joined" encompasses configurations by which an element is directly attached. to another element by affixing the element directly to another element, and configurations whereby an element is indirectly attached to another element by affixing the element to the intermediate member(s) which, in turn, are affixed to the other element). Generally, the topsheet 24 and the backsheet 25 are joined directly together at some locations (for example, on the periphery of the article or close to it), and are joined indirectly to each other at other locations through direct joining. to one or more elements of article 20.
[0071] The topsheet 24 is preferably pliable, soft to the touch and non-irritating to the wearer's skin. Additionally, at least a portion of the topsheet 24 is permeable to liquids, allowing liquids to rapidly penetrate through its thickness. A suitable topsheet can be manufactured from a wide range of materials such as porous foams, crosslinked foams, plastic films with apertures, or woven or non-woven materials made from natural fibers (eg wood or cotton fibers), synthetic filaments or fibers (eg bicomponent PE/PP or polyester or polypropylene fibers or mixtures thereof), or a combination of natural and synthetic fibres. If the topsheet 24 includes fibers, the fibers may be spunbond, carded, wetlaid, meltblown, hydroentangled, or otherwise processed as is known in the technique, in particular non-woven continuous spinning PP. A suitable topsheet comprising a batt of textile fiber length polypropylene fibers is produced by Veratec, Inc., a Division of the International Paper Company, of Walpole, MA under the designation P-8.
[0072] [092] Suitable formed film top layers are also described in US 3,929,135, US 4,324,246, US 4,342,314, US 4,463,045 and US 5,006,394. Other suitable topsheets can be produced in accordance with US 4,609,518 and 4,629,643 granted to Curro et al. Such formed films are available from The Procter & Gamble Company of Cincinnati, Ohio, as "DRI-WEAVE" and from Tredegar Corporation, based in Richmond, VA, as "CLIFF-T".
[0073] [093] Any portion of the topsheet may be coated with a lotion, as is known in the art. Examples of suitable lotions include those described in US 5,607,760, US 5,609,587, US 5,643,588, US 5,968,025 and US 6,716,441. The topsheet 24 may also include or be treated with antibacterial agents, some examples of which are disclosed in PCT publication WO95/24173. In addition, the topsheet, the backsheet or any portion of the top or bottom plies may be embossed and/or matte finished to provide a more fabric-like appearance.
[0074] The top layer 24 may comprise one or more openings to facilitate the penetration of exudates therethrough, such as urine and/or feces (solid, semi-solid or liquid). At least the size of the primary opening is important in achieving the desired waste encapsulation performance. If the primary opening is too small, debris may not pass through the opening, due to poor alignment of the debris source and the location of the opening, or due to fecal masses with a diameter larger than the opening. If the opening is too wide, the area of skin that can be contaminated by "soaking" from the article increases. Typically, the total area of openings in the surface of a diaper may have an area between about 10 cm2 and about 50 cm2, in particular between about 15 cm2 and 35 cm2. Examples of topsheet with apertures are disclosed in US 6632504, assigned to BBA NONWOVENS SIMPSONVILLE. WO2011/163582 also discloses a suitable colored topsheet which has a basis weight of 12 to 18 g/m2 and which comprises a plurality of bonded dots. Each of the attached stitches has a surface area of 2 mm2 to 5 mm2, and the accumulated surface area of the plurality of attached stitches is 10-25% of the total surface area of the topsheet.
Typical diaper topsheets have a basis weight of about 10 to about 28 g/m2, in particular between about 12 to about 18 g/m2, but other basis weights are possible. Bottom layer 25
[0076] The backsheet 25 is generally that portion of the absorbent article 20 that forms most of the outer surface of the article when worn by the user. The backsheet is positioned towards the underside of the absorbent core and prevents exudates absorbed and contained therein from soiling items such as sheets and underwear. The backsheet 25 is typically impervious to liquids (eg, urine). The backsheet may, for example, be or comprise a thin plastic film such as a thermoplastic film which has a thickness of from about 0.012 mm to about 0.051 mm. Exemplary bottom layer films include those manufactured by Tredegar Corporation, based in Richmond, VA, USA, and available under the tradename CPC2 Film. Other suitable backsheet materials can include breathable materials that allow vapors to escape from the diaper 20, while still preventing exudates from passing through the backsheet 25. Exemplary breathable materials can include materials such as fabric mats, mats. of non-woven, composite materials such as film-coated non-woven mats, microporous films as produced by Mitsui Toatsu Co., of Japan under the designation ESPOIR NO and by Tredegar Corporation of Richmond, VA, USA, and sold under the designation EXAIRE, and monolithic films such as those produced by Clopay Corporation, Cincinnati, OH, USA under the name HYTREL blend P18-3097. Some respirable composite materials are described in more detail in PCT Application No. WO 95/16746 published June 22, 1995 in the name of E.I. DuPont; US 5,938,648 to LaVon et al., US 4,681,793 to Linman et al., US 5,865,823 to Curro; and US 5,571,096 to Dobrin et al, US 6,946,585B2 to London Brown.
The backsheet 25 may be attached to the topsheet 24, the absorbent core 28 or any other element of the diaper 20 by any means of attachment known in the art. Suitable securing means are described above in connection with the means for joining the topsheet 24 to the other elements of the article 20. For example, the securing means may include a continuous uniform layer of adhesive, a shaped layer of adhesive or a matrix of separate lines, spirals or dots of adhesive. Suitable fastening means comprise an open pattern network of adhesive filaments as disclosed in US 4,573,986. Other suitable fastening means include several rows of adhesive filaments that are twisted into a spiral pattern, as illustrated by the apparatus and methods shown in US 3,911,173, US 4,785,996 and US 4,842,666. Adhesives found to be satisfactory are manufactured by the H.B. Fuller Company of St. Paul, Minnesota, USA, and are marketed under the designations HL-1620 and HL1358-XZP. Alternatively, the fastening means may comprise hot bonds, pressure bonds, ultrasonic bonds, dynamic mechanical joints or any other suitable fastening means, or combinations of such fastening means, as are known in the art.
[0078] The absorbent articles of the invention may comprise a capture layer 52, a distribution layer 54, or a combination of both (all collectively referred to herein as a capture and distribution system "ADS"). The function of ADS is typically to quickly capture fluid and efficiently distribute it to the absorbent core. The ADS can comprise one, two or more layers, which can form a unitary layer or which remain separate layers, which can be attached to each other. In the examples below, the ADS comprises two layers: a distribution layer 54 and a capture layer 52 disposed between the absorbent core and the top layer, but the invention is not restricted to that example.
[0079] Typically, the ADS will not comprise SAP, as it can decrease fluid capture and distribution. The prior art discloses many types of capture and delivery system, see for example WO2000/59430 (Daley), WO95/10996 (Richards), US 5,700,254 (McDowall) and WO 02/067809 (Graef). The ADS may comprise, although it is not necessary, two layers: a distribution layer 54 and a capture layer 52, which will now be exemplified in more detail. Distribution layer 54
[0080] The function of a distribution layer 54 is to spread the insulting fluid liquid over a larger surface within the article so that the absorbent capacity of the core can be used more efficiently. Typically, the distribution layer is produced from a non-woven material based on synthetic or cellulosic fibers, and with relatively low density. The density of the distribution layer may vary depending on the compaction of the article, but may typically range from 0.03 to 0.25 g/cm3, in particular from 0.05 to 0.15 g/cm3 measured at 2.07 KPa (0.30 psi). The distribution layer 54 may also be a material having a water retention value from 25 to 60, preferably from 30 to 45, measured as indicated in the procedure disclosed in US 5,137,537. The distribution layer may typically have an average basis weight of from 30 to 400 g/m2, in particular from 100 to 300 g/m2.
[0081] The distribution layer can, for example, comprise at least 50% by weight of crosslinked cellulose fibers. Crosslinked cellulosic fibers can be crimped, twisted or curled, or a combination thereof, which includes crimped, twisted and curled. This type of material has been used in the past in disposable diapers as part of a catch system, for example, in US 2008/0312622 A1 (Hundorf). Crosslinked cellulosic fibers provide greater resilience and therefore greater resistance to the first absorbent layer against compaction in the product packaging or under conditions of use, for example under the weight of the baby. This provides the core with increased void volume, permeability and liquid absorption and thus reduced leakage and optimized dryness.
Exemplary chemically crosslinked cellulosic fibers suitable for a distribution layer are disclosed in US 5,549,791, US 5,137,537, WO9534329 or US2007/118087. Exemplary crosslinking agents include polycarboxylic acids such as citric acid and/or polyacrylic acids such as acrylic acid and maleic acid copolymers. For example, the crosslinked cellulosic fibers can have between about 0.5 mol% and about 10.0 mol% of a C2-C9 polycarboxylic acid crosslinking agent, calculated on a molar basis of cellulose anhydroglucose, reacted with said fibers in an intrafiber ester crosslinked form. The C2-C9 polycarboxylic acid crosslinking agent can be selected from the group consisting of:- aliphatic and alicyclic C2-C9 polycarboxylic acids having at least three carboxyl groups per molecule; and - aliphatic and alicyclic C2-C9 polycarboxylic acids which have two carboxyl groups per molecule and which have a carbon-carbon double bond located alpha, beta to one or both of the carboxyl groups, wherein a carboxyl group in said crosslinking agent of C2-C9 polycarboxylic acid is separated from a second carboxyl group by two or three carbon atoms. The fibers may in particular have between about 1.5% by mol and about 6.0% by mol of crosslinking agent, calculated on a molar basis of cellulose anhydroglucose, reacted therewith as an ester crosslinked bond. intrafibers. The crosslinking agent can be selected from the group consisting of citric acid, 1, 2, 3, 4 tetracarboxylic acid butane and 1, 2, 3 tricarboxylic acid propane, in particular citric acid.
[0083] Polyacrylic acid crosslinking agents can also be selected from polyacrylic acid homopolymers, acrylic acid copolymers, and mixtures thereof. The fibers may have between 1.0% by weight and 10.0% by weight, preferably between 3% by weight and 7% by weight, of such crosslinking agents, calculated on a dry fiber weight basis. , reacted therewith in the form of intrafiber crosslinks. The crosslinking agent can be a polyacrylic acid polymer with a molecular weight of 500 to 40,000, preferably 1,000 to 20,000. The polymeric polyacrylic acid crosslinking agent may be a copolymer of acrylic acid and maleic acid, in particular wherein the weight ratio of acrylic acid to maleic acid is 10:1 to 1:1, preferably 5: 1 to 1.5:1. An effective amount of citric acid can be further mixed with said polymeric polyacrylic acid crosslinking agent.
[0084] The distribution layer comprising crosslinked cellulose fibers may comprise other fibers, but such layer may advantageously comprise at least 50%, 60%, 70%, 80% or 90%, or even up to 100%, by weight of the layer of crosslinked cellulose fibers (including crosslinking agents). Examples of such a layer of mixed crosslinked cellulose fibers may comprise about 70% by weight chemically crosslinked cellulose fibers, about 10% by weight polyester fibers (PET) and about 20% by weight weight, of untreated pulp fibres. In another example, the layer of crosslinked cellulose fibers may comprise about 70% by weight of chemically crosslinked cellulose fibers, about 20% by weight of lyocell fibers and about 10% by weight of PET fibers. In another example, the layer may comprise about 68% by weight of chemically crosslinked cellulose fibers, about 16% by weight of untreated pulp fibers and about 16% by weight of PET fibers. In another example, the layer of cross-linked cellulose fibers can comprise from about 90 to 100%, by weight, of chemically cross-linked cellulose fibers. capture layer 52
[0085] The absorbent article 20 may comprise a capture layer 52, the function of which is to quickly capture the fluid, removing it from the top layer, so as to provide good dryness for the user. Capture layer 52 is typically placed directly under the top layer. If present, the distribution layer can be at least partially placed under the capture layer. The capture layer may typically be or comprise a non-woven material, for example an SMS or SMMS material, which comprises a continuous spinning layer, a layer produced by extrusion in blocks with hot air flow at high speed ( meltblown) and an additional continuous spinning layer or, alternatively, a carded chemical bonded nonwoven. The non-woven material can, in particular, be consolidated with latex. Exemplary top capture layers 52 are disclosed in US7,786.341. Resin bonded and carded nonwovens can be used, in particular, when the fibers used are solid PET textile fibers rounded or rounded and hollow (50/50 or 40/60 blend of 6 denier and 9 denier fibers). An exemplary binder is a butadiene/styrene latex. Nonwovens have the advantage that they can be manufactured outside the converting line and stored and used as a material cylinder.
Additional useful nonwovens are described in U.S. Patent No. 6,645,569 to Cramer et al., U.S. Patent No. 6,863,933 to Cramer et al., U.S. Patent Application No. 7,112,621 to Rohrbaugh et al. , and copending patent applications U.S2003/148684 to Cramer et al. eUS2005/008839 by Cramer et al.
[0087] The capture layer 52 can be stabilized by a latex binder, for example a styrene-butadiene latex (SB latex) based binder. Processes for obtaining such screens are known, for example, from EP 149 880 (Kwok) and US 2003/0105190 (Diehl et al.). In certain embodiments, the binder can be present in capture layer 52 in excess of about 12%, about 14%, or about 16% by weight. SB latex is available under the trade name GENFLO™ 3160 (OMNOVA Solutions Inc.; Akron, Ohio, U.S.A.).
[0088] An additional capture layer can be used in addition to the first capture layer described above. For example, a fabric layer can be placed between the first capture layer and the distribution layer. The fabric may have improved capillary distribution properties compared to the capture layer described above. The fabric and first capture layer may be the same size, or may be different sizes, for example, the fabric layer may extend further into the back of the absorbent article than the first capture layer. An example of a hydrophilic fabric is a 13 to 15 g/m2 fabric with high moisture resistance, made from cellulose fibers obtained from the supplier Havix. Fixing system 42-44
[0089] The absorbent article may include a fastening system. The securing system can be used to provide lateral tensions around the circumference of the absorbent article to secure the absorbent article to the wearer. This fastening system is not required for the training diaper article as the waist region of these articles is already attached. The fastening system generally comprises a fastener such as ribbon tabs and hook and loop type fasteners, snap fasteners such as tabs, slots, buckles, buttons, snap fasteners and/or hermaphroditic fasteners, although any other means known in the art are generally acceptable. A contact zone is normally provided in the anterior waist region of the article so that the clasp is releasably secured. Some exemplary surface fastening systems are disclosed in US 3,848,594, US 4,662,875, US 4,846,815, US 4,894,060, US 4,946,527, US 5,151,092 and US 5,221,274 to Buell. An exemplary snap-on fastening system is disclosed in US Patent No. 6,432,098. The securing system may also provide a means of retaining the article in a discard configuration, as disclosed in US document No. 4,963,140, granted to Robertson et al.
[0090] [115] The fastening system may also include primary and secondary fastening systems as disclosed in US 4,699,622 to reduce displacement of overlapping portions or to improve fit as disclosed in US 5,242,436, US 5,499,978, US 5,507,736 and US 5,591,152. Fore and hind ears 46, 40
[0091] The absorbent article may comprise front ears 46 and hind ears 40, as is known in the art. The ears can be an integral part of the structure, for example formed from the top layer and/or the bottom layer as a side panel. Alternatively, as shown in Figure 1, they may be separate elements fixed by glue and/or hot embossing. Hind ears 40 are advantageously extensible to facilitate attachment of tabs 42 to contact zone 40 and to hold diapers with tapes in place around the wearer's waist. Hind ears 40 may also be elastic or extendable to provide a more comfortable and contoured fit, initially conformably fitting the absorbent article to the wearer and maintaining that fit over time of use, well after the absorbent article has been loaded with exudates, as the elasticized ears allow for contraction and expansion of the sides of the absorbent article. Barrier Leg Clamps 34 and Sealing Clamps 32
[0092] Absorbent articles, such as diapers or training diapers, may further typically comprise components that enhance the fit of the article around the user's legs, in particular, the clamps for the barrier legs 34 and the sealing clamps 32. The clamps for the barrier legs 32 may be formed of a piece of material, typically a non-woven, which is partially attached to the remainder of the article and which may be partially raised and thereby rise from the plane defined by the top layer when the article is pulled flat, as shown, for example, in Figures 1 to 2. Barrier leg clamps can provide improved containment of liquids and other body exudates approximately at the junction of the torso and legs. of user. Barrier leg clamps extend at least partially between the leading edge and trailing edge of the absorbent article on opposite sides of the longitudinal axis and are at least present at the level of the hook height (C).
[0093] The clamps for the barrier legs may be delimited by a proximal edge 64 joined to the rest of the article, typically the top layer and/or the lower layer, and a free end edge 66, which is intended to come into contact and form a seal with the user's skin. Barrier leg clamps 34 can be joined at the proximal edge 64 to the article frame by a bond 65 which can be made, for example, by gluing, fusion bonding or a combination of known bonding means. Bond 65 at proximal edge 64 can be continuous or intermittent.
The clamps for the barrier legs 32 may be integral with (i.e., formed from) the top layer or the bottom layer, or, more typically, be formed from a separate material joined to the remainder of the article. Typically, the material of the clamps for the barrier legs may extend through the entire length of the article, but is "adhesion bonded" to the top layer towards the leading edge and trailing edge of the article, so that in these sections , the barrier leg brace material remains level with the top layer. Each barrier leg brace 34 may comprise one, two or more elastic strands 35 proximate this free end edge 66 to provide a better seal.
[0095] In addition to the clamps for the barrier legs 34, the article may comprise sealing clamps 32, which are formed in the same plane as the structure of the absorbent article, and which, in particular, may be at least partially enclosed between the layer. upper and lower layer, and can be placed transversely outward to the barrier leg clamps. Sealing clamps can provide a better seal around the user's thighs. Generally, each leg clamp of the seal will comprise one or more elastic bands or elastic elements comprised in the diaper structure, for example, between the topsheet and the backsheet in the area of the leg openings.
[0096] US 3,860,003 describes a disposable diaper that provides a contractile opening for the legs that has a side flap and one or more elastic members to provide an elasticized leg clamp (a sealing clamp). Documents US 4,808,178 and US 4,909,803 granted to Aziz et al. describe disposable diapers with "upright" elasticized flaps (barrier leg clamps) that improve the confinement of the leg regions. Documents US 4,695,278 and US 4,795,454 to Lawson and Dragoo respectively describe disposable diapers having dual clamps, including sealing clamps and barrier leg clamps. All or a portion of the leg cuffs and/or barrier seal can be treated with a lotion. Elastic waist detail
[0097] The absorbent article may also comprise at least one elastic waist detail (not shown) that helps provide better fit and containment. The elastic waist detail is generally designed to elastically expand and contract to dynamically fit the wearer's waist. The elastic waist feature preferably extends at least longitudinally outwardly from at least one waist edge of the absorbent core 28 and generally forms at least a portion of the backside of the absorbent article. Disposable diapers can be constructed to have two elastic waist details, one positioned in the front waist region and one positioned in the back waist region. The elastic waist detail can be constructed in a number of different configurations, including those described in US 4,515,595, US 4,710,189, US 5,151,092 and US 5,221,274. Relationships between layers and components
[0098] Typically, adjacent layers will be joined using a conventional bonding method, such as adhesive coating via extrusion or spray coating, on all or part of the layer surface, or thermobonding, or pressure bonding, or combinations of the same. This connection is not shown in the figures (except for the connection 65 between the raised member of the leg clamps 34 and the top layer 24) for reasons of clarity and readability, but the connection between the layers of the article should be considered to be present, unless specifically excluded. Adhesives can typically be used to improve the adhesion of different layers, for example, between the backsheet and the core shell. The glue can be any standard hot melt glue as known in the art.
[0099] If a capture layer 52 is present, it may be advantageous for that capture layer to be larger or at least as large as the distribution layer 54 in longitudinal and/or transverse dimension. Thereby, the distribution layer 54 can be deposited onto the capture layer 52. This simplifies handling, particularly if the capture layer is a non-woven fabric that can be unrolled from a cylinder of stock material. The distribution layer may also be deposited directly onto the upper side of the absorbent core of the core wrap, or other layer of the article. Likewise, a capture layer 52 larger than the distribution layer allows you to directly glue the capture layer to the storage core (in the larger areas). This can provide greater article integrity and better net communication.
[00100] The absorbent core, and in particular its absorbent material deposition area 8, may advantageously be at least as large and long and advantageously be at least partially larger and/or longer than any of the layers in the ADS. This is because the absorbent material in the core can generally retain fluid more effectively and provide the benefits of drying over a larger area than ADS. The absorbent article may have a rectangular SAP layer and a non-rectangular (in terms of shape) ADS ADS. The absorbent article may also have a rectangular (unmoulded) ADS and a rectangular SAP layer. manufacturing method
[00101] The absorbent cores and articles of the invention can be produced by any conventional methods known in the art. In particular, articles can be produced by hand or industrially at high speed in a modern converting line. Experimental settings
[00102] The values indicated in the present invention are measured according to the methods indicated later in this document, unless otherwise specified. All measurements are performed at 21°C ± 2°C and 50% ± 20% relative humidity, unless otherwise specified. All specimens must be kept at least 24 hours in these conditions to equilibrate before testing, except where otherwise noted. All measurements must be reproduced on at least 4 samples, and the average value obtained indicated, except where otherwise indicated. Centrifugal Holding Capacity (CRC)
[00103] CRC measures the liquid absorbed by the superabsorbent polymer particles for free swelling in excess liquid. CRC is measured according to the EDANA WSP 241,2-05 method. Dry Absorbent Core Gauge Test
[00104] This test can be used to measure the caliper of the absorbent core (before use, ie without fluid loading) in a standardized manner.
[00105] Equipment: The measurement of the Mitutoyo hand caliper, with a resolution of 0.01 mm -- or an equivalent instrument.
[00106] Contact foot: Flat circular foot with a diameter of 17.0 mm (± 0.2 mm). A circular weight can be applied to the foot (ie, a weight with a slit to facilitate application around the instrument shaft) to obtain the target weight. The total weight of the foot and added weight (including axle) is selected to provide 2.07 KPa (0.30 psi) of pressure to the sample.
[00107] The caliper is mounted with the lower surface of the contact foot in a horizontal plane, so that the lower surface of the contact foot contacts the center of the flat horizontal upper surface of a baseplate, measuring approximately 20 x 25 cm. The gauge is set to zero reading with the contact foot on the base plate.
[00108] Ruler: Calibrated metal ruler graduated in mm.
[00109] Stopwatch: 1 second accuracy
[00110] Sample preparation: The core is conditioned for at least 24 hours as indicated above.
[00111] Measuring procedure: The core is arranged flat with the underside, i.e. the side which is to be placed towards the lower layer in the finished article facing downwards. The measuring point (eg hook height C) is carefully removed from the upper side of the core, taking care not to compress or deform the core.
[00112] The caliper contact foot is raised and the core is placed flat on the caliper base plate with the upper side of the core facing up, so that when lowered, the center of the foot is at the marked measurement point .
[00113] The foot is gently lowered onto the article and released (ensure calibration to "0" before starting the measurement). The caliper value is read to 0.01 mm accuracy 10 seconds after the foot is released.
[00114] The procedure is repeated for each measurement point. If there is a bend at the measurement point, it is performed in the area closest to that point, but without any bends. Ten articles are measured in this way for a given product, and the average gauge is calculated and reported with an accuracy of one-tenth of a mm. Absorbent article gauge test
[00115] The Absorbent Article Gauge Test can be performed as for the Dry Absorbent Core Gauge Test, with the difference that the gauge of the finished absorbent article is measured, rather than the gauge of the core. The measurement point can be the intersection of the longitudinal axis (80) and the transverse axis (90) of the absorbent article. If absorbent articles are provided folded and/or in a package, the articles to be measured are unfolded and/or removed from the central area of the package. If the package contains more than 4 articles, the outer two articles on each side of the package are not used in the test. If the pack contains more than 4 but less than 14 items, then more than one pack of items is required to complete the test. If the pack contains 14 or more items, then only one pack of items is needed to run the test. If the package contains 4 or fewer items, then all items in the package are measured, and multiple packages are needed to perform the measurement. Gauge readings should be taken 24 ± 1 hours after the article is removed from the packaging, unfolded and conditioned. The physical handling of the product must be minimal and restricted only to the preparation of the necessary sample.
[00116] Any elastic components of the article that prevent the article from being laid flat under the gauge foot are cut or removed. These may include leg braces or waist bands. Trouser-like items are opened or cut along the side seams as needed. Apply enough tension to even out any creases/wrinkles. Care must be taken to avoid touching and/or compacting the measurement area. Wet Channel Integrity Test
[00117] This test is designed to check the integrity of a groove in an absorbent core, after wet saturation.1. The total length (in millimeters) of the gutter is measured in the dry state (if the gutter is not straight, the curvilinear length through the middle of the gutter is measured).2. The absorbent core is then completely immersed in a large excess (eg 5 liters) of synthetic "saline" urine, with a concentration of 9.00 g of NaCl per 1,000 ml of solution prepared by dissolving the appropriate amount of sodium chloride in distilled water. The solution temperature should be 20 +/5 °C.3. After 1 minute in saline solution, the core is removed and held vertically at one end for 5 seconds to drain, then extended horizontally on a horizontal surface, with the upper side (the side intended to face the user in the article) facing up. If the core comprises extension elements, it is pulled to be adjusted so that no contraction is observed. The core can be fixed to a horizontal surface, by staples on its anterior edge and posterior edge, so that no contraction occurs.4. The absorbent core is covered with a suitably heavy rectangular rigid board, having the following dimensions: length equal to the total length of the core, and width equal to the maximum width of the core at the widest point.5. A pressure of 18.0 kPa is applied for 30 seconds over the area of the rigid plate mentioned above. Pressure is calculated based on the total area covered by the rigid plate. The pressure is achieved by placing additional weights at the geometric center of the rigid plate so that the combined weight of the rigid plate and additional weights results in a pressure of 18.0 kPa over the total area of the rigid plate. 6. After 30 seconds the additional weights and rigid plate are removed.7. Immediately thereafter, the cumulative length of the portions of the gutter that remained intact is measured (in millimeters; if the gutter is not straight, the curvilinear length through the middle of the gutter is measured). If no portion of the gutter has remained intact, then the gutter is not permanent.
[00118] The percentage integrity of the permanent gutter is calculated by dividing the cumulative length of the portions of the gutter that remained intact along the length of the gutter in the dry state, and then multiplying the quotient by 100. Wet Gauge and Compaction Force Test (WCACF)
[00119] This test measures a) the percentage increase in caliper of a saturated absorbent core after lateral compaction, and b) the force required to laterally compress the saturated absorbent core to a width of 40 mm. The WCACF test must be performed on an absorbent core, according to the instructions below.1. Mark the longitudinal axis on the absorbent core on the upper side of the core. The longitudinal axis generally divides the upper side of the core into two approximately symmetrical pieces along the length of the absorbent core when the core is viewed from the top, as shown illustratively in Figure 3. The upper side of the core is the side intended to be placed towards the user-facing side of the absorbent article. When in doubt, the upper side is usually more hydrophilic than the underside. If the upper side still cannot be identified, the test must then be performed on an equal number of colors on alternate sides, and the results are weighted. Marking can be done with any pen, and care must be taken not to damage the core when marking.2. Mark the line between the legs on the same side of the absorbent core as the longitudinal centerline. The line between the legs is perpendicular to the longitudinal axis and crosses the longitudinal axis at a distance equal to 45% of the length L of the absorbent core (0.45 L). This distance is measured from the front side of the absorbent core (see figure 3 for an exemplary illustration). The front side of the absorbent core is the side of the core intended to be placed towards the front of the absorbent article. If the intended orientation of the core is not known, the leading edge is on the side of the core where the amount of SAP is greatest. If the leading edge still cannot be identified, then half of the samples can be tested with a distance starting on one side, and the other half with a distance starting on the other side, and the results are weighted. The intersection of the line between the legs and the longitudinal axis is the hook height C.3. The absorbent core is then immersed in a large excess of, for example, 5 liters of synthetic urine "saline solution" with a concentration of 9.00 g of NaCl per 1,000 ml of solution, prepared by dissolving the appropriate amount. of sodium chloride in distilled water. The container must be large enough to accommodate the core in a flat configuration. The marked side of the core faces up during immersion.4. After 1 minute in saline solution, the absorbent core is removed and held vertically from the front side for 10 seconds to drain.5. The absorbent core is allowed to equilibrate for 10 minutes by pulling it flat on a horizontal surface, with the upper side facing downwards. Clamps placed on the anterior and posterior sides of the core can be used to keep the loaded core flat.6. The gauge of the loaded absorbent core prior to compaction is then measured at hook height and reported as Initial. For this purpose, a shoe with a diameter of 17.0 mm is used, and a pressure of 2.07 KPa (0.30 psi) is applied. The absorbent core is laid flat on a Plexiglass plate, with the marked side facing up, and the shoe is gently lowered so that it can be centered at hook height C. The Cinitial thickness is measured 30 ± 2 seconds after initial contact between the foot and the core, and is reported with an accuracy of 0.1 mm.7. The loaded absorbent core with its upper side facing upwards is then fixed onto a rigid plastic cylinder as schematically shown in Figure 7. The cylinder 600 has a diameter d equal to 150 mm (+-1 mm). The last 20.0 mm (+- 0.5 mm) of the leading edge 280 of the core 28 are first attached to the outer surface of the cylinder closest to the operator, by means of a double-sided tape previously applied over the cylinder or other means so that the absorbent core can be fixedly and releasably secured to the cylinder. The last 20.0 mm (+-0.5 mm) of the trailing edge 282 of the core 28 is then secured to the diametrically opposite outer surface of the cylinder at a height sufficient for the hook height C to coincide with the central axis 610 of the cylinder 600.8. It is understood that the cylinder needs to be high enough so that the trailing edge of the core can be attached to it.9. The absorbent core is then laterally compacted as detailed below. Compaction forces are applied to the absorbent core by an array comprised of a pair of compaction plates 630, 640, which stimulate the portion of the legs that compress the absorbent core during use. Each compaction plate must have dimensions of 90 mm (+- 1 mm) x 90 mm (+- 1 mm). The boards can be produced from any suitable material that can be formed into the required horizontal and square shape (eg aluminium, Plexiglass). The boards must be placed oppositely aligned with each other. Compaction plates are placed so that the line between the legs on the upper side of the core and the geometric center of each compaction plate are aligned and in a horizontal plane. 10. Each compaction plate is driven towards the hook height at a constant rate of 100 mm/min (the total closing speed equals 200 mm/min). The gap between both compaction plates starts at a distance of 140.0 mm +- 0.5 mm or more, if core width requires, and then narrows to a final gap of 40.0 mm +- 0.5 mm when the absorbent core is compacted. Compaction plates can, for example, use an apparatus such as a Zwick Z 1.0 or similar. The test instrument includes a right clamp for clamping one compaction plate and a left clamp for clamping another compaction plate. The equipment shall include a power cell with a suitable measuring range, eg up to 100 N, and an accuracy of at least +/- 0.01N.11. After the absorbent core has been compacted to 40 mm, compaction is maintained for 30 seconds. The force at the end of the 30 seconds immediately before the compression is released is recorded with a resolution of 0.01 N and reported as the "Wet Compression Force". The compaction plates can then return to their initial positions at a speed of 100 mm/min for each plate.12. Immediately thereafter, the absorbent core is removed from cylinder 600, taking care not to touch the area that has been compacted. If any absorbent material has leaked from the core wrap during the compaction step, that leaked absorbent material is collected and weighed. 13. The gauge at hook height C is measured again using the thickness measurement procedure as described above in step 6. This gauge value is reported as the final C.
[00120] This procedure is repeated for at least 4 core samples. The Relative Wet Gauge Increase (RWCI) of the absorbent core is then calculated as follows: Relative Wet Gauge Increase (%) = (∑Cfinal - ∑Cinitial)*100/ ∑Cfinal where ∑Cfinal is the sum of the Cend values measured for all samples, and ∑Start is the sum of the Cend values measured for all samples. The value of the Relative Wet Gauge Increase of the cores, according to the invention, is less than 10.0%, in particular, it is in the range of 1.0% to 9.5%, or from 2.0% to 9.0%, or from 2.5% to 8.0%.
[00121] If some amount of absorbent material has leaked out in step 12, the remainder of the absorbent material still contained in the core can be extracted and likewise weighed. If the amount leaked represents less than 5% by weight of the total absorbent material from the core (cast and extracted) then "substantially no absorbent material" is considered to have leaked out during the test. Advantageously, less than 2% or less than 1%, or even 0%, by weight of the absorbent material escapes from the core wrap during step 12. In particular, the core wrap should not, in any significant way, burst during the test.Experimentals
[00122] The following absorbent core, according to the invention, was prepared: Example of the invention 1:
[00123] The absorbent cores tested in this example were similar to the core illustrated in figure 3. The cores contained SAP as absorbent material, without cellulosic fibers. The core shell comprised two substrates forming the upper and lower sides of the core, the upper substrate forming a C-shaped shell along the longitudinal edges of the core, and the front and rear edges of the core being flatly attached. The core comprised two channels free of absorbent material in the region between the thighs. The channels that were symmetrical about the longitudinal axis 80 had a projected length of about 227 mm, a width of about 8 mm and a shorter distance between them of 20 mm. The core casing was further secured thereto through the channels.
[00124] The absorbent core comprised, in total, 14.1 g of fast-absorbing SAP applied in a deposition area with a length of 360 mm and a width of 110 mm (rectangular profile). The PAS were distributed so that the weight base of the PAS was greater in the region between the thighs than in the anterior region, and even smaller towards the posterior region. There was no SAP profile in the transverse direction ("cross-machine direction" or "DT", except for the channels that were free of absorbent material). The absorbent core was formed by SAP printing technology, as revealed in document US2010/0051166A1, which combines two non-woven substrates, each of which supports a layer of SAP and with an elastic microfiber glue applied to each layer of SAP , which immobilizes the SAP layer on the substrate. The runners were formed by the use of a suitable printing drum which limits the shape of the runners, further information on how to form runners can be found in EP order number EP12174117.7 using stamped SAP technology.
[00125] Auxiliary glue was applied between the SAP layer and the upper substrate 16, and was slit applied with 41 1 mm wide slits, with a distance of 1 mm between the slits, along the entire length of the casing for core (390 mm). 0.211 g and 0.168 g of the microfiber glue (from H.B. Fuller) were respectively applied to the upper and lower SAP layer, the application area having a width of 110 mm and a length of 390 mm, in each SAP layer.
The core shell had a length of 390 mm with two free end flaps of absorbent material, with a length of 15 mm on the back and front edge of the absorbent core. The core front and rear end seals were joined by slit glue, the glue slits having a length of 30 mm from the front end seal and 20 mm from the tail end seal. The folded width of the core shell was 120 mm.
The upper substrate 16 was a 10 g/m2 hydrophilically treated SMMS nonwoven, and the lower substrate 16' was a 10 g/m2 SMMS nonwoven. The upper substrate was cut to a length of 390 mm, and a cut width of 165 mm. The lower substrate had a cut length of 390 mm, and a cut width of 130 mm. The top substrate was wrapped in a C-shape around the bottom substrate, over the side edges of the core, and the side edges of the bottom layer were formed slightly upward over the edge of the core absorbent material, so that the full width of the core folded core casing was equal to about 120 mm. The C-shaped casing was made permanent by applying between the substrates a core bending glue applied at 20 g/m2 with 2 slits with a slit width of 3 mm and 390 mm in length on each side of the core.
[00128] The two substrates were additionally joined through the channels. The bond was formed by applying pressure and microfiber and auxiliary glue. The connection was strong. The core wrap seals resisted compression and no absorbent material escaped the core wrap during WCACF testing.Example of the Invention 2
[00129] The cores tested in this example had two pairs of channels and a molded deposition area similar to that shown in figure 6. The width of the deposition area of the absorbent material was 110 mm in the anterior and posterior regions, and 90 mm in the hook height of the absorbent deposition area.
[00130] The projected lengths of the long and short flutes on the longitudinal axis of the core were about 170 mm and 40 mm, respectively. The shortest distance between the longest channels was about 16 mm. The shortest distance between the shortest channels was about 14 mm. The cores comprised 11.53 g of SAP. The core shell comprised two nonwovens, the upper substrate (16) was a 10 g/m2 SMMS nonwoven treated with a surfactant to be hydrophilic. The bottom substrate (16') was an 11 g/m2 SMMS nonwoven SMMS. Auxiliary glue was applied between the lower SAP layer and its respective lower substrate, which coated the slits, 41 1 mm wide slits, with a distance of 1 mm between the slits, along the entire length of the core shell ( 390 mm). Microfiber glue (from HB Fuller) applied on each layer of SAP was uniformly applied with a width of 108 mm and length of 390 mm on each layer of SAP, 0.211g of the microfiber glue was used on the cover side of the core and 0.211 g on the side of the spray layer. The remainder of the core construction was substantially similar to the cores in Invention Example 1. Comparative Example
[00131] Comparative Example 1 was substantially similar to Invention Example 2, with the difference that the absorbent core did not comprise the channels without material. Test results
[00132] Four samples of each of the products mentioned above were tested according to the WCACF test described above, to measure the Relative Wet Gain Gain and Wet Compaction Force of the core. The weighted results are compiled below:
Discussion
[00133] Without being bound by theory, it is believed that the following features can provide, alone or in combination, an increase in relative wet gauge relative to an absorbent core without one or more of the features below. None of these features should be considered to be limited to the scope of the claims, unless specifically claimed. 1) The upper side of the wrapper, and the underside of the wrapper, can advantageously be at least partially connected together through the channels. Such connections can be continuous or intermittent, and can be made by gluing and/or hot bonding, and can advantageously be strong enough to at least partially resist delamination after fluid loading ("permanent channels"), as discussed above. By pressing the core wrap into the grooves, these connections increase the stretch of the core wrap and can decrease the wet gauge increase after core loading. 2) The core wrap may comprise a first (16) and a second substrate substrate (16'), both typically produced from a non-woven fabric, wherein the first substrate forms a C-shaped casing around the second substrate. The first substrate may form the upper side of the core shell, and the second substrate may form at least part of the underside of the core shell. Typically, the substrates can be bonded, for example, by glueing, along the wrapped flaps of the first substrate, along with the underside of the second substrate. The inventors believe that a C-shaped casing, specifically along part or all of the longitudinal sides of the absorbent core, can better prevent the absorbent material from breaking relative to the core after compaction.3) The Compaction Force a Wet is influenced by the amount of absorbent material and the shape of the core deposition area in the region between the thighs. It is believed that a smaller amount of absorbent material and/or a narrower deposition area in the region between the core thighs (as in a shaped area) can provide a lower Wet Compaction Force. The absorbent core of the invention may, by way of example, have a Wet Compaction Strength below 5.00N, in particular less than 3.00N, or from 1.00N to 5.00N, as measured by WCACF test.
[00134] The dimensions and values presented in the present invention are not to be understood as being strictly limited to the exact numerical values mentioned. Instead, except where otherwise specified, each of these dimensions is intended to mean both the stated value and a range of functionally equivalent values around that value. For example, a dimension displayed as "40 mm" is intended to mean "about 40 mm".
权利要求:
Claims (14)
[0001]
1. Absorbent core (28) suitable for use in an absorbent article (20), wherein the absorbent core comprises a core shell (16, 16') surrounding an absorbent material (60), wherein the absorbent material comprises at least 80% superabsorbent polymer ("SAP") by weight of the absorbent material, wherein the absorbent core (28) comprises a leading edge (280), a trailing edge (282), two longitudinal edges (284, 286), a region front, a posterior region and a region between the thighs in which the absorbent core (28) has a longitudinal axis (80') oriented in a longitudinal direction, and a length L as measured between the front edge and the posterior edge along the axis. lengthwise which is at least 320 mm, the absorbent core further comprising a first absorbent layer and a second absorbent layer, wherein the first absorbent layer comprises a first substrate (16) and a first layer of superabsorbent polymers (61) the second layer The absorbent comprises a second substrate (16') and a second layer of superabsorbent polymers (62), and the absorbent core further comprises a fibrous thermoplastic adhesive material (51) between the first absorbent layer and the second absorbent layer, in particular wherein the fibrous thermoplastic adhesive material (51) contributes, at least partially, to the bonding of each layer of superabsorbent polymer (61, 62) to its respective substrate (16, 16'), and wherein the first substrate and second substrate form the shell for core (16, 16') wherein the absorbent core comprises at least one pair of channels (26, 26') symmetrically arranged relative to the longitudinal axis of the core, characterized by the fact that none of the channels is known with the longitudinal axis, in which the channels have a length L' projected on the longitudinal axis of the core (80') which is at least 10% of the length L of the absorbent core, where the channels are free of absorbent material. vent, and preferably wherein the width of a portion of the channels (Wc) is equal to at least 2 mm, wherein the channels are formed by joining the first substrate directly to the second substrate, wherein the channels are disposed at least at the same longitudinal level as a point between the thighs C, where the point between the thighs is the point located at a distance of 45% of the length L from the anterior edge of the absorbent core, and where the channels extend from the region between the thighs to the posterior region, where the absorbent core has a Relative Wet Size Increase (RWCI) after compaction of less than 10.0%, where the core shell (16, 16') is at least partially sealed along the core edges.
[0002]
2. Absorbent core, according to claim 1, characterized in that the core has a Wet Compaction Strength (WCF) of less than 5.00 N.
[0003]
3. Absorbent core, according to claim 2, characterized in that the Wet Compaction Force (WCF) is from 1.00 to 3.00 N.
[0004]
4. Absorbent core according to claim 1, characterized in that the first substrate comprises a first non-woven (16) and the second substrate comprises a second non-woven (16'), and wherein the first non-woven forms a C-shaped wrap around the second nonwoven.
[0005]
5. Absorbent core according to claim 1, characterized in that the absorbent material (60) defines an absorbent material deposition area (8) within the core shell, and wherein the absorbent material deposition area (8) is rectangular or shaped with a width that has a minimum in the region between the thighs (81) of the absorbent core, wherein the region between the thighs is the region of the core that extends from the point between the thighs C towards the trailing edge and the leading edge of the absorbent core for a distance of one-quarter of an L (L/4) in both directions, toward the trailing edge and toward the leading edge.
[0006]
6. Absorbent core according to claim 5, characterized in that the basis weight of the superabsorbent polymer is not homogeneously distributed along the longitudinal axis of the core within the material deposition area, and wherein the basis weight of the superabsorbent polymer is at least 10% greater at the height of the point between the core thighs than elsewhere in the absorbent material deposition area about the longitudinal axis
[0007]
7. Absorbent core, according to claim 1, characterized in that the absorbent material (60) comprises at least 90% of the superabsorbent polymers, in total weight of the absorbent material.
[0008]
8. Absorbent core according to claim 1, characterized in that the absorbent material (60) comprises less than 10% natural or synthetic fibers, by total weight of the absorbent material.
[0009]
9. Absorbent core, according to claim 8, characterized in that the absorbent material is free of natural or synthetic fibers.
[0010]
10. Absorbent core, according to claim 1, characterized in that it comprises from 5 g to 60 g of superabsorbent polymers.
[0011]
11. Absorbent core, according to claim 10, characterized in that it comprises from 10 g to 50 g of superabsorbent polymers.
[0012]
12. Absorbent core, according to claim 1, characterized in that the core gauge, measured at the point between the thighs, is from 0.25 mm to 5.0 mm.
[0013]
13. Absorbent core, according to claim 12, characterized in that the core gauge, measured at the point between the thighs, is from 0.5 mm to 3.0 mm.
[0014]
14. Absorbent article (20), characterized in that it comprises a liquid-permeable topsheet, a liquid-impervious backsheet, and an absorbent core disposed between the topsheet and the backsheet; wherein the absorbent core comprises the absorbent core as defined in claim 1.
类似技术:
公开号 | 公开日 | 专利标题
BR112015013519B1|2021-07-27|ABSORBENT CORE WITH HIGH CONTENT OF SUPERABSORBENT MATERIAL
JP6416303B2|2018-10-31|Absorbent articles with high absorbent material content
US10786402B2|2020-09-29|Absorbent article with profiled acquisition-distribution system
BR112015013467B1|2021-08-03|ABSORBENT ARTICLE WITH HIGHLY ABSORBENT MATERIAL
US10071002B2|2018-09-11|Absorbent article and absorbent core forming channels when wet
ES2838027T3|2021-07-01|Absorbent article with improved core
US11273086B2|2022-03-15|Absorbent article and absorbent core forming channels when wet
BR112015013461B1|2021-09-28|ABSORBENT ITEMS WITH CHANNELS
BR112016014185B1|2022-01-11|ABSORBENT ARTICLE
同族专利:
公开号 | 公开日
MX2015006849A|2015-09-16|
DE202013012614U1|2017-12-06|
CN107496080A|2017-12-22|
BR112015013519A2|2017-07-11|
CA2894669A1|2014-06-19|
CA2894669C|2019-02-26|
US20140163502A1|2014-06-12|
RU2015120712A|2017-01-16|
JP6129986B2|2017-05-17|
WO2014093311A1|2014-06-19|
CL2015001585A1|2015-10-02|
CN104837454B|2017-12-08|
GB2522596A|2015-07-29|
CN107496080B|2020-12-04|
EP2740450A1|2014-06-11|
DE112013005898T5|2015-10-22|
GB201509856D0|2015-07-22|
CN104837454A|2015-08-12|
US20190336360A1|2019-11-07|
DE202013012616U1|2017-12-06|
DE202013012617U1|2017-12-08|
US9713556B2|2017-07-25|
RU2630891C2|2017-09-13|
JP2015536229A|2015-12-21|
US20170281426A1|2017-10-05|
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法律状态:
2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
2019-11-12| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
2021-05-11| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
2021-07-27| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 10/12/2013, OBSERVADAS AS CONDICOES LEGAIS. |
优先权:
申请号 | 申请日 | 专利标题
EP12196343.3A|EP2740450A1|2012-12-10|2012-12-10|Absorbent core with high superabsorbent material content|
EP12196343.3|2012-12-10|
PCT/US2013/074068|WO2014093311A1|2012-12-10|2013-12-10|Absorbent core with high superabsorbent material content|
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