FORMATTED NON WOVEN

专利摘要:
a non-woven fabric. the nonwoven fabric may include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surfaces. each of the three-dimensional resources can define a microzone comprising a first region and a second region. the first and second regions may have a difference in values for an intensive property, and, in at least one of the microzones, the first region is hydrophobic and the second region is hydrophilic.
公开号:BR112019015906A2
申请号:R112019015906-1
申请日:2018-01-25
公开日:2020-03-24
发明作者:Ashraf Arman；Thomas Weisman Paul；Grenier Adrien；Ian James Martin；Michele Sinigaglia Stefano
申请人:The Procter & Gamble Company；
IPC主号:

专利说明:

TECHNICAL FIELD FORMATTED NON-WOVEN [0001] This invention relates to formatted three-dimensional non-woven fabrics and articles made with formatted three-dimensional non-woven fabrics.
BACKGROUND OF THE INVENTION [0002] Nonwoven fabrics are useful for a wide variety of applications, including absorbent personal care products, garments, medical applications and cleaning applications. Non-woven personal care products include child care items like diapers, child care items like training diapers, female care items like sanitary napkins and adult care items like pants, sanitary napkins and incontinence products. Non-woven garments include protective work clothing and medical clothing, such as surgical coats. Other medical non-woven applications include non-woven wound bandages and surgical bandages. Applications for cleaning nonwovens include towels and handkerchiefs. In addition to these, there are other well-known uses of nonwoven fabrics. The above list is not considered to be exhaustive.
[0003] Various properties of non-woven fabrics determine the suitability of non-woven fabrics for different applications. Nonwoven fabrics can be manipulated to have different combinations of properties to suit different needs. Variable properties of nonwoven fabrics include
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2/173 properties related to liquids such as wettability, distribution and absorbency, properties related to resistance such as tensile strength and tear strength, softness properties, durability properties such as abrasion resistance and aesthetic properties. The physical shape of a nonwoven fabric also affects the functionality and aesthetic properties of the nonwoven fabric. Non-woven fabrics are initially made of sheets and, when resting on a flat surface, may have a substantially flat uninterrupted surface or may have an array of surface features such as openings, projections, or both. Non-woven fabrics with openings or projections are commonly called three-dimensional non-woven formatted fabrics. The present disclosure relates to three-dimensional nonwoven formatted fabrics.
[0004] Despite pre-existing advances in the technique of nonwoven fabrics, there is a need for improved nonwoven fabrics with three-dimensional surface features.
[0005] Additionally, there is a need for processes and equipment for manufacturing improved non-woven fabrics with three-dimensional surface features.
[0006] Additionally, there is a need for articles, including absorbent articles, that use non-woven fabrics
improved fabrics with resources in surface three-dimensional.[0007] Additionally, exists a necessity by articles
absorbents using non-woven fabrics with
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3/173 three-dimensional surfaces and that can be packed in a compressed manner with minimization of the loss of three-dimensional surface resources when removed from the packaging.
[0008] Additionally, there is a need for absorbent articles of non-woven fabrics of continuous spinning with three-dimensional surface features that have reduced properties of fluff formation when in use.
[0009] Additionally, there is still a need for improved nonwoven fabrics that have three-dimensional surface features and physical integrity, combined with softness as measured by a fabric softness analyzer marketed by Emtec Electronic GmbH.
[0010] Additionally, there is still a need for improved non-woven fabrics that have three-dimensional surface features with microzones and physical integrity, combined with at least one region of the microzones being hydrophobic and a different region of the same microzone being hydrophilic.
[0011] Additionally, there is a need for packs of absorbent articles that comprise soft non-woven materials with a reduced stacking height inside the bag compared to conventional packs of absorbent articles, so that the packs are convenient for handling and storing caregivers and so that manufacturers enjoy low distribution costs without losing aesthetic clarity, absorbency or softness of the absorbent article in the state in which it was produced.
SUMMARY OF THE INVENTION
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4/173 [0012] A non-woven fabric is revealed. The non-woven fabric may include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surfaces. Each of the three-dimensional features can define a microzone that comprises a first region and a second region. The first and second regions may have a difference in values for an intensive property, with the intensive property being one or more of thickness, weight or volumetric density, and in at least one of the microzones, the first region is hydrophobic and the second region is hydrophilic.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A Figure 1 is an photography in one example gives gift[0014] A revelation.Figure 2 is an photography in one example gives gift[0015] A revelation.Figure 3 is an photography in one example gives gift[0016] A revelation.Figure 4 is an section transversal in an portion of one
fabric of the present disclosure as shown in Figure 1.
[0017] Figure 5A it is a drawing schematic that illustrates The section transversal in one filament produced with one primary component A and one component secondary B in one arranged side by side. [0018] Figure 5B it is a drawing schematic that illustrates The section transversal in one filament produced with one
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5/173 primary component A and secondary component B in an eccentric sheath / core arrangement.
[0019] Figure 5C is a schematic drawing showing the cross section of a filament produced with a primary component A and a secondary component B in a concentric sheath / core arrangement.
[0020] Figure 6 is a photograph of a perspective view of a bicomponent trilobal fiber.
[0021] Figure 7 is a schematic representation of an apparatus for producing a fabric of the present disclosure.
[0022] Figure 8 is a detail of a portion of the apparatus for joining a portion of a fabric of the present disclosure.
[0023] Figure 9 is an additional detail of a portion of the apparatus for joining a portion of a fabric of the present disclosure.
[0024] Figure 10 is a detail of a portion of the apparatus for optional additional attachment of a portion of a fabric of the present disclosure.
[0025] Figure 11 is a photograph of an example of the present disclosure.
[0026] Figure 12 is a photograph of a portion of a training mat useful for the present disclosure.
[0027] Figure 13 is a cross-section of a portion of the training mat shown in Figure 12.
[0028] Figure 14 is an image of a portion of a mask used to make the training mat shown in Figure 12.
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6/173 [0029] Figure 15 is an image of a portion of a mask used to make the training mat shown in Figure 16.
[0030] Figure 16 is a photograph of a portion of a training mat useful for the present disclosure.
[0031] Figure 17 is an image of a portion of a mask used to make the training mat shown in Figure 18.
[0032] Figure 18 is a photograph of a portion of a training mat useful for the present disclosure.
[0033] Figure 19 is a photograph of a portion of a training mat useful for the present disclosure.
[0034] Figure 20 is an image of a mask used to make the training mat shown in Figure 19.
[0035] Figure 21 is a photograph of a fabric from the present disclosure produced on the formation mat shown in Figure 19.
[0036] Figure 22 is a schematic perspective view of a mat forming the present disclosure.
[0037] Figure 23 is a plan view of a nonwoven substrate including non-woven fabrics of the present disclosure.
[0038] Figure 24 is a plan view of a non-woven substrate including the non-woven fabrics of the present disclosure.
[0039] Figure 25A is a plan view of a fabric of the present disclosure with portions removed for measurement of local weight.
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7/173 [0040] Figure 25B is a plan view of a fabric of the present disclosure with portions removed for measurement of local weight.
[0041] Figure 26 is a graphical representation of crosswise directional variation of weight in a fabric of the present disclosure.
[0042] Figure 27 is a schematic view of a package of the present disclosure.
[0043] Figure 28 is a plan view of an article absorber of the present disclosure.[0044] Figure 29 is a plan view of an article absorbent of this revelation[0045] Figure 30 is a section view transversal Section 29-29 of Figure 28.[0046] Figure 31 is a plan view of an article absorber of the present disclosure.[0047] Figure 32 is a section view transversal Section 32-32 of Figure 31.[0048] Figure 33 is a plan view of an article absorber of the present disclosure.[0049] Figure 34 is a section view transversal Section 34-34 of Figure 33.[0050] Figure 35 is a section view transversal Section 35-35 of Figure 33.[0051] Figure 36 is a photograph of an example of present revelation.[0052] Figure 37 is a photograph of an example of present revelation.
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8/173 [0053] Figure 38 is a photograph of an example of the present disclosure.
[0054] Figure 39 is a cross-sectional view of the
example shown in Figure 38. [0055] Figure 40 is a perspective view of an image microtomography computerized (Micro TC) example of the present revelation. [0056] Figure 41 is a perspective view of an image microtomography computerized (Micro TC) example
of the present revelation.
[0057] Figure 42 is a computed microtomography (Micro TC) image of the example shown in Figures 40 and 41.
[0058] Figure 43 is a plan view of a computerized microtomography (Micro CT) image of the example shown in Figures 40 and 41.
[0059] Figure 44 is a graphical representation of the various benefits of the invention of the present disclosure.
[0060] Figure 45 is a photographic view image of a portion of an example of the present disclosure.
[0061] Figure 46 is a photographic view image of a portion of an example of the invention of the present disclosure.
[0062] Figure 47 is a photographic view image of a portion of an example of the invention of the present disclosure.
[0063] Figure 48 is a photographic view image of a
portion in an example of invention of this revelation. [0064] THE Figure 49 is photography of a section transversal example shown in the Figures 47 and 48.
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9/173 [0065] Figure 50 is a photographic view image of a portion of an example of the invention of the present disclosure.
[0066] Figure 51 is a photographic view image of a portion of an example of the invention of the present disclosure.
[0067] Figure 52 is a photographic view image of a portion of an example of the invention of the present disclosure.
[0068] Figure 53 is a photographic view image of a portion of an example of the invention of the present disclosure.
[0069] Figure 54 is a plan view of a computerized microtomography (Micro CT) image shown in Figures 40 and 41 after going through an additional process.
[0070] Figure 55 is a graphical representation of the various benefits of the invention of the present disclosure shown in Figure 54.
[0071] Figure 56 is a schematic representation of an apparatus for producing a textile product of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION [0072] The present disclosure provides a formatted nonwoven fabric formed directly on a formatted forming mat with continuous filaments of continuous spinning in a single forming process. The fabric of the present disclosure can take the shape that corresponds to the shape of the forming mat. A present disclosure fabric produced on a present disclosure forming mat in a method of the present disclosure can be particularly beneficial for use in personal care articles, garments, medical products and cleaning products. The formatted non-woven fabric
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10/173 may be fluid permeable for use as an upper, non-woven lower layer, capture layer, distribution layer or other component layers for a diaper, or an upper, non-woven lower layer, capture layer, distribution layer or other component layers for a sanitary pad, an upper, non-woven layer of the lower layer, capture layer, distribution layer or other component layers for a pants or adult incontinence pad, or a mop / sponge for floor cleaning implements.
[0073] The beneficial features of nonwoven fabric can be described in some embodiments of the present invention in the context of a total area of nonwoven fabric. The total area can be an area determined by dimensions suitable for certain uses, for which various features of the invention provide beneficial properties. For example, the total area of a fabric can be that of a fabric with dimensions that make it suitable for use as an upper layer, non-woven lower layer, capture layer, distribution layer or other component layers for a diaper , or an upper, non-woven lower layer, capture layer, distribution layer or other component layers for a sanitary napkin, an upper layer, non-woven lower layer, capture layer, distribution layer or other component layers for pants or an adult incontinence pad, or an absorbent for floor cleaning implements. In this way, the total area can be based on dimensions of width and length
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11/173 ranging from 3 cm wide to 50 cm wide and 10 cm long to 100 cm long, resulting in total areas from 30 cm ² to 500 cm ² . The previously mentioned ranges include, as if explicitly stated, all dimensions of integers between the range thresholds. As an example, a total area of 17 6 cm ² defined by a width of 11 cm and a length of 16 cm is revealed in the bands above. As will be understood from the description of the present invention, the total area of a formatted nonwoven fabric can be a smaller area than the area of the nonwoven blanket of which it is a part when produced commercially. That is, in a given commercially produced non-woven mat there may be a plurality of formatted non-woven fabrics of the invention, where each of the invented non-woven fabrics has a total area less than the area of the mat over which it is produced.
[0074] Photographs of representative examples of formatted nonwoven fabrics 10 are shown in Figures 1 to 3. Formatted nonwoven fabric 10 can be a nonwoven substrate of continuous spinning with a first surface 12 and a second surface 14. In the Figures 1 to 3, the second surface 14 is facing the observer and is opposite the first surface 12, which is hidden in Figures 1 to 3, but represented in Figure 4. The term surface is widely used to refer to two sides of a blanket for descriptive purposes, and is not intended to infer any need for smoothness or flatness. Although the
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12/173 formatted non-woven fabric 10 is soft and flexible, it will be described in a flat condition in the context of one or more XY planes parallel to the flat condition, and corresponding, in the blanket production technology, to the plane of the direction transverse to machine direction, DT, and machine direction, DM, respectively, as shown in Figures 1 to 3. The length, L, on the MD and the width, W, on the CD determine the total area A for the nonwoven fabric 10. As shown in Figure 4, which is a cross section of a portion of the nonwoven fabric 10 shown in Figure 1, for descriptive purposes, the three-dimensional features of the formatted nonwoven fabric are described as extending outwardly into a Z direction from an XY plane of the first surface 16 (see Figure 4). In one embodiment, a maximum dimension of three-dimensional features in the Z direction can define the maximum distance between the plane of the first surface 16 and an XY plane of the second surface 18, the distance of which can be measured as the average AC gauge of the non-woven fabric 10 The average caliber can be determined using non-contact optical means, or it can be determined by instruments that involve spaced flat plates that measure the caliber of the nonwoven placed between them under a given pressure. It is not necessary that all three-dimensional resources have the same maximum dimension in the Z direction, but a plurality of three-dimensional resources may have substantially the same maximum dimension in the Z direction determined by the fiber deposition process and the properties of the forming mat, discussed below. follow.
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13/173 [0075] The exemplary fabrics shown in Figures 1 to 4 (as well as other fabrics disclosed herein) are fluid permeable. In one embodiment, the entire fabric can be considered permeable to fluids. In a modality, regions or zones (described below) can be fluid-permeable. The term fluid permeable as used here in connection with the fabric means that the fabric has at least one zone that allows the passage of the liquid, under conditions of use, of a product intended for the consumer. For example, if used as a top layer in a disposable diaper, the fabric may have at least one area with a level of fluid permeability that allows urine, diarrhea, menstrual fluid or any other body exudate to pass through an underlying absorbent core . By fluid permeable as used here in relation to a region it is understood that the region has a porous structure that allows the passage of liquid.
[0076] As shown in Figures 1 to 4, the nonwoven fabric 10 can have a regular repetitive pattern of a plurality of distinctly different distinct three-dimensional features, including a first three-dimensional feature 20, a second three-dimensional feature 22 and a third three-dimensional feature 24, as shown in Figures 2 and 3. For example, in Figure 1, the first three-dimensional heart-shaped feature 20 is noticeably different from the second three-dimensional feature 22, which is smaller and in general triangular shape. Visible differences can be visual, such as visibly different sizes and or shapes.
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14/173 [0077] The three-dimensional features of non-woven fabric 10 can be formed by deposition, such as carding, air deposition, solution spinning, or fiber fusion spinning directly on a forming mat provided with a pattern of corresponding three-dimensional features. In a sense, non-woven fabric 10 is molded on a forming mat that determines the shapes of the three-dimensional resources of fabric 10. However, it is important to note, as described here, that the apparatus and method of the invention produce the non-woven fabric. -fabric 10, so that, in addition to acquiring the format of the training mat, due to the attributes of the training mat and the device for forming the fabric, the fabric is conferred beneficial properties for use in personal care articles, pieces of clothing, medical products and cleaning products. Specifically, due to the nature of the forming mat and other elements of the apparatus, as described below, the three-dimensional features of the non-woven fabric 10 have intensive properties that may diverge between the first and the second region within a microzone (described in more detail below), or from one resource to another in order to provide beneficial properties of non-woven fabric 10 when it is used in personal care articles, garments, medical products and cleaning products. For example, the first three-dimensional feature 20 may have a weight or density that is different from the weight or density of the second three-dimensional feature 22, and both may have a weight or density that is different
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15/173 of those of the third three-dimensional resource 24, which provides beneficial functional and aesthetic properties related to the absorption, distribution and / or capture of fluids in diapers or sanitary napkins.
[0078] It is believed that the differential of intensive property between the various three-dimensional resources of non-woven fabric 10 is due to the distribution and compacting of the fiber resulting from the apparatus and the method described below. Fiber distribution occurs during the fiber deposition process, unlike, for example, a post-production process such as hydroentangling or embossing processes. Due to the fact that the fibers are free to move during a process, as in a melt spinning process, with the movement being determined by the nature of the resources and the air permeability of the forming mat and other processing parameters, fibers are believed to be more stable and permanently formed in non-woven fabric 10.
[0079] As can be seen in Figures 1 to 3, and as understood based on the description of the present invention, the distinct three-dimensional features can be joined by visually discernible regions (in relation to the interior of the three-dimensional feature) that can take the form of a closed contour (like the heart shape in Figures 1 and 3 and the diamond shape in Figures 2 and 3). A closed contour can be a curvilinear closed contour like a heart shape in Figures 1 and 3. The visually discernible contour regions can be non-woven regions
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16/173 fabric 10 that are more closely adjacent to the first surface 12 in the Z direction, such as regions 21, as shown in Figure 4, and that can be arranged at least partially in the foreground 16 or on it, when in a flat condition . For example, as shown in Figure 1, the first three-dimensional feature 20 is heart-shaped, and as indicated as a first exemplary three-dimensional feature 20A, it is defined by a curved, closed heart-shaped element. A curvilinear element can be understood as a linear element with a tangential vector V at any point along its length, the closed shape being such that the tangential vector V has both DM and DT components that have their values changed above 50% the length of the linear element of the closed contour. Obviously, the contour does not have to be 100% closed, but the linear element can have breaks that do not prevent an overall impression of a closed contour. As discussed below in the context of the forming mat, the curvilinear closed heart-shaped element of visually discernible contour is formed by a corresponding elevated closed heart-shaped element on the forming mat to produce the closed contour of a heart in the fabric 10 In a repetitive pattern, individual shapes (in the case of the first three-dimensional feature in Figure 1, a heart shape) can result in cushioning, soft and pleasant features across the total OA area of the second surface 14 of fabric 10. In one embodiment where the non-woven fabric
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17/173 is used as a top layer for a diaper or sanitary napkin, the second surface 14 of the nonwoven fabric 10 can be turned towards the body to provide superior aesthetic and performance benefits related to softness, compressive strength and fluid absorption.
[0080] Specifically, in the regular repetition pattern of closed three-dimensional features shown in Figures 1 to 3, it is believed, without sticking to the theory, that the dimensions of the various features, the average weight of all the fabric 10 over its entire area total and other processing parameters described below that define the divergent intensive properties contribute to a beneficial improvement in compression recovery. The plurality of relatively padded, relatively small and closely spaced three-dimensional features is believed to act as springs to resist compression and recover once a compressive force is removed. Compression recovery is important in upper layers, lower layer nonwovens, capture layers, distribution layers or other layers of components of personal care items such as diapers, sanitary napkins or pants, adult diapers or incontinence pads, for example, due to the fact that such articles are typically packaged and folded under compression conditions. Manufacturers of personal care products want to retain most or all of the caliber in the state it was produced for purposes of aesthetics and performance. The three-dimensionality of resources
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18/173 formed provides important aesthetic benefits due to the visual and tactile sensations of softness and good appearance of well-defined and precise shapes, including very small shapes like the little hearts shown in Figure 2. Three-dimensional features also provide softness during use, absorbency improved, less tendency to leak and an optimized experience during use. However, the compression required during folding, packaging, transport and storage of personal care items can cause a permanent loss of caliber of an upper layer, lower layer nonwovens, capture layers, distribution layers or other component layers. absorbent article, which therefore degrades the functional benefits of the state in which it was produced. It was unexpectedly found that non-woven fabrics of the present disclosure significantly retain the three-dimensional features of the state in which they were produced even after being subjected to packaging compression and distribution in a packaged compressed state.
[0081] Table 1 below shows compression recovery data for two embodiments of the present disclosure. Example 1 corresponds to the nonwoven fabric 10 shown in Figure 1 and produced on a forming mat, as described with reference to Figures 12 and 14. Example 2 corresponds to the nonwoven fabric 10 shown in Figure 2 and produced on a mat formation, as described with reference to Figures 15 and 16. As can be seen from the data, the fabrics 10 of the invention show a
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19/173 significant benefit with respect to compression recovery when measured by the compression aging test. In one form, the packs of absorbent articles with compression recovery characteristics of the present disclosure may have a reduced stack height in a bag and still provide the benefits of softness, absorbency and aesthetics of the diaper in the state in which it was produced; or as if they had never been compressed for packaging. This invention provides reduced-stack, bag-height packaging that allows caregivers to easily handle and store them while also providing manufacturers with reduced costs, while maintaining aesthetic clarity, absorbency or soft performance of the absorbent article in the state in which it was produced. Example 1:
[0082] A bicomponent continuous spinning non-woven fabric produced by spinning at a 50:50 ratio between the polyethylene sheath (Aspun-6850-A obtained from the Dow Chemical Company) and the polypropylene core (PH-835 obtained from to LyondellBasell) in a trilobal fiber configuration, as shown in Figure 6, which is a scanning electron micrograph (SEM) showing a cross section of a bicomponent trilobal fiber. The nonwoven fabric was spun on a forming mat with a repetition pattern as described in Figure 12 as described below with respect to Figures 7 and 8 moving at a linear speed of about 25 meters per minute for an average weight of 30 grams per square meter with a
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20/173 heart shape repeat pattern as shown in Figure 1. The fibers of the fabric were additionally joined on the first side 12 by heat compaction cylinders 70, 72 (described below) at 130 ° C and by rolling on a reel on the reel 75.
Example 2:
[0083] A bicomponent nonwoven spinning fabric produced by spinning in 50:50 ratio between polyethylene sheath (Aspun-6850-A obtained from Dow chemical company) and polypropylene core (PH-835 obtained from LyondellBasell) in a trilobal fiber configuration, as shown in Figure 6, which is a scanning electron micrograph showing a cross section of a bicomponent trilobal fiber. The nonwoven fabric was spun on a forming mat with a repeat pattern as described in Figure 16 as described below with respect to Figures 7 and 8 moving at a linear speed of about 25 meters per minute from a fabric 10 with an average grammage of 30 grams per square meter with a rhombus shape repeat pattern as shown in Figure 2. The fibers of the fabric were additionally joined on the first surface 12 by heated compaction cylinders 70, 72 (described below) a 130 ° C.
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21/173
Table 1: Compression recovery
3D Nonwoven New (not woven out of cylinder) 4 KPa (-96 mm IBSH) 14 KPa (-84 mm IBSH) 35 KPa (-68 mm IBSH)Caliber Gauge after Compression Gauge retention percentage Gauge after Compression Gauge retention percentage Gauge after Compression Gauge retention percentage Example1 0.45 0.38 84.44 0.35 77.78 0.34 75, 56 Example2 0.43 0.36 83.72 0.36 83.72 0.31 72.09
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22/173 [0084] As can be seen from Table 1, fabrics 10 of the invention retain significant amounts of gauge after compression at relatively high pressures. For example, the samples in Example 1 and Example 2 retain over 70% of their original average caliber after testing by the Compression Aging Test at a pressure of 35 KPa. The Compression Aging Test is a simulation of the conditions that a non-woven fabric would encounter if it was packed in a high-compression diaper package, remained in such a state during distribution to a consumer, and then until the package was finally opened by a consumer.
[0085] The present disclosure may use the melt spinning process. In melt spinning, there is no loss of mass in the extrudate. Fusion spinning is different from other spinning techniques, such as wet or dry spinning from solution, in which a solvent is being eliminated from the extruded by volumizing or diffusing, resulting in a loss of mass.
[0086] Fusion wiring can take place at a temperature of about 150 ° C to about 280 °, or, in some embodiments, from about 190 ° to about 230 °. Fiber spinning speeds can be greater than 100 meters / minute and can be from about 1,000 to about 10,000 meters / minute, and can be from about 2,000 to about 7,000 meters / minute, and can be about 2,500 at about 5,000 meters / minute. Spinning speeds can affect the brittleness of the spun fiber and, in general, the higher
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23/173 the spinning speed, the fiber is less fragile. Continuous fibers can be produced using continuous spinning methods or spinning and melting spinning processes.
[0087] A non-woven fabric 10 of the present disclosure may include continuous multicomponent polymeric filaments comprising a primary polymeric component and a secondary polymeric component. The filaments can be continuous bicomponent filaments comprising a primary polymeric component A and a secondary polymeric component B. The bicomponent filaments have a cross section, a length and a peripheral surface. Components A and B can be arranged in substantially distinct areas throughout the cross-section of the bicomponent filaments and can extend continuously along the length of the bicomponent filaments. Secondary component B constitutes at least a portion of the peripheral surface of the bicomponent filaments continuously along the length of the bicomponent filaments. Polymeric components A and B can be spun by fusing multi-component fibers in conventional fusion spinning equipment. The equipment will be chosen based on the desired configuration for the multicomponent fiber. Commercially available fusion spinning equipment is available from Hills, Inc., located in Melbourne, Florida, USA. The wiring temperature ranges from about 180 ° C to about 230 ° C. The processing temperature is determined by the chemical nature, the molecular weights and the
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24/173 concentration of each component. The bicomponent filaments of continuous spinning can have an average diameter from about 6 to about 40 microns, and preferably from about 12 to about 40 microns.
[0088] Components A and B can be arranged either in a side-by-side arrangement, as shown in Figure 5A, or in an eccentric sheath / core arrangement, as shown in Figure 5B, to obtain filaments that exhibit a natural helical bead. . Alternatively, components A and B can be arranged in a concentric sheath / core arrangement as shown in Figure 5C. In addition, components A and B can be arranged in a multilobal sheath / core as shown in Figure 6. Other multi-component fibers can be produced using the compositions and methods of the present disclosure. The bicomponent and multicomponent fibers can be segmented in configurations of pie, ribbon, islands in the sea or any combination thereof. The sheath can be continuous or non-continuous around the core. The ratio of the weight of the sheath to the weight of the core is from about 5:95 to about 95: 5. The fibers of the present disclosure may have different geometries, which include circular, elliptical, star-shaped, rectangular and various other eccentricities.
[0089] Methods for extruding multicomponent polymeric filaments in such arrangements are well known to those skilled in the art.
[0090] A wide variety of polymers are suitable for practicing the present disclosure, including polyolefins (as
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25/173 polyethylene, polypropylene and polybutylene), polyesters, polyamides, polyurethanes, elastomeric materials and the like. Some non-limiting examples of polymeric materials that can be spun in filaments include natural polymers such as starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, chitin, chitosan, polyisoprene (cis and trans), peptides and poly (hydroxyalkanoate), and synthetic polymers including, but not limited to, thermoplastic polymers such as polyesters, nylon, polyolefins such as polypropylene, polyethylene, polyvinyl alcohol and polyvinyl alcohol derivatives, sodium polyacrylate (absorbent gel material), and copolymers of polyolefins such as polyethylene-octene or polymers comprising monomeric blends of propylene and ethylene, and biodegradable or compostable thermoplastic polymers such as polylactic acid filaments, polyvinyl alcohol filaments, and polycaprolactone filaments. In one example, the thermoplastic polymer selected from the group consisting of: polypropylene, polyethylene, polyester, poly (lactic acid), poly (hydroxyalkanoate), poly (vinyl alcohol), polycaprolactone, styrene-butadiene-styrene block copolymer, block copolymer of styrene-isoprene-styrene, polyurethane, and mixtures thereof. In another example, the thermoplastic polymer is selected from the group consisting of: polypropylene, polyethylene, polyester, polylactic acid, poly (hydroxyalkanoate), polyvinyl alcohol, polycaprolactone and mixtures thereof. Alternatively, the polymer can
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26/173 comprise a monomer derived from monomers that are biobased, such as bio-polyethylene or bio-polypropylene.
[0091] Primary component A and secondary component B can be selected so that the resulting two-component filament provides improved non-woven bonding and substrate softness. Primary polymeric component A has a melting temperature less than the melting temperature of secondary polymeric component B.
[0092] Primary polymeric component A may comprise polyethylene or random copolymers of propylene and ethylene. The secondary polymeric component B can comprise polypropylene or random copolymers of propylene and ethylene. Polyethylenes include linear low density polyethylene and high density polyethylene. In addition, the secondary polymeric component B may comprise additives that improve the natural helical bead of the filaments, which decreases the filament bond temperature and improves the abrasion resistance, strength and softness of the resulting fabric.
[0093] Inorganic fillers such as oxides of magnesium, aluminum, silicon and titanium can be added as low cost fillers or auxiliary elements for processing. Other inorganic materials include hydrous magnesium silicate, titanium dioxide, calcium carbonate, clay, chalk, boron nitride, limestone, diatomaceous earth, mica, glass, quartz and ceramics.
[0094] The filaments of the present invention also contain a slip additive in an amount sufficient to
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27/173 confer the desired haptic effect to the fiber. As used here, slip additive or slip agent means an external lubricant. The sliding agent, when blended by melting with the resin, gradually sweats or migrates to the surface during cooling or after manufacture, which therefore forms a thinly invisible and uniform coating, which therefore yields permanent lubrication effects. The gliding agent is preferably a gliding agent with rapid results, and can be a hydrocarbon having one or more functional groups selected from hydroxide, aryls and substituted aryls, halogens, alkoxyls, carboxylates, esters, carbon unsaturation, acrylates, oxygen , nitrogen, carboxyl, sulfate and phosphate.
[0095] During production or in a post-treatment, or even in both, the three-dimensional nonwovens of the present invention can be treated with surfactants or other agents to hydrophilize the mat or make it hydrophobic. This is a standard procedure for nonwovens used in absorbent articles. For example, a nonwoven fabric used for an upper layer can be treated with a hydrophilizing or surfactant material to make it permeable to body exudates such as urine. For other absorbent articles, the top layer can remain in its naturally hydrophobic state or produced even more hydrophobic by adding a hydrophobizing or surfactant material.
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28/173 [0096] Suitable materials for preparing the multi-component filaments of the fabric of the present disclosure include polypropylene PH-835 obtained from LyondellBasell and polyethylene Aspun-6850-A obtained from Dow chemical company. [0097] When polyethylene is component A (sheath) and polypropylene is component B (core), the bicomponent filaments can comprise from about 5 to about 95% by weight of polyethylene and from about 95 up to about 5% polypropylene. The filaments can comprise from about 40 to about 60% by weight of polyethylene and from about 60 to about 40% by weight of polypropylene.
[0098] Turning to Figure 7, a representative process line 30 for preparing tissues 10 of the present disclosure is disclosed. Process line 30 is arranged to produce a continuous bicomponent filament fabric, but it should be understood that the present disclosure comprises nonwoven fabrics produced with mono-component or multi-component filaments with more than two components. The bicomponent filaments can be trilobal.
[0099] Process line 30 includes a pair of extruders 32 and 34 driven by an extruder driver 31 and 33, respectively, to separately extrude primary polymer component A and secondary polymer component B. Polymer component A is fed to the respective extruder 32 from a first hopper 36 and the polymeric component B is fed to the respective extruder 34 from a second hopper 38. The
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29/173 polymeric components A and B can be fed from extruders 32 and 34 through respective polymeric ducts 40 and 42 to filters 44 and 45 and pumps for molten material 46 and 47, which pump the polymer to a turning group 48 The spinners for extruding two-component filaments are well known to those skilled in the art and are therefore not described in detail in this document. [0100] In general terms of description, the swivel assembly 48 includes a housing that includes a plurality of plates stacked on top of each other with a pattern of openings arranged to create flow paths to direct polymeric components A and B separately through the spinner. The pivot assembly 48 has openings arranged in one or more rows. The spinner openings form a downward extension curtain of filaments when the polymers are extruded through the spinner. For the purposes of the present disclosure, spinners can be arranged to form bicomponent filaments of sheath / core or side illustrated in Figures 5A, 5B and 5C, as well as non-cylindrical fibers, such as trilobal fibers, as shown in Figure 6. in addition, the fibers can be monocomponents comprising a polymeric component such as polypropylene.
[0101] Process line 30 also includes a cooling blower 50 positioned adjacent to the filament curtain that extends from the spinner. The air from the extinguishing air blower 50 cools the filaments extending from the spinner. The cooling air can
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30/173 be directed from one side of the filament curtain or from both sides of the filament curtain.
[0102] An attenuator 52 is positioned below the spinner and receives the cooled filaments. Fiber pulling units or vacuum cleaners for use as attenuators in polymer melt spinning are well known. Fiber pulling units suitable for use in the process of the present disclosure include a linear fiber attenuator of the type shown in US Patent No. 3,802,817 and eductive guns of the type shown in US Patent No. 3,692,618 and in US Patent No. 3,423,266, the disclosures of which are hereby incorporated by way of reference.
[0103] In general terms of description, the attenuator 52 includes an elongated vertical passage through which the filaments are pulled in by drawing in air entering the sides of the passage and flowing down through the passage. A formatted, infinite and at least partially porous forming mat 60 is positioned below the attenuator 52 and receives the continuous filaments from the outlet opening of the attenuator 52. The forming mat 60 is a mat and has a path around rollers -guide 62. A vacuum 64 positioned below the forming mat 60 on which the filaments are deposited pulls the filaments against the forming surface. Although the forming mat 60 is shown as a mat in Figure 8, it should be understood that the forming mat can also be in other forms, such as a drum. The details of particular shape forming mats are explained below.
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31/173 [0104] In the operation of process line 30, hoppers 36 and 38 are filled with the respective polymeric components A and B. The polymeric components A and B are melted and extruded by the respective extruders 32 and 34 through polymeric ducts 40 and 42 and the turning group 48. Although the temperatures of the molten polymers vary depending on the polymers used, when polyethylene and polypropylene are used as a component primary A and secondary component B respectively, the temperatures of the polymers can respectively vary from about 190 ° C to about 240 ° C.
[0105] As the extruded filaments extend below the spinneret, an air stream from the cooling blower 50 at least partially cools the filaments, and, for certain filaments, induces crystallization of molten filaments. The cooling air can flow in a direction substantially perpendicular to the length of the filaments at a temperature of about 0 ° C to about 35 ° C and at a speed of about 100 to about 400 feet per minute. The filaments can be cooled sufficiently before being collected on the forming mat 60 so that the filaments can be disposed by the forced air that passes through the filaments and the forming surface. Filament cooling reduces the stickiness of the filaments so that the filaments do not adhere to each other too strongly before they are joined and can be moved or arranged on the conveyor belt.
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32/173 formation during the filament collection on the formation mat and during the formation of the blanket.
[0106] After cooling, the filaments are pulled into the vertical passage of the attenuator 52 by a flow from the fiber pulling unit. The attenuator can be positioned 30 to 60 inches below the bottom of the spinner.
[0107] The filaments can be deposited through the outlet opening of the attenuator 52 on a formatted mobile forming mat 60. As the filaments contact the forming surface of the forming mat 60, the vacuum 64 pulls the air and the filaments against the forming mat 60 to form a continuous filament nonwoven blanket that takes on a shape corresponding to the shape of the forming surface. As discussed above, due to the fact that the filaments are cooled, the filaments are not too sticky and the vacuum can move or arrange the filaments on the forming mat 60 as the filaments are collected on the forming mat 60 and formed in the fabric 10.
[0108] Process line 30 additionally includes one or more joining devices such as cylindrical-shaped compaction cylinders 70 and 72, which form a choke through which the fabric can be compacted, that is, calendered, and which can be also heated to join fibers. One or both of the compaction cylinders 70, 72 can be heated to provide enhanced properties and benefits to the nonwoven fabric 10 by consolidating portions of the fabric. For example, it is believed that sufficient heating to provide thermal bonding can
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33/173 improving the textile products of the fabric 10. The compaction cylinders can be a pair of smooth-surface stainless steel cylinders with independent heating controllers. The compaction cylinders can be heated by electrical elements or by circulating hot oil. The gap between the compaction cylinders can be hydraulically controlled to impose desired pressure on the fabric as it passes through the compaction cylinders on the forming mat. In one embodiment, with a 1.4 mm forming belt gauge, and a continuous spinning nonwoven with a weight of 30 g / m2, the throttling gap between compaction rollers 70 and 72 can be about of 1.4 mm.
[0109] In one embodiment, the upper compaction cylinder 70 can be heated sufficiently to melt fibers on the first surface 12 of the fabric 10, to impart strength to the fabric so that it can be removed from the forming mat 60 without loss of integrity. As shown in Figures 8 and 9, for example, as cylinders 70 and 72 rotate in the direction indicated by the arrows, belt 60 with the continuous spinning fabric resting on it enters the choke formed by cylinders 70 and 72. The heated cylinder 70 it can heat the portions of nonwoven fabric 10 which are pressed against it by the high resin elements of the mat 60, that is, in regions 21, to create fibers joined at least 80 on the first surface 12 of fabric 10. As you can understood by the description of the present invention, the regions
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34/173 joins thus formed can assume the pattern of the elevated elements of forming mat 60. For example, the joined areas thus formed may be a substantially continuous network or a substantially semicontinuous network on the first surface 12 of regions 21 which does the same decoration pattern of Figure 1 and Figure 11. By adjusting the temperature and residence time, consolidation can be limited mainly to the fibers closest to the first surface 12, or thermal consolidation can be achieved on the second surface 14, as shown in Figure 11 (which also shows point joints 90, discussed in greater detail below) and Figures 45 to 49. The joint can also be a discontinuous network, for example, like point joints 90, discussed below.
[0110] The elevated elements of the forming mat 60 can be selected to establish various network characteristics of the forming mat and the joined regions of the non-woven substrate 11 or non-woven fabric 10. The mesh corresponds to the resin that makes up the elevated elements of the forming mat 60 and can be substantially continuous, substantially semicontinuous, discontinuous or combinations thereof. Such networks may be descriptive of the elevated elements of the forming mat 60 in terms of their appearance or composition in the X-Y planes of the forming mat 60 or of the three-dimensional features comprising the non-woven substrate 11 or non-woven fabric 10 of the present invention.
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35/173 [0111] A substantially continuous network refers to an area within which any two points can be connected by an uninterrupted line that passes entirely within that area along the entire length of the line. That is, the substantially continuous network has substantial continuity in all directions parallel to the foreground and is terminated only at the edges of that region. The term substantially, in conjunction with continuum, is intended to indicate that, although absolute continuity can be achieved, small deviations from absolute continuity may be tolerable, as long as those deviations do not considerably affect the performance of the fibrous structure (or of a limb). molding) as planned and intended.
[0112] A substantially semi-continuous network refers to an area that has continuity in all but at least one, directions parallel to the foreground and, in that area, no two points can be connected by an uninterrupted line that passes entirely within that area along the entire length of the line. The semi-continuous structure can be continued only in a direction parallel to the foreground. By analogy with the continuous region described above, while absolute continuity in all but at least one direction is preferred, small deviations from such a continuity may be tolerable, as long as those deviations do not considerably affect the performance of the fibrous structure.
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36/173 [0113] A discontinuous network refers to distinct areas, separated from each other that are discontinuous in all directions parallel to the foreground.
[0114] After compaction, the fabric can leave the forming mat 60 and be calendered through a choke formed by the calender rolls 71, 73, and later the fabric can be rolled onto a reel. As shown in the schematic cross section of Figure 10, the calender cylinders can be stainless steel cylinders with a standard engraved cylinder 84 and a smooth cylinder 86. The engraved cylinder can have raised portions 88 that can provide additional union and compaction to the fabric 10 The raised portions 88 can be a regular pattern of relatively small spaced pins that form a pattern of relatively small stitch joints 90 in the strangulation of calender rolls 71 and 73. The percentage of stitch joints in the nonwoven fabric 10 can be 3% to 30% or 7% to 20%. The embossed pattern may be a plurality of generally flat top pin shapes of generally close-spaced regular cylindrical shape, the pin heights being in a range ranging from 0.5 mm to 5 mm and, preferably, from 1 mm to 3 mm. Pin binding calender cylinders can form regular close-spaced stitch joints 90 on non-woven fabric 10, as shown in Figure 11. Additional joints can be made by joining through hot air, for example.
[0115] As described in relation to Figure 56 below, thermal consolidation through the air passage can be another
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37/173 approach to create higher aeration nonwoven structures that may be suitable for this application. Thermal consolidation by air passage involves the application of hot air to the surface of the nonwoven fabric. The hot air flows through the orifices in a full space positioned just above the nonwoven fabric. However, air is not pushed through the nonwoven, as is the case with ordinary hot air furnaces. Negative pressure or suction pulls air through the open conveyor belt that holds the nonwoven as it passes through the oven. The pull of air through the nonwoven fabric allows for a much faster and uniform heat transmission and minimizes fabric distortion. In addition to conventional airflow consolidation units, it can be envisaged to place the consolidation unit on top of the conveyor in 3D while a vacuum is adjusted under the conveyor to mimic the airflow consolidation process for this specific application.
[0116] Binders used in thermal consolidation by air passage, include crystalline binder fibers, bicomponent binder fibers and powders. When crystalline binder fibers or powders are used, the binder melts completely and forms molten droplets throughout the cross section of the nonwoven. Consolidation occurs at these points through cooling. In the case of sheath / core binder fibers, the sheath is the binder and the core is the supporting fiber. In one embodiment, in a nonwoven comprising sheath / core binder fibers, the
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The sheath comprises a polyethylene and the core comprises polypropylene. For a nonwoven of this type, the temperature of the thermal consolidation air per air passage can be in the range of 110 ° C to 150 ° C and the dwell time can be in the range of 0.5 to 10 seconds, from 5 30 seconds, or 30 to 60 seconds, since the consolidation time per air passage will depend on the weight, the desired resistance level and the operational speed. Products manufactured using airflow ovens tend to be bulky, open, soft, strong, extensible, breathable and absorbent.
[0117] Point consolidation as used here is a method of thermal consolidation of a nonwoven material, blanket or substrate. This method involves passing a blanket through a contact line between two cylinders that consist of a heated male metal cylinder with a pattern or notch and a smooth or standard metal cylinder. The male cylinder provided with a pattern can have a plurality of raised pins in a generally cylindrical shape that produces joints of circular points. The smooth cylinder may or may not be heated, depending on the application. In a non-woven production line, the non-woven fabric, which could be an unconsolidated fiber mat, is fed to the calender contact line and the fiber temperature is increased to the point where the fibers meet melt thermally with each other at the points of the notched points and against the smooth cylinder. The warm-up time is typically in the order of milliseconds. The properties
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39/173 of the fabric are dependent on process settings such as cylinder temperatures, blanket line speeds and contact line pressures, all of which can be determined by the person skilled in the art for the desired level of point consolidation. Other types of point consolidation generally known as hot rolling consolidation may consist of different geometries for consolidations (except circular shapes), such as oval, lines, circles, etc. In the exemplary embodiment presented in the present invention, point consolidation produces a pattern of point joints being circles of 0.5 mm in diameter with 10% of total consolidation area. Other embodiments comprise consolidation formats in which the raised pins have a longer dimension through the connecting surface of a pin of about 0.1 mm to 2.0 mm and the total joining area varies from 5% to 30%.
[0118] As shown in Figure 11, in one embodiment, the heated compaction cylinder 70 can form a connection pattern, which can be a substantially continuous network connection pattern 80 (for example, interconnected heart-shaped connections) in the first surface 12 of the nonwoven 10 (not shown in Figure 11, since it faces away from the viewer), and the notched calender cylinder 73 can form relatively small dot connections 90 on the second surface 14 of the fabric 10. Point 90 joints hold loose fibers that would otherwise have a tendency to form fluff or accumulate during
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40/173 use of fabric 10. The advantage of the resulting non-woven fabric structure 10 is most evident when it is used as an upper layer in a personal care article such as a diaper or sanitary napkin. In use in a personal care article, the first surface 12 of the nonwoven fabric 10 can be relatively flat (relative to the second surface 14) and have a relatively large amount of consolidation due to the formation of bonds 80 by the heated compaction cylinder in the areas of the fabric pressed by the elevated elements of the forming mat 60. This union provides structural integrity to the non-woven fabric 10, but can be relatively rough or rigid for a user's skin. Therefore, the first surface 12 of the nonwoven fabric 10 can be oriented in a diaper or sanitary napkin to be turned into the article, that is, away from the user's body. Similarly, the second surface 14 can be facing the body during use, and in contact with the body. The relatively small dot joints 90 are less likely to be visually or tactfully perceived by the user, and the relatively soft three-dimensional features remain visually free of fluff and huddle and maintain a soft feeling for the body during use. Additional couplings can be used instead of the couplings mentioned above or in addition to them.
[0119] Forming mat 60 can be produced according to the methods and processes described in US Patent No. 6,610,173, issued to Lindsay et al. On August 26,
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2003, or in US patent No. 5,514,523 granted to Trokhan et al. on May 7, 1996, or in US patent 6,398,910 issued to Burazin et al. on June 4, 2002, or US Patent No. 2013/0199741, published in the name of Stage et al. on August 8, 2013, each with the same enhanced features and standards revealed here to produce nonwoven blankets with continuous spinning. The Lindsay, Trokhan, Burazin and Stage disclosures describe mats that are representative of papermaking mats produced with cured resin on a fabric reinforcing member, whose mats, with improvements, can be used in the present disclosure as described herein.
[0120] An example of a forming mat 60 of the type useful in the present disclosure and which can be produced according to the disclosure of US patent no 5,514,523, is shown in Figure 12. As shown therein, a reinforcement member 94 (like a woven filament mat 96) is minutely coated with a liquid photosensitive polymeric resin to a pre-selected thickness. A negative film or mask that incorporates the desired high element pattern that repeats elements (for example, Figure 14) is juxtaposed in a liquid photosensitive resin. The resin is then exposed to light of an appropriate wavelength through the film, as UV light for a UV-curable resin. This exposure to light causes the resin to cure in the exposed areas (that is, in the white portions or portions not printed on the mask). The uncured resin (resin under opaque portions on the mask) is removed from the system, leaving
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42/173 behind the cured resin, which forms the illustrated pattern, for example, the elements of
Figure 12. Other cured resin patterns 92 shown in can also be formed, as discussed in this document.
[0121] Figure 12 shows a portion of a forming mat 60 useful for producing the nonwoven fabric 10 shown in Figure 1. As shown, forming mat 60 can include cured resin elements 92 in a woven reinforcement member 94. Reinforcement member 94 can be produced from woven filaments 96 as is known in the art of papermaking mats, including resin-coated papermaking mats. The cured resin elements can have a general structure shown in Figure 12, and are produced using a mask 97 with the dimensions indicated in Figure 14. As shown in the schematic cross section in Figure 13, cured resin elements 92 move and are cured to lock onto reinforcement member 94 and can have a width at a distal end DW of about 0.020 inch to about 0.060 inch, or from about 0.025 inch to about 0.030 inch, and at a total height of the reinforcement element 94, called the upper level, OB, from about 0.030 inch to about 0.120 inch or about 0.50 inch to about 0.80 inch, or about 0.060 inch. Figure 14 represents a portion of a mask 97 showing the design and representative dimensions for a repeat unit of the repeat heart design on the non-woven fabric 10 shown in
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Figure 1. The white portion 98 is transparent to UV light, and in the mat production process, as described in US Patent No. 5,514,523, it allows the UV light to cure an underlying resin layer that is cured to form the elevated elements 92 in the reinforcement member 94. After the uncured resin is washed away, the forming mat 60 with a cured resin design, as shown in Figure 12, is produced by sewing the ends of a mat length, whose length can be determined by the design of the device, as shown in Figure 7.
[0122] Similarly, Figure 15 represents a portion of a mask 97 that shows the design for a repeat unit of the repeat design on the nonwoven 10 shown in Figure 2. White portion 98 is transparent to UV light, and in the mat production process, it allows the UV light to cure an underlying resin layer that is cured to reinforcement member 94. After the uncured resin is washed away, the forming mat 60 has a cured resin design , as shown in Figure 16, is produced by sewing the ends of a belt length, the length of which can be determined by the design of the apparatus, as shown in Figure 7.
[0123] Additionally, in another non-limiting example, Figure 17 represents a portion of a mask showing the design for a repeat unit of the repeat design on the nonwoven fabric 10 shown in Figure 18. White portion 98 is transparent to UV light, and in the mat production process, allows UV light to cure a layer
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44/173 of underlying resin that is cured to reinforcement member 94. After the uncured resin is washed away, forming mat 60 with a cured resin design as shown in Figure 18 is produced by sewing the ends of a fabric length 10.
[0124] Another example of a portion of a forming mat 60 of the type useful in the present disclosure is shown in Figure 19. The portion of forming mat 60 shown in Figure 19 is a distinct pattern of mat 61 which may be of length L and a width W corresponding to the length L and width W of the total area OA of a nonwoven fabric 10. That is, the forming mat 60 may have distinct patterns of mat 61 (as discussed in more detail with reference to Figure 22 below ), each having a total area of distinct pattern of DPOA mat that corresponds to the total area OA of the nonwoven fabric 10. Figure 20 represents a portion of a mask showing the design for a repeat design unit. repetition in the nonwoven fabric 10 shown in Figure 21. The white portion 98 is transparent to UV light, and in the mat production process, it allows the UV light to cure an underlying resin layer that is cured to reinforcement member 94. After the uncured resin is washed away, the mat forming material 60 with a cured resin design as shown in Figure 19 is produced by sewing the ends of a mat length.
[0125] The training mat portion shown in Figure 19 illustrates another benefit of the present disclosure. The portion
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45/173 of a forming mat 60 shown in Figure 19 can make up a fabric 10 shown in Figure 21. The nonwoven fabric 10 shown in Figure 21 can have dimensions of width W and length L and a total area OA that makes it suitable for use as a top layer in a disposable diaper, for example. The non-woven fabric 10 produced on a forming mat 60, as exemplified in Figure 19, differs from that shown in Figures 1 to 3, in which the pattern of three-dimensional features formed by the different resin elements 92 on the forming mat 60 are not in a regular repetitive pattern over the entire area. Instead, the pattern of elevated three-dimensional elements in the distinct pattern of the total DPOA mat area can be described as an irregular pattern that encompasses distinct portions called zones. The distinction between the zones can be visual, that is, a visually discernible difference, or in the non-woven fabric 10 the distinction can produce a difference in medium intensive properties such as weight or density, or combinations of visual and intensive properties. There will be a visually discernible difference if an observer in common indoor lighting conditions (20/20 vision, sufficient lighting for reading, for example) can visually perceive a pattern difference between the zones, such as the first zone 112 and the second zone 122.
[0126] Non-woven fabric 10 may also have visually discernible zones corresponding to the areas of the forming mat. As shown in Figure 21, for example, the
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46/173 tissue 10 can have at least two, three or four visually discernible zones. A first zone 110, with a first pattern of three-dimensional features and first intensive properties, may have a first area located generally centrally within the total area OA. A second zone 120, with a second pattern of three-dimensional features and second intensive properties, may have a second area generally distributed around, and in one embodiment, completely surrounding, the first zone 110 within the total area OA. A third zone 130, with a third pattern of three-dimensional features and third intensive properties, may have a third area generally distributed around, and in one embodiment, completely surrounding, the second zone 120 within the total area OA. A fourth zone 140, with fourth three-dimensional features and fourth medium intensive properties, can have a fourth area positioned within the total OA area at any location, such as a frontal area of an upper layer, such as the heart design shown in Figure 21. In general, there can be n zones, where n is a positive integer. Each of the n zones can have an nth pattern of three-dimensional features and an nth area and nth intensive properties.
[0127] The visually discernible zones as shown in Figure 21 can comprise visually discernible three-dimensional features. These distinct three-dimensional features can be joined by regions of relatively higher density (with respect to the interior of the feature
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47/173) that can be in the form of a closed outline, such as the heart shape in Figures 1 and 3, and the diamond shape in Figures 2 and 3. In general, as discussed in more detail below, including in In the context of microzones, three-dimensional resources can be defined by a first region and a second region, the first region and the second region being visually distinct and there is a common intensive property associated with each of the first and second regions and there is a difference in the value of intensive property common in the first region and the second region. In one embodiment, three-dimensional features can be defined by a first region and a second region, with the first region being at a higher elevation (dimension measured in the Z direction) than the second region in relation to the plane of the first surface. In one embodiment, three-dimensional features can be defined by a first region and a second region, with the first region being on a higher base than the second region.
[0128] As can be understood, instead of having a repetition pattern that is uniform throughout the forming mat, the forming mat 60 of the present disclosure allows the production of a non-woven material that can repeat the distinct irregular patterns mat 61, each distinct mat pattern 61 is similar to the distinct mat pattern shown in Figure 19. Each of the distinct mat patterns 61 can be used to form a nonwoven 10 with a total OA area suitable for
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48/173 use in a disposable absorbent article, such as a diaper or sanitary napkin, for example. Nonwovens 10 can be produced sequentially, that is, in line, and optionally sequentially in parallel lanes, each lane being a sequential line of nonwoven fabrics 10. The sequential line of nonwovens 10 can be produced in a machine direction along a geometric axis parallel to the machine direction. The nonwoven material can then be split or otherwise cut to the desired size to produce nonwoven fabrics 10 used as topsheets in disposable absorbent articles, such as diapers or sanitary napkins.
[0129] In one embodiment, the pattern within each total area of distinct pattern of DPOA mat can be the same or different. That is, the different mat patterns spaced sequentially may be substantially identical or may differ in visual appearance and / or in the intensive properties produced on non-woven substrates produced therein. For example, as shown schematically in Figure 22, the pattern of three-dimensional elevated elements in the first forming zone 112 of the distinctive track pattern 61A may be different from the pattern of three-dimensional elevated elements in the first forming zone 112 of the distinctive track pattern 61B. The forming mat 60 therefore offers flexibility in the production of non-woven blankets 10 suitable for use in consumer goods, including disposable absorbent articles. For example, in a diaper pack, the top layers of at least
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49/173 two diapers can be different in that they were produced sequentially in a continuous spinning process as described here, with different sequential belt patterns having different zone patterns. In one embodiment, the top layer or bottom layer nonwoven pattern for a diaper size may be different from the top layer or bottom layer nonwoven of another diaper size, which therefore gives the caregiver a visual indication as to the size of the diaper. Similarly, sanitary napkins may use a fabric 10 for an upper layer, with the visual pattern of three-dimensional features denoting the absorbency of the sanitary napkin. In any case, the various fabric patterns 10 can be produced on a single belt producing different distinct belt patterns as desired.
[0130] Therefore, the invention can be described with reference to Figures 22, as a forming mat with a geometric axis A parallel to the longitudinal direction which is a machine direction. The forming mat 60 may have a plurality of distinct mat patterns 61 arranged in at least one sequential relation with respect to the longitudinal direction. Each distinct pattern of track 61 may have a total area of distinct pattern of DPOA track defined, in a rectangular shape pattern, by a length L and width W, as indicated with respect to the distinct track pattern 61A. Each distinct belt pattern within its total DPOA area can have a first formation zone 112 with a first elevated pattern
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50/173 three-dimensionally extending outward from the plane of the first surface and a second forming zone 122 with second elevated three-dimensional elements extending outwardly from the plane of the first surface. The first forming zone can have a first air permeability value and the second forming zone can have a second air permeability value, and the first air permeability value can be different from the second air permeability value. The pattern within each total area ordered sequentially from a distinct DPOA mat pattern can be the same or different.
[0131] As an example, and with reference to the distinct pattern of mat 61 of forming mat 60 shown in Figure 19, and the nonwoven fabric 10 shown in Figure 21, the following properties have been determined. The first zone 110 of nonwoven fabric 10 can have an average weight of about 5 g / m ² to about 30 g / m ² ; the second zone 120 can have an average weight of about 50 g / m ² to about 70 g / m ² ; and the third zone 130 can have an average weight of about 25 g / m ² to about 60 g / m ² . The difference in weight from one zone to the other can be attributed to the difference in air permeability of the forming mat 60. In the modality used to produce the non-woven fabric 10 shown in Figure 20, in which the weights for zones 110, 12 0 and 130 are 15 g / m ² , 53 g / m ² and 25 g / m ² , respectively, the air permeability of the respective zones 112, 122 and 132 of the forming mat 60 is 379 cubic feet / minute,
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805 cubic feet / minute and 625 cubic feet / minute, respectively. Therefore, by varying the air permeability in zones on the formation mat 10, the intensive properties of the average weight and the average density in zones can be facilitated throughout the total area of fabric 10. [0132] As can be understood from from the description of the forming mat 60 described in Figure 22, and with reference to Figure 23, in one embodiment of the nonwoven substrate 11 produced on the mat 60, a nonwoven substrate 11 with a plurality of portions described herein can be described. as fabrics 10 ordered in at least one sequential relation to the longitudinal direction, that is, the machine direction, when produced on the forming mat 60. Figure 23 is a schematic representation of a nonwoven substrate with continuous spinning 11 that shows fabrics 10 ordered sequentially, each fabric 10 having a different pattern within the various zones. Each fabric 10 can have a defined total area OA, a pattern of regular shape, by a length L and a width W. Each fabric 10 arranged sequentially can have within its total area OA at least a first zone 110 with a first pattern of three-dimensional resources and intensive first products, and a first area located within the total OA area; a second zone 120, which has a second pattern of three-dimensional resources and second medium intensive properties, with a second area located within the total area OA. Optionally, more zones, for example, a third zone 130, having a third pattern of three-dimensional features and
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52/173 third intensive properties and having a third area within the total OA area may be present. As shown in the exemplary schematic representation of Figure 23, the first pattern 110A of fabric 10A may be different from the first pattern 110B of fabric 10B, and may be different from the first pattern 110C of fabric 10C. The same may be true of the second zones 120A, 120B and 120C.
[0133] In general, the sequentially ordered non-woven fabrics 10 of the non-woven material 11 produced on the forming mat 60 may vary in terms of their respective total areas, intensive properties and visual appearances. A common intensive property is an intensive property present in more than one zone (with respect to zonal patterns, as shown in Figure 21) or region (for three-dimensional features such as regular repetitive patterns, as shown in Figure 1). Such intensive properties of nonwovens 10 may be average values and may include, but are not limited to, density, volumetric density, weight, thickness and opacity. For example, if a density is an intensive property common to two different regions or zones, a density value in one region or zone may differ from a density value in the other region or zone. Zones (such as a first zone and a second zone) are identifiable areas that are visually distinguishable from each other and through different intensive properties weighted within the zone.
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53/173 [0134] Once produced, individual nonwovens 10 can be cut to the desired size and used for the purposes for which they are intended, such as for top layers in disposable absorbent articles. For example, a disposable diaper 1006 in a flattened orientation is shown in Figure 24. A fabric 10 is cut in a suitable total area and adhered to diaper 1006 by means known in the art. Fabrics 10 can be cut before being mounted on a diaper 1006, or during the diaper production process, non-woven substrate 11 can be unified with other blanket-shaped diaper components, cut to an appropriate size after assembly .
[0135] As can be understood with reference to Figure 24, in a embodiment of the nonwoven substrate 11 produced on the mat 60, a nonwoven fabric 11 can be described with a plurality of portions described herein as fabrics 10 arranged in at least one sequential relation to the longitudinal direction, that is, the machine direction when produced on the forming mat 60 in at least one side-to-side relationship, that is, the machine direction, when produced on the forming mat 60. Figure 24 is a schematic representation of a nonwoven substrate of continuous spinning 11 showing fabrics 10 sequentially arranged in adjacent lanes of machine direction lanes 13, with adjacent lanes having fabrics 10 side by side, shown in Figure 24 as 10D, 10E and 10F. Each fabric 10 can have a defined total OA area, a regular shape pattern, for a length
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L and a width W. Each fabric 10 arranged sequentially can have within its total area OA at least a first zone 110 with a first pattern of three-dimensional features and first intensive products, and a first area located within the total area OA; a second zone 120, which has a second pattern of three-dimensional features and second medium intensive properties, with a second area located within the total area OA. Optionally, more zones, for example, a third zone 130, having a third pattern of three-dimensional resources and third intensive properties and having a third area within the total area OA may be present. Each fabric 10 in streaks arranged side by side may be substantially identical, or may be different in size, visual appearance and / or intensive properties. Once produced, the non-woven substrate 11 can be rolled up to split into lanes for processing into consumer products, or split and then rolled up.
[0136] As a representative sample to compare the grammage differentials in a fabric 10 produced with a regular repetitive uniform pattern and a fabric 10 produced with a non-uniform zonal pattern, the nonwoven fabric 10 of Example 1 was compared to a fabric that has a pattern similar to that shown in Figure 21 and called Example 3. Example 3 is a two-component continuous spinning non-woven blanket produced in the apparatus disclosed here using the 50:50 polyethylene sheath spinning ratio ( Aspun6850-A obtained from the Dow Chemical Company) and
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55/173 polypropylene (PH-835 obtained from LyondellBasell) in a trilobal fiber configuration. The bicomponent three-component fibers of continuous spinning were placed on a forming mat 60 that moves at a linear speed of about 25 meters per minute to an average weight of 30 grams per square meter on a forming mat with a zonal pattern as shown in Figure 19. The second substrate was formed under identical conditions, but had at least one section having a uniformly repetitive regular pattern on a forming mat, as shown in Figure 16, from which the weight was determined. The conditions of fiber spinning, processing capacity, belt line speed and compaction roller consolidation temperature were identical for both substrates. Example 3 [0137] A two-component continuous spinning nonwoven fabric that was produced using a 50:50 polyethylene sheath spinning ratio (Aspun-6850-a obtained from Dow Chemical Company) and the polypropylene core (PH-835 obtained from LyondellBasell) in a trilobal fiber configuration for an average weight of 30 grams per square meter. A non-woven fabric was produced, as described with respect to Figures 7 and 8, by moving at a linear formation mat speed of about 25 meters per minute to form a fabric that has a zonal pattern as shown in Figure 20 The fibers of the fabric were additionally bonded to the first surface 12
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56/173 through heated compaction cylinders 70, 72 to 130 ° C, and the fabric was rolled on a reel in the roller 75. Example 4 [0138] A bicomponent continuous spinning nonwoven fabric that was produced using a 50:50 polyethylene sheath spinning ratio (Aspun-6850-a obtained from Dow Chemical Company) and the polypropylene core (PH-835 obtained from LyondellBasell) in a trilobal fiber configuration for an average weight of 30 grams per square meter. A non-woven fabric was produced, as described with respect to Figures 7 and 8, by moving at a linear formation mat speed of about 25 meters per minute to form a fabric that has a repetitive (non-zonal) pattern, as shown in Figure 2. The fibers of the fabric were additionally bonded on the first surface 12 by heated compaction cylinders 70, 72 130 ° C, and by rolling on a reel in the roller 75.
[0139] Table 2 below shows the average local weight, measured according to the Localized Weight test method of the present invention, the average being calculated in relation to 10 samples. The measurement samples were obtained from tissues, as shown in Figures 25A and 25B, in which the dark rectangles are at the point where a 3 cm ² sample was removed for measurement. As can be seen, the fabrics are marked along the transverse direction (DT) as A to E. The measurements show not only a significant difference in weight
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57/173 between the zones of the zonal tissue, but also a distribution in the DT shown graphically in Figure 26.
Table 2: Distribution of average weight measured on non-woven fabric 10 in grams per square meter (g / m ² )
Region as shown inFigure 25 Example 3: Weights of Zonal Fabric Example 4: Non-zonal tissue weights THE 48 g / m ² 43 g / m ² B 7 9 g / m ² 37 g / m ² Ç 14 g / m ² 32 g / m ² D 65 g / m ² 3 6 g / m ² AND 54 g / m ² 3 6 g / m ²
[0140] As can be seen in Table 2, fabrics 10 produced on forming mats 60 that have different air permeability zones demonstrate substantial variation in fiber deposition and thus weight in the DT of non-woven fabric 10, which suggests the ability of the fibers to move with air to areas of high permeability. The regular non-zonal repetitive pattern fabric 10 exhibits approximately the same weight in the tissue DT.
[0141] In addition to the differences in air permeability of the various areas of the forming mat 60, the structure of the forming mat 60 can affect other intensive properties of zones in the fabric 10, such as medium caliber, medium softness, compressive strength medium and fluid absorption properties.
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58/173 [0142] Another aspect of this invention relates to commercial lines of continuous spinning in which multiple bundles are used to improve the opacity and uniformity of application of the fabric. In some cases, the apparatus may include three beams of continuous spinning (known in the art as SSS), and may be combined with melt blowing (M), for example, in an apparatus known as an SSMMS continuous spinning line.
[0143] By calendering the non-woven fabric 10 to obtain stitches 90, the formation of fluff can be reduced. The formation of fluff refers to the tendency of fibers to loosen and be removed from the fabric 10. Loosening and removal can happen because of friction coupling with the manufacturing equipment during the production of disposable absorbent articles, or other surfaces, like the skin of a person who interacts with the fabric 10. In some uses, for example, as upper layers in disposable absorbent articles, the formation of fluff is a negative phenomenon for the consumer. However, the connection of fibers to the site can also be negative for the consumer, as this can generate the roughness of a surface of a soft non-woven substrate. It has been found that the substrates of non-woven fabrics and non-woven fabrics of the present disclosure can withstand increased binding (and a consequent decrease in the formation of fluff) with minimal loss of softness. The connection can be made by point connections with relatively close spacing 90, the spacing being determined by the desired level of reduction of formation of
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59/173 fluff. Bonding can also be achieved by known methods for chemically or thermally bonding nonwoven fibers, such as thermal bonding, ultrasonic bonding, pressure bonding, adhesive bonding with latex and combinations of such methods. The reduction of fluff formation upon bonding is illustrated with respect to Examples 5 and 6 below.
Example 5 [0144] A two-component continuous spinning non-woven fabric produced by spinning at a 50:50 ratio between the polyethylene sheath (Aspun-6850-A obtained from the Dow Chemical Company) and the polypropylene core (PH-835 obtained from LyondellBasell) in a trilobal fiber configuration at an average weight of about 30 grams per square meter on a forming mat, as described in Figures 7 and 8, moving at a linear speed of about 25 meters per minutes to form a fabric with the repeating pattern shown in Figure 36. The fibers of the fabric were further consolidated on the first surface 12 by means of compaction rollers 70, 72 with the compaction roll 70 heated to 130 ° C to form substantially bonds 80.
Example 6 [0145] A two-component continuous spinning nonwoven fabric was produced by spinning at a 50:50 ratio between the polyethylene sheath (Aspun-6850-A obtained from the Dow Chemical Company) and the polypropylene core (PH- 835 obtained from LyondellBasell) in a trilobal fiber configuration at an average weight of about 30 grams per meter per meter
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60/173 square on a formation mat, as described in relation to Figures 7 and 8, moving at a linear speed of about 25 meters per minute to form a fabric having the repetition pattern described in relation to Figure 37. The fibers of the fabric were additionally bonded to the first surface 12 by compaction cylinders 70, 72, with the compaction cylinder 70 heated to 130 ° C to form substantially continuous bonds 80. The fibers of the fabric were additionally joined by calendering on the calender rolls 71, 73, with roll 73 being an engraved roll having elevated portions 88 in the form of pins 1.25 mm high and 0.62 mm gap opening in a 10% stitch connection pattern. The roll 73 was heated to 135 ° C to form dot connections 90 on the second side 14 of the fabric 10, as shown in Figure 11.
[0146] Tissues 10 of Examples 5 and 6 differ only in the absence or presence of 90 point bonds. The second side 14 of tissues 10 were subjected to fluff formation test, according to the Formation Level Test Felpa, to determine the effectiveness of stitch connections to attach the fibers to the fabric surface. The results of the fluff formation test of Examples 5 and 6 are shown in Table 3.
Table 3: Results of Felp Formation in DM
specimen No. Value of Formation of Dander in DM (mg / cm ² ) Example 5 0.36 Example 6 0, 19
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61/173 [0147] As shown above, the 90 point bindings result in a dramatic decrease in the Value of Dander Formation in the DM. The softness, absorbency and aesthetic benefits were unexpectedly maintained, despite the bonding treatment and there is now also the desired resistance to the formation of fluff through use by the consumer. The absorbent articles of the present description are generally placed in packaging for transport, storage and sale. The packages may comprise polymeric films and / or other materials. Graphics and / or symbols related to the properties of absorbent articles can be formed in, printed on, positioned on and / or placed on the outer portions of the packages. Each package can comprise a plurality of absorbent articles. Absorbent articles can be packed under compression in order to reduce the size of the packages, while still providing an adequate amount of absorbent articles per package. By packaging absorbent articles under compression, caregivers can easily manipulate and store packages, while also providing distribution savings for manufacturers due to the size of the package. Figure 27 illustrates an exemplary package 1000 comprising a plurality of absorbent articles 1004. Package 1000 defines an internal space 1002 in which the plurality of absorbent articles 1004 are located. The plurality of absorbent articles 1004 are arranged in one or more stacks 1006.
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62/173 [0148] Consequently, the packs of absorbent articles of the present disclosure can have a stacking height of bags less than about 100 mm, less than about 95 mm, less than about 90 mm, less than about 85 mm, although greater than about 75 mm, less than about 80 mm, less than about 7 8 mm, less than about 7 6 mm, or less than about 74 mm, specifically mentioning all 0.1 increments % within the ranges specified above and all bands formed on or by them, according to the bag stacking height test described here. Alternatively,
packaging From articles absorbent gives gift invention may have an height of stacking in scholarships about 70 mm to fence 100 mm, about in 7 0 mm a about 95 mm about 72 mm to about 85 mm, from about 72 mm fence 80 mm or fence in 7 4 mm a about
mm, specifically mentioning all 0.1% increments within the ranges specified above and all bands formed on or by them, according to the bag stacking height test described here.
General Description of the Absorbent Article Example [0149] The three-dimensional non-woven fabrics 10 of the present disclosure can be used as a component of absorbent articles, such as diapers, child care articles, such as training pants, feminine hygiene articles, as sanitary pads, and adult care products like incontinence products, pads, and pants. An exemplary absorbent article in the form of
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63/173 a diaper 220 is shown in Figures 28 to 30. Figure 28 is a plan view of the diaper example 220, in an extended, flat state, with portions of the structure being cut out to show the construction of diaper 220 more clearly. The user-facing surface of the diaper 220 of Figure 28 is facing the viewer. This diaper 220 shows, for illustration purposes only, how the three-dimensional nonwoven materials of the present disclosure can be used as one or more components of an absorbent article, such as the top layer, the capture layer, the top layer and the layer capture system or the upper layer and the capture and / or distribution system (ADS). In any event, the three-dimensional nonwoven fabrics of the present disclosure can be liquid-permeable.
[0150] Absorbent article 220 may comprise a liquid-permeable material or upper layer 224, a liquid-impermeable material or lower layer or 225, an absorbent core 228 positioned at least partially between the upper layer 224 and the lower layer 225, and barrier leg clamps 234. The absorbent article may also comprise an ADS 250, which in the example shown comprises a distribution layer 2 54 and a capture layer 252, which will be described in detail below. The absorbent article 220 may also comprise elasticized sealing clamps 232 comprising rubber bands 233 joined to a structure of the absorbent article, typically by means of the upper layer and / or the lower layer, and substantially flat with the diaper structure.
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64/173 [0151] Figures 28 and 31 also show typical tapered diaper components, such as a fastening system comprising flaps 242 fixed towards the rear edge of the article and which cooperate with contact zone 244 at the front of the article pad. The absorbent article may also comprise other typical elements, which are not shown, such as a posterior elastic waist feature, an anterior elastic waist feature, cross leg leg clamp (s) and / or an application lotion, for example.
[0152] The absorbent article 220 comprises an edge of the anterior waist 210, an edge of the posterior waist 212 longitudinally opposite the edge of the anterior waist 210, a first lateral edge 203 and a second lateral edge 204 laterally opposite the first lateral edge 203. A edge of the front waist 210 is the edge of the article that is intended to be placed towards the front of the user when used, and the edge of the back waist 212 is the opposite edge. The absorbent article 220 may have a longitudinal axis 280 that extends from the lateral midpoint of the edge of the anterior waist 210 to a lateral midpoint of the edge of the posterior waist 212 of the article and which divides the absorbent article into two substantially symmetrical halves in with respect to that longitudinal axis 280, with the article placed flat, extended and viewed from above, as in Figure 28. The absorbent article 220 may also have a lateral axis 290 that extends from the longitudinal midpoint of the first lateral edge 203 to the point
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65/173 longitudinal median of the second lateral edge 204. The length, L, of the article can be measured along the longitudinal axis 280 from the edge of the anterior waist 210 to the edge of the posterior waist 212. The width, W, of the article absorbent can be measured along side axis 290 from first side 203 to second side edge 204. The absorbent article may comprise a hook height C defined as the point placed on the longitudinal axis at a distance of two fifths (2 / 5) from L starting from the front edge 210 of the article 220. The article may comprise a region of the anterior waist 205, a region of the posterior waist 206 and a hook region 207. The region of the anterior waist 205, the region of the waist rear 206 and the hook region 207 each define 1/3 of the longitudinal length, L, of the absorbent article.
[0153] The top layer 224, the bottom layer 225, the absorbent core 228 and the other components of the article can be assembled in a variety of configurations, in particular by gluing or thermal embossing, for example.
[0154] The absorbent core 228 may comprise an absorbent material comprising at least 80% by weight, at least 85% by weight, at least 90% by weight, at least 95% by weight, or at least 99% by weight of superabsorbent polymers, and a core wrap around the superabsorbent polymers. The core wrap can typically comprise two materials, substrates or non-woven materials 216 and 216 'for the top and bottom side of the core. These types of cores are known as cores
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66/173 free from aerated felt. The core may comprise one or more channels, shown in Figure 28 as the four channels 226, 226 'and 227, 227'. Channels 226, 226 ', 227 and 227' are optional features. Instead, the core may not have any channels or it may have any number of channels. [0155] These and other components of the absorbent article examples will now be discussed in more detail.
Top layer [0156] In the present disclosure, the top layer (the portion of the absorbent article that comes into contact with the user's skin and that receives fluids) can be formed from a portion of, or all, one or more of the materials not - three-dimensional fabrics described herein and / or having one or more of the non-woven materials positioned on it and / or joined to it, so that the non-woven material (s) is (are) in contact with the skin of the user. Other portions of the top layer (in addition to three-dimensional non-woven fabrics) may also come into contact with the user's skin. Three-dimensional non-woven fabrics can be positioned as a strip or adhesive on top of a typical top layer 224. Alternatively, the three-dimensional non-woven material can form only a central area in the DT of the top layer. The central area in the transverse direction can extend over the entire MD length of the top layer or over part of the MD length of the top layer.
[0157] The top layer 224 can be joined to the bottom layer 225, the absorbent core 228 and / or any
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67/173 other layers, as is known to those skilled in the art. Generally, the top layer 224 and the bottom layer 225 are joined directly to each other, in some places (for example, on or near the periphery of the absorbent article), and are joined indirectly to each other in other places, through direct joining one or more of the other elements of Article 220.
[0158] The top layer 224 can be malleable, soft to the touch and non-irritating to the user's skin. In addition, a portion of the top layer 224, or the entire top layer, may be permeable to liquids, allowing liquids to penetrate rapidly through its thickness. In addition, a portion or all of the top layer 224 can be treated with surfactants or other agents both to hydrophilize the mat and to make it hydrophobic. Any portion of the top layer 224 can be coated with a skin care lotion and / or composition, as is generally known in the art. The top layer 224 can also comprise or be treated with antibacterial agents.
Bottom Layer [0159] The bottom layer 225 is, in general, that portion of the absorbent article 220 in a position adjacent to the surface facing the garment of the absorbent core 228 and that prevents, or at least inhibits, the bodily fluids and exudates absorbed and confined in it soiling articles such as sheets and underwear. The bottom layer 225 is typically impermeable, or at least substantially impermeable, to fluids (e.g., urine). The bottom layer can therefore
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68/173 example, be or comprise a thin plastic film, such as a thermoplastic film, having a thickness of about 0.012 mm to about 0.051 mm. Other suitable lower layer materials may include breathable materials, which allow vapors to escape from the absorbent article (220) while still preventing, or at least inhibiting, the passage of fluids through the lower layer 225.
[0160] The lower layer 225 can be joined to the upper layer 224, the absorbent core 228 and / or to any other element of the absorbent article 220 by means of any fastening methods known to those skilled in the art.
[0161] The absorbent article may comprise a lower layer comprising an outer covering or an outer covering nonwoven. An outer or non-woven lining of the absorbent article 220 may cover at least a portion or the entire lower layer 225 to form a soft surface facing the garment of the absorbent article. The outer covering or the outer nonwoven can be formed from the high-thickness three-dimensional nonwoven materials described herein. Alternatively, the outer or non-woven outer jacket may comprise one or more known outer jacket materials. If the outer sheath comprises one or more of the three-dimensional nonwoven materials of the present disclosure, the three-dimensional nonwoven material of the outer sheath may or may not match (for example, same material, same pattern) with the three-dimensional nonwoven material used in the upper layer.
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69/173 or the upper layer and the absorbent article capture layer. In other cases, the outer covering may have a patterned or otherwise applied pattern that corresponds or visually resembles the pattern of the three-dimensional non-woven materials used as the top layer or laminate of the top layer and capture layer of the absorbent article. The outer coating can be joined to at least a portion of the bottom layer 225 by mechanical, ultrasonic, thermal, adhesive, or other suitable attachment methods.
Absorbent Core [0162] The absorbent core is the component of the absorbent article that has the greatest absorption capacity and that comprises an absorbent material and a wrap around the core or core pouch that surrounds the absorbent material. The absorbent core does not include the capture and / or delivery system or any other components of the absorbent article which is not an integral part of the core wrap or core pouch and is not placed inside the core wrap or core pouch. The absorbent core may comprise, consist essentially of, or consist of, a core wrap, an absorbent material (e.g., superabsorbent polymers and a small or zero amount of cellulose fibers) as discussed, and glue.
[0163] The absorbent core 228 may comprise an absorbent material with a high amount of superabsorbent polymers (hereinafter abbreviated as SAP) enclosed within the core shell. SAP content can
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represent 70% to 100% or to minus 70% , 75%, 80%, 85%, 90%, 95%, 99% or 100% by weight of material contained absorbent at the wrap from the core. 0 wrap the core does not is considered as absorbent material for the purpose in percentage rating in SAP on absorbent core. 0 abso core rvente can contain felt aerated with or without
superabsorbent polymers.
[0164] By absorbent material is meant a material that has some absorbency or liquid retention property, such as SAP, cellulosic fibers, as well as synthetic fibers. Typically, glues used in the production of absorbent cores do not have, or have few, absorbency properties and are not considered to be absorbent material. The SAP content can be greater than 80%, for example, at least 85%, at least 90%, at least 95%, at least 99% and up to and including 100% of the weight of the absorbent material contained within the wrapper. core. This aerated felt-free core is relatively thin compared to the conventional core, which typically comprises between 40 and 60% SAP, by weight, and a high cellulose fiber content. In particular, the absorbent material may, in particular, comprise less than 15% by weight or less than 10% by weight, of natural, cellulosic or synthetic fibers or less than 5% by weight, less than 3% by weight, less than 2% by weight, less than 1% by weight, or it can be substantially free of natural, cellulosic, and / or synthetic fibers.
[0165] As mentioned above, aerated felt cores with very little or no cellulosic and / or synthetic fibers
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71/173 or natural are very thin compared to conventional cores, thus making the absorbent article as a whole thinner than absorbent articles with cores comprising SAP and mixed cellulosic fibers (eg 40 to 60% cellulose fibers) . In the consumer's perception, this thin core can be seen as a core with reduced absorption capacity and performance, although technically this is not the case. Currently, these thin cores have typically been used with substantially flatter top layers or provided with openings. In addition, absorbent articles with these thin cores free from aerated felt have reduced capillary voids since there are few or no natural, cellulosic or synthetic fibers in the cores. Therefore, sometimes there may not be enough capillary voids in the absorbent article to fully accept multiple insults of bodily exudates, or a single significant insult.
[0166] To solve these problems, the present disclosure provides absorbent articles with these thin cores free from aerated felt, in combination with one of the high-thickness three-dimensional nonwoven materials described here as a top layer or as a top layer laminate and top layer. catch. In this case, the consumer's perception of absorbency and performance, through the increased thickness of the absorbent article due to the additional thickness provided by the high-thickness three-dimensional nonwoven material, is increased. In addition, three-dimensional non-woven materials, when used with these thin
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72/173 aerated felt and like the upper layer or the laminate of the upper layer and the capture layer, they add the capillary voids again in the absorbent articles, while allowing minimum stacking heights, thus passing on a reduction of costs for consumers and manufacturers. As such, the absorbent articles of the present disclosure can easily absorb multiple insults of bodily exudates or a single significant insult due to this increased capillary void. In addition, absorbent articles comprising non-woven materials such as the top layer or the top layer laminate and capture layer, provide consumers with an aesthetically pleasing top layer compared to a flatter top layer or a top layer with openings with increased thickness and, thus, consumer perceptions of absorbency and performance.
[0167] The example of absorbent core 228 of absorbent article 220 of Figures 31 to 32 is shown isolated in Figures 33 to 35. The absorbent core 22 8 can comprise a front side 480, a rear side 282 and two longitudinal sides 284, 286 joining the front side 480 and the rear side 282. The absorbent core 228 may also comprise a generally flat top side and a generally flat bottom side. The front side 480 of the core is the side of the core intended to be placed towards the edge of the anterior waist 210 of the absorbent article. The core 228 may have a longitudinal axis 280 'which substantially corresponds to the longitudinal axis 280 of the absorbent article 220, as
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73/173 seen from above in a flat view, as in Figure 28. The absorbent material can be distributed in a greater amount towards the front side 480 than towards the rear side 282, since more absorbance may be required on the front side in specific absorbent articles. The front and rear sides 480 and 282 of the core may be shorter than the longitudinal sides 284 and 286 of the core. The core wrap can be formed of two non-woven materials, substrates, laminates or other materials, 216, 216 ', which can be sealed at least partially along the sides 284, 286 of the absorbent core 228. The core wrap can be sealed at least partially along its front side 480, rear side 282 and on two longitudinal sides 284, 286, so that substantially no absorbent material leaks out of the absorbent core wrap. The first material, substrate or nonwoven 216 may at least partially surround the second material, substrate or nonwoven 216 'to form the core wrap, as shown in Figure 34. The first material 216 may surround a portion of the second material 216 'adjacent to the first and second side edges 284 and 286.
[0168] The absorbent core may comprise adhesive, for example, to help immobilize the SAP within the core wrap and / or to ensure the integrity of the core wrap, in particular, when the core wrap is made of two or more substrates. The adhesive may be an available heat-resistant adhesive, by H.B. Fuller, for example. The core wrap can extend
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74/173 if for an area larger than strictly necessary to contain the absorbent material inside.
[0169] The absorbent material can be a continuous layer present in the core shell. Alternatively, the absorbent material may comprise individual pockets or strips of absorbent material enclosed within the core wrap. In the first case, the absorbent material can, for example, be obtained by applying a single continuous layer of absorbent material. The continuous layer of absorbent material, particularly SAP, can also be obtained by combining two absorbent layers having discontinuous absorbent material application patterns, in which the resulting layer is substantially continuously distributed over the entire area of polymer material absorbent particulate, as disclosed in US patent publication No. 2008 / 0312622A1 (Hundorf), for example. The absorbent core 228 may comprise a first absorbent layer and a second absorbent layer. The first absorbent layer may comprise the first material 216 and a first layer 261 of absorbent material, which may comprise 100% or less of SAP. The second absorbent layer may comprise the second material 216 'and a second layer 262 of absorbent material, which may also comprise 100% or less of SAP. The absorbent core 228 may also comprise a fibrous thermoplastic adhesive material 251 which at least partially bonds each layer of absorbent material 261, 262 to its respective material 216
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75/173 or 216 '. This is illustrated in Figures 34 and 35, as an example, where the first and second layers of SAP were applied as transversal strips or flat areas having the same width as the desired absorbent material deposition area on their respective substrate before being combined. The strips may comprise different amounts of absorbent material (SAP) to provide a profiled weight along the longitudinal axis of the core 280. The first material 216 and the second material 216 'can form the core wrap.
[0170] The fibrous thermoplastic adhesive material 251 can be at least partially in contact with the absorbent material 261, 2 62 in the flat areas and at least partially in contact with the materials 216 and 216 'in the joint areas. This gives an essentially three-dimensional structure to the fibrous layer of thermoplastic adhesive material 251, which itself is essentially a two-dimensional structure of relatively small thickness, compared to the dimension in the length and width directions. Thus, the fibrous thermoplastic adhesive material can provide cavities to cover the absorbent material in the flat areas and thereby immobilize that absorbent material, which can be 100% or less of SAP.
[0171] The thermoplastic adhesive used for the fibrous layer can have elastomeric properties, so that the blanket formed by the fibers in the SAP layer can be extended as the SAP expands.
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Superabsorbent Polymer (SAP) [0172] The SAP useful in the present disclosure may include a variety of water-insoluble but water-swellable polymers capable of absorbing large amounts of fluids.
[0173] The superabsorbent polymer can be in the form of particulate so that it can flow when in a dry state. Particulate absorbent polymeric materials can be produced from polymers of poly (meth) acrylic acid. However, absorbent particulate polymeric material based on starch can also be used, as well as polyacrylamide copolymer, ethylene-maleic anhydride copolymer, cross-linked carboxymethylcellulose, poly (vinyl alcohol) copolymers, cross-linked polyethylene oxide and polyacrylated amide polyacrylonitrile copolymer. .
[0174] Superabsorbent polymers (SAP) can have numerous shapes. 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. SAP particles can be in the form of fibers, that is, elongated acicular superabsorbent polymer particles. The fibers can also be in the form of a long filament, which can be woven. SAP can be sphere-like particles. The absorbent core may comprise one or more types of SAP.
[0175] For most absorbent articles, a user discharges liquids predominantly in the front half of the absorbent article, in particular for a diaper. The previous half of the article (as defined by the region
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77/173 between the leading edge and a transverse line placed at a distance of half L from the edge of the anterior waist 210 or the edge of the posterior waist 212 can therefore comprise most of the absorbent capacity of the core. Thus, at least 60% of the SAP or at least 65%, 70%, 75%, 80% or 85% of the SAP can be present in the front half of the absorbent article, while the remaining SAP can be arranged in the back half of the article pad. Alternatively, the SAP distribution can be uniform across the core or it can have other suitable distributions. [0176] The total amount of SAP present in the absorbent core can also vary according to the expected user. Diapers for newborns may require less SAP than diapers for babies, children or adult incontinence. The amount of SAP in the core can be about 5 to 60 g, or 5 to 50 g. The weight of SAP in the (or at least one, if several are present) deposition area 8 of SAP can be at least 50, 100, 200, 300, 400, 500 or more g / m ² . The channel areas (e.g., 226, 226 ', 227, 227') present in the absorbent material deposition area 8 are deducted from the absorbent material deposition area to calculate this average weight.
Core Wrap [0177] The core wrap can be made of a single substrate, material or nonwoven folded around the absorbent material, or it can comprise two (or more) substrates, material or non-woven that are fixed together. Typical fixings are so-called
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78/173 C and / or sandwich wraps. In a C-shaped envelope, as illustrated, for example in Figures 29 and 34, the longitudinal and / or transverse edges of one of the substrates are folded over the other substrate to form flaps. These flaps are then joined to the outer surface of the other substrate, typically by gluing.
[0178] The core wrap can be formed using any materials suitable for receiving and containing the absorbent material. Typical substrate materials used in the production of conventional cores, in particular paper, fabrics, films, woven or nonwoven materials, or laminates or composites of any of them, can be used.
[0179] Substrates can also be permeable to air (in addition to being permeable to liquid or fluid). The films useful for the present invention can therefore comprise micropores.
[0180] The core wrap can be sealed at least partially along all sides of the absorbent core so that substantially no absorbent material will leak out of the core. By substantially no absorbent material it means that less than 5%, less than 2%, less than 1% or about 0% by weight of absorbent material escapes from the core shell. The term sealing must be understood in a broad sense. The seal does not need to be continuous along the entire periphery of the core shell, but it can be discontinuous along part or all of it, for example formed by a series of sealing points spaced in a line. A seal can be formed by gluing and / or heat sealing.
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79/173 [0181] If the core wrap is formed by two substrates 216, 216 ', four seals can be used to wrap the absorbent material 260 within the core wrap. For example, a first substrate 216 can be placed on one side of the core (the upper side, as shown in Figures 33 to 35) and extend around the longitudinal edges of the core to at least partially surround the opposite bottom side of the core . The second substrate 216 'can be present between the rolled tabs of the first substrate 216 and the absorbent material 260. The tabs of the first substrate 216 can be glued to the second substrate 216' to provide a strong seal. This so-called C-shell construction can provide benefits such as improved resistance to breakage in a full and wet state compared to a sandwich seal. The front and back sides of the core shell can then be sealed by gluing the first substrate and the second substrate to each other to provide complete encapsulation of the absorbent material throughout the periphery of the core. For the front and rear sides of the core, the first and second substrates can extend and join in a substantially flat direction, giving these edges a so-called sandwich construction. In the so-called sandwich construction, the first and second substrates can also extend outwardly on all sides of the core and can be sealed flat, or substantially flat, along all or parts of the periphery of the core, typically , by gluing and / or joining to
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80/173 hot / by pressure. In one example, neither the first nor the second substrates need to be shaped, so that they can be cut rectangularly to facilitate production; however, other formats are also within the scope of the present disclosure.
[0182] The core wrap can also be formed through a single substrate that can surround, as in a partial wrapping, the absorbent material and be sealed along the front and back side of the core and a longitudinal seal.
SAP Deposition Area [0183] The absorbent material deposition area 208 can be defined by the periphery of the layer formed by the absorbent material 260 inside the core envelope, as seen from the upper side of the absorbent core. The deposition area for absorbent material 208 can take various shapes, in particular a dog bone or hourglass shape, which shows a taper along its width towards the middle or in the region between the thighs of the core. In this way, the deposition area for absorbent material 8 can be relatively narrow in an area of the core intended to be placed in the region between the thighs of the absorbent article, as illustrated in Figure 28. This can provide better wearing comfort. The deposition area of the absorbent material 8 can also be generally rectangular, for example, as shown in Figures 31 to 33, but other deposition areas, such as the T, Y, hourglass or dog bone shapes are also
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81/173 within the scope of this disclosure. The absorbent material can be deposited using any suitable techniques, which can allow the relatively accurate deposition of the SAP at relatively high speed.
Channels [0184] The deposition area for absorbent material 208 can comprise at least one channel 226, which is oriented, at least partially, in the longitudinal direction of article 280 (ie, it has a longitudinal vector component) as shown in Figures 28 and 29. Other channels can be at least partially oriented in the lateral direction (that is, it has a lateral vector component) or in any other direction. Next, the plural form channels will be used to mean at least one channel. The channels can have a length L 'projected on the longitudinal axis 280 of the article which is at least 10% of the length L of the article. Channels can be formed in several ways. For example, the channels can be formed by zones within the deposition area for absorbent material 208 which can be substantially free, or free, of absorbent material, in particular SAP. In another example, the channels can be formed by zones within the absorbent material deposition area 208 where the core absorbent material comprises cellulose, aerated felt, SAP, or combinations thereof and the channels can be substantially free of, or free of absorbent material, in particular SAP, cellulose or aerated felt in addition or alternatively, the channel (or channels) also
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82/173 can be formed by continuously or continuously joining the top side of the core wrap to the bottom side of the core wrap through the absorbent material deposition area 208. The channels can be continuous, however, it is not excluded that the channels are intermittent. The capture-distribution system or layer 250, or another layer of the article, may also comprise channels, which may or may not correspond to the channels of the absorbent core.
[0185] In some instances, the channels may be present at least at the same longitudinal level as the hook height C or the lateral axis 260 in the absorbent article, as shown in Figure 28 with the two channels extending longitudinally 226, 226 ' . The channels can also extend from the region between the thighs 207 or can be present in the region of the anterior waist 205 and / or in the region of the posterior waist 206 of the article.
[0186] The absorbent core 228 may also comprise more than two channels, for example, at least 3, at least 4, at least 5 or at least 6 or more. Short channels may also be present, for example, in the posterior waist region 206 or in the anterior waist region 205 of the nucleus, as represented by the pair of channels 227, 227 'in Figure 28 towards the front of the article. The channels may comprise one or more pairs of channels arranged symmetrically, or arranged differently in relation to the longitudinal geometric axis 280.
[0187] The channels can be particularly useful in the absorbent core when the deposition area of absorbent material
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83/173 is rectangular, since the channels can optimize the flexibility of the core as there is less advantage in using a non-rectangular (formatted) core. Of course, channels can also be present in an SAP layer that has a formatted deposition area.
[0188] The channels can be completely oriented longitudinally and parallel to the longitudinal axis or completely oriented transversely and parallel to the
lateral axis, but curved. also have at fewer portions than are [0189] To reduce the risk of fluid leakage, the main channels longi tudinai n do not extend up until
any of the edges of the absorbent material deposition area 208 and can thus be fully enclosed within the absorbent material deposition area 208 of the core. The shortest distance between a channel and the nearest edge of the absorbent material deposition area 208 may be at least 5 mm.
[0190] The channels can have a width Wc along at least part of their length that is at least 2 mm, at least 3 mm, at least 4 mm, up to for example 20 mm, 16 mm or 12 mm, for example . The width of the channel (s) can be constant across substantially the entire length of the channel or can vary along its length. When the channels are formed by an area free of absorbent material inside the deposition area of absorbent material 208, the width of the channels is considered as the width of the area free of material, regardless of the possible presence of the
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84/173 core inside the channels. If the channels are not formed through free zones of absorbent material, for example, mainly by connecting the casing to the core through the zone of absorbent material, the width of the channels will be the width of that connection.
[0191] At least part or all of the channels can be permanent channels, which means that their integrity is maintained, at least partially, in both the dry and wet states. Permanent channels can be obtained by supplying one or more adhesive materials, for example, a fibrous layer of adhesive material or a construction glue that helps in the adhesion of a substrate with an absorbent material within the walls of the channel. The permanent channels can also be formed by joining the upper side and the lower side of the core envelope (for example, the first substrate 216 and the second substrate 216 ') and / or from the upper layer 224 to the lower layer 225 through the channels . Typically, an adhesive can be used to bond both sides of the core wrap or the top layer and the bottom layer through the channels, but it is possible to make the connection through other known processes, such as pressure bonding, ultrasound bonding, the thermal connection or combination thereof. The core wrap or top layer 224 and bottom layer 225 can be continuously connected or intermittently connected along the channels. The channels can advantageously remain or become visible at least through the top layer and / or the bottom layer when the absorbent article is
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85/173 fully charged with a fluid. This can be achieved by producing channels substantially free from SAP, so that they do not swell, and large enough, so that they do not close when wet. In addition, connecting the core wrap to itself or the top layer to the bottom layer through the channels, can be advantageous.
Barrier Leg Clamps [0192] The absorbent article may comprise a pair of leg barrier clamps 34. Each leg barrier clamp may be formed of a piece of material that is attached to the absorbent article so that it it can extend upwards from a user-facing surface of the absorbent article and provide improved fluid and other body exudate containment at approximately the junction between the user's torso and legs. The barrier clamps for the feathers are bounded by a proximal edge 64 joined directly or indirectly to the top layer 224 and / or the bottom layer 225 and a free end edge 266, which is intended to contact and form a seal with the skin of user. Barrier leg clamps 234 extend at least partially between the edge of the front waist 210 and the edge of the rear waist 212 of the absorbent article on opposite sides of the longitudinal geometric axis 80 and are present at least at the height level of hook (C) or the region between the thighs. Barrier leg clamps can be joined at the proximal edge 264 with the article structure by a connection 265 that can be
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86/173 produced, for example, by gluing, fusion joining or a combination of other suitable joining processes. The Union
265 at the proximal edge 264 can be continuous or intermittent. The connection 265 closest to the raised leg clamp section delimits the proximal edge 264 of the raised leg clamp section.
[0193] Barrier leg clamps can be integral with top layer 224 or bottom layer 225, or they can be formed from a separate material attached to the article structure. Each leg barrier clamp 234 may comprise one, two or more elastic strips 235 near the free end edge
266 to provide a better seal.
[0194] In addition to the barrier leg clamps 234, the article may comprise sealing clamps 232, which are attached to the structure of the absorbent article, in particular the upper layer 224 and / or the lower layer 225 and are placed externally in barrier leg clamps. Sealing clamps 232 can provide a better seal around the user's thighs. Each sealing clamp may comprise one or more elastic threads or elastic elements 233 in the structure of the absorbent article between the upper layer 224 and the lower layer 225 in the area of the leg openings. The whole or a portion of the barrier leg clamps and / or the sealing clamps can be treated with a lotion or other skin care composition.
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Capture-distribution system [0195] The absorbent articles of the development may comprise a layer or system of capture and distribution 250 (ADS, acquisition-distribution system). A function of the ADS is to quickly acquire one or more of the fluids and effectively distribute the same (s) to the absorbent core. The ADS can comprise one, two or more layers, which can form a unitary layer or remain as isolated layers that can be attached to each other. In one example, the ADS can comprise two layers: a distribution layer 254 and a capture layer 252 arranged between the absorbent core and the top layer, but the present disclosure is not limited in this way.
[0196] In one example, the high-thickness three-dimensional nonwoven materials of the present disclosure may comprise the top layer and the capture layer as a laminate. A distribution layer can also be provided on the garment-facing side of the top layer / capture layer.
Support Layer [0197] In a case where the high-thickness three-dimensional nonwoven materials of the present disclosure comprise a top layer and capture layer laminate, the distribution layer may need support through a support layer ( not illustrated) which may comprise one or more nonwoven materials or other materials. The distribution layer can be applied to or positioned on the support layer. As such, the layer of
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88/173 support can be positioned between the capture layer and the distribution layer and be in a face-to-face relationship with the capture layer and the distribution layer.
Distribution Layer [0198] The ADS distribution layer can comprise at least 50%, by weight, of cross-linked cellulose fibers. The cross-linked cellulosic fibers can be crimped, twisted or curly, or a combination thereof, which includes crimped, twisted and curly. This type of material is disclosed in US Patent Publication No. 2008/0312622 Al (Hundorf). The cross-linked 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 user's weight. This can provide the core with a higher empty volume, permeability and liquid absorption and thus reduced leakage and optimized dryness.
[0199] The distribution layer comprising the crosslinked cellulose fibers of the present disclosure can comprise other fibers, however that layer can advantageously comprise at least 50% or 60% or 70% or 80% or 90% or even 100%, by weight of the layer, of cross-linked cellulose fibers (including cross-linking agents).
Capture Layer [0200] If a three-dimensional nonwoven material of the present disclosure is provided only as the top layer of an absorbent article, the ADS 250 can comprise a capture layer 252. The capture layer can be arranged between the
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The distribution layer 254 and the top layer 224. In such a case, the capture layer 252 can be or comprise a non-woven material, such as a hydrophilic SMS or SMMS material, which comprises a continuous spinning layer, a produced by block extrusion with high speed hot air and an additional continuous spinning layer, or alternatively a non-woven chemically fixed with carded textile fiber. The non-woven material can be glued with latex.
Fixation System [0201] The absorbent article may comprise a fixation system. The fixing system can be used to provide lateral tensions around the circumference of the absorbent article to hold the absorbent article in the user, as is typically typical for diaper fixed with tape. This fixing system may not be necessary for training diaper articles since the waist area of these articles is already joined. The fastening system may comprise a fastener such as fastening tape tabs, hook and loop fastening components, snap fasteners such as flaps & slits, buckles, buttons, pressure fasteners and / or hermaphrodite fastening components, although any other suitable attachment mechanisms are within the scope of the present disclosure. A contact zone 244 is normally provided on the surface facing the front waist garment 205 for the fastener to be releasably attached to it.
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Anterior and posterior ears [0202] The absorbent article may comprise anterior ears 246 and posterior ears 240. The ears may be an integral part of the structure, as formed from the upper layer 224 and / or the lower layer 226 as side panels. Alternatively, as shown in Figure 28, the ears can be separate elements fixed by hot gluing and / or embossing and / or pressure joining. The rear ears 240 can be extended to facilitate the attachment of the flaps 242 to the contact zone 244 and to keep the diapers fixed with the tape in place around the user's waist. The rear ears 240 can also be elastic or extensible to provide more comfort and contour adjustment initially through the conforming fit of the absorbent article to the user and sustaining this adjustment throughout the time of use even when the absorbent article is loaded with fluids and others bodily exudates, since the elasticized ears allow the sides of the absorbent article to expand and contract.
Elastic Waist Feature [0203] Absorbent article 220 may also comprise at least one elastic waist feature (not shown) that helps provide better fit and containment. The elastic feature of the waist is generally intended to expand and contract elasticly, to be dynamically adjusted to the user's waist. The elastic waist detail can extend at least longitudinally outward from at least one edge of the waist of the absorbent core 228
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91/173 and, in general, forms at least a portion of the end edge of the absorbent article. Disposable diapers can be constructed to have two elastic waist features, one positioned in the anterior waist region and one positioned in the posterior waist region.
Color signs [0204] In one form, the absorbent articles of the present disclosure may have different colors in different layers, or portions thereof (for example, the top layer and the capture layer, the top layer and the non-core coating) -fabric, a first portion and a second portion of an upper layer, a first portion and second portion of the capture layer). The different colors can be shades of the same color (for example, dark blue and light blue) or they can be really different colors (for example, purple and green). The different colors can have a Delta E in the range of about 1.5 to about 10, about 2 to about 8, or about 2 to about 6, for example. Other Delta E bands are also covered by the scope of this disclosure.
[0205] In one example, several layers of absorbent articles can be joined using a colored adhesive. The colored adhesive can be arranged in any suitable layer or layers in a pattern. The pattern of the adhesive may or may not complement the pattern of the top layer. Such a pattern can increase the appearance of depth in an absorbent article. In certain instances, the colored adhesive may be blue.
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92/173 [0206] In other examples, any of the layers may comprise symbols, such as printed ink to aid appearance, depth printing, absorbency printing or quality printing of absorbent articles.
[0207] In other examples, colors can be complementary or aligned with the three-dimensional resource patterns of non-woven fabric 10 used as a component in an absorbent article. For example, a fabric that has a first and a second zone of visually distinct patterns of three-dimensional features may also have printed in the same color to emphasize, emphasize, contrast with or otherwise change the visual appearance of the fabric 10. The highlights of color can be beneficial in communicating to a user of an absorbent article certain functional characteristics of non-woven fabric 10 when in use. In this way, color can be used in combination with three-dimensional structural features in a component or in combinations of components to deliver a visually distinctive absorbent article. For example, a top layer or secondary capture layer may have a color pattern or colors printed on it that complement the three-dimensional pattern of a fabric 10 used as a top layer on an absorbent article. Another example is an absorbent article comprising 1) an absorbent core that comprises a channel, 2) an upper layer with a registered three-dimensional pattern or that highlights the channel or channels in the core, and 3) a component
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93/173 color graphics, printed ink or symbols visible from the top layer view surface (body contact surface) or the bottom layer view (surface facing the garment) to further emphasize the functional features of the channel or core channels and the overall performance of the absorbent article.
[0208] The additional characterization of the innovative aspects of the present revelation can be accomplished by concentrating on three-dimensional resources in a visually discernible zone. Each zone, such as zones 110, 120, and 130, discussed above, can be described in more detail in relation to microzones. A microzone is a portion of the nonwoven tissue 10 within a zone, which has at least two visually discernible regions, with a difference in intensive property common between these two regions. A microzone can comprise a portion of the non-woven fabric 10 that crosses two or more zone boundaries that have at least two visually discernible regions, with a difference in intensive property common between these two regions [0209] The benefit of considering the microzones in the The present disclosure is to illustrate that, in addition to the differences in mean intensive properties with a zone, such as zones 110, 120, and 130, as discussed above, the present disclosure also provides fabrics that have differences in actual and / or mean intensive properties between regions defined by three-dimensional features in a zone, with three-dimensional features positioned precisely according to
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94/173 with the design of the training mat used to produce the fabrics. The difference between the intensive properties between the three-dimensional resource regions provides other visual and functional benefits. The sharp visual contrast between the regions can provide extremely thin and visually distinct designs within a zone and between zones. Similarly, the precise positioning of the regions provided by the precisely manufactured forming mat can provide excellent and adjusted properties of softness, strength and fluid handling of the zones. Thus, the invention in one embodiment provides the unexpected combination of differences in mean intensive properties between zones and, simultaneously, differences in the intensive properties of the regions that make up a microzone.
[0210] The regions defined by three-dimensional features can be understood with reference to Figure 38 and Figure 39. Figure 38 shows an optical microscope image of a portion of a tissue 10 according to the present disclosure, and Figure 39 is a scanning electron micrograph (SEM) of a cross section of the tissue portion shown in Figure 38. Thus, Figures 38 and 39 show a portion of a nonwoven fabric 10 enlarged for a more accurate description of the tissue features visually discernible differently. The portion of the nonwoven fabric 10 shown in Figure 38 is about 36 mm in the DT and exhibits portions of at least three visually distinct zones, as discussed below.
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95/173 [0211] In Figures 38 and 39 showing a portion of a pattern of a nonwoven fabric 10, a first zone 110 (on the left side of Figure 38) is characterized by rows of first regions 300 of generally variable width oriented in the machine direction (MD) separated by rows of second regions 310 of variable width oriented in the machine direction (MD). The first region is also the three-dimensional feature 20 that defines the first and second regions 300, 310. In one embodiment, a three-dimensional feature is a portion of the nonwoven fabric 10 that has been formed between or around an elevated element of the mat formation that in this description is the first region 300, so that the resulting structure has a relatively larger dimension in the Z direction. The second adjacent region 310, in general, has an intensive property common with the first region 300, and in a modality has relatively lower thickness values, that is, smaller dimension in the Z direction. The relative dimensions in the Z direction in relation to a plane of the first surface 16, as described above, can be seen in Figure 39. The absolute dimensions are not criticisms; but dimensional differences can be visually discernible on non-woven fabric 10 without magnification.
[0212] The invention of the description allows the beneficial characteristics to be better expressed in relation to the regions defined by three-dimensional resources in microzones. For example, as shown in Figure 38, in zone 110 for each three-dimensional feature 20 there is a visible distinction between a first region 300 and a second region 310.
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As previously mentioned, the visible distinction can exist in non-woven fabric 10 without magnification; the enlarged views used in the present invention are for the purposes of clarity of disclosure. Any area that extends beyond the contour between a sufficient portion of the first region 300 and the second region 310, so that a difference in their respective intensive properties can be determined within the area, can be a microzone. In addition, optical microscopy or computerized microtomography (micro CT) images of a structure can also be used to establish the location of regions and the area of a microzone.
[0213] The portion of nonwoven fabric 10 shown in Figure 38 further illustrates another beneficial feature of fabric 10, in which the differences in intensive properties between adjacent regions can be differences between zones. In this way, a microzone covering an area surrounding the second region 310 of zone 120 and the first region 300 of zone 130 can be identified. In certain embodiments, including the non-woven fabric 10 shown in Figures 38 and 39, the difference in the intensive properties displayed by the regions in microzones shows that a zonal contour can be significantly different in magnitude than the differences between the intensive properties displayed by the regions within a zone.
[0214] Regardless of which zone or zonal contour a specific microzone covers, three-dimensional features can be characterized by differences between
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97/173 intensive properties of the regions defined by them. In general, the nonwoven of the present disclosure can be a continuous spinning nonwoven fabric that has a first surface that defines a plane of the first surface. The fabric can have a plurality of three-dimensional resources, with each three-dimensional resource defining a first region and a second region, the regions having a common intensive property that has a different value between them. In one embodiment, the first region can be distinguished as being at a higher elevation than the second region in relation to the plane of the first surface, thus presenting a difference in the common intensive property of thickness in each region. The two regions can also be distinguished as having different densities, weights and volumetric densities. That is, the two regions can be distinguished within a microzone from the nonwoven fabric of continuous spinning as being different from common intensive properties, including properties such as thickness, density, weight and volumetric density. In one embodiment, one or both regions of a microzone may be fluid permeable. In one embodiment, the higher density region of a microzone may be fluid permeable.
[0215] Within zone 110 of the fabric portion shown in Figure 38, for example, there may be three-dimensional features 20 defining at least two regions, a first region 300 and a second region 310. The difference in thickness, weight and volumetric density between the first and the
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98/173 second regions for zone 110 shown in Figure 38 can be 274 microns, 1 g / m ² and 0.437 g / cc, respectively.
[0216] Similarly, within zone 130 of the fabric portion shown in Figure 38, for example, there may be three-dimensional features 20 defining at least two regions, a first region 300 and a second region 310. The difference in thickness, weight and volumetric density between the first and second regions for zone 130 shown in Figure 38 can be 2083 microns, 116 g / m ² and 0.462 g / cc, respectively.
[0217] Additionally, within zone 120 of the fabric portion shown in Figure 38, for example, there may be three-dimensional features 20 defining at least two regions, a first region 300 and a second region 310. The difference in thickness, weight and the volumetric density between the first and the second region for the tissue portion shown in Figure 38 can be 204 microns, 20 g / m ² and 0.53 g / cc, respectively. In the embodiment shown, zone 120 forms what, in a non-magnified view of the nonwoven fabric 10, appears to be a contour sewn between zones 110 and 130.
[0218] Additionally, a zone that covers the contour between zones 120 and 130 of the fabric portion shown in Figure 38, for example, there are at least two regions, a first region 300 in zone 130 and a second region 310 in zone 120 The difference in thickness, weight and volumetric density between the first and second regions for the tissue portion shown in Figure 38 can be 2027 microns, 58 g / m ² and 0.525 g / cc, respectively.
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99/173 [0219] Microzones are discussed in more detail with reference to Figures 40 to 42 and the data shown in Figure 44. Figures 40 to 42 are computerized microtomography (Micro-CT) scans of a portion of non-tissue -fabric 10 in a pattern similar to that of nonwoven fabric 10 shown in Figure 38. Computed microtomography (Micro-CT) allows the description of the same features as shown in Figure 38 in a slightly different way and in order to allow a very accurate measurement intensive properties.
[0220] As shown in Figure 40, zones 110, 120 and 130 are clearly visible, with their respective three-dimensional features 20. As shown in Figures 40 and 41, the three-dimensional features are the dark colored portions, with the dark color also representing the first region 300 of a three-dimensional feature 20, and the adjacent light-colored portions representing the second region 310 for the three-dimensional feature 20.
[0221] Computed microtomography scanning allows the image to be cut and cut in cross section, as shown by the cutting plane 450 in Figure 41. A cutting plane can be placed anywhere on the image; for the purposes of the present disclosure, the cutting plane 450 cuts a cross section substantially parallel to the geometric axis Z in order to produce the image in cross section in Figure 42.
[0222] Computed microtomography technology allows intensive properties to be measured directly
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100/173 and with precision. Thickness measurements can be made directly from images of cross sections based on the scale enlargement, such as the cross section shown in Figure 42. Additionally, the color differential between the first regions and the second regions is representative and proportional to the differences in weight, volumetric density, and other intensive properties, which can likewise be measured directly. The computed microtomography methodology is explained below in the Test Methods section.
[0223] Figure 43 is a computerized microtomography scan image of the nonwoven fabric 10 shown in Figures 40 and 41. The use of the technique allows analysis of the first and second specific regions shown as numbered portions of the nonwoven fabric. 10. In Figure 43, specific regions were selected manually and analyzed to measure thickness, weight and volumetric density, and the data are shown in Figure 44.
[0224] Figure 44 shows data for groupings of the measurements of the first and second regions made within the three zones represented in Figure 44. The geometric axis x represents the regions, with the numbers corresponding to the numbered regions in Figure 43. Measurements of first regions are identified as Fn (for example, Fl) and measurements of the second regions are identified as Sn (for example, Sl). Thus, regions 1 to 5 are the first F1 regions, each in zone 110. The
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101/173 regions 6 to 10 are the second Sl regions, also in zone 110. Similarly, the first F2 regions are regions 16 to 20 in zone 120, and regions 11 to 15 and 21 to 25 are second S2 regions in zone 120. Finally, regions 31 to 35 are the first F3 regions in zone 130 and regions 26 to 30 are the second S2 regions in zone 130. The numbered regions are represented consistently in all three graphs of Figure 44, but for the sake of simplicity, zones 110, 120 and 130 are represented only on the thickness map.
[0225] The graphs shown in Figure 44 graphically represent the magnitude of the difference in intensive properties between the first regions and the second regions within any of the zones, and can be used to graphically display the difference in intensive properties for pairs of regions that make up a microzone. For example, it can be seen that in zone 110 the weight between the two regions can be substantially the same, but the thickness (caliber) can vary from about 400 microns in the first regions to about 40 microns in the second regions, or a differential around 10X. The volumetric density in zone 110 can range from about 0.1 g / cc to about 0.6 g / cc. Similar quantifiable distinctions can be understood for each of the zones shown.
[0226] Thus, with reference to Figure 43 and Figure 44 together, an additional characterization of the beneficial structure of a fabric 10 of the present disclosure can be understood. Non-woven fabric 10 can be described as having at least
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102/173 two visually distinct zones, for example, zones 110 and 120, with each zone having a pattern of three-dimensional resources, each of the three-dimensional resources defining a microzone comprising the first and second regions, for example , regions 300, 310, and the difference in values for at least one of the microzones in the first zone is quantifiably different from the difference in values for at least one of the microzones in the second zone. For example, in Figure 43, two representative microzones 400 in zone 130 are designated as the pair of regions marked as areas 31 and 27 and 33 and 26. That is, the first region 31 and the second region 27 form a microzone, and the first region 33 and second region 26 form a microzone. Similarly, two representative micro-zones 400 in zone 120 are designated as the pair of regions marked as areas 19 and 24 and 17 and 22. From Figure 44, Tables 4 to 7 can be completed as shown:
Table 4: Illustrative examples of differences in thickness in microzones
Thickness (microns) Difference in thickness (microns) Zone130 Microzone1 First region 31 1802 1709 Second region 27 93 Microzone2 First region 33 2548 2484 Second region 26 64 Zone Microzone First 242 172
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120 1 region 19 Second region 24 70 Microzone2 First region 17 235 183 Second region 23 52
Table 5: Illustrative examples of differences in weight in microzones
Weights (g / m ² ) Difference in weights (g / m ² ) Zone130 Microzone1 First region 31 124 107 Second region 27 17 Microzone2 First region 33 106 72 Second region 26 34 Zone120 Microzone1 First region 19 32 5 Second region 24 27 Microzone2 First region 17 42 30 Second region 23 12
Table 6: Illustrative examples of differences in volumetric density in microzones
Volumetric density (g / cc) Difference in volumetric density (g / cc) Zone130 Microzone1 First region 31 0.069 0.116
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Second region 27 0. 185Microzone2 First region 33 0.041 0.49 Second region 26 0.531 Zone120 Microzone1 First region 19 0.133 0.251 Second region 24 0.384 Microzone2 First region 17 0. 185 0.04 Second region 23 0.229
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Table 7: Illustrative examples of differences in intensive properties within different zones:
Thickness (microns) Thickness differences Weights (g / m ² ) Weight differences Volumetric density (g / cc) Differences in volumetric density Zone 130First region 32 2147 2118 149 135 0.069 0.423 Zone 110Second region 8 29 14 0.492
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106/173 [0227] The four representative microzones of two zones are shown in Tables 4 to 6 for illustration. But, as can be understood, each pair of first and second regions in Figure 43 could likewise be quantified to additionally fill additional rows in Table 4, but they are not for the sake of brevity. In general, for any fabric with two or more zones, each zone having a pattern of three-dimensional features defining microzones, the intensive properties can be measured and organized as illustrated here with reference to Figures 43 and 44 so that it can be understood both the difference in values for intensive properties within a zone, such as differences in values for intensive properties between a region in the first zone and another region in a second zone.
[022 8] A microzone that covers two zones, such as the zones
110 and zone 130, can have an even greater difference in intensive properties compared to a microzone within a single zone. For example, the visualization of data for a microzone covering a first region of zone 130, for example, in the first region 32, and a second region of zone 110, for example, in the second region 8, the microzone presents drastic differences in all properties of thickness, weight and volumetric density. The thickness of the first region 32 of zone 130 is about 2100 microns, while the thickness of the second region 8 of zone 110 is about 29 microns, or a spread of about 72X. Similarly, the weight of the first region 32 in zone 130 can be as high as 150 g / m ² , while the weight of the
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107/173 second region 8 of zone 110 can be about 14 g / m ² , or a differential of about 10X. In addition, the volumetric density of the first region 32 of zone 130 can be about 0.069 g / cc, while the volumetric density of the second region 8 of zone 110 can be 0.492 g / cc, or a differential of about 7X.
[0229] For each of the intensive property parameters measured from the various regions of a microzone, such measurement is made using the computed microtomography method described here. The resolution of the method supports the establishment of the intensive properties of the microzone regions, in order to be able to scale the comparisons of differences and ratios of regions, as described here.
[0230] The further characterization of a fabric 10 can be carried out by reference to Figures 45 to 49, which are SEMs showing in more detail certain aspects of the non-woven fabric 10 and regions in it. Figures 45 to 49 are photographs of enlarged portions of zone 110 of the fabric shown in Figure 38. The nonwoven fabric 10 shown in Figure 38 was produced according to the process described above with reference to Figure 7 in which the fabric was processed through a contact line formed by the compaction cylinders 70 and 72, with the cylinder 72 that comes into contact with the first side 12 which is heated to cause the partial union of fibers in the second regions 301. Figures 45 (facing the mat) and 46 (facing the heated compaction cylinder) are SEMs from a portion of the second surface 14 and the first surface 12,
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108/173 respectively, expanded to 20X. Figures 47 (facing the mat) and 48 (facing the heated compaction cylinder) are photographs of a portion of the second surface 14 and the first surface 12, respectively, enlarged 90X, and show in detail the beneficial structural feature of the joint part of the fibers formed by the compaction cylinders 70 and 72.
[0231] As can be best seen in Figures 47 and 48, as well as in the cross-sectional view of Figure 49, the heated compaction cylinders can cause the thermal bonding of the fibers in different degrees with a beneficial effect on the entire fabric 10. As shown, fibers in contact with a heated cylinder, for example cylinder 70 in contact with the first surface 12 of the fabric 10, can be fused so that the first surface 12 experiences a relatively greater fiber-to-fiber bond than than the second surface 14. In one embodiment, the joined fibers 80 of the first surface can be substantially and completely joined by melting to form, in effect, a film of joined fibers film, while the fibers in the second region 310 on the second side 14 may experience little or no union. This feature allows a non-woven fabric 10 for use in a disposable absorbent article, for example, as a top layer, to maintain physical integrity during manufacture and use, as well as the relative softness on one side, which can be the side in contact with the skin facing the user.
[0232] Even in microzones with the greatest thickness differential, this effect of bonding coating has the
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109/173 purpose of maintaining the integrity of the mat, while not significantly affecting softness, or other beneficial properties such as fluid handling properties. As can be understood with reference to Figures 50 to 53, the differential in the extent of thermal bonding of the fibers may be such that the fibers in the first surface 12 in a second region 310 may be complete or substantially complete, while the extent of the thermal bonding of the fibers. fibers on the second surface 14 in a first region 300 can be minimal, without thermal consolidation.
[0233] Figure 50 again shows the portion of nonwoven fabric 10 shown in Figure 38. Figures 51 to 53 show enlarged images of a microzone, shown in Figure 50 as a first region 300 and a second region 310, which looks visually be a hole or an opening. Figures 51 and 52 show the microzone as it appears on the second surface 14 enlarged by 40X and 200X, respectively. Figure 53 shows the second region 310 as it appears on the first side 12 under 200X magnification. The fibers in the second region 310 are completely, or substantially completely joined, while the fibers in the first region 300 are completely or substantially completely not joined. The benefit of the illustrated structure is that a microzone can function as a fluid-permeable opening, while the joined regions of the second region 310 function simultaneously to maintain the physical integrity of the tissue 10.
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110/173 [0234] Microzones therefore play a significant role in the overall physical structure and functioning of a tissue 10 of the present invention. With the production of three-dimensional resources designed with precision and with relatively close spacing, made possible by the formation mat of the present description, a fabric 10 can exhibit visually distinct zones, microzones and three-dimensional resources that provide functional superiority in areas of at least softness and handling. fluids, as well as visually appealing aesthetic designs. The potential difference in the physical properties of the first and second surfaces allows non-woven fabric 10 to be designed for both strength and softness, both in shape and function.
[0235] Figure 54 is a computerized microtomography scan image of the portion of nonwoven fabric 10 similar to that shown in Figures 40 and 41, but having undergone the additional processing step of forming point 90 joints in the contact line of the calender cylinders 71 and 73. As described above, in relation to the discussion of Figures 43 and 44, for specific point joining microzones 400, the first and second regions shown as numbered portions of the nonwoven fabric 10 can be analyzed and include regions of point unions, specifically in areas numbered 31 to 35. For example, adjacent regions 32 and 26 form a microzone 400 in the third zone 130. In Figure 54, specific regions have been visually discerned to identify regions that include union regions of points
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111/173 and analyzed to measure the thickness, weight and volumetric density, the data being shown in Figure 55, where the thickness, weight and volumetric density of all regions, including the regions where points are joined, are quantified and compared.
[0236] Figure 55 shows data for groupings of the first and second region measurements made within the three zones represented in Figure 54. The x-axis represents regions, with numbers corresponding to the numbered regions in Figure 43. Measurements of first regions are identified as Fn (for example, Fl) and measurements of the second regions are identified as Sn (for example, Sl). Thus, regions 1 to 5 are the first Fl regions, each in zone 110. Regions 6 to 10 are the second regions Sl, also in zone 110. Similarly, the first F2 regions are regions 16 to 20 in zone 120, and regions 11 to 15 and 21 to 25 are the second S2 regions in zone 120. Finally, regions 31 to 35 are second regions but are point unions 90 designated in Figure 55a BI to distinguish them in this revelation as having been formed by a punctual consolidation process. The first F3 regions in zone 130 are regions 26 to 30 and 36 to 40, while regions 41 to 44 are the second S2 regions in zone 130. The numbered regions are represented consistently in all three graphs in Figure 55, but for the sake of simplicity, zones 110, 120 and 130 are only represented on the thickness map.
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112/173 [0237] The graphs shown in Figure 54 graphically represent the magnitude of the difference in intensive properties between the first and second regions within any of the zones of a fabric submitted to a point consolidation step by calendering, and can be used to graphically display the difference in intensive properties for pairs of regions that make up a microzone. For example, it can be seen that in zone 110 this weight between the two regions can vary within a narrower range than the thickness or volumetric density. For example, the thickness (caliber) can vary from about 325 microns in the first regions to about 29 microns in the second regions of zone 110, or a differential around 10X. The volumetric density in zone 110 can vary from about 0.08 g / cc to about 0.39 g / cc. Similar quantifiable distinctions can be understood for each of the zones shown.
[0238] In general, the regions of a microzone can have widely varying values for grammage, thickness and volumetric density.
[0239] Thus, with reference to Figures 54 and Figure 55 together, the further characterization of the beneficial structure of a fabric 10 of the present disclosure can be understood specifically in relation to the thermal calender stitch 90 joints. With a focus on the purposes of description in zone 130, the three-dimensional resources that define a microzone comprising first and second regions that are regions connected by points, can be identified and quantified
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113/173 the values of intensive properties. For example, in Figure
54, a representative dot union microzone 400 in zone 130 can be the pair of regions marked as areas 26 and 32 or 30 and 35. That is, the first region 26 and second region 32 form a dot union microzone 400, and the first region 30 and the second region 35 form a dot-joining microzone 400.
[0240] The differences in certain intensive properties for the dot joining microzones can be seen in Figure
55. For example, taking the two point-joining micro-regions 400 described above, for example, the two point-joining micro-regions 400 from regions 26 and 32 and 30 and 35, respectively, it can be seen that there is a slight weight difference between the first and second regions in the range of about 55 to about 60 g / m ² , but the same regions exhibit a significant difference in thickness from about 430 microns to about 460 microns to about 125 microns , and a significant difference in volumetric density from about 0.13 to 0.14 g / cc to about 0.41 to 0.48 g / cc. Other differences in intensive properties can be seen with reference to Figure 55.
[0241] The joining points 90 can play a significant role in the overall physical structure and functioning of a fabric 10 of the present invention. By adding connection points 90 to the fabric 10 comprising three-dimensional features designed with precision and relatively close spacing, made possible by the formation mat of the present disclosure, a fabric 10 can be
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114/173 additionally enhanced to exhibit an unexpected combination of zones, microzones and visually distinctive three-dimensional features that provide functional superiority in the areas of softness, strength and fluid handling, as well as visually attractive aesthetic designs. The bonding point feature provides a non-woven fabric 10 designed for the best combined performance of strength, softness, fluid handling and visual aesthetics, especially considering both form and function.
[0242] One benefit of the nonwoven blankets formatted in the present disclosure is improved softness. Softness can be measured using the Emtec fabric softness analyzer, available from Emtec Paper Testing Technology, Emtec Electronic, GmbH. Table 5 below shows softness values as TS7 measurements from the fabric softness analyzer Emtec, according to the Emtec test method below. For all Examples 7 to 9 below, the nonwoven was produced on a mat as described in Figure 16, with the nonwoven blanket having a similar appearance to that shown in Figure 2.
Table 5: TS7 values for formatted non-woven from development
Example Number Side TS7 value(dB V2 rms) FS / SS ratio Example 7 First surface 10.30 1.35 Second surface 7.59 Example 8 First surface 3.51 0.98
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Second surface 3.59Example 9 First surface 9, 61 1.48 Second surface 6, 47
Example 7:
[0243] A two-component, non-woven spinning blanket that was produced using a 50:50 spinning ratio between the polyethylene sheath (Aspun-6850-A obtained from the Dow Chemical Company) and the polypropylene core (PH-835 obtained from LyondellBasell) in a trilobal fiber configuration, as discussed above with reference to Example 2. The nonwoven fabric was spun on a forming mat with a repetition pattern as described in Figure 16 moving in linear speed of about 25 meters per minute to form a textile product 10 with an average weight of 25 grams per square meter with a repetition pattern of rhombus shapes as shown in Figure 2. The fibers of the textile product were compacted by cylinders of compaction 7 0, 72, instead of being calendered, an additional consolidation was obtained by a consolidation unit by passing hot air through perforated cylinder, as described below with respect to Figure 56, at a temperature of 145 ° C.
Example 8:
[0244] A bicomponent continuous spinning nonwoven fabric was produced using a 30:70 spinning ratio between the polyethylene sheath (Aspun-6850-A obtained from the
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Dow Chemical Company) and the polypropylene core (HG475 FP obtained from Borealis) in a cylindrical fiber configuration, using a double-beam continuous spinning process, as described in Figure 56. The non-woven fabric was spun in a forming mat with a repeating pattern as described in Figure 16, as described above in relation to Figure 7 moving at a linear speed of about 152 meters per minute to an average weight of 35 grams per square meter to form a pattern repetition of diamond shapes as shown in Figure 2. The difference between the formatted nonwoven blankets produced according to the process of Figure 7 and Example 8 is that in Example 8 they were produced in a hybrid of the process described in Figure 7 and that described in Figure 56 below. Specifically, the process involved two wiring bundles as shown in Figure 56, however the final heating step was performed by calendering cylinders 71, 73, instead of consolidation by passing hot air through a perforated cylinder. The fibers of the fabric were consolidated on the first surface 12 by heated compaction cylinders 70A and 72A at 110 ° C after the first beam 48A and by compaction cylinders 7 OB and 72B at 110 ° C after the second beam 48B, and the calendering at about 140 ° C on calendering cylinders 71 and 73 before being rolled on a reel in reel 75.
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Example 9:
[0245] A two-component continuous spinning nonwoven fabric was produced using a 30:70 spinning ratio between the polyethylene sheath (Aspun-6850-A obtained from the Dow Chemical Company) and the polypropylene core (HG475 FP obtained from Borealis) in a cylindrical fiber configuration, using a double-beam continuous spinning process, as described in Figure 56. The nonwoven fabric was spun on a forming mat with a repeat pattern as described in Figure 16 moving at a linear speed of about 228 meters per minute to an average weight of 25 grams per square meter to form a repetition pattern of diamond shapes as shown in Figure 2. The fibers of the fabric were further consolidated in the first surface 12 by heated compaction cylinders 70A and 72A at 110 ° C after the first beam 48A and by compaction cylinders 70B and 72B at 110 ° C after the second beam 48B, and according to hot air in three heating zones of the consolidation equipment through the air passage 76 (as shown in Figure 56) of 100 ° C, 135 ° C and 135 ° C before being rolled on a reel in the reel 75.
[0246] Examples 7 to 9 are representative of formatted nonwoven fabrics of the present disclosure that exhibit improved softness, as indicated by Emtec measurements. Emtec measured values can be from about 1 dB V ² rms to about 15 dB V ² rms, or from about 3 dB V ² rms to about 10 dB V ² rms, or from about 5 dB V ² rms about
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118/173 dB V ² rms. In general, Emtec measured values for the first surface or the second surface can be any integer value up to about 15 dB V ² rms, and any range of integers between 1 and 15. Additionally, in general , the ratio of the measured value of Emtec between the first side and the second side can be between 1 and 3 and any real number between 1 and 3.
[0247] Without adhering to the theory, it is believed that the improvement in softness exhibited by the formatted non-woven fabrics of the present invention is obtained by the method and equipment of the invention, which enable differential intensive properties in relatively small areas, including the zones and the revealed microzones. The ability to design and produce non-woven fabrics formatted with the revealed differences in weight, density or thickness, for example, while simultaneously providing a consolidated fabric useful for upper layers in absorbent articles, for example, eliminates previously existing technical contradictions between texture and surface softness. That is, the formatted non-woven fabrics of the present disclosure can provide a visibly perceptible surface texture, including in irregular patterns, as well as superior softness, as indicated by the measured values of Emtec. In addition, the formatted non-woven fabrics of the present disclosure can provide a visibly perceptible surface texture in combination with physical integrity and reduced pile formation properties, as well as superior softness, as indicated by the measured values of Emtec.
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119/173 [0248] As discussed above, in one example, a process for producing a formatted nonwoven fabric can be a modified version of the process described in relation to Figure 7. A modification is described in relation to Figure 56. As shown in Figure 56, the process may include a belt 60, as described above, in a melt spinning process in which more than one spinning beam is employed. As illustrated schematically showing only the spinning bundles 48A and 48B, two bundles can be used to fuse spinning fibers in the belt 60, with a compaction operation 70A, 72A and 70B, 72B taking place after each bundle, respectively. Vacuum boxes 64A and 64B can also be operationally associated with each wiring bundle 48A and 48B, respectively.
[0249] After spinning the fibers on conveyor 60, and after being compacted, optionally including thermal consolidation during compacting as described above, the formatted non-woven blanket can be subjected to additional heating by an air passage heater 76, which can have multiple chambers, for example, three chambers 7 6A, 76B and 7 6C, each having the temperature independently controlled.
[0250] Examples 7 and 9 above were produced on a double beam process line and consolidated by the air passage in a process schematically shown in Figure 56. Without adhering to the theory, it appears that consolidation by the passage of hot air in perforated cylinder preserves much of the three-dimensionality of the three-dimensional resources of the
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120/173 formatted non-woven fabric, as indicated by the difference in the TS7 values in Table 5. Alternatively, if a less lateralized formatted non-woven fabric is desired, it appears that calender consolidation tends to equalize the TS7 values, as shown by Example 8 in Table 5. In this way, the process parameters can be controlled as described here to achieve a predetermined softness on the side, ie surface, of a formatted non-woven fabric.
[0251] In addition to the benefits detailed above, another benefit of the formatted nonwoven blankets of the present disclosure is the ability to provide a nonwoven blanket with microzones that have a separate hydrophobic and hydrophilic region. The hydrophilicity and / or hydrophobicity in a specific region of the microzone can be determined by a measurement of capillary action time using the capillary action time test method as described here and / or by a measurement of the contact angle with the use of the contact angle test method as described here. As used in the present invention, the term hydrophilic, in reference to a particular region of the microzone, means that, when performing the test using the capillary action time test method, the capillary action time for that specific region is less than 10 seconds. As used in the present invention, the term hydrophobic, in reference to a specific region of the microzone, means that when performing the test
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121/173 using the contact angle test method, the contact angle for that specific region is 90 ° or more.
[0252] Table 6 below details the contact angle and capillary action time measurements for non-woven fabrics formatted as detailed here. For both Examples 10 and 11 below, the nonwoven was produced on a mat as described in Figure 16, with the nonwoven blanket having a similar appearance to that shown in Figure 2.
Table 6: Values of contact angle and capillary action time for formatted non-woven fabrics
Example Number Region Contact angle (θο) Capillary action time (seconds) Example 10 First region 135 60 Second region 0 0.307 Example 11 First region 126 60 Second region 0 2,360
Example 10:
[0253] A two-component, nonwoven spinning blanket that was produced using a 50:50 spinning ratio between the polyethylene sheath (Aspun-6850-A obtained from the Dow Chemical Company) and the polypropylene core (PH-835 obtained from LyondellBasell) in a trilobal fiber configuration, as discussed above with reference to Example 2. The nonwoven fabric was spun on a forming mat with a repetition pattern as described in Figure 16 moving in linear speed of about 25 meters per minute to form a textile product 10 with an average weight of 25 grams per
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122/173 square meter with a repeat pattern of diamond shapes as shown in Figure 2. The fibers of the fabric were compacted by compaction cylinders 70, 72, instead of being calendered, further consolidation was achieved by a consolidation unit through the passage of hot air in a perforated cylinder as described below in relation to Figure 56, at a temperature of 145 ° C.
[0254] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylates and PEG diesters), supplied by Pulcra Chemicals, was then disposed on the rear side surface of the non-woven fabric (ie the smooth side surface opposite the side with relatively padded three-dimensional features arranged therein) by means of a contact coating process. The coating process was carried out using a Reicofil contact cylinder and an Omega drying process, both of which are commonly known in the art. The surfactant used in this contact cylinder process was at a 6% surfactant concentration in water at a temperature of 40 ° C. The contact angle of the contact cylinder was set at 250 ° and the drying temperature was 80 ° C. The non-woven fabric was then placed in contact with the contact cylinder operating at a speed of 13 rpm, providing 0.45%, by weight, of surfactant to the non-woven fabric (the percentage of surfactant is the weight of added surfactant per 1 m ² divided by weight of 1 m ² of non-woven fabric).
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Example 11:
[0255] A two-component, non-woven spinning blanket that was produced using a 50:50 spinning ratio between the polyethylene sheath (Aspun-6850-A obtained from the Dow Chemical Company) and the polypropylene core (PH-835 obtained from LyondellBasell) in a trilobal fiber configuration, as discussed above with reference to Example 2. The nonwoven fabric was spun on a forming mat with a repetition pattern as described in Figure 16 moving in linear speed of about 25 meters per minute to form a textile product 10 with an average weight of 25 grams per square meter with a repetition pattern of rhombus shapes as shown in Figure 2. The fibers of the fabric were compacted by cylinders of compaction 70, 72, instead of being calendered, additional consolidation was achieved by a consolidation unit by passing hot air through a perforated cylinder as described below in with respect to Figure 56, at a temperature of 145 ° C.
[0256] A surfactant, Stantex S 6327 (a combination of castor oil ethoxylates and PEG diesters), supplied by Pulcra Chemicals, was then disposed on the front side surface of the nonwoven fabric (ie the side with three-dimensional features) relatively padding arranged therein) by means of an inkjet printing process. The inkjet printing process was performed using a Dimatix DMP 2831 inkjet printer, equipped with a cartridge
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124/173 model No. DMC-11610 / PM 700-10702-01 (10pL). The printhead temperature was 40 ° C. The surfactant used in the inkjet printing process consisted of 75% w / w Stantex S 6327 and 25% w / w ethanol. The surfactant was printed on the second regions of the non-woven microzones by orienting the sample of the non-woven fabric so that the second regions of a first row of microzones were aligned with the direction of the printhead and a first series was printed of straight lines, with the droplet spacing set at 170 µm. The sample of nonwoven fabric was then rotated at an angle so that the second regions of a second row of microzones were aligned with the printhead and a second series of straight lines was printed at 170 µm. The weight of the fibers in the second region is about 16.0 g / m2. The weight of the surfactant that was printed on ink in the second region is about 0.25 g / m2. Consequently, the amount of surfactant printed locally in the second region was determined to be about 1.6%, by weight, of surfactant (0.25 g / m2 / 16.0 g / m2). In general, the amount of surfactant printed on the non-woven fabric sample was determined by the ratio between the width of the printed line and the line spacing to be about 0.2%, by weight, of surfactant.
[0257] In addition to Stantex S 6327, the use of other surfactants to make the first and / or second region of specific microzones hydrophilic and / or hydrophobic (by any application method) is considered within the scope of
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125/173 present disclosure. Other potential surfactants to be used in the processes and non-woven fabrics detailed herein include non-ionic surfactants including esters, amides, carboxylic acids, alcohols, polyoxyethylene ethers, polyoxypropylene, sorbitan, ethoxylated fatty alcohols, allyphenol polyethoxylates, lecithin, glycerol esters and its ethoxylates, and sugar-based surfactants (polysorbates, polyglycosides), and anionic surfactants including sulphonates, sulphates, phosphates, alkali metal salts of fatty acids, sulfuric acid monoesters of sulfuric acid, linear alkylbenzenesulfonates, alkyldiphenylsulfonates, sulfonates , olefin sulfonates, sulfosuccinates, and sulfated ethoxylates of fatty alcohols, and cationic surfactants, including amines (primary, secondary, tertiary), quaternary ammoniums, pyridinium, QUATS quaternary ammonium salts, alkylated pyridinium salts, primary, secondary amines in alkyl, and alkanolamides, and zwitterionic surfactants, including amino acids and derivatives, amine oxide, betaines, and alkylamine oxides, and polymeric surfactants, including polyamines, polymers and copolymers of carboxylic acid, EO / PO block copolymers, polymers and copolymers ethylene oxide, and polyvinylpyrrolidone, and silicone surfactants, including dimethylsiloxane polymers with hydrophilic, and perfluorocarboxylic acid and fluoroturfactant salts.
[0258] The formatted non-woven fabrics detailed above have microzones with regions having differences in
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126/173 intensive properties, such as weight, density, or thickness, for example. These same formatted non-woven fabrics may also have simultaneously those regions of the microzones that are particularly and separately hydrophobic and / or hydrophilic. Any of the examples of formatted nonwoven fabric detailed here (for example, samples that include zones and / or microzones with regions having differences in thickness, weight and / or volumetric density, and / or surfaces with the various TS7 values disclosed here) it may also have regions of a microzone with differences in hydrophilicity as detailed here. Hydrophilicity can be provided through targeted application (s) of surfactant (s) in specific regions of the microzones of the formatted non-woven fabric. For example, the second region of a microzone may have a surfactant in it, whereas the first region of the same microzone may have no surfactant in it. In addition, the first region of a microzone may have a surfactant in it, while the second region of the same microzone may have no surfactant in it. For example, in a microzone, the first or second region can be from about 0.01% to about 5.0%, from about 0.05% to about 4.0%, from about 1, 0% to about 3.0%, and any concentric range within a range of about 0.01% to about 5.0% of surfactant, and the other region has no surfactant (ie, no surfactant) . As an example, in a microzone, the second region can be from about 0.01% to about 5.0%, from about 0.05% to about 4.0%, from about
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127/173 from 1.0% to about 3.0%, and any concentric range within a range of about 0.01% to about 5.0% of surfactant, and the first region has no surfactant (or that is, free of surfactant). Consequently, some formatted non-woven fabrics disclosed here have a microzone with at least one between the first and the second region having a surfactant, and the ratio between the percentage of surfactant in the first region and the percentage of surfactant in the second region is less than 1 In addition, some formatted non-woven fabrics disclosed here have a microzone with at least the second region of the microzone having a surfactant, and the ratio between the percentage of surfactant in the first region and the percentage of surfactant in the second region is less than 1.
[0259] As another example, the second region of a microzone may have a specific amount of surfactant or percentage of surfactant disposed in it, while the first region of the same microzone may have a different amount of surfactant or percentage of surfactant disposed in it in the same. For example, in a microzone, the first region can be from about 0.01% to about 2.0%, from about 0.05% to about 1.5%, from about 0.1% to about 1.0%, and any concentric range within a range of about 0.01% to about 2.0% of surfactant, and the second region can have a different amount. In addition, in a microzone, the second region can range from about 0.01% to about 5.0%, from about 0.05% to about 4.0%, from about 1.0% to about 3.0%, and any concentric range within a range of about 0.01% to about 5.0% of surfactant, and the first
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128/173 region may have a different amount. The percentage of surfactant for a specific region of a microzone can be determined by dividing the amount in grams per square meter of surfactant disposed in the specific region by the grammage of the fibers of the formatted non-woven fabric contained within the same region. The quantity in grams per square meter of surfactant disposed in a specific region can be determined using any method currently known in the art (for example, gravimetric, etc.). The grammage of the fibers of the formatted non-woven fabric contained in a specific region of a microzone can also be determined using any method currently known in the art (for example, gravimetric, computed microtomography (micro-CT), etc.). For specific microzone examples, the weight ranges / fiber examples contained in the first and second regions are detailed above.
[0260] A surfactant can be applied to non-woven fabrics formed by any method known in the art. Specific examples include contact coating, inkjet printing, gravure printing, offset gravure printing, flexographic surfactant printing and registered surfactant printing. Any such method can lay the surfactant on the first and / or second surface of the formatted non-woven fabrics. For the total formatted non-woven fabric (taking into account all individual zones and microzones in the fabric), the surfactant can be added to the non-woven fabric
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129/173 formatted tissue in an amount of about 0.01% to about 2.0%, from about 0.05% to about 1.5%, from about 0.1% to about 1, 0%, and any concentric range within a range of about 0.01% to about 2.0%. To calculate the percentage of surfactant added to the total formatted nonwoven fabric, divide the amount in grams per square meter of surfactant in the total formatted nonwoven fabric by the weight of the total formatted nonwoven fabric. The quantity in grams per square meter of surfactant disposed in the total formatted non-woven fabric can be determined using any method currently known in the art (for example, gravimetric, etc.). The weight of the total formatted non-woven fabric can also be determined using any method currently known in the art (for example, gravimetric, computed microtomography (micro-CT), etc.).
[0261] Referring again to Figures 38 and 39 showing a portion of a nonwoven pattern 10, a first zone 110 (on the left side of Figure 38) is characterized by rows of first regions 300 of generally variable width in the machine direction (MD) separated by rows of second regions 310 of variable width oriented in the machine direction (MD) (the first and second region being within a microzone). The first region is also the three-dimensional feature 20 that defines the first and second regions 300, 310. In one embodiment, a three-dimensional feature is a portion of the non-woven fabric 10 that was formed between or at the
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130/173 around an elevated element of the forming mat which in this description is the first region 300, so that the resulting structure has a relatively larger dimension in the Z direction, a relatively higher weight and a lower volumetric density when compared to the second region 310. In addition, the first region 300 can be hydrophobic and the second region 310 can be hydrophilic. The targeted addition of a surfactant to the second region 310 of the microzone can render the second region hydrophilic. Consequently, the first region 300 of the microzone can have a contact angle greater than about 90 °, or between about 90 ° and about 140 °, or between about 110 ° and about 135 °, or between about 125 ° and about 135 °, or any concentric range contained within between about 90 ° and about 140 °, when tested by the contact angle test method detailed here. The second region 310 of the microzone can have a contact angle less than 90 ° when tested by the contact angle test method detailed here. The first region 300 of the microzone can have a capillary action time value greater than about 10 seconds, or between about 10 seconds and 60 seconds, as measured by the capillary action time test method detailed here. The second region 310 of the microzone may have a capillary action time value of less than about 10 seconds, less than about 5 seconds, or less than about 2.5 seconds, or less than about 1 second, or less than about 0.5 seconds, as measured by the capillary action time test method detailed here. The non-woven fabrics formatted here
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131/173 contemplated include any of the parameter ranges detailed above for measurements of contact angle and / or capillary action time for the first region and / or for the second region in combination with any of the other intensive properties / property differences here revealed to the same or different regions in the same or different microzone in the formatted non-woven fabric.
[0262] Formatted non-woven fabrics having the above detailed microzones with regions having differences in weight, density or thickness, for example, while also simultaneously having these specific regions of a specific microzone being separately hydrophobic and / or hydrophilic , can provide several useful applications, for example, top layer materials for baby care, feminine hygiene products and adult incontinence, as well as use in medical pillows, wipes and cleaning cloths, etc.
[0263] The dimensions and values disclosed in the present invention should not be understood as being strictly limited to the exact numerical values and / or dimensions mentioned. Instead, unless otherwise specified, each such dimension and / or value is intended to signify the mentioned dimension and / or value and a functionally equivalent range surrounding that dimension and / or value. For example, a dimension revealed as 40 mm is meant to mean about 40 mm.
[0264] Any document cited in the present invention, including any cross-reference, patent or application
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132/173, is hereby incorporated in its entirety for reference, unless expressly excluded or otherwise limited. The mention of any document is not an admission that it constitutes prior art in relation to any invention revealed or claimed in this document, nor that it, alone or in any combination with any other reference or references, teaches, suggests or reveals such an invention. In addition, if there is a conflict between any meaning or definition of a term mentioned in this document and any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document will take precedence.
[0265] Although specific modalities of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is intended, therefore, to cover in the appended claims all such changes and modifications that fall within the scope of the present invention. Test methods:
Compression Aging Test
Initial gauge measurement:
• Cut five 3-inch by 3-inch samples by non-woven fabric to be measured.
• Number each sample from 1 to 5.
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133/173 • Measure the gauge at 0.5 kPa with the standard 65 mm foot using the Thwing-Albert gauge tester according to standard procedures.
• Report initial gauge for each of the five samples.
• Report the average gauge of the five samples.
Aged Compression Method and Aged Gauge Measurement • Stack the five samples in an alternating way with each separated by a paper towel, the stack starting and ending with sample number 1 and 5, respectively.
• Place the stacked samples alternately in an aluminum sample holder with an appropriate weight on the samples (4 KPa, 14 KPa or 35 KPa).
• Place the stacked samples with the weight in an oven at 40 ° C for 15 hours.
• Remove the weight after 15 hours, separate the samples and measure the caliber of each sample at 0.5 kPa with a standard Thwing-Albert gauge tester with a 65 mm foot, according to standard procedures.
• Report the aged gauge value for each of the five samples.
• Report the average aged gauge of the five samples.
Analysis Reports:
• Report the average initial and aged gauges by position number • Report the Gauge Recovery index:
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134/173 (Medium Aged Gauge / Medium Starting Gauge) * 100
Localized Weight [0266] The localized weight of non-woven fabric can be determined by several available techniques, but a simple representative technique involves a perforation matrix that has an area of 3.0 cm ² that is used to cut a sample piece of the blanket in the selected region of the total area of a non-woven fabric. The sample piece is then weighted and divided by its area to produce the localized grammage of the nonwoven fabric in units of grams per square meter. The results are reported as an average of 2 samples per selected region.
Fluff Content Test [0267] The fluff content test is used to determine the amount of fibers removed from non-woven materials under an abrasive force (ie, fluff content).
[0268] The fluff test uses the following materials:
• 2 lb weight Sutherland Ink Rub friction tester, available from Danilee Co, San Antonio, TX, USA.
• Cloth rolls with 320 grain aluminum oxide manufactured by Plymouth Coatings, (617) 447-7731.
This material can also be purchased from McMaster Carr, part number 468.7A51, (330) 995-5500.
• 3M 409 double-sided tape, available from the Netherland Rubber Company, (513) 733-1085.
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135/173 • 3M 3187 fiber removal tape, available from Netherland Rubber Company, (513) 733-1085.
• Analytical balance (+ / - 0.0001 g) • Paper cutter • Weight 2200 g (metal) 170 mm x 63 mm.
• Thick lining cardboard with a gauge of 0.0445 inch (1.13 mm).
Material preparation:
[0269] Measure and cut a 7.5 inch (19.0 cm) long piece of aluminum oxide cloth. Measure and cut 6.5 inch (16.5 cm) lengths of 3M tape No. 3187, two pieces of tape for each specimen. Fold approximately 0.25 inch (0.6 cm) at each end of 3M No. 3187 tape for easy handling. Place the 3M tape No. 3187 on the thick lining cardboard for later use.
Sample preparation [0270] Before handling or testing any material, wash your hands with soap and water to remove excess oil. Optionally, use latex gloves. Cut a sample of the non-woven fabric to be tested with a size of at least 11 cm in the DM and 4 cm in the DT. Open the sample of non-woven fabric to be tested, with the side to be tested facing down. Cut a piece of at least 11 cam length of 3M double-sided tape No. 409. Remove the paper strip and apply the side of the double-sided tape that was facing the paper tape to the non-woven fabric sample on direction of the machine direction (DM). Replace the paper tape on the exposed side.
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Using the paper cutter, cut test samples of 11 cm in the MD and 4 cm in the DT, from the tape area.
Test Procedure
1. Assemble the cut piece of the aluminum oxide cloth to the Sutherland Ink Rub friction tester using the weight of 2 lb. Place a second cut piece of aluminum oxide cloth on the cardboard (a new piece is used for each test). Place both on the weight of 2 1b. The sides will fold into the clips. Confirm that the aluminum oxide cloth and cardboard are flat.
2. Mount the specimen on the Sutherland Ink friction tester platform, centering it on the metal plate. Place the weight of 2,200 g on the specimen for 20 seconds.
3. Connect the metal plate and the weight of 2 1b to the Sutherland Ink Rub tester.
4. Connect the friction tester. If the meter light does not come on, press the reset button. Press the counter button to set the friction in 20 cycles. Select speed 1 (low speed) (the light does not come on) using the speed button. Press Start.
5. When the tester turns off, carefully remove the cloth and weight, taking care not to lose loose (fluffed) microfibers. In some cases, the microfibers will be attached to both the aluminum oxide cloth and the surface of the nonwoven sample. Place the weight upside down on the bench.
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6. Weigh the fiber removal tapes with the removable paper attached to them. Holding the fiber removal tape by its folded ends, remove the removable paper and set it aside. Gently place the tape over the aluminum oxide cloth to remove all the fluff. Remove the fiber removal tape and put it back on the removable paper. Weigh and record the weight of the fiber removal tapes.
7. Hold, by its folded ends, another piece of the pre-weighed fiber removal tape. Gently place the fiber removal tape over the surface of the rubbed nonwoven sample. Place a flat metal plate on the fiber removal tape.
8. Place the weight of 2.2 00 g on the metal plate for 20 seconds. Remove the fiber removal tape. Hold the pre-weighed fiber removal tape by its folded ends (to avoid fingerprints). Place the pre-heavy tape removal tape back on the removable paper. Weigh and record the weight of the fiber removal tapes.
9. The weight of the fluff is the sum of the weight increase of both fiber removal tapes.
10. The reported pile weight is the average of 10 measurements.
Calculations [0271] For a given sample, add the weight in grams of the fluff collected from the aluminum oxide cloth and the weight in gram of the fluff collected from the rubbed non-woven sample. Multiply the combined weight in grams by
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1,000 to convert to milligrams (mg). To convert this measurement of absolute weight loss into weight loss per unit area, divide the total weight of fluff by the area of the rubbed region.
Air Permeability Test [0272] The air permeability test is used to determine the level of airflow in cubic feet per minute (ft3 / min) through a forming mat. The air permeability test is performed on a Textest Instruments Air Permeability Tester, model FX3360 Portair, available from Textest AG, Sonnenbergstrasse 72, CH 8603 Schwerzenbach, Switzerland. The unit uses a 20.7 mm orifice plate for air permeability ranges between 300 and 1,000 cubic feet / minute. If air permeability is less than 300 cubic feet / minute, the orifice plate needs to be reduced; if it is greater than 1,000 cubic feet / minute, the orifice plate needs to be increased. Air permeability can be measured in localized areas of a formation mat to determine differences in air permeability along a formation mat.
Test Procedure
1. Turn on the FX3360 instrument.
2. Select a predetermined style that has the following configuration:
The. Material: Standard
B. Measurement Property: Air Permeability (AP)
ç. Test Pressure: 125 Pa (Pascal)
d. T factor: 1.00
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and. Test point pitch: 0.8 inch.
3. Position the 20.7 mm orifice plate on the top side of the forming mat (the side with the three-dimensional protrusions) in the position of interest.
4. Select Spot Measurement on the test unit's touchscreen.
5. Reset the sensor before measurement, if necessary.
6. Once reset, select the Start button to start the measurement.
7. Wait until the measurement stabilizes and note the ft3 / min reading on the screen.
8. Select the Start button again to stop the measurement.
Pile stack height test [0273] The stack stack height of a pack of absorbent articles is determined as follows:
Equipment [0274] A thickness tester with a rigid and flat horizontal sliding plate is used. The thickness tester is configured so that the horizontal sliding plate moves freely in a vertical direction with the horizontal sliding plate always kept in a horizontal orientation directly above a rigid and flat horizontal base plate. The thickness tester includes a device suitable for measuring the gap between the horizontal sliding plate and the horizontal base plate within ± 0.5 mm horizontal. The horizontal sliding plate and the horizontal base plate are larger than the packaging surface of the absorbent article
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140/173 that comes in contact with each plate, that is, each plate extends after the contact surface of the packaging of the absorbent article in all directions. The horizontal sliding plate exerts a downward force of 850 ± 1 gram-force (8.34 N) on the packaging of the absorbent article, which can be achieved by placing an appropriate weight in the center of the packaging that does not come into contact with the surface top of the horizontal sliding plate so that the total mass of the sliding plate plus the added weight is 850 ± 1 grams.
Test Procedure [0275] The packs of absorbent articles are balanced at 23 ± 2 ° C and 50 ± 5% relative humidity before measurement.
[0276] The horizontal sliding plate is raised and an absorbent article package is placed centrally under the horizontal sliding plate, in such a way that the absorbent articles inside the package are in a horizontal orientation (see Figure 27). Any cable or other characteristic of the packaging on the surface that could be in contact with the plates is folded horizontally against the surface of the packaging in order to minimize its impact on the measurement. The horizontal sliding plate is slowly lowered until it contacts the upper surface of the package and then released. The span between the horizontal plates is measured within ± 0.5 mm, ten seconds after the horizontal sliding plate is released. Five identical packages (same size and count of absorbent articles) are measured and the arithmetic mean is recorded as the package width.
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The stacking height of bags = (packing width / count of absorbent articles per stack) χ 10 is calculated and reported within ± 0.5 mm.
Intensive property measurement method by computed microtomography (Micro-TC) [0277] The intensive property measurement method by computed micrography measures the values of grammage, thickness and volumetric density in the visually discernible regions of a substrate sample. It is based on the analysis of a three-dimensional image of an x-ray sample obtained on a computerized microtomography instrument (a suitable instrument is the Scanco pCT 50 available from Scanco Medicai AG, Switzerland, or equivalent). The computed microtomography instrument is a cone beam microtomograph with an armored cabinet. A maintenance-free X-ray tube is used as the source with an adjustable diameter focal point. The x-ray beam passes through the sample, where some of the x-rays are attenuated by the sample. The extent of attenuation is correlated to the mass of material through which the x-rays will have to pass. The transmitted x-rays continue to the digital detector matrix and generate a two-dimensional projection image of the sample. A three-dimensional image of the sample is generated by collecting several individual projection images of the sample as it is rotated, which are then reconstructed into a single three-dimensional image. The instrument is interfaced with software that runs on a computer to control image capture and save
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142/173 raw data. The three-dimensional image is then analyzed using image analysis software (suitable image analysis software is MATLAB available from Mathworks, Inc., Natick, MA, USA or equivalent) to measure weight, thickness and the volumetric density intensive properties of regions within the sample.
Sample Preparation:
[0278] To obtain a sample for measurement, horizontally position a single layer of the dry substrate material and cut a circular piece with a diameter of 30 mm by matrix.
[0279] If the substrate material is a layer of an absorbent article, for example an upper, non-woven layer of the lower layer, capture layer, distribution layer or other component layer; tape the absorbent article to a flat, rigid surface in a flat configuration. Carefully separate the individual layer of substrate from the absorbent article. A scalpel and / or cryogenic spray (such as Cyto-Freeze, Control Company, Houston, TX, USA), can be used to remove a layer of substrate from the additional underlying layers, if necessary, to avoid any longitudinal and lateral extension of the material . Once the substrate layer has been removed from the article, proceed with matrix cutting of the sample as described above.
[0280] If the substrate material is in the form of a wet wipe, open a new wipe pack and remove the entire stack from the pack. Remove a single tissue from the middle of the stack, position it horizontally and
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143/173 let it dry completely before matrix cutting the sample for analysis.
[0281] A sample can be cut from any location containing the visually discernible zone to be analyzed. Within a zone, the regions to be analyzed are those associated with a three-dimensional resource that defines a microzone. Microzone comprises at least two visually discernible regions. A zone, three-dimensional feature or microzone can be visually discernible due to changes in texture, elevation or thickness. The regions within different samples taken from the same substrate material can be analyzed and compared with each other. Care must be taken to avoid folds, creases or tears when selecting a sampling location.
Image capture:
[0282] Configure and calibrate the computerized microtomography instrument according to the manufacturer's specifications. Place the sample in the appropriate support, between two rings of low density material, which have an internal diameter of 25 mm. This will allow the central portion of the sample to be horizontal and to be swept without having any other materials directly adjacent to its upper and lower surfaces. Measurements must be made in this region. The three-dimensional field of view of the image is approximately 35 mm on each side in the XY plane with a resolution of approximately 5,000 by 5,000 pixels and a sufficient number of 7 micron thick slices collected to fully include the Z direction.
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144/173 of the sample. The resolution of the reconstructed 3D image contains 7 micron isotropic voxels. The images are captured with the source at 45 kVp and 133 μΑ without an additional low energy filter. These current and voltage settings can be optimized to produce maximum contrast in the projection data with sufficient X-ray penetration through the sample, but once optimized they are kept constant for all substantially similar samples. A total of 1500 projection images are obtained with an integration time of 1,000 ms and 3 averages. The projection images are reconstructed in the 3D image and saved in 16-bit RAW format to preserve the output signal from the complete detector for analysis.
Image processing:
[0283] Load the 3D image into the software for image analysis. Establish a threshold for the 3D image at a value that separates and removes the background signal due to air, but that keeps the signal coming from the sample fibers inside the substrate.
[0284] Three intensive 2D images are generated from the 3D threshold image. The first is the weight image. To generate this image, the value for each voxel in a slice in the xy plane is added to all of its corresponding voxel values in the other slices in the z direction containing the sample signal. This creates a 2D image in which each pixel now has a value equal to the cumulative signal across the entire sample.
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145/173 [0285] To convert the raw data values in the weight image into real values, a weight calibration curve is generated. Obtain a substrate with a composition substantially similar to the sample under analysis and a uniform weight. Follow the procedures described above to obtain at least ten replicated samples of the calibration curve substrate. Accurately measure the weight, taking the mass with a resolution of 0.0001 g, divide by the sample area and convert to grams per square meter (g / m ² ), of each of the single layer calibration samples and calculate the average with resolution 0.01 g / m ² . Following the procedures described above, capture a microtomograph1 computerized image of a single layer of the calibration sample substrate. Following the procedure described above, process the computerized microtomography image, and generate a grammage image containing raw data values. The actual weight value for this sample is the average weight value measured in the calibration samples. Then, stack two layers of the calibration substrate samples on top of each other, and capture a microtomography image of the two layers of calibration substrate. Generate an image of raw weight data for both layers together, whose actual weight value is equal to twice the average weight value measured in the calibration samples. Repeat this procedure for stacking single layers of the calibration substrate, capturing a microtomography image
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146/173 computed from all layers, generating an image of raw data of weight equal to the number of layers times the average value of weight measured in the calibration samples. A total of at least four different weight calibration images are obtained. The weight values of the calibration samples must include values above and below the weight values of the original sample being analyzed to ensure an accurate calibration. The calibration curve is generated by performing a linear regression on the raw data as a function of the actual weight values for the four calibration samples. This linear regression must have an R2 value of at least 0.95, otherwise the entire calibration procedure must be repeated. This calibration curve is now used to convert the raw data values to actual weights.
[0286] The second image of intensive 2D property is the thickness image. To generate this image, the upper and lower surfaces of the sample are identified, and the distance between these surfaces is calculated by giving the sample thickness. The top surface of the sample is identified starting at the highest slice in the z direction and evaluating each slice that passes through the sample to locate the voxel in the z direction for all pixel positions in the xy plane where the sample signal was first detected . The same procedure is followed to identify the bottom surface of the sample, except that the voxels in the z-direction located are all positions on the xy plane where the sample signal was detected last
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147/173 time. Once the upper and lower surfaces are identified, they are smoothed with a 15x15 median filter to remove the lost fiber signal. The 2D thickness image is then generated by counting the number of voxels that exist between the upper and lower surfaces for each of the pixel positions in the xy plane. This gross thickness value is then converted into real distance, in microns, by multiplying the voxel count by the 7 pm slice thickness resolution.
[0287] The third image of intensive property in 2D is the image of volumetric density. To generate this image, divide each pixel value in the xy plane in the weight image, in units of g / m ² by the corresponding pixel in the thickness image, in units of microns. The units of the volumetric density image are grams per cubic centimeter (g / cc).
Weight, thickness and intensive properties of volumetric density through computed microtomography:
[0288] Begin by identifying the region to be analyzed. A region to be analyzed is a region associated with a three-dimensional feature that defines a microzone. Microzone comprises at least two visually discernible regions. A zone, three-dimensional feature or microzone can be visually discernible due to changes in texture, elevation or thickness. Then, identify the contour of the region to be analyzed. The outline of a region is identified by discerning visual differences in
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148/173 intensive properties compared to other regions within the sample. For example, a region contour can be identified based on the discernment of a visual difference in thickness compared to another region in the sample. Any of the intensive properties can be used to discern the contours of the region in the physical sample itself of any of the images of intensive property by computed microtomography. Once the contour of the region has been identified, trace an oval or circular region of interest (RDI) within the region. The RDI must have an area of at least 0.1 mm ² , and be selected to measure an area with intensive property values representative of the identified region. From each of the three images of intensive property calculate the average weight, thickness and volumetric density within the RDI. Note these values as the weight of the region with 0.01 g / m ² resolution, thickness with 0.1 micron resolution and volumetric density with 0.0001 g / cc resolution.
Emtec test method [0289] TS7 and TS750 values are measured using an Emtec fabric softness analyzer (Emtec TSA) (Emtec Electronic GmbH, Leipzig, Germany) in interface with a computer running Emtec TSA software (version 3.19 or equivalent). According to Emtec, the TS7 value correlates with the actual softness of the material, whereas the TS750 value correlates with the smoothness / roughness felt in the material. The Emtec TSA comprises a rotor with vertical blades that rotate in the test sample at a speed of
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149/173 defined and calibrated rotation (defined by the manufacturer) and 100 mN contact force. The contact between the vertical blades and the test piece generates vibrations, which create a sound that is recorded by a microphone inside the instrument. The recorded sound file is then analyzed by the Emtec TSA software. Sample preparation, instrument operation and test procedures are performed according to the instrument manufacturer's specifications.
Sample preparation [0290] Test samples are prepared by cutting square or circular samples from a finished product. The test samples are cut to a length and width (or diameter, if circular) of no less than about 90 mm and no more than about 120 mm, in any of these dimensions, to ensure that the sample can be properly attached to the TSA equipment. Test samples are selected to avoid punctures, creases or folds within the test region. Prepare 8 samples in substantially similar replicates for the test. Balance all samples under standard TAPPI temperature and relative humidity (23 ° C ± 2 ° C and 50% ± 2%) conditions for at least 2 hours before performing the TSA test, which is also conducted under TAPPI conditions .
Test procedure [0291] Calibrate the instrument according to the manufacturer's instructions using the 1-point calibration method with Emtec reference standards (samples ref.2). If these reference samples are no longer
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150/173 available, use the appropriate reference samples provided by the manufacturer. Calibrate the instrument according to the manufacturer's recommendations and instructions, so that the results are comparable to those obtained when using the 1-point calibration method with Emtec reference standards (samples ref.2).
[0292] Provide eight samples in replica of a test fabric. Mount a test sample on the instrument with a surface facing up and perform the test according to the manufacturer's instructions. Upon completion of the test, the software displays the values of TS7 and TS750. Record each of these values as close to 0.01 dB V ² rms. The test sample is then taken from the instrument and discarded. This test is performed individually on the same surface of four of the replicate samples and then on the other surface of the other four replicate samples. The first surface tested can be either the first surface 12 or the second surface 14 of a formatted non-woven fabric, as disclosed herein.
[0293] The four test result values for TS7 and TS750 for the first tested surface are weighted (using a simple numerical average); the same is done for the four test result values for TS7 and TS750 on the second tested surface. Report individual mean values of TS7 and TS750 for both first and second surfaces tested on a specific test sample as close to 0.01 dB V ² rms. Additionally, the ratio of TS7 between the first surface
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151/173 tested and the second tested surface is calculated by dividing the average TS7 of the first tested surface by the average TS7 of the second tested surface.
Capillary action time and contact angle test methods [0294] Capillary action time and contact angle measurements are determined using a sessile drop experiment. A specified volume of Type II reagent distilled water (as defined in the ASTM D1193 method) is applied to the surface of a test sample using an automated liquid application system. A high-speed video camera captures images with a timestamp of the drop over a period of 60 seconds at a rate of 900 frames per second. The contact angle between the drop and the test sample surface is determined for each image captured by the image analysis software. The capillary action time is determined to be the time required for the contact angle of a drop that is absorbed into the test sample to decrease to a contact angle <10 °. All measurements are carried out at constant temperature (23 ° C ± 2 ° C) and relative humidity (50% ± 2%).
[0295] Automated equipment for testing the contact angle is required to perform this test. The system consists of a light source, a video camera, a horizontal specimen stage, a liquid application system with a pump and microsyringe and a computer equipped with software suitable for video image capture, image analysis and for report contact angle data. a
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152/173 suitable instrument is the OCA 20 Optical Contact Angle Measurement System (DataPhysics Instruments, Filderstadt, Germany), or equivalent. The system must be able to release an 8.2 microliter drop and be able to capture images at a rate of 900 frames per second. The system is calibrated and operated according to the manufacturer's instructions, unless explicitly stated otherwise in this test procedure.
[0296] To obtain a test sample for measurement, place a single layer of the dry substrate material flat and cut a rectangular test sample 15 mm wide and about 70 mm long. The sample width can be reduced as needed to ensure that the test region of interest is not obscured by
resources surrounding during the test. With one strip in sample more narrow, care must be taken that the drop in liquid not reach the edge of sample in test during O test, case contrary the test should to be repeated. Pre- condition the samples at 23 ° C ± 2 ° C and 50% ± 2% of moisture
2 hours before testing.
Sample preparation [0297] A test sample can be cut from any location containing the visually discernible zone to be analyzed. Within a zone, the regions to be analyzed are those associated with a three-dimensional resource that defines a microzone. Microzone comprises at least two visually discernible regions. A zone, three-dimensional feature or microzone can be visually discernible due to
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153/173 changes in texture, elevation or thickness. The regions within different test samples taken from the same substrate material can be analyzed and compared with each other. Care must be taken to avoid folds, creases or tears when selecting a sampling location.
[0298] If the substrate material is a layer of an absorbent article, for example, an upper layer or lower layer of nonwoven, a capture layer, a distribution layer or another component layer; tape the absorbent article to a flat, rigid surface in a flat configuration. Carefully separate the individual layer of substrate from the absorbent article. A scalpel and / or cryogenic spray (such as Cyto-Freeze, Control Company, Houston, TX, USA), can be used to remove a layer of substrate from the additional underlying layers, if necessary, to avoid any longitudinal and lateral extension of the material . Once the substrate layer has been removed from the article, proceed with cutting the test sample. If the substrate material is in the form of a wet wipe, open a new pack of wet wipes and remove the entire stack from the pack. Remove a single tissue from the middle of the stack, position it horizontally and allow it to dry completely before cutting the sample for analysis.
Test procedure [0299] The test sample is positioned in the horizontal specimen stage with the test region in the camera's field of view below the liquid delivery system needle, with the test side facing up. The sample
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154/173 of the test is fixed so that it is flat, but not tensioned, and any interaction between the liquid drop and the underlying surface is avoided to prevent undue capillary forces. A 27 gauge stainless steel needle with a blunt tip (inner diameter 0.23 mm, outer diameter 0.41 mm) is positioned above the test sample with at least 2 mm of the needle tip in the camera's field of view. Adjust the specimen stage to achieve a distance of about 3 mm between the tip of the needle and the surface of the test sample. An 8.2 microliter drop of reagent distilled water is formed at a rate of 1 microliter per second and allowed to drop freely onto the surface of the test sample. Video image capture is initiated before the drop comes into contact with the surface of the test sample, and subsequently a continuous series of images is collected over a period of 60 seconds after the drop comes in contact with the sample surface. of test. Repeat this procedure for a total of 5 (five) substantially similar replica test regions. Use a new test sample or ensure that the previous area wetted by the drop is avoided during subsequent measurements.
[0300] In each of the images captured by the video camera, the test sample surface and the drop outline are identified and used by the image analysis software to calculate the contact angle for each drop image and are reported in the nearest 0.1 degree. The contact angle is the angle formed by the surface of the test sample and the tangent to the surface of the liquid drop
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155/173 in contact with the test sample. For each series of test images, time zero is the time in which the liquid drop makes contact with the surface of the test sample. Measure and record the contact angle in the drop image that corresponds to time zero plus 5 (five) seconds. 0 contact angle in five seconds is reported as 0 ⁱⁿ case the droplet has been completely absorbed by the test sample in 5 seconds. Repeat this procedure for the five replica test regions. Calculate the arithmetic mean of the contact angle at time zero plus five seconds for the five test regions in replica and report this value as the contact angle as close to 0.1 degree.
[0301] The capillary action time is defined as the time necessary for the contact angle of a drop that is absorbed within the test sample to decrease to a contact angle <10 °. Capillary action time is measured by identifying the first image in a given series in which the contact angle has decreased to a contact angle <10 ° and then, based on that image, the time is calculated and reported. elapsed since time zero. Capillary action time is reported to be 60 seconds if a contact angle less than 10 ° is not reached in 60 seconds. Repeat this procedure for the five replica test regions. Calculate the arithmetic mean of the capillary action time for the five replicate test regions and report this value as close to 0.1 millisecond.
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156/173 [0302] The invention of the present disclosure can be described by any of the following combinations, detailed in the following paragraphs:
A. A non-woven fabric of continuous spinning comprising:
The. a first surface and a second surface and at least a first and a second zone visually discernible on at least one between the first and the second surface, each of which between the first and the second zone has a pattern of three-dimensional features, being that each of the three-dimensional resources defines a microzone comprising a first region and a second region, the first and second region having a difference in values for an intensive property; and
B. the difference in values for an intensive property for at least one among the microzones in the first zone is different in relation to the difference in values for the intensive property for at least one among the microzones in the second zone;
being that, in at least one among the microzones, the first region is hydrophobic and the second region is hydrophilic.
B. The non-woven fabric of continuous spinning in accordance with paragraph A, the difference in values for the intensive property for one among the microzones in the first zone having an order of magnitude different in
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157/173 relation to the difference in values for at least one of the microzones in the second zone.
C. Continuous spinning non-woven fabric in accordance with paragraphs A and B, the difference in values for the intensive property for one of the microzones in the first zone being 1.2X to about 10X different from the difference in values for at least one of the microzones in the second zone.
D. The non-woven fabric of continuous spinning according to paragraphs A to C, the intensive property being the thickness, and the thickness of each region is greater than zero.
E. The non-woven fabric of continuous spinning according to paragraphs A to D, the difference in thickness in the first zone being greater than about 25 microns.
F. The non-woven fabric of continuous spinning according to paragraphs A to E, the intensive property being the grammage, and the grammage of each region is greater than zero.
G. The continuous spinning non-woven fabric according to paragraphs A to F, the difference in weight in the first zone being greater than about 5 g / m2.
H. The non-woven fabric of continuous spinning according to paragraphs A to G, the intensive property being the volumetric density, and the volumetric density of each region is greater than zero.
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I. The spinning non-woven fabric continues according to paragraphs A to H, where the difference in volumetric density in the first zone is greater than about 0.042 g / cc.
J. The non-woven fabric of continuous spinning according to paragraphs A to I, additionally comprising a
third zone by having one standard of resources three-dimensional, being what each one define a microzone understanding an first region and a
second region, and a difference in values for an intensive property for one among the microzones in the third zone is a) different from the difference in values for an intensive property for at least one among the microzones in the first zone, and b) different from the difference in values for the intensive property for at least one of the microzones in the second zone.
K. Non-woven fabric with continuous spinning according to paragraphs A to J, at least one of the surfaces has a TS7 value less than about 15 dB V ² rms.
L. The non-woven fabric of continuous spinning according to paragraph K, the first surface having a TS7 value of about 2 to about 12 dB V ² rms and the second surface having a TS7 value different from the value of TS7 from the first surface.
Μ. The non-woven fabric of continuous spinning in accordance with paragraph L, the second surface having a
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159/173 TS7 value that is less than the TS7 value of the first surface.
N. The non-woven fabric of continuous spinning according to paragraph K, the second surface having a TS7 value of about 3 to about 8 and the first surface having a TS7 value different from the TS7 value of the first surface.
O. The continuous spinning nonwoven fabric according to paragraph N, the first surface having a TS7 value which is greater than the TS7 value of the second surface.
Q. An absorbent article comprising a nonwoven of continuous spinning as described in paragraphs A to 0.
Q. A package of absorbent articles, each absorbent article comprising a nonwoven of continuous spinning as described in paragraphs A to P.
A. The package according to paragraph Q, the package having a stack height in the bag between about 70 mm and about 100 mm, according to the stack height test in the bag of the present invention.
S. A continuous spinning nonwoven fabric comprising: a. a first surface and a second surface and at least a first and a second visually discernible zones on at least one between the first and the second surfaces, each of which between the first and the second zones
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160/173 has a three-dimensional resource pattern, with each of the three-dimensional resources defining a microzone comprising a first region and a second region, the first and second regions having a difference in values for an intensive property; and
B. the difference in values for an intensive property for at least one of the microzones in the first zone is different in relation to the difference in values for the intensive property for at least one of the microzones in the second zone;
being that, in at least one among the microzones, the second region comprises a surfactant and the first region is free of surfactant.
T. Continuous spinning non-woven fabric according to paragraph S, the surfactant being selected from a group consisting of: non-ionic surfactants including esters, amides, carboxylic acids, alcohols, ethers - polyoxyethylene, polyoxypropylene, sorbitan, ethoxylated fatty alcohols, allyphenol polyethoxylates, lecithin, glycerol esters and their ethoxylates, and sugar-based surfactants (polysorbates, polyglycosides), anionic surfactants including sulfonates, sulfates, phosphates, alkali metal salts of fatty acids, monoesters sulfuric acid, linear alkylbenzenesulfonates, alkyldiphenyloxy sulfonates, lignin sulfonates,
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161/173 olefin sulfonates, sulfosuccinates, and sulfated ethoxylates of fatty alcohols, cationic surfactants, including amines (primary, secondary, tertiary), quaternary ammonia, pyridinium, quaternary ammonium salts - QUATS, alkylated pyridinium salts, primary amines, primary amines , alkyl tertiary, and alkanolamides, zwitterionic surfactants, including amino acids and derivatives, amine oxide, betaines, and alkylamine oxides, polymeric surfactants, including polyamines, polymers and copolymers of carboxylic acid, EO / PO block copolymers, polymers and copolymers of ethylene oxide, and polyvinylpyrrolidone, silicone surfactants, including dimethylsiloxane polymers with hydrophilic, and perfluorocarboxylic acid salts and fluorotensive agents.
The continuous spinning nonwoven fabric according to paragraphs S to T, the surfactant being a combination of castor oil ethoxylates and PEG diesters.
V. The non-woven fabric of continuous spinning according to paragraphs S to U, the difference in values for the intensive property for one among the microzones in the first zone having a different order of magnitude in relation to the difference in values for the least one among the microzones in the second zone.
W. The non-woven fabric of continuous spinning in accordance with paragraphs S to V, the difference in values
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162/173 for the intensive property for one among the microzones in the first zone is about 1.2X to about 10X different from the difference in values of at least one among the microzones in the second zone.
X. The continuous spinning non-woven fabric according to paragraphs S to W, the intensive property being the thickness, and the thickness of each region is greater than zero.
Y. The non-woven fabric of continuous spinning according to paragraphs S to X, the difference in thickness in the first zone being greater than about 25 microns.
Z. The non-woven fabric of continuous spinning in accordance with paragraphs S to Y, the intensive property being the grammage, and the grammage of each region is greater than zero.
AA. The spinning nonwoven fabric according to paragraphs S to Z, the difference in weight in the first zone being greater than about 5 g / m2.
BB. The nonwoven fabric of continuous spinning according to paragraphs S to AA, the intensive property being the volumetric density, and the volumetric density of each region is greater than zero.
CC. The non-woven fabric of continuous spinning according to paragraphs S to BB, the difference in volumetric density in the first zone being greater than about 0.042 g / cc.
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DD. The continuous spinning non-woven fabric according to paragraphs S to CC, further comprising a
third zone by having one standard of resources three-dimensional, being what each one define a microzone understanding an first region and a
second region, and a difference in values for an intensive property for one among the microzones in the third zone is a) different from the difference in values for an intensive property for at least one among the microzones in the first zone, and b) different from the difference in values for the intensive property for at least one of the microzones in the second zone.
AND IS. The spinning nonwoven fabric according to paragraphs S to DD, at least one of the surfaces having a TS7 value less than about 15 dB V ² rms.
FF. The continuous spinning nonwoven fabric according to paragraph EE, the first surface having a TS7 value of about 2 to about 12 dB V ² rms and the second surface having a TS7 value different from the TS7 value of the first surface.
GG. The continuous spinning nonwoven fabric according to paragraph FF, the second surface having a TS7 value which is less than the TS7 value of the first surface.
HH. The non-woven fabric of continuous spinning in accordance with paragraph EE, the second surface having
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164/173 a TS7 value of about 3 to about 8 and the first surface has a TS7 value different from the TS7 value of the first surface.
II. The continuous spinning nonwoven fabric according to paragraph HH, the first surface having a TS7 value which is greater than the TS7 value of the second surface.
JJ. An absorbent article comprising a nonwoven of continuous spinning as described in paragraphs S to II.
KK. A package of absorbent articles, each absorbent article comprising a nonwoven of continuous spinning as described in paragraphs S to JJ.
LL. The package according to paragraph KK, the package having a stack height in the bag between about 70 mm and about 100 mm, according to the stack height test in the bag of the present invention.
MM. Continuous spinning nonwoven fabric comprising:
The. a first surface and a second surface and at least a first and a second visually discernible zones on at least one between the first and the second surfaces, each of which between the first and the second zones has a three-dimensional feature pattern, with each of the three-dimensional resources defines a microzone comprising a first region and a second region, the first and the second
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165/173 second regions have a difference in values for an intensive property; and
B. the difference in values for an intensive property for at least one of the microzones in the first zone is different in relation to the difference in values for the intensive property for at least one of the microzones in the second zone;
being that, in at least one of the microzones, The first and the second region understand one surfactant and the reason between the percentage in surfactant at first region and the percentage in
surfactant in the second region is less than 1.
NN. The spinning non-woven fabric continues according to the MM paragraph, the surfactant being selected from a group consisting of: non-ionic surfactants including esters, amides, carboxylic acids, alcohols, ethers - polyoxyethylene, polyoxypropylene, sorbitan, fatty alcohols ethoxylates, allyphenol polyethoxylates, lecithin, glycerol esters and their ethoxylates, and sugar-based surfactants (polysorbates, polyglycosides), anionic surfactants including sulfonates, sulphates, phosphates, fatty acid alkali metal salts, fatty alcohol monoesters sulfuric, linear alkylbenzenesulfonates, alkyldiphenyloxy sulfonates, lignin sulfonates, olefin sulfonates, sulfosuccinates, and sulfated fatty alcohol ethoxylates, cationic surfactants,
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166/173 including amines (primary, secondary, tertiary), quaternary ammonia, pyridinium, quaternary ammonium salts - QUATS, alkylated pyridinium salts, primary, secondary, tertiary alkyl amines, and alkanolamides, zwitterionic surfactants, including amino acids and derivatives, amine oxide, betaines, and alkylamine oxides, polymeric surfactants, including polyamines, carboxylic acid polymers and copolymers, EO / PO block copolymers, ethylene oxide polymers and copolymers, and polyvinylpyrrolidone, silicone surfactants, including polymeric surfactants dimethylsiloxane with hydrophilic, and perfluorocarboxylic acid salts and fluorotensive agents.
00. 0 non-woven fabric in spinning continuous according withMM paragraphs to NN, being that the surfactant is ancombination of ethoxylates Castor oil withdiesters of PEG. PP. 0 non-woven fabric in spinning continuous according withMM paragraphs to 00 , and the difference in
values for the intensive property for one among the microzones in the first zone have a different order of magnitude in relation to the difference in values for at least one among the microzones in the second zone.
QQ. The non-woven fabric of continuous spinning according to paragraphs MM to PP, the difference in values for the intensive property for one among
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167/173 the microzones in the first zone is about 1.2X to about 10X different from the difference in values of at least one among the microzones in the second zone.
RR. The nonwoven fabric of continuous spinning according to paragraphs MM to QQ, the intensive property being the thickness, and the thickness of each region is greater than zero.
SS. The non-woven fabric of continuous spinning according to paragraphs MM to RR, the difference in thickness in the first zone being greater than about 25 microns.
TT. The continuous spinning non-woven fabric according to paragraphs MM to SS, the intensive property being the grammage, and the grammage of each region is greater than zero.
UU. The non-woven fabric of continuous spinning according to paragraphs MM to TT, the difference in weight in the first zone being greater than about 5 g / m2.
W. The continuous spinning non-woven fabric according to paragraphs MM to UU, the intensive property being the volumetric density, and the volumetric density of each region is greater than zero.
WW. The continuous spinning nonwoven fabric according to paragraphs MM to W, the difference in volumetric density in the first zone is greater than about 0.042 g / cc.
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XX. The non-woven fabric of continuous spinning according to paragraphs MM to WW, additionally comprising a third zone having a pattern of three-dimensional features, each of which defines a microzone comprising a first region and a second region, with a difference in values for an intensive property for one of the microzones in the third zone it is a) different from the difference in values for the intensive property for at least one among the microzones in the first zone, and b) different from the difference in values for the intensive property for at least one among the microzones in the second zone.
YY. The continuous spinning non-woven fabric according to paragraphs MM to XX, with at least one of the surfaces having a TS7 value less than about 15 dB V ² rms.
ZZ. The non-woven continuous spinning fabric according to paragraph YY, the first surface having a TS7 value of about 2 to about 12 dB V ² rms and the second surface having a TS7 value different from the TS7 value of the first surface.
ΑΆΑ. The continuous spinning nonwoven fabric according to paragraph ZZ, the second surface having a TS7 value which is less than the TS7 value of the first surface.
BBB. The non-woven fabric of continuous spinning in accordance with paragraph YY, the second surface having
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169/173 a TS7 value of about 3 to about 8 and the first surface has a TS7 value different from the TS7 value of the first surface.
CCC. The continuous spinning nonwoven fabric according to the BBB paragraph, the first surface having a TS7 value which is greater than the TS7 value of the second surface.
DDD. An absorbent article comprising a nonwoven of continuous spinning as described in paragraphs MM to CCC.
EEA. A pack of absorbent articles, each absorbent article comprising a nonwoven of continuous spinning as described in paragraphs MM to DDD.
FEE. The package according to the EEE paragraph, the package having a stack height in the bag between about 70 mm and about 100 mm, according to the stack height test in the bag of the present invention.
GGG. A non-woven fabric, comprising a first and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surfaces, each of the three-dimensional features defining a microzone comprising a first and a second region, being that the first and second regions have a difference in values for an intensive property, with the intensive property being one or more among:
The. thickness,
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B. weight, and
ç. volumetric density; and, in at least one of the microzones, the first region is hydrophobic and the second region is hydrophilic.
HHH. The non-woven fabric according to paragraph GGG, with the difference in values of the intensive property of one of the microzones in the first zone having a different order of magnitude in relation to the difference in values of at least one among the microzones in the second zone.
III. The non-woven fabric according to paragraphs GGG to HHH, the difference in values for the intensive property for one among the microzones in the first zone is about 1.2X to about 10X different from the difference in values of at least one of the microzones in the second zone.
JJJ. The non-woven fabric according to paragraphs GGG to III, the intensive property being the thickness, and the thickness of each region is greater than zero.
KKK. The non-woven fabric according to paragraphs GGG to JJJ, the difference in thickness in the first zone is greater than about 25 microns.
LLL. Non-woven fabric according to paragraphs GGG to KKK, the intensive property being the grammage, and the grammage of each region is greater than zero.
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MMM. The non-woven fabric according to paragraphs GGG to LLL, the difference in weight in the first zone being greater than about 5 g / m2.
NNN. The non-woven fabric according to paragraphs GGG to MMM, the intensive property being the volumetric density, and the volumetric density of each region is greater than zero.
000. The non-woven fabric according to paragraphs GGG to NNN, the difference in volumetric density in the first zone being greater than about 0.042 g / cc.
PPP. The non-woven fabric according to paragraphs GGG to 000, with at least one of the surfaces having a TS7 value less than about 15 dB V ² rms.
QQQ. The non-woven fabric according to the PPP paragraph, the first surface having a TS7 value of about 2 to about 12 dB V ² rms and the second surface having a TS7 value different from the TS7 value of the first surface .
RRR. The nonwoven fabric according to paragraph QQQ, the second surface having a TS7 value which is less than the TS7 value of the first surface.
SSS. The nonwoven fabric according to the PPP paragraph, the second surface having a TS7 value of about 3 to about 8 and the first surface having a TS7 value different from the TS7 value of the first surface.
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ΤΤΤ. It is non-woven fabric according to paragraph SSS, the first surface having a TS7 value that is greater than the TS7 value of the second surface.
UUU. An absorbent article comprising a nonwoven as described in paragraphs GGG to TTT.
VW. The packaging of absorbent articles, each absorbent article comprising a non-woven fabric as described in paragraphs GGG to VW.
WWW. The packaging according to paragraph VW, the packaging having a stacking height in the bag between about 70 mm and about 100 mm, according to the stacking height test in the bag of the present invention.
XXX. Non-woven fabric according to paragraphs GGG to WWW, non-woven fabric is a continuous spinning construction.
[0303] The dimensions and values disclosed in the present invention should not 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 mentioned value and a range of functionally equivalent values around that value. For example, a dimension revealed as 40 mm is meant to mean about 40 mm.
[0304] Each document cited in the present invention, including any patent or patent application in cross-referenced or related reference, and any patent application or patent in
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173/173 that this request claims priority or benefit from it, is hereby fully incorporated herein by reference, except when expressly excluded or otherwise limited. The mention of any document is not an admission that it constitutes prior art in relation to any invention revealed or claimed in this document, nor that it, alone or in any combination with any other reference or references, teaches, suggests or reveals such an invention. In addition, if there is a conflict between any meaning or definition of a term mentioned in this document and any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document will take precedence.
[0305] Although specific modalities of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is intended, therefore, to cover in the appended claims all such changes and modifications that fall within the scope of the present invention.

权利要求:
Claims (15)
[1]
1. Non-woven fabric, characterized by the fact that it comprises a first and a second surface and a visually discernible pattern of three-dimensional features on one of the first or the second surface, each of the three-dimensional features defining a microzone comprising a first and a second region, with the first and second regions having a difference in values for an intensive property, with the intensive property being one or more among:
The. thickness,
B. weight, and
ç. volumetric density; and, in at least one of the microzones, the first region is hydrophobic and the second region is hydrophilic.
[2]
2/3
2. Non-woven fabric, according to claim 1, characterized by the fact that the difference in values of the intensive property of one of the microzones in the first zone has a different order of magnitude in relation to the difference in values of at least one among the microzones in the second zone.
[3]
3/3 surface has a TS7 value different from the TS7 value of the first surface.
3. Non-woven fabric, according to any of the previous claims, characterized by the fact that the difference in values of the intensive property of one of the microzones in the first zone is 1.2X to 10X different from the difference in values of at least one among the microzones in the second zone.
[4]
4. Non-woven fabric, according to any of the previous claims, characterized by the fact that the intensive property is the thickness, and the thickness of each region is greater than zero.
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[5]
5. Non-woven fabric, according to claim 4, characterized by the fact that the difference in thickness in the first zone is greater than 25 microns.
[6]
6. Non-woven fabric, according to any of the previous claims, characterized by the fact that the intensive property is the grammage, and the grammage of each region is greater than zero.
[7]
7. Non-woven fabric, according to claim 6, characterized by the fact that the difference in weight in the first zone is greater than 5 g / m2.
[8]
8, characterized by the fact that the difference in volumetric density in the first zone is greater than 0.042 g / cc.
8. Non-woven fabric, according to any of the previous claims, characterized by the fact that the intensive property is the volumetric density, and the volumetric density of each region is greater than zero.
[9]
9. Non-woven fabric according to the claim
[10]
10. Non-woven fabric, according with any of claims previous, characterized fur fact of what at least one between the surfaces has one value of TS7
less than 15 dB V ² rms.
[11]
11. Non-woven fabric, according to claim 10, characterized by the fact that the first surface has a TS7 value of 2 to 12 dB V ² rms and the second surface has a TS7 value different from the TS7 value of the first surface.
[12]
12. Non-woven fabric according to claim 11, characterized by the fact that the second surface has a TS7 value that is less than the TS7 value of the first surface.
[13]
13. Non-woven fabric according to claim 10, characterized by the fact that the second surface has a TS7 value of 3 to 8 and the first
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[14]
14. Non-woven fabric according to claim 13, characterized by the fact that the first surface has a TS7 value that is greater than the TS7 value of the second surface.
[15]
15. Absorbent article, characterized by the fact that it comprises a non-woven fabric as described according to any of the preceding claims.

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US10888471B2|2021-01-12|Shaped nonwoven

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RU2703390C1|2019-10-17|Molded nonwoven material

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BR112020024573A2|2021-03-09|NON-WOVEN FABRICS AND ABSORBENT ITEMS THAT HAVE TEXTURIZED, SOFT AND FORMATED NON-WOVEN FABRICS

同族专利:

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公开号 | 公开日

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GB2571693A|2019-09-04|

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GB201909896D0|2019-08-21|

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CN110198693A|2019-09-03|

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WO2018144295A1|2018-08-09|

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JP2020505520A|2020-02-20|

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WO2018144293A1|2018-08-09|

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CN110191982A|2019-08-30|

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DE112018000611T5|2019-12-12|

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EP3576700A1|2019-12-11|

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US20210140082A1|2021-05-13|

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US10934645B2|2021-03-02|

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US20200240062A1|2020-07-30|

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GB2571897A|2019-09-11|

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US10655257B2|2020-05-19|

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JP2020505522A|2020-02-20|

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US20180216271A1|2018-08-02|

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US20180216269A1|2018-08-02|

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US20210180228A1|2021-06-17|

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EP3576699A1|2019-12-11|

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GB201909891D0|2019-08-21|

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US10968552B2|2021-04-06|

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RU2725401C1|2020-07-02|

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DE112018000618T5|2019-12-12|

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法律状态:
2021-05-04| B11A| Dismissal acc. art.33 of ipl - examination not requested within 36 months of filing|

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2021-07-20| B11Y| Definitive dismissal - extension of time limit for request of examination expired [chapter 11.1.1 patent gazette]|

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2021-10-13| B350| Update of information on the portal [chapter 15.35 patent gazette]|

优先权:

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申请号 | 申请日 | 专利标题

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US201762452518P| true| 2017-01-31|2017-01-31|

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US62/452,518|2017-01-31|

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PCT/US2018/015122|WO2018144295A1|2017-01-31|2018-01-25|Shaped nonwoven|

---