US20050153615A1 - Fibrous material with high functional particle load - Google Patents

Fibrous material with high functional particle load Download PDF

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Publication number
US20050153615A1
US20050153615A1 US10/501,696 US50169604A US2005153615A1 US 20050153615 A1 US20050153615 A1 US 20050153615A1 US 50169604 A US50169604 A US 50169604A US 2005153615 A1 US2005153615 A1 US 2005153615A1
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previous
gsm
sap
weight percent
lanes
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Jacek Dutkiewicz
Michael Kalmon
Brian Boehmer
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Georgia Pacific Nonwovens LLC
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BKI Holding Corp
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Priority to US10/501,696 priority Critical patent/US20050153615A1/en
Assigned to BKI HOLDING CORPORATION reassignment BKI HOLDING CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BOEHMER, BRIAN E., DUTKIEWICZ, JACEK K., KALMON, MICHAEL
Assigned to BKI HOLDING CORPORATION reassignment BKI HOLDING CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KALMON, MICHAEL, BOEHMER, BRIAN E., DUTKIEWICZ, JACEK K.
Assigned to BKI HOLDING CORPORATION reassignment BKI HOLDING CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KALMON, MICHAEL, BOEHMER, BRIAN E., DUTKIEWICZ, JACEK K.
Publication of US20050153615A1 publication Critical patent/US20050153615A1/en
Assigned to BKI HOLDING CORPORATION reassignment BKI HOLDING CORPORATION CORRECTED ASSIGNMENT:PLEASE CORRECT THE ADDRESS OF THE RECEIVING PARTY RECORDED 7/16/04 AT REEL/FRAME:016260/0029 Assignors: BOEHMER, BRIAN E., DUTKIEWICZ, JACEK K., KALMAN, MICHAEL
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15617—Making absorbent pads from fibres or pulverulent material with or without treatment of the fibres
    • A61F13/15658—Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/531—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad
    • A61F13/532—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad
    • A61F13/5323—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad having absorbent material located in discrete regions, e.g. pockets
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/534—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
    • A61F13/535—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/407—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing absorbing substances, e.g. activated carbon
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F2013/530481—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials
    • A61F2013/53051—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials being only in particular parts or specially arranged
    • A61F2013/530547—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials being only in particular parts or specially arranged positioned in a separate layer or layers
    • A61F2013/530562—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials being only in particular parts or specially arranged positioned in a separate layer or layers being arranged in discontinuous pattern
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]

Definitions

  • This invention relates to fibrous material, including fibrous structures containing particle, which are useful in the manufacture of disposable diapers, adult incontinence pads, sanitary napkins and the like. More particularly, the invention is directed to fibrous articles having very high loads of particles, particularly particles of superabsorbent polymer.
  • Absorbent articles such as disposable diapers, adult incontinence pads, sanitary napkins, panty liners and the like, are generally provided with an absorbent core to receive and retain body liquids.
  • the absorbent core is usually sandwiched between a liquid pervious top sheet, whose function is to allow the passage of fluid to the core, and a liquid impervious backsheet, whose function is to contain the fluid and to prevent it from passing through the absorbent article to the garment of the wearer of the absorbent article.
  • An absorbent core for diapers and adult incontinence pads frequently includes fibrous batts or webs constructed of defiberized, loose, fluffed, hydrophilic, cellulosic fibers.
  • the core may also include a layer or stratum containing superabsorbent polymer (SAP) particles, granules, flakes or fibers, often referred to as the storage layer or stratum.
  • SAP superabsorbent polymer
  • Such an article may be obtained by decreasing the thickness of the diaper core, by reducing the amount of fibrous material used in the core while increasing the amount of SAP particles, and by calendering or pressing the core to reduce caliper and hence, increase density.
  • Such higher density cores do not absorb liquid as rapidly as lower density cores because the compacting of the core (densification) results in smaller effective pore size. Accordingly, to maintain suitable liquid absorption, it is necessary to provide a lower density layer having a larger pore size above the high-density absorbent core to increase the rate of uptake of liquid discharged onto the absorbent article.
  • the low-density layer is typically referred to as an acquisition layer. Multiple layer absorbent core designs involve a more complicated manufacturing process.
  • the storage layer portion of a disposable diaper for example is generally formed in place, during the converting process, from loose, fluffed cellulose.
  • Such cellulose material is generally not available in preformed roll form because it exhibits insufficient web strength, owing to its lack of interfiber bonding or entanglement, to be unwound directly onto and handled in absorbent pad-making equipment.
  • Ultra-thin feminine napkins are generally produced from roll-goods based nonwoven material. Such a roll of preformed absorbent core material is unwound directly onto the absorbent article converting equipment without the defiberization step required for fluff-based products, such as diapers and incontinence pads.
  • the nonwoven web is typically bonded or consolidated in a fashion that gives it sufficient strength to be handled in the converting process. These webs may also contain SAP particles.
  • the web consolidation mechanisms used in the roll-goods approach to making preformed cores provide strength and dimensional stability to the web.
  • Such mechanisms include latex bonding, bonding with thermoplastic or bicomponent fibers or thermoplastic powders, hydroentanglement, needle punching, carding or the like.
  • the core structures exhibit poor particle containment. In other words, some of the particles tend to escape from the structure during manufacture, handling, shipping and converting and in use. This can result in the fouling of manufacturing and converting equipment as well as negative consumer perception of the product.
  • the material comprises from about 0.1 weight percent to about 10 weight percent total binder which comprises a first binder, a second binder, and, optionally, a third binder, where each binder can be the same as or different from any other binder.
  • the material may further comprise (H) a carrier, which may be a cellulosic tissue carrier or a synthetic material.
  • the material may further comprise
  • this invention is a nonwoven material with a pliability of about 400 1/N or greater comprising from about 75 to about 95 weight percent SAP.
  • this invention is a process for the production of a material comprising depositing on a removable support, a carrier or on a carrier on a support a mixture of SAP, fibers and binder, where the material comprises from about 60 weight percent to about 95 weight percent SAP and has a pliability of about 400 I/N or greater.
  • the material of the invention as well as a core of this type can be produced in a continuous process which is a series of unit operations, preferably including unit operations involving airlaying of fibrous mixtures through individual airlaying heads.
  • the absorbent core may also be produced with adhesives in a conventional converting operation.
  • the materials of this invention and cores containing them are useful in various fields including us in absorbent products in the form of a diaper, training pant, incontinent device, feminine hygiene device, surgical drape, wound dressing, or cable wrap.
  • FIG. 1 is a top view of a functional particle stratum made according to the present invention, showing multiple lanes of particle material, forming particle-free zones or spaces.
  • FIG. 2 is a top view of a functional particle stratum made according to the present invention, showing multiple lanes of particle material, forming particle-free zones or spaces.
  • the lanes are offset from the lanes of the stratum of FIG. 1 .
  • FIG. 3 is a cross-sectional view of a fibrous web or article made according to the present invention showing alternating matrix fiber strata and functional particle strata.
  • FIG. 4 is a top view of a functional particle stratum made according to the present invention, showing multiple lanes of particle material, wherein the lanes are S-shaped.
  • FIG. 5 is a top view of a functional particle stratum made according to the present invention, showing multiple lanes of particle material, wherein the lanes are hourglass-shaped.
  • FIG. 6 is a top view of a functional particle stratum made according to the present invention, showing multiple lanes of particle material, wherein the lanes are circle-shaped.
  • FIG. 7 is a top view of a functional particle stratum made according to the present invention, showing multiple lanes of particle material, wherein the lanes are intermittent.
  • FIG. 11 is a schematic view of the folding of an absorbent core of the present invention.
  • the present invention is directed to a stratified fibrous web which comprises a plurality of functional particle strata.
  • Each functional particle stratum includes lanes or zones of functional particles, and each lane or zone is separated from an adjacent lane or zone.
  • FIG. 1 there is shown a top view of a functional particle stratum.
  • the structures of the present invention are prepared using airlaid technology.
  • the Figures show the structures of the present invention as elongated in the MD or machine direction, also referred to as the Y-direction.
  • the CD or cross-direction is perpendicular to the MD.
  • the Z-direction refers to the thickness of the structure and is orthogonal to the X-Y plane.
  • Stratum 2 of FIG. 1 includes a plurality of lanes 6 and 8 extending longitudinally in the Y-direction. Each lane includes functional particles. The edges 10 of stratum 2 are free of functional particles. Between each lane are spaces 14 , also free of functional particles. Stratum 2 may be applied over another functional particle stratum or over another stratum not containing functional particles. Referring to FIG. 2 , a second functional particle stratum 4 is shown. This stratum also includes longitudinally extending lanes of functional particles. However, the lanes are positioned such that when stratum 2 is applied over stratum 4 the lanes will not superimpose, when viewed in the Z-direction. Similarly, the lanes of stratum 2 will not superimpose over the lanes of stratum 4 , even when an intervening stratum not containing functional particles is placed between strata 2 and 4 .
  • stratum 4 is positioned over stratum 20 such that lanes 12 do not superimpose on lanes 6 or 8 of stratum 2 .
  • stratum 22 is provided over stratum 4 .
  • strata 18 , 20 and 22 contains no functional particles and contains the same or different types and amount of fibers as either strata or each other.
  • the resultant multistrata structure includes alternating strata of fibers and functional particles, such that the lanes of functional particles are substantially surrounded by fibers.
  • the lateral edges of the multistrata structure of FIG. 3 are optionally provided with an edge seal as described in PCT application WO 00/71790 the disclosure of which is hereby incorporated by reference.
  • the multistrata structure of FIG. 3 is depicted for illustrative purposes as having three functional particle strata. However, the structure may contain as few as two such strata or as many as is suitable for a particular application. In a preferred embodiment, six such strata are provided.
  • lanes of the functional particle strata are shown in FIGS. 1-3 as being parallel and extending continuously in the MD or Y-direction of the strata.
  • lanes or zones may be arranged in other ways suitable to the present invention.
  • the lanes can remain as parallel but the particles may be provided intermittently to provide lane segments with gaps between the segments, as shown in FIG. 7 .
  • the lanes can be applied in a S-shape in the longitudinal direction with S-shaped spaces between the lanes, as shown in FIG. 4 .
  • the lanes may be hour-glass shaped, as shown in FIG. 5 .
  • Other patterns may be used as well, such as circle-shaped ( FIG. 6 ).
  • each functional particle stratum contain both lanes containing functional particles and spaces not containing functional particles, and the pattern must be arranged such that lanes or zones of a first functional particle stratum will not superimpose over the lanes or zones of a second next adjacent functional particle stratum. Notwithstanding the foregoing, superimposition of a small percentage (less than 15%) of the area of lanes or zones, is considered to meet this definition.
  • the preferred amount of coverage of a given functional particle stratum by the functional particles depends upon the application and the thickness, density and other parameters of the particles. Generally, it is preferred that the lanes of the stratum cover at least 30% and preferably 40% and most preferably 50% of the X-Y area of the stratum.
  • the functional particle lane is intended to receive particles, flakes, powder, granules, or the like.
  • the particles may include any functional powder or other particles having a particle diameter of up to 3,000 microns ( ⁇ ).
  • the particle area may include a particle loading of from 2 to 2,000 gsm (grams per square meter), more preferably from 2 to 1,000 gsm, even more preferably from 10 to 600 gsm, and most preferably from 100 to 250 gsm.
  • the particles may be superabsorbent polymers (“SAP”) or other functional material.
  • SAP superabsorbent polymers
  • suitable particles include odor control agents, e.g., zeolites or calcium carbonate, fragrances, detergents and the like.
  • a superabsorbent polymer is a water soluble compound that has been cross-linked to render it water insoluble but still swellable to at least about 15 times its own weight in physiological saline solution.
  • These superabsorbent materials generally fall into three classes, namely starch graft copolymers, cross-linked carboxymethylcellulose derivatives, and modified hydrophilic polyacrylates.
  • examples of absorbent polymers include hydrolyzed starch-acrylontrile graft co-polymer, saponified acrylic acid ester-vinyl co-polymer, modified cross-linked polyvinyl alcohol, neutralized cross-linked polyacrylic acid, cross-linked polyacrylate salt, and carboxylated cellulose.
  • the preferred superabsorbent materials upon absorbing fluids, form hydrogels.
  • the superabsorbent polymer materials have relatively high gel volume and relatively high gel strength as measured by the shear modulus of the hydrogel. Such preferred materials also contain relatively low levels of polymeric materials which can be extracted by contact with synthetic urine.
  • Superabsorbent polymers are well-known and are commercially available.
  • One example is a starch graft polyacrylate hydrogel marketed under the name IM 1000 (Hoechst-Celanese, Portsmouth, Va.).
  • SAP surface cross-linked acrylic acid based powder
  • Stockhausen 9350 or SX FAM 70 Greensboro, N.C.
  • the fibers suitable for use in the structures of the present invention may include cellulosic or synthetic fibers or blends thereof. Most preferred is wood cellulose. Also preferred is cotton linter pulp, chemically modified cellulose such as crosslinked cellulose fibers and highly purified cellulose fibers, such as Buckeye HPF (each available from Buckeye Technologies Inc., Memphis, Tenn.). The fluff fibers may be blended with synthetic fibers, for example polyester such as PET, nylon, polyethylene or polypropylene.
  • the fiber-containing strata may also include thermoplastic binding material, which may be blended with the cellulosic or synthetic fibers.
  • Suitable thermoplastic binding material includes thermoplastic fibers, such as bicomponent thermoplastic fibers (“bico”).
  • Preferred thermoplastic binding fibers provide enhanced adhesion for a wide range of materials, including synthetic and natural fibers, particles, and synthetic and natural carrier sheets.
  • An exemplary thermoplastic bico fiber is Celbond Type 255 Bico fiber from Hoechst Celanese.
  • thermoplastic fibers include polypropylenes, polyesters, nylons and other olefins, or modifications thereof.
  • a preferred thermoplastic fiber is FiberVisions type AL-Adhesion-C Bicomponent Fiber, which contains a polypropylene core and an activated copolyolefin sheath.
  • each stratum positioned between the functional particle strata may preferably contain from about 1 to 20 gsm of cellulosic of synthetic fibers.
  • a thermoplastic bonding material may be present in the stratum in the amount of 2 to 50% by weight, more preferably 3 to 20%, most preferably about 10% of the total weight of the stratum.
  • the stratum between the functional particle strata includes 3.0 gsm fluff pulp and 1.0 gsm of bico.
  • binders in liquid form or having a liquid carrier include binders in liquid form or having a liquid carrier, including latex binders.
  • Useful latex binders include vinyl acetate and acrylic ester copolymers, ethylene vinyl acetate copolymers, styrene butadiene carboxylate copolymers, and polyacrylonitriles, and sold, for example, under the trade names of Airbond, Airflex and Vinac of Air Products, Inc., Hycar and Geon of Goodrich Chemical Co., and Fulatex of H. B. Fuller Company.
  • the binder may be a non-latex binder, such as epichlorohydrin and the like.
  • the invention contemplates two separate binder applications.
  • the binder is applied to the structure so as to contact only the particle free area or lane, which is adjacent the areas or lanes containing the particles disposed between the first and second layers.
  • the binder may be applied in the form of a spray, foam, or mist.
  • the binders are diluted to contain 3 to 25% solids, more preferably 6 to 12% solids, most preferably 10%.
  • a binder which is diluted to have a relatively high solids content (such as 10%) is ideal for acting in the highly compacted, small pore environment of the particle free area, wherein the seals are formed.
  • the environment results in fast wicking, and the high solids content reduces migration of the binder to the other areas of the web.
  • the second binder application involves application of a binder, in the form of a foam, spray or mist, to substantially the entire surface of the structure (as an “overall binder”), in order to reduce dust-off on the exterior and interior of the structure.
  • the overall binders are diluted to contain 1 to 20% solids, more preferably 2 to 10% solids, even more preferably 2 to 4% solids, and most preferably about 3.5% solids. While the binder will penetrate to reduce dust-off and to immobilize the functional particles, it will not provide a significant contribution to the structural integrity of the web.
  • the use of two binder applications allows independent control of the seal area stiffness and the non-seal area stiffness.
  • the stiffness of either region can be controlled by the selection of binder type, solids content and amount of binder applied to the respective regions. This addresses the need to deliver requisite seal strength and maintain sufficient flexibility for the comfort of the user.
  • the fibers of the structures of the present invention may be fixed in place to provide integrity to the structure using heat-activated fibers or other binding agents.
  • a thermoplastic binding material is used and seals are formed when the structure is compacted or densified by pressure or pressure and heat.
  • the seals may be further strengthened by subsequent curing in a curing oven. It is preferred to use thermoplastic fibers as the binder fiber, and heat as the curing agent. Heat can be applied to cure the fibers at the end of the airlaying process, or alternatively, periodically at various stages of the process.
  • the sealing may be provided by the application of a liquid binder (or binder in a liquid carrier), after compacting or densification of the web.
  • the binder is targeted to contact the particle-free areas, and to avoid the particle areas.
  • the binder wicks into the densified region, and forms seals upon drying and curing.
  • the upper and lower strata optionally contain a thermoplastic binding material.
  • seals are formed by application of a liquid binder (or a binder in a liquid carrier) in the particle free zone only, wherein the binder wicks into the densified region and forms strong seals upon drying and curing, without densification of the particle free zone.
  • seals are formed by compacting or densification of the particle-free areas, followed by application of a binder which is targeted to contact the particle-free areas, and to avoid the particle areas.
  • the binder wicks into the densified region, and forms seals upon drying and curing.
  • the upper and lower strata each contain a thermoplastic binding material, which strengthens the seals upon densification and curing.
  • the article is an absorbent article.
  • the fibrous structure having improved particle containment may be delivered in roll-goods form, or in other packaging formats such as festooning, and is particularly useful as an absorbent core for disposable absorbent articles such as diapers, adult incontinence pads and briefs, and feminine sanitary napkins.
  • the structure of the present invention is prepared as an airlaid web.
  • the airlaid web is typically prepared by disintegrating or defiberizing a cellulose pulp sheet or sheets, typically by hammermill, to provide individualized fibers.
  • the individualized fibers are then air conveyed to forming heads on the airlaid web forming machine.
  • forming heads include rotating or agitated drums, generally in a race track configuration, which serves to maintain fiber separation until the fibers are pulled by vacuum onto a foraminous condensing drum or foraminous forming conveyor (or forming wire).
  • Fibers such as a synthetic thermoplastic fiber
  • a fiber dosing system which includes a fiber opener, a dosing unit and an air conveyor.
  • a fiber opener a fiber opener
  • a dosing unit a fiber opener
  • an air conveyor a fiber conveyor
  • multiple layers such as a distribution layer and an acquisition layer
  • separate forming heads may be provided for each type of layer.
  • the material and structures of the invention contain a carrier tissue.
  • a compaction roll prior to the introduction of the particle areas can be used to eliminate the need for the tissue.
  • one or more forming heads of the airlaid web forming machine distributes the desired fiber for the lower layer of the absorbent structure.
  • SAP granules or other particles are then applied to the upper surface of this web.
  • the particles are applied in lanes in the machine direction with particle-free zones or lanes therebetween.
  • Other particles include odor control agents, e.g., zeolites or calcium carbonate, fragrances, detergents and the like.
  • FIG. 6 depicts a process of making a fibrous web according to the present invention.
  • a carrier tissue 20 a may be unwound from the supply roll 21 .
  • the tissue 20 a is rolled on to screen 18 .
  • the tissue may alternatively be used as a carrier or as the lower stratum 16 of the absorbent article.
  • a forming head 24 of the airlaid web-forming machine distributes the desired fiber to form the lower stratum 16 of the absorbent structure.
  • Cellulosic fibers may be obtained by disintegrating or defiberizing a cellulose pulp sheet or sheets, typically by hammermill, to provide individualized fibers. The individualized fibers are then air conveyed to forming heads on the airlaid web-forming machine.
  • Cellulosic fiber and optionally thermoplastic fibers are added to the cellulose tissue 20 a by forming head 24 .
  • the forming heads include rotating drums, or agitators generally in a racetrack configuration, which serve to maintain fiber separation until the fibers are pulled by vacuum onto a foraminous condensing drum or foraminous forming conveyor (or forming wire).
  • the forming head includes a rotary agitator above a screen.
  • Other fibers such as a synthetic thermoplastic fiber, may also be introduced to the forming head through a fiber dosing system, which includes a fiber opener, a dosing unit and an air conveyor.
  • multiple strata are desired, such as a fluff pulp distribution stratum and a synthetic fiber acquisition stratum, multiple forming heads are provided, one for each type of stratum.
  • the fibers are optionally compressed to the desired thickness and density.
  • the lower stratum 16 may be compacted at this point in the manufacturing process to close the pores of the web if the particles are fine and to prevent spillage on to the forming wire.
  • Particles are applied to the lower stratum 16 by particle applicator 28 .
  • SAP granules or other particles are thus applied to the upper surface of the lower stratum 16 .
  • the particles are applied in a plurality of lanes 6 in the machine direction with particle-free zones or lanes 8 located between the particle lanes.
  • Lanes are areas in which particles are specifically delivered.
  • Other suitable particles include odor control agents, e.g., zeolites or calcium carbonate, fragrances, detergents and the like.
  • a second strata of fibers 18 is applied by forming head 34 , which applies cellulosic fibers, and optionally can also apply a thermoplastic fiber such as a bicomponent fiber. Subsequent layers can be added on top of the second layer.
  • the web may pass under another particle applicator 28 (not shown) to apply another stratum of particles, followed by another stratum of fibers applied by another forming head 34 (not shown). In this way, the web may be built up by a desired number of alternating strata of fibers and particles.
  • a series of ovens is used in processes of the invention, for drying, curing or thermal bonding.
  • the airlaid web 23 is heated to a temperature in the range of from 125 to 180° C. at oven 50 .
  • a temperature in the range of from 125 to 180° C. at oven 50 .
  • thermoplastic fibers including preferably bico fibers
  • the curing temperature and dwell time must be sufficient to melt the fibers and cause binding.
  • An overall binder is applied to the airlaid web 23 at 52 . This binder can be applied by spray, foam or mist, and is applied to reduce dust-off on the surface of the structure.
  • the air laid web 23 is heated in a second oven 54 at a temperature in the range of from 125 to 180° C.
  • the airlaid web 23 can be treated at pressure in the range of from 0.1 to 10 psi, preferably 1.5 psi.
  • heat seals between the thermoplastic material and the fibers of the upper and lower layers are formed.
  • the heat seals are substantially free of particles (especially SAPs), which could disrupt the heat seal upon exposure to moisture.
  • the finished web is then rolled for future use. This continuous band of fibrous web can be slit or cut to form individual absorbent articles in a cutting unit, which has not been depicted in this figure.
  • the finished web may be slit or perforated at the heat seal to yield narrow slit core material having a heat seal along both edges.
  • the heat seals to be slit must be of sufficient width to provide two effective seals after slitting.
  • various other layers containing other types and amounts of fibers may be applied above or below the upper and lower layers of the structure of the present invention.
  • the absorbent article may also contain a fluid previous top sheet and a fluid impervious backsheet.
  • Exemplary absorbent articles which can be formed from absorbent cores of the invention include diapers, feminine sanitary napkins, and adult incontinence products.
  • Examples 1, 2, 4 and 5 were manufactured on a airlaid pilot machine made by Danweb which has three forming heads, and to which has been added a between-the-head SAP dosing system.
  • the structures were made by passing the web through the forming process more than once. On each pass the material was slightly pressed at the end of the line. The final thickness was adjusted on the last pass.
  • the SAP powder was placed in discrete lanes with the aid of divider boxes as depicted schematically in FIG. 9 . which masks about half of the area of the airlaid forming wire.
  • the dividers in the following Examples were 1.27 cm in width and the spaces between the dividers were 1.27 cm in width.
  • the raw materials used in the Examples are Foley Fluff (FF), a southern softwood bleached kraft fluff pulp, Buckeye Technologies Inc.; T-255 polyolefin bicomponent fiber, 2.8 dpf, KoSa; 3024 cellulosic carrier tissue, 18 gsm, Cellu Tissue Co; T-224 polyester fiber, 15 dpf ⁇ 6 mm, KoSa; Sumitomo SA60S superabsorbent polymer granules, Sumitomo, Japan, Favor 880 superabsorbent polymer granules, Degussa, USA, Kolon GS3500 superabsorbent polymer granules, Kolon, Korea and Airflex 124 latex emulsion, Air Products Chemicals.
  • FF Foley Fluff
  • T-255 polyolefin bicomponent fiber 2.8 dpf, KoSa
  • 3024 cellulosic carrier tissue 18 gsm, Cellu Tissue Co
  • Examples 1, 2, 4 and 5 have a plurality of layers produced in two passes through the three head airlaying machine, with layer 1 made first on the cellulosic carrier, followed by the first SAP feed in lanes, followed by layer 2 , followed by a second SAP feed in lanes, where the lanes of SAP from the second SAP feeder are offset in the cross machine direction from the location of the lanes of SAP from the first SAP feeder, so that, looking at the material from the top down the Z dimension perpendicular to the machine direction and the cross machine direction, the lanes of SAP from successive feeds do not superimpose.
  • SAP amounts in grams per square meter (gsm) for a particular SAP feed are an overall basis weight for that feed. Since the SAP is laid down in lanes, the amount of SAP at successive locations in the cross machine direction varies from zero or about zero between the lanes of SAP to about 100 percent in the lanes.
  • the first pass through the three head airlaid forming system laid the materials in the amounts indicated below in reverse order, starting with Head 1 laying a FF and bico mixture on the cellulosic carrier tissue.
  • layer 4 was laid by Head 3 .
  • the first pass through the three head airlaid forming system laid the materials in the amounts indicated below in reverse order, starting with Head 1 laying a FF and bico mixture on the cellulosic carrier tissue.
  • the second pass started with between head SAP feeder 1, followed by airlaying Layer 4 by Head 2 .
  • a web was manufactured on the three-head Danweb airlaid machine with the SAP fed through the forming heads.
  • the raw materials used were ND416 compressible pulp, Weyerhaeuser, Tacoma Wash.; T-255 bicomponent fiber, 2.8 dpf, KoSa; 3024 cellulosic carrier tissue, 18 gsm, Cellu Tissue Co; T-224 polyester fiber, 15 dpf ⁇ 6 mm, KoSa; Kolon GS3500 superabsorbent polymer granules, Kolon, Korea; and Airflex 124 latex emulsion, Air Products Chemicals.
  • the basis weight was 318 gsm, and the caliper was 0.9 mm.
  • pliability is the inverse of the amount of force necessary to bend a sheet of material of the invention. As the force necessary to bend the sheet increases, the pliability of the sheet decreases.
  • Pliability can be measured by the following procedure, using a Gurley tester (Model 4171, Gurley Precision Instruments, Troy, NY).
  • lever arm is not moving. Press motor button to move sample towards lever arm.
  • Stiffness which is expressed in milligrams force, mg.
  • Table 1 below has data for Examples 1, 2, 4 and 5 of this invention, Comparative Example 3 and for several prior art materials which are used in commercial products.
  • TABLE 1 Basis SAP basis weight, weight, SAP Pliability, Thickness, Material gsm gsm content, % 1/N mm
  • Example 1 323 263 81 918 1.2
  • Example 2 318 272 85 1250 0.9 Comparative 325 184 57 334 2.0
  • Examples 1, 2, 4 and 5 New bonded structures
  • Example 3 Prior-art bonded structure
  • Competitive airlaid core Nova Thin, no binder
  • This structure was produced in three individual passes through the three head airlaid line.
  • the first forming head deposited a mixture of 21.5 gsm Foley fluff and 2.3 gsm T-255 KoSa 2.8 dpf bicomponent fibers onto an 18 gsm forming tissue from Cellutissue.
  • 45.0 gsm of Kolon MG2600 from Kolon Chemical company was deposited in lanes onto the web.
  • the second forming head added a mixture of 21.5 gsm Foley fluff and 2.3 gsm T-255 KoSa 2.8 dpf bicomponent fibers.
  • 2.0 gsm AF-124 latex foam was added to the tissue side of the absorbent. Basis weight at this point was 113 gsm.
  • the second pass started by using the structure made in the first pass as the carrier material.
  • the first head added 3.0 gsm Foley fluff and 1.0 gsm T-255 KoSa 2.8 dpf bicomponent fibers.
  • 45.0 gsm of Kolon MG2600 from Kolon Chemical company was deposited in lanes onto the web. This addition of SAP to the web was aligned so the SAP lanes in the first structure were not directly below.
  • the second forming head added a mixture of 21.5 gsm Foley fluff and 2.3 gsm T-255 KoSa 2.8 dpf bicomponent fibers. Again, 45.0 gsm of Kolon MG2600 from Kolon Chemical company was deposited in lanes onto the web.
  • the third head deposited a mixture of 21.5 gsm Foley fluff and 2.3 gsm T-255 KoSa 2.8 dpf bicomponent fibers.
  • the third pass started by using the structure made in the second pass as the carrier material. Only the third head was used in this pass.
  • the third head added a mixture of 27.0 gsm Wellman 213 ⁇ 1 6 dpf polyester fibers and 53.0 gsm AL-Delta 6.7 dtx fibers from ES Fiber Visions.
  • the final thickness was reached by compaction of the web to 2.5 mm.
  • the basis weight was 332 gsm.
  • This structure was produced in two individual passes through the three head airlaid line.
  • the first forming head deposited a mixture of 20.0 gsm Foley fluff and 2.0 gsm T-255 KoSa 2.8 dpf bicomponent fibers onto an 18 gsm forming tissue from Cellutissue.
  • 30.0 gsm of Kolon MG2600 from Kolon Chemical company was deposited in lanes onto the web.
  • the second forming head added a mixture of 21.0 gsm Foley fluff and 2.0 gsm T-255 KoSa 2.8 dpf bicomponent fibers.
  • Basis weight was 93 gsm at this point.
  • the second pass started by using the structure made in the first pass as the carrier material. Only the third head was used in this pass. The third head added a mixture of 17.0 gsm Wellman 213 ⁇ 1 6 dpf polyester fibers and 33.0 gsm AL-Delta 6.7 dtx fibers from ES Fiber Visions. The final thickness was reached by compaction of the web to 2.2 mm. The basis weight was 140 gsm.
  • An absorbent core was made by joining the material of Example 7 as an upper layer ASP (acquisition and storage ply) with the material of Example 5 as a lower layer DSP (distribution and storage ply) in a DUOCORE absorbent core structure.
  • the materials were joined by means of a polymer spray adhesive, Super 77 available from 3 M, St. Paul, Minn.
  • the area of the ASP was less than that of the DSP.
  • An alternative version of this core with no adhesive was made as part of the acquisition time test procedure which follows.
  • the result for this core was a 1 st insult acquisition time of 49.2 seconds, 2 nd of 104 seconds and third of 129 seconds.
  • This core was made by the procedure used in Example 8, except that the ASP was the material of Example 6 and the SAP was the material of Example 5.
  • the result for this core was a 1st insult acquisition time of 42.9 seconds, 2nd of 80 seconds and third of 102 seconds.
  • Table 4 illustrate the effect of the Treated FOLEY FLUFF®on the performance of the Absorbent System I composed of the topsheet, curly-fiber layer, airlaid insert, fluff and poly backsheet.
  • the acquisition of Example 15 with Treated FOLEY FLUFF® was significantly faster than the acquisition of Example 11 with FOLEY FLUFF®.
  • the sample with SW-16 fibers had also improved capacity over the sample with FF.
  • Table 5 illustrate the effect of the Treated FOLEY FLUFF® and C-folding on the performance of the Absorbent System 2 composed of the topsheet, curly-fiber layer, airlaid insert, fluff and poly backsheet.
  • the acquisition of the C-folded EXAMPLE 15 WITH TREATED FOLEY FLUFF® was significantly faster than the acquisition of the C-folded Example 11 with FOLEY FLUFF®.
  • the sample with Treated FOLEY FLUFF® fibers had also improved capacity over the sample with FOLEY FLUFF®.
  • All examples were manufactured on a 3-head airlaid pilot Danweb machine with 2 between-head SAP dosing systems.
  • the SAP powder was placed in discrete lanes along the machine direction (MD).
  • the lanes were formed with the aid of divider boxes depicted in FIG. 9 of the original application.
  • the divider boxes were used that masked 50% of the area of an airlaid forming wire.
  • the dividers were 1.27 cm in width and the voids between the dividers were 1.27 cm in width. With this divider box, the same amount of SAP can be distributed over half of the area, resulting in SAP stripes of twice the overall basis weight.
  • Examples 17 and 18 comprise a thicker layer of bonded cellulose fibers for enhanced wicking performance.
  • Any conventional means of dosing SAP onto an airlaid forming wire may be used with the divider box shown in FIG. 9 .

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US20090306253A1 (en) * 2006-03-22 2009-12-10 Morten Rise Hansen Fibre-reinforced thermoplastic material
US20110189911A1 (en) * 2007-01-10 2011-08-04 Ritesh Mehbubani High loft nonwoven sheet material and method of construction thereof
US20120165770A1 (en) * 2010-12-28 2012-06-28 Peiguang Zhou Absorbent article with stimulation composite
EP2521523A4 (fr) * 2010-01-06 2014-01-15 Mcneil Ppc Inc Article absorbant ultra-mince
US9302248B2 (en) 2013-04-10 2016-04-05 Evonik Corporation Particulate superabsorbent polymer composition having improved stability
US9375507B2 (en) 2013-04-10 2016-06-28 Evonik Corporation Particulate superabsorbent polymer composition having improved stability
AU2015202516B2 (en) * 2010-01-06 2017-03-09 Mcneil-Ppc, Inc. Ultra-thin absorbent article
US20220160037A1 (en) * 2014-03-27 2022-05-26 Essentra Filter Products Development Co. Pte. Ltd Smoking article

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JP3878085B2 (ja) * 2002-08-09 2007-02-07 ユニ・チャーム株式会社 使い捨ての体液吸収性着用物品
BR112017014938A2 (pt) * 2015-01-12 2018-03-13 Georgia Pacific Nonwovens Llc material de aquisição não-tecido em múltiplas camadas, material não-tecido em múltiplas camadas e compósito absorvente
CN108313660B (zh) * 2017-01-16 2024-05-03 北京想象无限科技有限公司 用于吸收体的定向系统及定向方法

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US20090306253A1 (en) * 2006-03-22 2009-12-10 Morten Rise Hansen Fibre-reinforced thermoplastic material
US8530548B2 (en) * 2006-03-22 2013-09-10 Glatfelter Falkenhagen Gmbh Fibre-reinforced thermoplastic material
US20110189911A1 (en) * 2007-01-10 2011-08-04 Ritesh Mehbubani High loft nonwoven sheet material and method of construction thereof
EP2521523A4 (fr) * 2010-01-06 2014-01-15 Mcneil Ppc Inc Article absorbant ultra-mince
AU2015202516B2 (en) * 2010-01-06 2017-03-09 Mcneil-Ppc, Inc. Ultra-thin absorbent article
US20170189245A1 (en) * 2010-01-06 2017-07-06 Edgewell Personal Care Brands. LLC Ultra-Thin Absorbent Article
US10940055B2 (en) * 2010-01-06 2021-03-09 Edgewell Personal Care Brands, Llc Ultra-thin absorbent article
US20120165770A1 (en) * 2010-12-28 2012-06-28 Peiguang Zhou Absorbent article with stimulation composite
US9302248B2 (en) 2013-04-10 2016-04-05 Evonik Corporation Particulate superabsorbent polymer composition having improved stability
US9375507B2 (en) 2013-04-10 2016-06-28 Evonik Corporation Particulate superabsorbent polymer composition having improved stability
US10307732B2 (en) 2013-04-10 2019-06-04 Evonik Corporation Particulate superabsorbent polymer composition having improved stability and fast absorption
US20220160037A1 (en) * 2014-03-27 2022-05-26 Essentra Filter Products Development Co. Pte. Ltd Smoking article

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CA2473524A1 (fr) 2003-07-31
EP1465569A2 (fr) 2004-10-13

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