ABSORBENT ARTICLE WITH HEAT ACTIVATABLE WEB
Material webs suitable for use in conjunction with disposable absorbent articles are disclosed herein. The material webs comprise a melt additive that when subjected to thermal energy may be encouraged to bloom across the entirety of the web or in localized areas of the web where localized thermal energy is applied.
The disclosure herein relates generally to thermoplastic polymeric materials with varying property zones created via the application of thermal energy and articles incorporating such materials.
BACKGROUND OF THE INVENTIONNonwovens and films have been used in a myriad of absorbent articles over the past several years. In some particular absorbent articles, e.g. diapers, feminine hygiene pads, nonwovens and/or films may be utilized as a topsheet, backsheet, or some other feature of these particular absorbent articles.
The requirements for these absorbent articles may be disparate depending use. For example, a nonwoven and/or film used as a topsheet for diapers may not be suitable for adult incontinence products. Similarly, a nonwoven and/or film suitable as a topsheet for adult incontinence products may not be suitable for feminine hygiene pads.
Additionally, requirements for nonwoven and/or films in absorbent articles may vary by geography. For example, in one geography an absorbent article with a soft topsheet may be a factor which is foremost in consumer's minds. In another geography, absorbent articles which minimize the amount of rewet may be foremost in consumer's minds. In yet another geography, the speed of acquisition of liquid insults may be foremost in consumer's minds. In yet another geography, the amount of masking provided by a topsheet may be foremost in consumer's minds.
It would be beneficial for a nonwoven and/or film web to address one or more of the above concerns and allow for the flexibility of addressing multiple of the above concerns. It would also be beneficial to have a process which facilitated the production of nonwoven and/or film webs capable of addressing one or more of the above concerns and to provide a process providing the flexibility to address multiple of the above concerns.
SUMMARY OF THE INVENTIONDisclosed herein are material webs which can be used in absorbent articles including disposable absorbent articles. Some exemplary uses include a topsheet or a backsheet of a diaper or feminine pad or as an overwrap for a tampon. Some additional uses are discussed herein. The material webs of the present invention, when utilized as a topsheet of a feminine hygiene article, can provide a soft feel to the user and can provide quick acquisition of menses/urine insults. Other benefits and configurations are discussed hereinafter. The material webs of the present invention may be heated treated to create discrete melt additive bloom areas. In other forms, the material webs of the present invention may be heated treated across the entirety of the web to encourage melt additive blooming across the entirety of the web. Still in other forms, the addition of nucleating agents can facilitate blooming of melt additive either across the entirety of a web or increase blooming in melt additive bloom areas. Additional benefits are described herein.
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the present invention, it is believed that the invention can be more readily understood from the following description taken in connection with the accompanying drawings, in which:
As used herein “disposable absorbent article” or “absorbent article” shall be used in reference to articles such as diapers, training pants, diaper pants, refastenable pants, adult incontinence pads, adult incontinence pants, feminine hygiene pads, tampons, and pessary devices.
As used herein “hydrophilic” and “hydrophobic” have meanings well established in the art with respect to the contact angle of a referenced liquid on the surface of a material. Thus, a material having a liquid contact angle of greater than about 90 degrees is considered hydrophobic, and a material having a liquid contact angle of less than about 90 degrees is considered hydrophilic. Compositions which are hydrophobic, will increase the contact angle of a referenced liquid on the surface of a material while compositions which are hydrophilic will decrease the contact angle of a referenced liquid on the surface of a material. Notwithstanding the foregoing, reference to relative hydrophobicity or hydrophilicity between material(s) and/or composition(s) does not imply that the material or composition are hydrophobic or hydrophilic. For example, a composition may be more hydrophobic than a material. In such a case neither the composition nor the material may be hydrophobic; however, the contact angle of water droplets on the composition is greater than that of water droplets on the material. As another example, a composition may be more hydrophilic than a material. In such a case, neither the composition nor the material may be hydrophilic; however, the contact angle with respect to water droplets exhibited by the composition may be less than that exhibited by the material. In general, materials which demonstrate a high surface energy may be considered to be more hydrophilic than materials which have a low surface energy.
As used herein, “spunbond filaments” refers to small diameter filaments which are formed by extruding molten thermoplastic material as filaments from a plurality of fine capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced. Spunbond filaments are generally not tacky when they are deposited on a collecting surface. Spunbond filaments are generally continuous and have average diameters (from a sample of at least 10) larger than 7 microns, and more particularly, between about 8 and 40 microns.
The term “filament” refers to any type of artificial continuous strand produced through a spinning process, a meltblowing process, a melt fibrillation or film fibrillation process, or an electrospinning production process, or any other suitable process to make filaments. The term “continuous” within the context of filaments are distinguishable from staple length fibers in that staple length fibers are cut to a specific target length. In contrast, “continuous filaments” are not cut to a predetermined length, instead, they can break at random lengths but are usually much longer than staple length fibers.
By “substantially randomly oriented” it is meant that, due to processing conditions of a nonwoven web, there may be a higher amount of filaments oriented in the machine direction (MD) than the cross direction (CD), or vice-versa.
The material webs of the present invention may comprise a film, a nonwoven, or a laminate created therefrom, e.g. a film/nonwoven laminate, a film/film laminate, a nonwoven/nonwoven laminate. Additionally, the material webs of the present invention may comprise any suitable nonwoven and/or any suitable film. Some exemplary nonwovens and films are discussed in additional detail in the section entitled, “Precursor Material.” The material webs of the present invention are suitable for use in disposable absorbent articles.
Referring to
The material web 100 of the present invention comprises a constituent composition. The constituent composition comprises a thermoplastic polymeric material and a melt additive. For example, in the case of nonwoven materials, the fibers or filaments of the material web 100 may comprise a hydrophobic melt additive, a hydrophilic melt additive, or a softness melt additive. Suitable melt additives are discussed hereafter.
The melt additive may be homogeneously mixed with the thermoplastic polymeric material. In the case of bi-component or multi-component fibers or filaments, the melt additive may homogeneously mixed with a component of the bi-component or multi-component fiber or filament but not necessarily across the entirety of the fiber or filament. For example, a fiber or filament having a core-sheath configuration may comprise a melt additive homogeneously mixed with the thermoplastic polymeric material of the sheath, while the core does not comprise the melt additive of the sheath. Or, the core may comprise the melt additive of the sheath, but in a different amount than that of the sheath.
In some forms of the present invention, processing of the web as described herein can create discrete melt bloom areas, e.g. discrete areas with lower surface energy, discrete areas with higher surface energy, discrete soft areas, areas with higher or lower coefficient of friction, etc. The inventors have surprisingly found that the application of thermal energy to the material web 100, can facilitate the blooming of the melt additive to the surface of the material web. For example, the application of localized thermal energy to the material web 100 can promote the creation of discrete melt additive bloom areas on the material web 100, e.g. on the first surface 20 and/or second surface 30. As such, a material web 100, despite having a homogenous mixture of polymer material and melt additive, can have discrete areas of higher or lower surface energy, higher or lower coefficient of friction, or softness.
“Discrete” as used herein does not mean that the “discrete” melt additive bloom areas must be completely isolated from one another. Rather, where thermal energy is applied in localized areas, melt additive blooming will be promoted. As such, the melt additive bloom areas corresponding to the localized thermal energy areas should have more melt additive that blooms to the surface of the material in those localized areas than those without localized application of thermal energy. In some cases—where the melt additive forms fibrils or some other topographical structure at the surface of the filament—the enhanced blooming may be seen via SEM in that there may be a stark difference between fibril growth on the material web in one portion versus another. The stark difference in fibril growth can be a sign of localized heat treatment. Or, one of the other methods described herein may determine whether melt additive bloom areas are localized as opposed to being provided across the entirety of the material web.
In general, discrete melt bloom areas versus adjacent non-thermally treated areas exhibit a migration coefficient which is two times that of a non-thermally treated area of a material web. Depending on the thermal conductance of the thermoplastic polymeric material, the localized application of thermal energy may create heat affected zones which also encourages blooming. So when measuring, care should be taken to ensure that a centralized location of expected thermal energy application should be analyzed.
Still referring to
As another example, thermal energy can be applied to the entirety of the material web 100 to facilitate the melt additive blooming across the first surface and/or second surface of the material web 100. This can provide the ability to raise or lower the surface energy of the material web 100 where normal processing, e.g. coating, would not be feasible. For example, where the material web 100 comprises multiple strata (discussed hereafter), post treatment of the material web 100 may impact the entirety of the material web 100 rather than a desired stratum which may not be desirable.
So, the amount of melt additive which blooms in the material web can increase with the application of heat. Accordingly, the material webs may be rendered more hydrophobic, more hydrophilic, or softer than what would otherwise be the case sans the heat treatment of the material web. This allows for much versatility of the use of the material web. For example, a material web with a hydrophobic melt additive may be processed into a liquid-impermeable barrier material. However, such material may also be subsequently processed into, a liquid-permeable material (with the provision of apertures or appropriate basis weight selection), a soft feeling material, etc., depending, in part, on the thermal treatment applied.
Notwithstanding the potential drawbacks of topically applied chemistries, the material webs of the present invention may be combined/laminated with other webs which comprise topically applied chemistries. As noted, the topically applied chemistry of the other webs should occur prior to the combination with the material web to minimize the possibility of the topically applied chemistry from impacting the material web.
Material Web—Processing, in GeneralThere are many methods by which the material web 100 of the present invention may be provided with discrete melt additive bloom areas. Similarly, there are a myriad of methods by which the material web 100 of the present invention may be provided with melt additive blooming across its entirety. Some specific examples—regarding discrete melt additive bloom area creation—are provided with regard to
As shown in
In some forms, the discontinuities may extend away from the first surface 20 or the second surface 30 in a positive Z-direction or negative Z-direction. In such forms, the discontinuities may comprise a distal end which is superjacent to the first surface or subjacent to the second surface, sidewalls extending from the distal end toward the first surface or second surface, and, in some specific forms, a base disposed between the sidewalls and the first surface or second surface. Discontinuities are discussed in additional detail hereafter.
The first unit operation 140, in some forms of the present invention, may provide sufficient thermal energy in a plurality of discrete locations on the precursor material 102 to provide the material web 100 with a plurality of discrete melt additive bloom areas sans the formation of discontinuities. The discrete melt additive bloom areas correspond with the discrete locations of applied thermal energy. In some forms, at least a portion of the plurality of melt additive bloom areas may be joined together to form a pattern. Examples of melt additive bloom areas and their formation are discussed hereafter. In some forms, as noted above, the first unit operation 140 may provide sufficient thermal energy to the entirety of the material web 100 to increase the melt additive bloom areas for the entire material web 100.
The precursor material 102, which as shown in
The precursor material 102 may be extensible, elastic, or non-elastic. Further, the precursor material 102 may be a single layer material or a multilayer material. For example, the precursor material 102 may be joined to a polymeric film to form a laminate. As another example, the precursor film 102 may comprise two or more layers of film, two or more layers of nonwoven material, or combinations thereof.
Additionally, forms of the present invention are contemplated where the precursor material 102 comprises a nonwoven web composite comprising multiple strata. A nonwoven stratum may comprise spunbond, staple, or fine fibers, e.g. meltblown or nanofibers. For example, in some forms, a first spinbeam may deposit a first plurality of spunbond filaments onto a belt thereby forming a first nonwoven stratum. A second spinbeam may deposit a second plurality of spunbond filaments onto the belt over the top of the first plurality of spunbond filaments. The second plurality of spunbond filaments form a second nonwoven stratum. Additional forms of the present invention are contemplated where additional spinbeams are provided to provide additional spunbond filaments/nonwoven strata. As another example, a first nonwoven stratum may comprise a plurality of staple fibers upon which a plurality of spunbond filaments are deposited. Additionally, the precursor webs 102/material webs 100 of the present invention may comprise a third stratum a fourth stratum and so on. And, the strata of the precursor web 102/material web 100 may be configured such that at least two of the strata are different. As such, precursor web 102/material web 100 may be one layer comprising multiple strata as described herein and/or may comprise multiple layers in addition to multiple strata.
The precursor material 102 may be provided as discrete webs, e.g. sheets, patches, etc. of material for batch processing. For commercial processing, however, the precursor material 102 may be supplied as roll stock, and, as such it can be considered as having a finite width and an infinite length. In this context, the length is measured in the machine direction (MD). Likewise, the width is measured in the cross machine direction (CD).
Zoned Application of Thermal EnergyAs noted previously, in some forms, thermal energy may be applied to the web during the formation of discontinuities within the precursor material 102. In such forms, localized areas of the precursor material 102 may be heated which promotes discrete melt bloom areas which correspond to the localized heat application. Exemplary processes are discussed below.
AperturesReferring to
Referring to
The patterned calendar roller 110 is configured to have a cylindrical surface 114, and a plurality of protuberances or pattern elements 116 which extend outwardly from the cylindrical surface 114. The pattern elements 116 are illustrated as a simplified example of a patterned calendar roller 110, but more detailed patterned calendar rollers are contemplated and will be discussed hereafter. The protuberances 116 may be disposed in a predetermined pattern with each of the protuberances 116 being configured and disposed to precipitate a weakened, melt-stabilized location in the weakened precursor material 102 to affect a predetermined pattern of weakened, melt-stabilized locations 202. The protuberances 116 may have a one-to-one correspondence to the pattern of melt stabilized locations in the weakened precursor material 102. As shown in
Referring back to
Referring now to
Referring to
Referring back to
If desired, the incremental stretching step or the cross machine directional stretching step described herein may be performed at elevated temperatures. For example, the weakened precursor material 102 and/or the rolls may be heated. Utilizing heat in the stretching step may serve to soften the material, and may aid in extending the fibers without breaking.
Still referring to
It is important to note that the overbonding step illustrated in
Referring to
In some forms, the calendar roller 110 may be heated such that the pattern elements 116 apply thermal energy to the precursor material 102. In such forms, the surface 114 of the calendar roller 110 may comprise an insulating material such that any thermal energy provided by the surface 114 to the precursor web is reduced/minimized. Forms of the present invention are contemplated where a portion of the pattern elements 116 are insulated. In such forms, a plurality of melt additive bloom areas 320 may be provided to the weakened precursor web 102 in a pattern. Any suitable insulating material may be utilized. Some examples include ceramics and/or rubber based compositions. Thermal insulators are generally known in the art.
For those forms of the present invention where the melt additive is hydrophilic, the heat applied by the pattern elements 116 during the formation of the melt-stabilized areas 202 can cause the hydrophilic melt additive to bloom on the melt-stabilized areas 202 and portions of the weakened precursor web 102 in close proximity to the melt-stabilized areas 202. However, for the remainder of the weakened precursor material 102, the hydrophilic melt additive may be locked in the polymer matrix of the precursor material 102.
Referring back to
Regarding
Additionally, referring back to
The apertures 204 may be any suitable size. For example, apertures 204 may have an Effective Aperture AREA in the range of about 0.1 mm2 to about 15 mm2, about 0.3 mm2 to about 14 mm2, about 0.4 mm2 to about 12 mm2, and about 1.0 mm2 to about 5 mm2, specifically including all 0.05 mm2 increments within the specified ranges and all ranges formed therein or thereby. All Effective Aperture Areas are determined using the Aperture Test described herein. Effective Aperture Area is discussed in further detail in U.S. patent application Ser. Nos. 14/933,028; 14/933,017; and Ser. No. 14/933,001. For those forms of the present invention where the melt additive bloom areas 320 comprise a hydrophilic composition, acquisition speeds may be improved particularly where Effective Aperture Areas are small. Smaller apertures may be more aesthetically pleasing to users of absorbent articles; however, the smaller apertures can have a negative impact on fluid acquisition speed.
Additional processes for aperturing nonwoven webs are described in U.S. Pat. Nos. 8,679,391 and 8,158,043, and U.S. Patent Application Publication Nos. 2001/0024940 and 2012/0282436. Other methods for aperturing nonwoven webs are provided in U.S. Pat. Nos. 3,566,726; 4,634,440; and 4,780,352. Regardless of the process utilized to create the apertures 204, the addition of thermal energy can create the melt additive bloom areas as discussed herein in localized areas where thermal energy is applied to the precursor material 102 or the material web 100. In such forms, referring back to
Additional forms of the present invention are contemplated where the melt additive comprises a hydrophobic composition. In such forms, referring to
Additional forms of the present invention are contemplated where the apertures are provided to the material web 100 in an array and/or pattern or a plurality thereof. Such configurations and processes are described in additional detail in U.S. patent application Ser. Nos. 14/933,028; 14/933,017; and Ser. No. 14/933,001.
EmbossmentsReferring to
The apparatus 400 may comprise a forming roll 402 comprising a plurality of forming elements 416 and an anvil roll 404. The forming elements 416 of the forming roll 402 may protrude outward from a surface 414 of the forming roll 402. The anvil roll 404 may comprise a smooth outer surface.
In contrast to fusion bond sites, discussed hereafter, embossments 420 generally do not cause the fusion of the constituent material of the material web 100 to adjacent materials. Instead, embossments 420 tend to compress the material web 100. Embossments 420 can provide an acquisition zone in an absorbent article. For example, where the material web 100 forms a portion of a topsheet of an absorbent article, the embossment 420 may not readily receive a liquid insult. Instead, the embossment 420 may act as a fluid highway which can distribute the insult to multiple areas of an absorbent core in the absorbent article.
An exemplary cross section of the material web 100 in an absorbent article 421 after embossing is shown in
Forms are contemplated where 100 percent of each of the forming elements provides heat to the material web 100 and optionally additional materials. In some forms, only portions of the forming elements may provide thermal energy to the material web 100 and optionally other components.
With the application of thermal energy to the forming elements 416 (shown in
In some forms, the melt additive bloom area 490 may comprise a hydrophobic composition. The compression which creates the embossments 420 can inhibit fluid acquisition in the embossment 420. A hydrophobic composition in the distal end 454 of the embossment 420 can assist in transporting liquid insults to additional areas of the absorbent article. Additionally, the hydrophobic composition can provide a cleaner look to the absorbent article in the area of the embossment 420 since the hydrophobic composition would discourage liquid insults from residing in the embossment 420.
In contrast, forms of the present invention are contemplated where the melt additive bloom areas 490 comprise a hydrophilic composition. In such forms, the hydrophilic composition may facilitate fluid acquisition by the embossments 420. It is worth noting however, that in such forms, the level of compression in the embossments 420 can offset the hydrophilic composition. For example, where the embossments 420 are formed with high compression, the embossments 420 have an increased density which generally inhibits fluid acquisition. In contrast, embossments 420 derived from lighter compression can drive better interaction between layers of the absorbent article 421 which can improve liquid acquisition.
Embossments 420 may be used in conjunction with apertures 204 or may be utilized independently thereof. Any suitable embossment pattern may be utilized in conjunction with the material web 100 of the present invention. Some suitable examples of embossment patterns are provided with regard to U.S. Pat. Nos. 6,170,393; 6,652,500; 7,056,404; 8,030,535; 8,492,609; 8,496,775; and U.S. Patent Application Publication Nos. 2013/0281953; and 2014/0031779.
Tunnel Tufts/Filled TuftsReferring to
Roll 504 is similar to roll 502, but rather than having ridges that extend unbroken about the entire circumference, roll 504 comprises a plurality of rows of circumferentially-extending ridges that have been modified to be rows of circumferentially-spaced teeth 510 that extend in spaced relationship about at least a portion of roll 504. The individual rows of teeth 510 of roll 504 are separated by corresponding grooves 512. In operation, rolls 502 and 504 intermesh such that the ridges 506 of roll 502 extend into the grooves 512 of roll 504 and the teeth 510 of roll 504 extend into the grooves 508 of roll 502. A nip 516 is formed between the counter-rotating intermeshing rolls 502 and 504. Both or either of rolls 502 and 504 can be heated by means known in the art such as by using hot oil filled rollers or electrically-heated rollers.
The apparatus 500 is shown in a configuration having one patterned roll, e.g., roll 504, and one non-patterned grooved roll 502. However, in certain forms it may be preferable to use two patterned rolls similar to roll 504 having either the same or differing patterns, in the same or different corresponding regions of the respective rolls. Such an apparatus can produce material webs with tufts protruding from both sides of the material web 100.
Material webs 100 of the present invention can be made by mechanically deforming the precursor material 102 that can be described as generally planar and two dimensional prior to processing by the apparatus shown in
The process described with regard to
The tunnel tuft 570 may be created when localized areas of constituent material of the material web 100 are urged in the positive Z-direction such that material of the material web 100 in the localized area may be disposed superjacent to the first surface 20 of the material web 100. The disposition of the material web 100 in the localized areas may form the tunnel tuft 570. For such forms, an opening 285 may be produced on the second surface 30 of the material web 100 which corresponds to the tuft 570. And, as shown in
In some forms, material webs 100 of the present invention may comprise a plurality of tunnel tufts 570 for which there are no corresponding outer tufts 530 and/or similarly may comprise a plurality of tunnel tufts 570 each of which are disposed within a corresponding outer tuft 530.
Additional arrangements of tunnel tufts 570 and outer tufts 530 are provided with respect to
Another characteristic of the tunnel tufts 570 and outer tufts 530 shown in
The extension and/or urging of the material of the material web 100, as shown in
Referring to
Referring specifically to
Referring to
Referring specifically to
Referring to
Tunnel tufts 570 and/or outer tufts 530 can provide a masking benefit for liquid insults in a disposable absorbent article. Additionally, tunnel tufts 570 and/or outer tufts 530 can provide a softness benefit as well. Tunnel tufts 570 and outer tufts 530 are discussed in additional detail, including methods of making, in U.S. Pat. Nos. 7,172,801; 7,838,099; 7,754,050; 7,682,686; 7,410,683; 7,507,459; 7,553,532; 7,718,243; 7,648,752; 7,732,657; 7,789,994; 8,728,049; and 8,153,226.
The tunnel tufts 570 and/or outer tufts 530 may be used in conjunction with the apertures, and/or embossments. Or, the tunnel tufts 570 and/or outer tufts 530 may be utilized independently thereof.
In contrast to the tunnel tufts 570 shown in
In such forms, the melt additive bloom area 590 may comprise a hydrophobic composition. Where the material web 100 is utilized as a topsheet of a disposable absorbent article, such forms can allow for reduction in rewet while providing adequate liquid acquisition. Additionally, in such forms, the melt additive bloom area 590 may help with masking of liquid insults to a disposable absorbent article.
Referring to
In such forms, the melt additive bloom area 592 may comprise a hydrophobic composition, and the melt additive bloom area 590 may comprise a hydrophilic composition. In some forms, the melt additive bloom area 592 may comprise a hydrophobic composition and the melt additive bloom area 590 may comprise a hydrophobic composition.
Regarding
Where the material webs 100 of the present invention comprise crimped filaments, the material web 100 has a higher caliper for a given basis weight. This higher caliper can in turn deliver consumer benefits of comfort due to cushiony softness, faster absorbency due to higher permeability, and improved masking. Additional benefits may include less redmarking, higher breathability and resiliency.
Methods of making filled tufts 572 and outer tufts 530 are discussed in U.S. Pat. Nos. 7,172,801; 7,838,099; 7,754,050; 7,682,686; 7,410,683; 7,507,459; 7,553,532; 7,718,243; 7,648,752; 7,732,657; 7,789,994; 8,728,049; and 8,153,226. Filled tufts 572 and corresponding outer tufts 530 are discussed in additional detail in U.S. patent application Ser. No. 14/933,028.
The filled tufts 572 and/or outer tufts 530 may be used in conjunction with the apertures and/or embossments. Or, the filled tufts 572 and/or outer tufts 530 may be utilized independently thereof.
Referring back to
Another example of a first unit operation 140 (shown in
The first forming member (such as “male roll”) 602 has a surface comprising a plurality of first forming elements which comprise discrete, spaced apart male forming elements 612. The male forming elements are spaced apart in the machine direction and in the cross-machine direction. The term “discrete” does not include continuous or non-discrete forming elements such as the ridges and grooves on corrugated rolls (or “ring rolls”) which have ridges that may be spaced apart in one, but not both, of the machine direction and in the cross-machine direction.
As shown in
The base 616 and the top 618 of the forming elements 612 may have any suitable plan view configuration, including but not limited to: a rounded diamond configuration as shown in
Additional forms of the male forming elements 612 are possible. For example, the top 618 of the forming elements 612 can be of different shapes from those shown in the drawings. As another example, the male forming elements 612 can be disposed in other orientations on the first forming member 602 rather than having their length oriented in the machine direction (including CD-orientations, and orientations between the MD and CD). The male forming elements 612 on the first forming member 602 may, but need not, all have the same configuration or properties. In certain embodiments, the first forming member 602 can comprise some male forming elements 612 having one configuration and/or properties, and other male forming elements 612 having one or more different configurations and/or properties.
Referring again to
As discussed above, the recesses 614 may be deeper than the height H1 of the forming elements 612 so the precursor web 102 is not nipped (or squeezed) between the male and female rolls 602 and 604 to the extent possible. However, it is understood that passing the precursor web between two rolls with a relatively small space therebetween will likely apply some shear and compressive forces to the material. The present method, however, differs from some embossing processes in which the top of the male elements compress the material to be embossed against the bottom of the female elements, thereby increasing the density of the region in which the material is compressed.
The depth of engagement (DOE) is a measure of the level of intermeshing of the forming members. As shown in
Still referring to
Some of the aforementioned forming element 612 configurations alone, or in conjunction with the second forming member 604 and/or recess 614 configurations may provide additional advantages. This may be due to by greater lock of the precursor material on the male elements 612, which may result in more uniform and controlled strain on the precursor material. The apparatus 600 is further described in U.S. patent application Ser. No. 14/844,459.
As shown in
Referring now to
As shown, the nested tufts 632 may have a width, W, that varies from one end 660 to the opposing end 660 when the nested tufts 632 are viewed in plan view. As shown, the width W may be generally parallel to a transverse axis TA. The width W may vary with the widest portion of the nested tufts 632 in the middle of the nested tufts 632, and the width of the nested tufts 632 decreasing at the ends 660 of the nested tufts 632. In other cases, the nested tufts 632 could be wider at one or both ends 60 than in the middle of the nested tufts 632. In still other cases, nested tufts 632 can be formed that have substantially the same width from one end of the nested tufts 632 to the other end of the nested tufts 632. If the width of the nested tufts 632 varies along the length of the nested tufts 632, the portion of the nested tufts 632 where the width is the greatest is used in determining the aspect ratio of the nested tufts 632.
Similarly, the nested tufts 632 may have a length L which is generally parallel to a longitudinal axis LA. When the nested tufts 632 have a length L that is greater than or less than their width W, the length of the nested tufts 632 may be oriented in any suitable direction relative to the material web 100. For example, the length of the nested tufts 632 (that is, the longitudinal axis, LA, of the nested tufts 632) may be oriented in the MD, the CD, or any desired orientation between the MD and the CD. As shown, the transverse axis TA is generally orthogonal to the longitudinal axis LA in the MD-CD plane. In some forms, as shown, the longitudinal axis LA is parallel to the MD. In some forms, all the spaced apart nested tufts 632 may have generally parallel longitudinal axes LA.
Referring to
Referring to
Still referring to
The nested tufts 632 have a depth D measured from the second surface 30 of the material web 100 to the interior of the nested tufts 632 at the distal end 654 of the nested tufts 632. The nested tufts 632 have a height H measured from the second surface 30 of the material web 100 to the exterior of the nested tuft 632 at the distal end 654. In most cases the height H of the nested tufts 632 will be greater than the thickness T of the first region 640. The relationship between the various portions of the nested tufts 632 may be such that as shown in
For those forms of the present invention where the material web 100 comprises a nonwoven material, the nested tufts 632 may, in some cases, be formed from looped fibers (which may be continuous) that are pushed outward so that they extend away from the first surface 20 in the Z-direction or away from the second surface 30 in the negative Z-direction. The nested tufts 632 will typically comprise more than one looped fiber. In some cases, the nested tufts 632 may be formed from looped fibers and at least some broken fibers. In addition, in the case of some types of nonwoven materials (such as carded materials, which are comprised of shorter fibers), the nested tufts 632 may be formed from loops comprising multiple discontinuous fibers. Multiple discontinuous fibers in the form of a loop are described in U.S. patent application Ser. No. 14/844,459. The looped fibers may be: aligned (that is, oriented in substantially the same direction); not be aligned; or, the fibers may be aligned in some locations within the protrusions 32, and not aligned in other parts of the protrusions.
In some forms, if male/female forming elements are used to form the nested tufts 632, and the female forming elements substantially surround the male forming elements, the fibers in at least part of the nested tufts 632 may remain substantially randomly oriented (rather than aligned), similar to their orientation in the precursor web(s). For example, in some cases, the fibers may remain substantially randomly oriented in the cap of the nested tufts 632, but be more aligned in the sidewalls such that the fibers extend in the Z-direction (positive or negative depending on the orientation of the nested tuft 632) from the base of the protrusions to the cap. In addition, if the precursor web comprises a multi-layer nonwoven material, the alignment of fibers can vary between layers, and can also vary between different portions of a given nested tufts 632 within the same layer.
Where the precursor web comprises a nonwoven material, the nested tufts 632 may comprise a plurality fibers that at least substantially surround the sides of the nested tufts 632. This means that there are multiple fibers that extend (e.g., in the positive or negative Z-direction) from the base 650 of the nested tufts 632 to the distal end 654 of the nested tufts 632, and contribute to form a portion of the sides 656 and cap 652 of a nested tufts 632. In some cases, the fibers may be substantially aligned with each other in the Z-direction in the sides 656 of the nested tufts 632. The phrase “substantially surround”, thus, does not require that each individual fiber be wrapped in the X-Y plane substantially or completely around the sides of the nested tufts 632. If the fibers are located completely around the sides of the nested tufts 632, this would mean that the fibers are located 360° around the nested tufts 632. The nested tufts 632 may be free of large openings at their ends 660. In some cases, the nested tufts 632 may have an opening at only one of their ends, such as at their trailing end.
In some forms, similar-shaped looped fibers may be formed in each layer of multiple layer nonwoven materials, including in the layer 630A that is spaced furthest from the discrete male forming elements during the process of forming the nested tufts 632 therein, and in the layer 630B that is closest to the male forming elements during the process. In the nested tufts 632, portions of one layer such as 630B may fit within the other layer, such as 630A. These layers may be referred to as forming a “nested” structure in the nested tufts 632. Formation of a nested structure may require the use of two (or more) highly extensible nonwoven precursor webs. In the case of two layer materials, nested structures may form two complete loops, or (as shown in some of the following drawing figures) two incomplete loops of fibers.
The nested tufts 632 may have certain additional characteristics. As shown in
The sidewalls 656 of the nested tufts 632 can have any suitable configuration. The configuration of the sidewalls 656, when viewed from the end of the nested tuft such as in 6G, can be linear or curvilinear, or the sidewalls can be formed by a combination of linear and curvilinear portions. The curvilinear portions can be concave, convex, or combinations of both. For example, the sidewalls 656 may comprise portions that are curvilinear concave inwardly near the base of the nested tuft and convex outwardly near the cap of the nested tuft. The sidewalls 656 and the area around the base opening 644 of the nested tuft may have significantly lower concentration of fibers per given area (which may be evidence of a lower basis weight or lower opacity) than the portions of the first region 640. The nested tufts 632 may also have thinned fibers in the sidewalls 656. The fiber thinning, if present, will be apparent in the form of necked regions in the fibers. Thus, the fibers may have a first cross-sectional area when they are in the undeformed precursor material 102, and a second cross-sectional area in the sidewalls 656 of the nested tufts 632 of the deformed material web 100, wherein the first cross-sectional area is greater than the second cross-sectional area. The sidewalls 656 may also comprise some broken fibers as well. In some forms, the sidewalls 656 may comprise greater than or equal to about 30%, alternatively greater than or equal to about 50% broken fibers.
In some forms, the distal end 654 of the nested tufts 632 may be comprised of original basis weight, non-thinned, and non-broken fibers. If the base opening 44 faces upward, the distal end 654 will be at the bottom of the depression that is formed by the nested tuft. The distal end 654 will be free from apertures formed completely through the distal end. Thus, the nonwoven materials may be nonapertured. The term “apertures”, as used herein, refers to holes formed in the nonwovens after the formation of the nonwovens, and does not include the pores typically present in nonwovens. The term “apertures” also does not refer to irregular breaks (or interruptions) in the nonwoven material(s) resulting from localized tearing of the material(s) during the process of forming nested tufts therein, which breaks may be due to variability in the precursor material(s). The distal end 654 may have relatively greater fiber concentration in comparison to the remaining portions of the structure that forms the protrusions. The fiber concentration can be measured by viewing the sample under a microscope and counting the number of fibers within an area.
The nested tufts 632 may be of any suitable shape. Since the nested tufts 632 are three-dimensional, describing their shape depends on the angle from which they are viewed. When viewed from above (that is, perpendicular to the plane of the web, or plan view) such as in
In some forms, the length of the cap 652 may be in a range from about 1.5 mm to about 10 mm. In some forms, the width of the cap (measured where the width is the greatest) may be in a range from about 1.5 mm to about 5 mm. The cap portion of the protrusions may have a plan view surface area of at least about 3 mm2. In some embodiments, the protrusions may have a pre-compression height H that is in a range from about 1 mm to about 10 mm, alternatively from about 1 mm to about 6 mm. In some embodiments, the protrusions may have a post-compression height H that is in a range from about 0.5 mm to about 6 mm, alternatively from about 0.5 mm to about 1.5 mm. In some embodiments, the protrusions may have a depth D, in an uncompressed state that is in a range from about 0.5 mm to about 9 mm, alternatively from about 0.5 mm to about 5 mm. In some embodiments, the protrusions may have a depth D, after compression that is in a range from about 0.25 mm to about 5 mm, alternatively from about 0.25 mm to about 1 mm.
For those forms of the present invention where the material web 100 comprises a first layer and a second layer many configurations may be achieved. In such forms, the first layer may be incorporated into an absorbent article as, for example, an acquisition layer and the second layer may be a topsheet of the absorbent article. Each of the first layer and the second layer may form nested tufts which fit into one another. Such examples are described with regard to
For the examples shown in
As shown in
As shown in
Alternatively, as shown in
For dual layer and other multiple layer structures, the basis weight distribution (or the concentration of fibers) within the material web 100, as well as the distribution of any thermal point bonds can be different between the layers. As used herein, the term “fiber concentration” has a similar meaning as basis weight, but fiber concentration refers to the number of fibers/given area, rather than g/area as in basis weight. In the case of bond sites, the fibers may be melted which may increase the density of the material in the bond sites 46, but the number of fibers will typically be the same as before melting.
Some such dual and multiple layer nonwoven materials may be described in terms of such differences between layers, without requiring one or more of the other features described herein (such as characteristics of the cap portion; controlled collapse under compression; and varying width of the protrusions). Of course such dual and multiple layer nonwoven materials may have any of these other features.
In such dual and multiple layer nonwoven materials each of the layers comprises a plurality of fibers, and in certain embodiments, the nested tufts 632 will be formed from fibers in each of the layers. Referring back to
Referring back to
Forms of the present invention are contemplated where only a portion of the number of forming elements are heated and/or only a portion of the number of recesses 614 are heated. For example, in some forms, every third forming member 612 may be heated and/or every third recess 614 may be heated. Any suitable configuration may be utilized. In some forms, patterns of heated forming elements 612 and/or recesses 614 may be utilized.
For those forms comprising heated forming elements 612 and/or recesses 614, melt additive blooms may be provided in the resultant material web. For example, as shown in
For those forms of the present invention where the material web 100 comprises multiple layers, the nested tufts 632 may comprise a plurality of melt additive bloom areas. For example, as shown in
The nested tufts 632 of the present invention may be utilized in conjunction with the tunnel tufts, outer tufts, filled tufts, apertures, and/or embossments described herein.
CorrugationsAnother example of a first unit operation 140 (shown in
Subsequent to the blasting of the precursor web 102 with air streams, the material web 100 may comprise a plurality of corrugations. Some exemplary corrugations are shown in
As noted above, the air streams which impact the precursor web 102 are heated. And as the corrugations 770 form between adjacent air streams, the air streams form the grooves 775 of the material web 100. The heat associated with the air streams can create melt additive blooms in the material web 100. For example, still referring to
Additional forms of the present invention are contemplated where the corrugations 770 comprise a melt additive bloom area in addition to the melt additive bloom area 790 in the grooves 775. For such forms, the suction box 712 may comprise discrete heated portions which correspond to the distal ends 754 of the material web 100.
The utilization of corrugations 770 may provide softness benefits to the material web 100. Additionally, the material web 100 may have higher permeability in the corrugations 770. The utilization of corrugations may be done in conjunction with apertures, embossments, outer tufts, tunnel tufts, and/or nested tufts described herein. Referring to
As shown, the precursor material 102 may be provided to a nip 706 between intermeshing rolls 702 and 704. The intermeshing rolls 702 and 704 may comprise a surfaces wherein each of the surfaces comprise concave and convex patterns, for example, as shown in
In some forms, the roll 702 and/or 704 may be selectively heated. For example, as shown, the convex portion of roll 704 may be heated to provide melt additive bloom areas 790 on the distal ends 754 of the corrugations. In some forms, the corresponding concave portions of roll 702 may also be heated to provide the melt additive bloom areas 790 on the distal ends 754 of the corrugations. The heating of the convex portions of roll 704 and/or the concave portions of roll 702 may also provide the melt additive bloom area 790 on the sidewalls 756 of the corrugations 770.
In other forms, the convex portions of roll 702 may be heated to provide melt additive bloom areas in the grooves 775 between adjacent corrugations. The concave portions of the roll 704 may similarly be heated to facilitate the creation of the melt additive bloom areas in the grooves. The heating of the convex portions of the roll 702 and/or the concave portions of the roll 704 may also provide melt additive bloom areas on the sidewalls 756 of the corrugations 770. Forms of the present invention are contemplated where only a portion of the distal ends 754 comprise a melt additive bloom area 790.
Referring to
As shown, the second roll 2204 comprises a plurality of grooves 2240 and ridges 2250. The grooves 2240 have a bottom surface 2242 and the ridges 2250 have a top surface 2252. Here, the distance between the top surfaces 2252 of the ridges 2250 and the bottom surfaces 2242 of the grooves 2240 is substantially the same around the circumference of the roll. The teeth 2230 and ridges 2220 of the first roll 2202 extend toward the axis A of the second roll 2204, intermeshing to a depth beyond the top 2252 of at least some of the ridges 2250 on the second roll 2204.
Teeth suitable for this process may be conducive to aperturing webs. The teeth on the rolls may have any suitable configuration. A given tooth can have the same plan view length and width dimensions (such as a tooth with a circular or square shaped plan view). Alternatively, the tooth may have a length that is greater than its width (such as a tooth with a rectangular plan view), in which case, the tooth may have any suitable aspect ratio of its length to its width. Suitable configurations for the teeth include, but are not limited to: teeth having a triangular-shaped side view; square or rectangular-shaped side view; columnar shaped; pyramid-shaped; teeth having plan view configurations including circular, oval, hour-glass shaped, star shaped, polygonal, and the like; and combinations thereof. Polygonal shapes include, but are not limited to rectangular, triangular, pentagonal, hexagonal, or trapezoidal. The side-walls of the teeth may taper at a constant angle from the base to the tip, or they may change angles. The teeth may taper towards a single point at the tooth tip, like that shown in
The apparatus 2200 can deform the precursor web creating alternating regions of higher and lower caliper, and alternating regions of higher and lower basis weight, with the higher caliper and higher basis weight regions being located in the tops of the ridges and bottoms of the grooves, and the regions with lower caliper and lower basis weight located in the sidewalls in-between.
In the case of a nonwoven, the basis weight is also decreased in the stretched areas, again resulting in a web with alternating regions of higher and lower basis weight, with the higher basis weight regions located in the tops of the ridges and bottoms of the grooves, and the lower basis weight regions located in the sidewalls in-between.
Webs made by the processes and apparatuses described herein may comprise ridges that run discontinuously across a deformed zone, or, ridges that run continuously across a deformed zone. To create such apertured web materials, the rolls used may comprise zones of ridges and grooves. Or, the rolls can have zones where the ridges are different heights, thereby creating differing depth of engagement (DOE), differing depth below the raised ridge, and thus apertures with differing widths and open areas. Alternatively or in addition, the rolls may comprise different zones, wherein ridge heights are different in different zones.
Referring back to
In some forms, the second roll 2204 may be heated. For example, the ridges 2250 of the second roll 2204, particularly the top surface 2252, may provide the material web 100 with melt additive bloom areas which correspond to the ridges on the material web 100. In such forms, the melt additive bloom areas may comprise a hydrophobic composition. In such forms, particularly where the material web 100 forms a portion of a topsheet of an absorbent article, where the ridges are oriented toward the wearer of the absorbent article. In such forms, the material web 100 can provide masking benefits to liquid insults.
Still in other forms of the present invention, the material web 100 may comprise rib like elements 3770 (corrugations) shown in
Referring now to
Where the rolls 3852 and/or 3854 are heated, the corrugations may comprise melt additive bloom areas 3790. The melt additive bloom areas 3790 may be disposed in the distal ends 3754 of the corrugations. Additionally, the melt additive bloom areas 3790 may extend along the sidewalls 3756 as well. In some forms, the melt additive bloom area 3790 may extend the entirety of the sidewalls 3756. In some forms, the material web 100 may be utilized as a topsheet of an absorbent article. In such forms, where the distal ends 3754 are oriented in the positive Z-direction, the melt additive bloom areas 3790 may comprise a hydrophobic melt additive. In such forms, the hydrophobic melt additive may provide good masking of liquid insults. Additionally, in such forms, the hydrophobic melt additive may reduce the likelihood of rewet by liquid insults. Where the distal ends 3754 are oriented toward an absorbent core of the disposable absorbent article, the melt additive bloom areas 3790 may comprise a hydrophilic composition. In such forms, the hydrophilic composition can improve liquid acquisition.
Instead of rolls, plates may be utilized to create the corrugations 3770. In such forms, teeth of one or more of the plates may be heated such that at least a portion of the corrugation may be provided with a corresponding melt additive bloom area 3790. Processes for forming the corrugations 3770 are discussed in additional detail in U.S. Patent Application Publication No. 2004/0137200.
Fusion BondsStill another exemplary process which may be utilized as a first unit operation 140 (shown in
During the bonding operation, the bonding roll 806 may rotate in a first direction 828 around the axis of rotation 808 of the bonding roll 806, and the anvil roll 810 may rotate in a second direction 830, opposite the first direction 828, around the axis of rotation 812 of the anvil roll 810. The precursor material 102 and second substrate 104 may advance in a machine direction MD between the bonding roll 806 and the anvil roll 810. As shown, the precursor material 102 includes a first surface 832 and a second surface 834 opposite the first surface 832, and the second substrate 104 includes a first surface 836 and a second surface 838 opposite the first surface 836. As such, the first surface 832 of the precursor material 102 is contacted by the bonding roll 806, and the second surface 838 of the second substrate 104 is contacted by the anvil roll 810. And the second surface 834 of the precursor material 102 and the first surface 836 of the second substrate 104 contact each other. As the precursor material 102 and second substrate 104 advance through the nip 826 between the bonding surface of a nub 816 and the anvil roll 810, the nub 816 contacts the precursor material 102 and compresses the precursor material 102 and second substrate 104 between the bonding surface of the nub 816 and the anvil roll 810. In turn, heat generated by the nip pressure causes the precursor material 102 and second substrate material to yield. The bonding surface of the nubs 816 presses yielded material of the precursor material 102 and second substrate 104 together to form a plurality of discrete bond sites 842 between the precursor material 102 and second substrate 104. Thus, the apparatus 800 may form the material web 100 which includes the precursor material 102 and the second substrate 104 bonded together by discrete bond sites 842, without the use of adhesives. It is to be appreciated, however, that the bonding apparatus 800 may also be used in combination with adhesives. Although
As shown in
As shown, the melt additive bloom areas 890 may be provided in a distal end 854 of the discrete bond site 842 and on a portion of sidewalls 856 of the discrete bond sites 842. In such forms, the melt additive bloom areas 890 may comprise a hydrophobic composition. Where the material web 100 is utilized as a topsheet of a disposable absorbent article, the hydrophobic composition of disposed in the discrete bond sites 842 can reduce the likelihood that liquid insults stay in the bond site 842. As such, the hydrophobic composition can help provide a cleaner looking article even post liquid insult.
The utilization of discrete bond sites 842 may be done in conjunction with apertures, embossments, outer tufts, tunnel tufts, nested tufts, and/or corrugations described herein.
Distal End/Land Area BondsStill another exemplary process which may be utilized as a first unit operation 140 (shown in
Referring to
Referring to
As shown in 9B, the process of
As noted above, the bonding roll 950 may apply heat during the bonding process. In such forms, a melt additive bloom area may correspond to the tip bonded portion 952. Without wishing to be bound by any particular theory, it is believed that bonding material web 100 at the distal ends 954 of the tufts 970 may provide benefits which include: 1) increased perception of the depth of base openings 944 when the base openings 944 are oriented toward the consumer, as well as 2) improved dryness (by reducing the hang-up of fluid in the bottoms of the tufts 970 when the base openings 944 are oriented toward the consumer); and 3) reduction or elimination of the need to glue or otherwise bond the layers of a dual or multilayer precursor web 102 together.
In other forms of the present invention, an apparatus may bond the material web 100 adjacent the tufts 970—adjacent the base 50, 650 (shown in
Another exemplary process for the first unit operation 140 (shown in
There are a number of variations of the roll configurations in the bonding step. The surface of the bonding roll 1060 may be substantially smooth or may comprise a plurality of bonding elements 1064. Similarly, the second roll 904 may comprise a smooth surface or may comprise a plurality of bonding elements 1062 (shown in
Referring to
As shown in
Referring to
As noted above, the bonding roll 1060 may apply heat during the bonding process. In such forms, a melt additive bloom area may correspond to the base bond portions 1068. In such forms, the melt additive bloom areas may be disposed adjacent the base opening 944 about the tuft 970. And, the melt additive bloom areas may comprise a plurality of discrete portions or may be continuous as shown in
Still another apparatus for use as the first unit operation 140 (shown in
The apparatus shown in
As shown in
Referring back to
Still other examples of first unit operations 140 (shown in
As an example, a material web that is apertured can be exposed to ultrasonic and/or laser energy. In such forms, melt additive bloom areas may be provided over the majority of the material web with the exception of the apertures. Such forms, may be useful as a topsheet of a disposable absorbent article, particularly when the melt additive bloom areas comprise a hydrophobic composition. In other forms, a material web may comprise one or more of the discontinuities described herein, apertures, embossments, tunnel tufts, outer tufts, filled tufts, nested tufts, ridges, grooves, etc. In such forms, the material web may be exposed to ultrasonic and/or laser energy. In such forms, melt additive bloom areas may be provided over the majority of the material web with the exception of the apertures. Where the material web is utilized as a topsheet of a disposable absorbent article, the melt additive bloom areas may comprise a hydrophobic composition. Such forms, may be useful in reducing the likelihood of rewet while the addition of apertures can allow for adequate liquid acquisition time.
Additionally, forms are contemplated, as discussed previously, where the material web comprises multiple layers or strata. In such forms, an upper layer or strata may comprise a hydrophobic melt additive while a subjacent layer or strata may comprise a hydrophilic melt additive. In such forms, the application of ultrasonic and/or laser energy to the material web, can provide disparate melt additive bloom areas in the upper layer or strata versus the lower layer or strata. In such forms, the discontinuities comprising tufts, e.g. outer tufts, tunnel tufts, filled tufts, nested tufts, corrugations may provide good reduction in the likelihood of rewet while also providing good liquid acquisition properties.
Another example of a process which can be utilized in the first unit operation 140 (shown in
The air flow rate may be controlled by controlling the pressure inside the header 2112. The air pressure inside the header 12 is between about 1-12 inches of water (2-22 mm Hg) or between about 4-10 inches of water (8-18 mm Hg). The volume of hot air required to effect the desired level of inter-fiber bonding may be reduced by increasing the temperature of the hot air.
Extending from the header 2112 are three spaced apart hot air conduits 2124, 2126, and 2128. The conduits may be rigid or flexible, but are preferably made of a flexible material in order to permit adjustment and/or movement. The conduits are each connected at one end to the header 2112, and are connected at their other ends to a plenum/hot air knife slot 2134, 2136, and 2138. Hot air from the header 2112 is preferably supplied at roughly equal volume and velocity to each of the conduits 2124, 2126, and 2128. This equal division of flow can be accomplished in simple fashion, by ensuring that the conduits are of equal dimensions and size and that the air pressure is uniform at the entrances to the conduits. On the other hand, if a particular application warranted feeding more or less air into some of the conduits than the others, different flow rates can be accomplished by individually valving the conduits, by designing them with different sizes, or by valving the plenums.
As the precursor web 102 passes under the plenum/hot air knife slots 2134, 2136, and 2138, a stream of heated air at a very high flow rate, generally from about 1000 to about 10000 feet per minute (fpm) (305 to 3050 meters per minute), is directed at the precursor web 102. As noted above, the air is heated to a temperature insufficient to melt the polymer in the precursor web 102 but sufficient to soften it slightly. The focused stream of air is arranged and directed by at least one slot of about 3 to 25 mm in width, particularly about 9.4 mm, serving as the exit for the heated air towards the precursor web 102.
The application of heated air to the precursor web 102 as described above can increase bonding between constituent fibers of the precursor web 102—for those forms where the precursor web 102 is a nonwoven. Additionally, the application of heated air to the precursor web 102 can provide the material web 100 with a plurality of melt additive bloom sites 2190. The melt additive bloom sites 2190 may correspond to the width of the hot air knife slots which discharge the hot air that impacts the precursor web 102. As shown, the melt additive bloom areas 2190 may be provided to the material web 100 in a plurality of stripes. Forms of the present invention are contemplated where one or more hot air knife slots are provided which span the entire width of the precursor web 102 in the CD. In such forms, the melt additive bloom areas provided to the material web 100 may be across the width of the material web 100 in the CD.
Additional details regarding the use of hot air knifes is provided in U.S. Pat. Nos. 5,707,468 and 6,066,221.
Thermal Energy Application across the entire Web
In contrast to the aforementioned processes which can create discrete melt additive bloom areas, as noted previously, in some forms, it may be beneficial to provide melt additive bloom areas across the entirety the material web. In such forms, any suitable method of thermal energy application may be utilized.
Some examples include the use of microwave (radio frequency) radiation. This approach is particularly powerful if a salt solution (e.g. potassium acetate in poly ethylene glycol) has been sprayed onto the surface of the material web. The radiation will then let the ions of the salt vibrate, which causes friction, which causes heat. Ultrasonic may also be used alternatively. In one specific example, if hydrophobic melt additives are used to make carded nonwovens, the heat exposure of the carding process can be leveraged (hot air oven of 160° C. at a comparably long contact time of 1-2 s).
And, combining both on-line heating and tempering can synergistically increase the effect. An optimized heat activation step (highly effective in line heat insertion, e.g. via IR dryer) can be translated into further usage reduction and/or better performance.
The heat application of the aforementioned processes may be applied as part of the making process, directly after spinning of the fibers and laydown of the web—as part of the bonding process (via a heated calendar) or a subsequent step (e.g. drum dryer or, most effectively, infrared heater). In this case typically high temperatures can be applied. An exposure in the seconds or even mili seconds range may be sufficient depending on the composition of the material web. Additionally, the amount of thermal energy required to promote melt additive blooming depends on whether the application of thermal energy is performed within a short period of time after formation of the material web. For material webs which are subjected to thermal energy application immediately subsequent to production, a lower amount of thermal energy may be required to promote melt additive blooming as opposed to material webs which were not subjected to thermal energy application subsequent to formation.
Alternatively the heat activation can be done via tempering of the final material web over several days, e.g. 30 days. It has been found that for the Techmer glycerol tristearate Masterbatch that the temperature window for such tempering can be between about 30 to less than about 52° C. (as of 52° C. the glycerol tristearate fibrils will melt again) between about 32° C. to about 50° C., between about 35° C. to about 47° C., between about 37° C. to about 45° C., specifically including all values within these ranges and any ranges created thereby. In some forms, a temperature of 37° C. Tempering can be done with fresh samples (not more than a few hours after making). Older samples may require additional thermal energy input.
Melt Additive Bloom AreasReferring to back
However, the inventors have also found that care must be taken when processing material webs particularly when discrete melt additive bloom areas are desired. Many nonwoven webs are calendar bonded to provide strength in the CD. The calendar bonding process is often a heated process which adds thermal energy to the web as it is bonded. Subsequently, the web is often rolled up for storage. But, such storage provides insulation for the thermal energy from the calendar bonding process. So, instead of melt additive bloom areas that are discrete, these webs often have melt additive boom areas well outside of the areas of applied localized thermal energy. Other processes which impart thermal energy to the material web may experience the same type of effect is rolled and stored. To counteract such heat diffusion in the material web, when not desired, chilled rolls may be utilized to cool the material web after the calendar bonding process or other thermal processes. Each of Examples 2-4 demonstrate this aspect of material webs which comprise melt additives and are subjected to calendar bonding.
The above phenomena can be even more prevalent in bi-component fibers/filaments. For example, where melt additive is provided in the sheath of sheath-core bi-component fibers/filaments, the diffusion length for the melt additive in the sheath will be shorter than the diffusion length for mono-component fibers. This phenomena is demonstrated with Examples 35 and 36 below. Each of these webs was subjected to calendar bonding and subsequently would up.
EXAMPLESExemplary material webs in accordance with the present disclosure were produced. The material webs were dual layer constructions. The upper layer was 25 gsm polypropylene 1/polypropylene 2 (“PP1/PP2”) crimped fiber spun bond comprising a hydrophobic melt additive which was 16 percent by weight glycerol tristearate master batch (Techmer PPM15000) in both polypropylene components. The lower layer was 25 gsm PP1/PP2 crimped fiber spun bond comprising 0.4 percent by weight topical surfactant Silastol PHP26. The two layers were overbonded together (see
As shown in
The melt additive may form between about 0.5 percent by weight to about 10 percent by weight of the material web 100. In some forms, the melt additives may be less than about 10 percent by weight, less, less than about 8 percent by weight, less than about 5 percent by weight, less than about 2.5 percent by weight, specifically including any values within these ranges or any ranges created thereby. In some forms, the melt additive may be about 6 percent by weight of a master batch containing 40 percent by weight of the melt additive. In some forms, the melt additive may form between about 0.5 percent by weight to about 6 percent by weight of the master batch or from about less than 4 percent by weight of the master batch or any value within these ranges and any ranges created thereby.
The inventors have found that if the concentration of melt additive by weight percent is too low, the melt additive bloom areas provided with localized heat application may not be sufficient to provide the desired functionality. In contrast, if the melt additive concentration is too high, melt additive bloom areas may occur without the localized heat application—auto blooming. Without wishing to be bound by theory, it is believed that the diffusion coefficient (explained in additional detail below) of the melt additive increases with the concentration of melt additive in the polymer matrix of the thermoplastic polymeric material of the material web.
Without wishing to be bound by theory, it is believed that the glass transition temperature of the polymer which makes up the material of the web, the molecular weight of the melt additive, as well as the chain length of the melt additive impacts the blooming capability of the melt additive. It is believed that where the polymer is in its glassy state, the glassy state of the polymer matrix can “lock away” the melt additive and discourage blooming.
For those polymers which comprise a high Tg, e.g. polystyrene—100 degrees C.; polycarbonate—145 degrees C.—the melt additives that can be utilized may be more extensive than for those polymers with lower glass transition temperatures. For those polymers with lower Tg's, e.g. polypropylene, polyethylene, the melt additives which can be utilized are limited to some extent. With lower Tg's of the thermoplastic polymeric material, some melt additives may auto bloom at room temperature.
For those polymers with a high Tg, any suitable melt additive may be utilized. Some examples of suitable hydrophobic melt additives include fatty acids and fatty acid derivatives. The fatty acids may originate from vegetable, animal, and/or synthetic sources. Some fatty acids may range from a C8 fatty acid to a C30 fatty acid, or from a C12 fatty acid to a C22 fatty acid. In other forms, a substantially saturated fatty acid may be used, particularly when saturation arises as a result of hydrogenation of fatty acid precursor. Examples of fatty acid derivatives include fatty alcohols, fatty acid esters, and fatty acid amides. Suitable fatty alcohols (R—OH) include those derived from C12-C30 fatty acids.
Suitable fatty acid esters include those fatty acid esters derived from a mixture of C12-C30 fatty acids and short chain (C1-C8, preferably C1-C3) monohydric alcohols preferably from a mixture of C12-C22 saturated fatty acids and short chain (C1-C8, preferably C1-C3) monohydric alcohols. The hydrophobic melt additive may comprise a mixture of mono, di, and/or tri-fatty acid esters. An example includes fatty acid ester with glycerol as the backbone as illustrated in [1].
where R1, R2, and R3 each is an alkyl ester having carbon atoms ranging from 11 to 29. In some forms, the glycerol derived fatty acid ester has at least one alkyl chain, at least two, or three chains to a glycerol, to form a mono, di, or triglyceride. Suitable examples of triglycerides include glycerol thibehenate, glycerol tristearate, glycerol tripalmitate, and glycerol trimyristate, and mixtures thereof. In the case of triglycerides and diglycerides, the alkyl chains could be the same length, or different length. Example includes a triglyceride with one alkyl C18 chain and two C16 alkyl chain, or two C18 alkyl chains and one C16 chain. Preferred triglycerides include alkyl chains derived from C14-C22 fatty acids.
Suitable fatty acid amides include those derives from a mixture of C12-C28 fatty acids (saturated or unsaturated) and primary or secondary amines. A suitable example of a primary fatty acid amide includes those derived from a fatty acid and ammonia as illustrated in [2].
where R has a number of carbon atoms ranging from 11 to 27. In at least one other form, the fatty acids may range from a C16 fatty acid to a C22 fatty acid. Some suitable examples include erucamide, oleamide and behanamide. Other suitable hydrophobic melt additives include hydrophobic silicones, ethoxylated fatty alcohols. Additional suitable hydrophobic melt additives are disclosed in U.S. patent application Ser. No. 14/849,630 and U.S. patent application Ser. No. 14/933,028. Another suitable hydrophobic melt additive is available from Techmer PM in Clinton, Tenn. under the trade name PPM17000 High Load Hydrophobic. One specific example of a melt additive is glycerol tristearate.
Similarly, for those polymers with a high Tg, any suitable hydrophilic additive can be used. Some suitable examples include those available from Techmer PM, Clinton, Tenn. sold under the trade name of Techmer PPM15560; TPM12713, PPM19913, PPM 19441, PPM19914, (for polypropylene), and PM19668 (for polyethylene). Additional examples are available from Polyvel Inc. located in Hammonton, N.J., sold under the trade name of Polyvel VW351 PP Wetting Agent; from Goulston Technologies Inc. located in Monroe, N.C. sold under the trade name Hydrosorb 1001; as well as those hydrophilic additives disclosed in US Patent Application Publication No. 2012/0077886 and U.S. Pat. Nos. 5,969,026 and 4,578,414. Other suitable hydrophilic melt additives are Unithox 720 and Unithox 750 and Techsurf 15560 from Techmer in general.
For those polymers with a lower glass transition temperature, e.g. polypropylene, polyethylene, the list of available melt additives may be much more restrictive assuming that the desired outcome is to discourage auto blooming. Note, that the discouragement of auto blooming does not necessarily coincide with the preclusion of auto blooming. Without wishing to be bound by theory, it is believed that for those polymers with a lower Tg, the chain length and molecular weight of the melt additives become much more critical in whether auto blooming will occur. It is believed that for those melt additive compositions having a higher chain-length and a higher molecular weight, a lower diffusion coefficient in the polymer exists at room temperature. So, it is believed that for higher chain length melt additive compositions, auto blooming will be discouraged at room temperature, e.g. about 25 degrees C.
Some suitable examples of hydrophobic melt additives suitable for use in conjunction with polypropylene and/or polyethylene is glycerol tristearate. As used herein, glycerol tristearate is defined as a mixture of long-chained triglycerides containing predominately C18 and C16 saturated alkyl chain lengths. Additionally, there could be varying degrees of unsaturation and cis to trans unsaturated bond configurations. The alkyl chain lengths could range from about C10 to about C22. The degrees of unsaturation typically will range from 0 to about 3 double bonds per alkyl chain. The ratio of cis to trans unsaturated bond configurations can range from about 1:100 to about 100:1. Other suitable examples for use with polypropylene and/or polyethylene, a triglyceride which contains either stearic acid or palmic acid or both as the fatty acid components, or a mixture of such triglycerides.
In one specific example, polypropylene fibers which were spun from a mixture of the resin Polypropylene Moplen HP561R and 6 percent by weight glycerol tristearate Masterbatch (containing 40 percent by weight of the melt additive) from Techmer, processed at a temperature of 250° C. with a residence time of 9 minutes in the extruder showed no blooming at room temperature.
An exemplary hydrophilic melt additive which can be utilized in combination with polypropylene and/or polyethylene is Polyvel surfactant S-1416. It is believed that homologues with a higher molecular weight than Polyvel surfactant S-1416 in a polypropylene or polyethylene matrix may also be utilized.
The Polyvel S-1416 is a silicon surfactant with a (hydrophilic) poly ethylene oxide (PEO) chain and molecular weight above 700 g/mol. Polyvel S-1416 is available from Polyvel Inc. and is also known under the trade name “VW351.” Without wishing to be bound by theory, it is believed that the “resistance to blooming” is controlled via the length of the PEO chain. Namely, it is believed that the longer the PEO chain, the larger the resistance to blooming. S-1416 has a chain of 10 or 11 ethylene oxide repeat units. Additionally, activation of S-1416 requires besides heating a humid environment (e.g. 80% relative humidity or in the presence of water sprayed onto the surface). It further believed that under these conditions the hydrophilic tail is flipped outward.
For those forms of the present invention where auto-blooming is desired, then the melt additive list provided with regard to the higher Tg polymers may be utilized in conjunction with polymers having a lower Tg, e.g. polypropylene and/or polyethylene. And, in such instances, the application of heat to the material web as described herein can enhance the blooming of the melt additive, namely increasing the amount of melt additive which blooms to the surface. In contrast, for those forms of the present invention where the discouragement of auto blooming is desired, then the thermoplastic polymeric material and the melt additive may be matched as described herein such that auto blooming of the melt additive is discouraged.
For those forms where the material web 100 (shown in
And, while conventional wisdom may promote post filament production enhancement of hydrophobicity/hydrophilicity, e.g. topical application, applications of such compositions may be cause additional strife. For example, many topically applied treatments can migrate to other structures within an absorbent article. However, the inventors have surprisingly discovered that where fibers being heat treated as described herein, the discrete melt additive bloom areas do not migrate or migrate to a much lesser extent than topically applied compositions. Migration of the melt bloom areas is discussed in additional detail hereafter.
In some forms of the present invention, additional melt additives are contemplated. For example, the melt additive may comprise a composition which improves tactile sensation, e.g. softness additive. A suitable example of an additive for softness includes Erucamide which may be provided in amounts ranging from about 0.1 to about 20 percent by weight. Additional suitable additive may be provided with regard to reduction of coefficient of friction, or the like. The melt additive which pertains to softness may be beneficial for those forms of the present invention where the material web 100 comprises a plurality of discontinuities selected from outer tufts, tunnel tufts, filled tufts, nested tufts, corrugations, and combinations thereof. While erucamide may auto bloom when used in conjunction with polypropylene and/or polyethylene, the erucamide which blooms to the surface can be enhanced, particularly in the tufts (described herein) and/or corrugations which in some forms may contact a user's skin. So for example, heat application as described herein may enhance the amount of erucamide that blooms in the distal ends of the tufts and/or corrugations. Additional melt additives for softness that are contemplated, include stereamide and oleamide or mixtures thereof. In some forms, mixtures of erucamid, stereamide and/or oleamide may be provided the melt additive.
In some forms, the melt additive bloom areas can be utilized to improve the adhesion of ink and/or of glues to the material web. For example melt additive bloom areas comprising hydrophilic compositions can increase the surface energy of the material web at the location of the melt additive bloom areas. The increased surface energy can increase the adhesion of inks and glues. In contrast, where the melt additive bloom areas comprise a hydrophobic composition, the melt additive bloom areas may be selected to occur where ink and/or glues will not be present. In general, inks and/or glues tend to wash off of hydrophobic compositions/substrates. In such forms, auto blooming may be desired.
In some forms, the melt additive bloom areas can be utilized to form anchoring points at which subsequent coupling of molecules can provide additional functionality of the melt additive bloom areas. For example the melt additive bloom areas may comprise a composition comprising a functional group which can be used for subsequent chemical reaction. The chemical reaction in the subsequent step should be carried out under mild enough conditions (e.g. low enough temperature, below the softening points of the polymer and the melt additive) so that the material web and the melt additive bloom areas are not damaged. The reaction can be any nucleophilic addition reaction or nucleophilic substitution reaction, e.g. with one reactant having hydroxyl groups and the chemical bond formed being an ester. In one specific form, the melt additive bloom may be utilized to improve the stability of other topical applications. For example, soil release polymers that wouldn't normally bind to polyolefins could bind to compositions in melt additive bloom areas.
In another example, the melt additive can comprise a carboxylic acid group (—COOH). This can be an anchoring point for a molecule comprising a hydroxyl group (—OH) as a second molecule which reacts with the carboxylic acid group to form an ester. Reversely, the melt additive can comprise a hydroxyl group and the second molecule can comprise a carboxylic acid group. The formation of an ester bridge is only one out of numerous examples for the formation of a chemical bond with one reactant being a carboxylic acid or a carboxylic acid derivative. The person skilled in the art will easily identify alternative routes. In the selection of the reactants it is important that the reaction can be carried out under mild enough conditions (e.g. low enough temperature, below the softening points of the polymer and the melt additive) so that the substrate and the patterned structure are not damaged. Also the reactant used as melt additive should not or only to a negligible degree decompose under the conditions of processing.
As discussed previously, the inventors have surprisingly found that the melt additive bloom areas do not migrate to the same extent as topically applied compositions. Without wishing to be bound by theory, it is believed that the glass transition temperature of the melt additive composition or the melt temperature of the melt additive (whichever is higher) needs to be above 40 degrees C. Additionally, it believed that the diffusion coefficient plays an important part of whether a melt additive blooms. The melt additive diffusion coefficient can be defined as:
where Deff is the diffusion coefficient, x=radius of the fiber or half caliper of the film, and t=storage time. In order for the melt additive to stay within the polymer matrix of the material web (no melt additive bloom areas sans the application of thermal energy), the diffusion coefficient needs to fulfill the condition:
at room temperature or
at 40° C., assuming that 0.5 years accelerate aging at 40° C. is predictive of 3 years aging at room temperature (25° C.). With such low diffusion coefficients (10−18 m2/s at room temperature and 10−17 m2/s at 40° C. for a fiber with 40 μm diameter) the melt additive is in practical terms immobile in the polymer matrix and does not diffuse to the surface. After 3 years at room temperature or 0.5 years at 40° C. the blooming to the surface outside the defined zones is so limited (if it happens at all) that the melt additive bloom areas provided by the application of thermal energy are maintained with little to no migration.
It is believed that these low effective diffusion coefficients (“locking the melt additive in the polymer matrix”) can be achieved by using melt additives in a polymer matrix with (i) no non-glassy amorphous domains or (ii) large size melt additives in a polymer matrix with a very limited portion of non-glassy amorphous domains at temperatures up to 40° C. For case (i), the polymer matrix may for example, by a completely amorphous polymer which is in its glassy state at an environmental temperature of 40° C. (i.e. Tg>40° C.). For case (ii), the polymer matrix may for example, be a semi-crystalline polymer in which a large parts or all of the amorphous domains are in the glassy state at 40° C.
One example of a suitable polymer for use in the material webs of the present invention is polypropylene. Polypropylene (PP) can have two types of amorphous domains: type I and type II. Type I can be influenced by adjacent crystalline domains and has a Tg of ˜75°. (“Influenced” means that one end of the chain is still tied to the crystal.) The diffusion coefficient for melt additives in these domains is close to zero below 75° C. Type II is uninfluenced by the crystalline domains and has a Tg of ˜5° C. At room temperature the melt additive is only able to effectively migrate in these uninfluenced amorphous domains (Tg˜5° C.). Dependent on the portion and size of the available Type II amorphous domains, the melt additive may not be able anymore to effectively migrate in the polymer matrix, particularly if the melt additive molecules are large and bulky. In undrawn fibers, the crystals are of the form of spherulites with sufficient uninfluenced amorphous domains around. In drawn fibers (rapid cooling with rate of 2000 K/s plus stretching), fibrillous crystals form with less and smaller amorphous domains around. Large melt additives, e.g. molecular weight of GTS=891.5 g/mol, entrapped in such structure are kinetically hindered from diffusion.
With the processes described herein, it is believed that the application of heat during processing can increase the diffusion coefficient into the range of:
Achieving the above diffusion coefficient, the melt additive is able to bloom to the surface of the material web in the areas of thermal energy application with an optional post-processing curing period of up to 24 hours. If the effective diffusion coefficient of the melt additive in the polymer matrix is, for example, changed to 10−13 m2/s due to the application of thermal energy, the melt additive bloom areas may occur within 30 min for a fiber with 40 μm diameter. It is believed that the increase of the diffusion coefficient with the application of thermal energy is caused by a local change of the micro-structure of the host polymer upon application. For smaller diameter fibers, the melt additive bloom areas may occur even quicker than 30 minutes.
Some specific examples regarding thermal energy application across the entirety of a material web are provided below.
Examples 1-4Spunbonded (S) single layer nonwoven fabrics were produced from 100-x wt % Ziegler-Natta polypropylene and X wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic) and were thermally bonded. Each of the single S-layers had a weight of 20 g/m2. The contents of the hydrophobic additive in Examples 1-4 are summarized in Table 1.
Examples 1-4 were tested for Low Surface Tension Strike Through (LST-ST)—measured in seconds. The results are summarized in Table 2. Each sample was tested 15 times, the average is provided below in Table 2.
Three S single layer nonwovens were produced from 100% Ziegler-Natta polypropylene and were thermally bonded. Each of the single S-layers had a weight of 20 g/m2. After the web making process of the nonwovens they were thermally treated with an in-line Omega Drying oven at 90° C., 120° C. and 135° C., for Example 5, 6 and 7, respectively.
Example 8An S single layer nonwoven was produced from 100% Ziegler-Natta polypropylene and was thermally bonded. The single S-layer had a weight of 20 g/m2. After the web making process the nonwoven was thermally treated with an in-line IR-heater set to 65% power at the center and 60% at the edge of the nonwoven web.
Example 9An S single layer nonwoven was produced from 100% Ziegler-Natta polypropylene and was thermally bonded. The single S-layer had a weight of 20 g/m2. After the web making process the nonwoven was thermally treated with an in-line Omega Drying oven at 120° C. Opposite Example 6, the through put had been decreased in the production of the material, resulting in a decreased line speed to increase the duration of the heat treatment. The resulting heat treatment of Example 9 was 15% longer than that of Example 6.
Four S single layer nonwovens were produced from 90 wt % Ziegler-Natta polypropylene and 10 wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic) and were thermally bonded. Each of the single S-layers had a weight of 20 g/m2. After the web making process of the nonwovens they were thermally treated with an in-line Omega Drying oven set to 90° C., 105° C., 120° C. and 135° C. for Example 10, 11, 12 and 13, respectively.
Examples 14-17Four S single layer nonwovens were produced from 90 wt % Ziegler-Natta polypropylene and 10 wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic) and were thermally bonded. Each of the single S-layers had a weight of 20 g/m2. After the web making process of the nonwovens they were thermally treated with an in-line IR-heater set to 50% power at the center and 45% at the edge of the nonwoven web, 60% power at the center and 55% at the edge of the nonwoven web, 65% power at the center and 50% at the edge of the nonwoven web, and 70% power at the center and 65% at the edge of the nonwoven web for Example 14, 15, 16 and 17, respectively.
Example 18An S single layer nonwoven was produced from 90 wt % Ziegler-Natta polypropylene and 10 wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic) and was thermally bonded. The single S-layer had a weight of 20 g/m2. After the web making process of the nonwoven it was thermally treated with an in-line IR-heater set to 65% power at the center and 60% at the edge of the nonwoven web, followed by heating in an Omega Drying oven at 120° C.
The hydrophobic additive content and heat treatment for Examples 10-18 are summarized in Table 4 below.
LST-ST was measured on Example 10-18. The results are shown in Table 5.
An S single layer nonwoven was produced from 90 wt % Ziegler-Natta polypropylene and 10 wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic) and was thermally bonded. The single S-layer had a weight of 20 g/m2. Compared to Example 4, the temperature of the calender thermally bonding the nonwoven was increased with +10° C.
Table 6 below shows the LST-ST results from Example 19.
It can be see that when increasing the calender temperature with 10° C., the LST ST increases from 13.59 seconds (4) to 27.25 seconds (19).
Example 20An S single layer nonwoven was produced from 90% Ziegler-Natta polypropylene and 10 wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic) and was thermally bonded. The single S-layer had a weight of 20 g/m2. After the web making process the nonwoven was thermally treated with an in-line Omega Drying oven at 120° C. As Example 13, the through put had been decreased in the production of the material, resulting in a decreased line speed to increase the duration of the in-line heat treatment. The resulting heat treatment of Example 20 was 15% longer than that of Example 12 and comparable to the heat treatment of Example 6.
Table 7 below shows the LST-ST results from Example 20.
It can be seen that when increasing the heat treatment time with 15%, it increases the performance in terms of LST ST from 186.30 seconds (Example 12) to 354.86 seconds (Example 20).
Example 21A Spunbond single layer fabric was produced with bi-component core/sheath configuration, consisting of 70 wt % core and 30 wt % sheath. The core comprised 100% Ziegler-Natta polypropylene. The sheath comprised 67 wt % Ziegler-Natta polypropylene and 33 wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic). The nonwoven was thermally bonded. The single S-layer had a weight of 20 g/m2.
Example 22-24Spunbond single layer fabrics were produced with bi-component core/sheath configuration, consisting of 70 wt % core and 30 wt %. The core comprised 100 wt % Ziegler-Natta polypropylene. The sheath comprised 100-X wt % Ziegler-Natta polypropylene and X wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic). The nonwoven was thermally bonded. Each of the single S-layer had a weight of 20 g/m2. After the web making process of the nonwovens they were thermally treated by an in-line IR-heater set to 65% power at the center and 50% at the edge of the nonwoven web.
The contents of the hydrophobic additive in the sheath of the fiber in Examples 22-24 are summarized in below Table 8.
Table 9 below shows LST-ST results on Examples 21-24.
A spunbond single layer fabric was produced with bi-component core/sheath configuration, consisting of 70 wt % core and 30 wt %. The core comprised 100 wt % Ziegler-Natta polypropylene. The sheath comprised 67 wt % propylene-based elastomer (consisting of approx. 15 wt % ethylene) and 33 wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic). The nonwoven was thermally bonded. The single S-layer had a weight of 20 g/m2.
Table 10 below shows the LST-ST results on Example 25:
Example 21 to Example 25 reveals an increase in LST-ST from 28.47 seconds to 100.34 seconds when substituting Ziegler-Natta polypropylene in the sheath of the bi-component fiber with a propylene-based elastomer in the sheath of the bi-component fiber.
Example 26A spunbond single layer fabric was produced was produced from 80 wt % Ziegler-Natta polypropylene, 10 wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic), and 10 wt % of a Calcium Carbonate masterbatch (Fiberlink 201S). The fabric was thermally bonded. The single S-layer had a weight of 20 g/m2. After the web making process of the nonwoven it was thermally treated by an in-line IR-heater set to 65% power at the center and 60% at the edge of the nonwoven web followed by in-line heating in an Omega Drying oven at 120° C.
Example 27A spunbond single layer fabric was produced was produced from 90 wt % Ziegler-Natta polypropylene, and 10 wt % of Calcium Carbonate masterbatch (Fiberlink 201S) and was thermally bonded. The single S-layer had a weight of 20 g/m2. After the web making process of the nonwoven it was thermally treated in an in-line Omega Drying oven at 120° C.
An overview of Example 26 and 27 is provided in Table 11 below.
LST-ST results on Examples 26 and 27 are illustrated in Table 12 below.
The LST-ST results reveal a LST ST of 5.51 seconds for Example 27, which shows that the presence of CaCO3 alone does not increase the LST-ST performance. The LST-ST of Example 26 compared to Example 18, reveals that the presence of CaCO3 and the applied heat treatments of the IR-heater and Omega Drying oven increases the LST ST from 230.33 seconds to 679.98 seconds. When comparing the state of the art of Example 4 to Example 26, the performance increases from 13, 59 seconds to 679.98 seconds.
Examples 28-29Two SMMS-multilayered nonwoven fabrics were produced from Ziegler-Natta polypropylene. A hydrophobic additive (PPM17000 High Load Hydrophobic) was added to the various layers as described in Table 13. After the web making process of Example 29 the fabric was heat treated with an in-line Omega Drying oven.
Table 13 gives an overview on material layup, additive content and heat treatment.
Examples 28-29 were tested for Low Surface Tension Strike Through (LST-ST). The results are summarized in Table 14.
Three SS materials were produced with the spunbond fibers in both layers being bi-component fibers of core/sheath configuration with a polyethylene sheath, accounting for 30 wt % of the total fiber, and polypropylene core, accounting for 70 wt % of the total fiber. A hydrophobic additive (PM16310) was added in 17% to the bi-component's PE sheath of both of S layers for Examples 30-32. After the web making process of Example 31-32, the nonwovens were heat treated with an in-line Omega Drying oven of 100° C. and 120° C. for Example 31 and Example 32, respectively.
Table 15 gives an overview on material layup, additive content and heat treatment.
Examples 30-32 were tested for Low Surface Tension Strike Through (LST-ST). The results are summarized in Table 16.
Some of the above samples were tested via FTIR along with some additional examples. The results are shown in Tables 17-19.
For the bi-component nonwovens, no melt additive was provided in the core. The melt additive levels and fiber compositions are provided below with regard to Table 20.
Table 21 provides information regarding the style and temperature of the heating applied to the nonwoven examples.
Table 22 provides information regarding permeability and basis weight and whether fibrillation was observed.
Examples 37-40 are polyethylene films comprising 0.6 percent by weight of melt additive. Sample 37 comprised 0 percent by weight of high density polyethylene and was exposed to a temperature of 25 degrees C. Sample 38 comprised 0 percent by weight of high density polyethylene and was exposed to a temperature of 35 degrees C. for 6 hours. Sample 39 comprised 40 percent by weight of high density polyethylene and was exposed to a temperature of 25 degrees C. Sample 40 comprised 40 percent by weight of high density polyethylene and was exposed to a temperature of 35 degrees C. for 6 hours.
Similarly, the material webs of the present invention begin with the thermoplastic polymeric material. As noted previously, the material webs of the present invention may comprise any suitable material for example, nonwoven webs, film webs, or laminates created therefrom. Where the material webs of the present invention comprise laminates, the laminates may comprise a plurality of nonwoven layers, a plurality of film layers, or at least one nonwoven layer and at least one film layer. Additional forms are contemplated where the material webs of the present invention comprise a nonwoven web comprising multiple nonwoven strata. Regardless of the form of the material web, any suitable material may be utilized.
For those forms where the material webs comprise a nonwoven, any suitable thermoplastic polymer may be utilized. Some suitable thermoplastic polymers are polymers that melt and then, upon cooling, crystallize or harden, but can be re-melted upon further heating. Suitable thermoplastic polymers used herein have a melting temperature (also referred to as solidification temperature) from about 60° C. to about 300° C., from about 80° C. to about 250° C., or from 100° C. to 215° C. And, the molecular weight of the thermoplastic polymer should be sufficiently high to enable entanglement between polymer molecules and yet low enough to be melt spinnable.
The thermoplastic polymers can be derived any suitable material including renewable resources (including bio-based and recycled materials), fossil minerals and oils, and/or biodegradeable materials. Some suitable examples of thermoplastic polymers include polyolefins, polyesters, polyamides, copolymers thereof, and combinations thereof. Some exemplary polyolefins include polyethylene or copolymers thereof, including low density, high density, linear low density, or ultra low density polyethylenes such that the polyethylene density ranges between 0.90 grams per cubic centimeter to 0.97 grams per cubic centimeter, between 0.92 and 0.95 grams per cubic centimeter or any values within these ranges or any ranges within these values. The density of the polyethylene may be determined by the amount and type of branching and depends on the polymerization technology and co-monomer type.
Some suitable examples of polypropylene and/or polypropylene copolymers, include atactic polypropylene; isotactic polypropylene, syndiotactic polypropylene, and combination thereof, “hereafter propylene polymers” can also be used. Polypropylene copolymers, especially ethylene can be used to lower the melting temperature and improve properties. These polypropylene polymers can be produced using metallocene and Ziegler-Natta catalyst systems. These polypropylene and polyethylene compositions can be combined together to optimize end-use properties. Polybutylene is also a useful polyolefin and may be used in some embodiments. Other suitable polymers include polyamides or copolymers thereof, such as Nylon 6, Nylon 11, Nylon 12, Nylon 46, Nylon 66; polyesters or copolymers thereof, such as maleic anhydride polypropylene copolymer, polyethylene terephthalate; olefin carboxylic acid copolymers such as ethylene/acrylic acid copolymer, ethylene/maleic acid copolymer, ethylene/methacrylic acid copolymer, ethylene/vinyl acetate copolymers or combinations thereof; poly-lactic acid; polyacrylates, polymethacrylates, and their copolymers such as poly(methyl methacrylates).
Non-limiting examples of suitable commercially available polypropylene or polypropylene copolymers include Basell Profax PH-835 (a 35 melt flow rate Ziegler-Natta isotactic polypropylene from Lyondell-Basell), Basell Metocene MF-650W (a 500 melt flow rate metallocene isotactic polypropylene from Lyondell-Basell), Moplen, HP2833, HP462R and S, HP551R, HP552N, HP552R, HP553R, HP561R, HP563S, HP567P, HP568S, RP3231, Polybond 3200 (a 250 melt flow rate maleic anhydride polypropylene copolymer from Crompton), Exxon Achieve 3854 (a 25 melt flow rate metallocene isotactic polypropylene from Exxon-Mobil Chemical), Mosten NB425 (a 25 melt flow rate Ziegler-Natta isotactic polypropylene from Unipetrol), Danimer 27510 (a polyhydroxyalkanoate polypropylene from Danimer Scientific LLC), Achieve 3155 (a 35 melt flow rate Ziegler-Natta isotactic polypropylene from Exxon Mobil),
The thermoplastic polymer component can be a single polymer species as described above or a blend of two or more thermoplastic polymers as described above, e.g. two different polypropylene resins. As an example, the constituent fibers of the first nonwoven layer can be comprised of polymers such as polypropylene and blends of polypropylene and polyethylene. The second nonwoven layer may comprise fibers selected from polypropylene, polypropylene/polyethylene blends, and polyethylene/polyethylene teraphthalate blends. In some embodiments, the second nonwoven layer may comprise fibers selected from cellulose rayon, cotton, other hydrophilic fiber materials, or combinations thereof. The fibers can also comprise a super absorbent material such as polyacrylate or any combination of suitable materials.
The fibers of the first nonwoven layer and/or the second nonwoven layer can be monocomponent, bi-component, and/or bi-constituent, round or non-round (e.g., capillary channel fibers), and can have major cross-sectional dimensions (e.g., diameter for round fibers) ranging from 0.1-500 microns. The constituent fibers of the nonwoven precursor web may also be a mixture of different fiber types, differing in such features as chemistry (e.g. polyethylene and polypropylene), components (mono- and bi-), denier (micro denier and >2 denier), shape (i.e. capillary and round) and the like. The constituent fibers can range from about 0.1 denier to about 100 denier.
As used herein, the term “monocomponent” fiber refers to a fiber formed from one extruder using one or more polymers. This is not meant to exclude fibers formed from one polymer to which small amounts of additives have been added for coloration, antistatic properties, lubrication, hydrophilicity, etc.
As used herein, the term “bi-component fibers” refers to fibers which have been formed from at least two different polymers extruded from separate extruders but spun together to form one fiber. Bi-component fibers are also sometimes referred to as conjugate fibers or multicomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the bi-component fibers and extend continuously along the length of the bi-component fibers. The configuration of such a bi-component fiber may be, for example, a sheath/core arrangement wherein one polymer is surrounded by another, or may be a side-by-side arrangement, a pie arrangement, or an “islands-in-the-sea” arrangement. Some specific examples of fibers which can be used in the first nonwoven layer include polyethylene/polypropylene side-by-side bi-component fibers. Another example, is a polypropylene/polyethylene bi-component fiber where the polyethylene is configured as a sheath and the polypropylene is configured as a core within the sheath. Still another example, is a polypropylene/polypropylene bi-component fiber where two different propylene polymers are configured in a side-by-side configuration.
Bi-component fibers may comprise two different resins, e.g. a first polypropylene resin and a second polypropylene resin. The resins may have different melt flow rates, molecular weights, or molecular weight distributions. Ratios of the 2 different polymers may be about 50/50, 60/40, 70/30 or any ratio within these ratios. The ratio may be selected to control the amount of crimp, strength of the nonwoven layer, softness, bonding or the like.
As used herein, the term “bi-constituent fibers” refers to fibers which have been formed from at least two polymers extruded from the same extruder as a blend. Bi-constituent fibers do not have the various polymer components arranged in relatively constantly positioned distinct zones across the cross-sectional area of the fiber and the various polymers are usually not continuous along the entire length of the fiber, instead usually forming fibrils which start and end at random. Bi-constituent fibers are sometimes also referred to as multi-constituent fibers. In other examples, a bi-component fiber may comprise a multi-constituent components.
As used herein, the term “non-round fibers” describes fibers having a non-round cross-section, and includes “shaped fibers” and “capillary channel fibers.” Such fibers can be solid or hollow, and they can be tri-lobal, delta-shaped, and can be fibers having capillary channels on their outer surfaces. The capillary channels can be of various cross-sectional shapes such as “U-shaped”, “H-shaped”, “C-shaped” and “V-shaped”. One practical capillary channel fiber is T-401, designated as 4DG fiber available from Fiber Innovation Technologies, Johnson City, Tenn. T-401 fiber is a polyethylene terephthalate (PET polyester).
The fibers of the first nonwoven layer and/or the second nonwoven layer may comprise additives in addition to their constituent material. For example, suitable additives include additives for coloration, antistatic properties, lubrication, softness, hydrophilicity, hydrophobicity and the like and combinations thereof.
Further regarding coloration, the first layer and/or the second layer may comprise pigments, inks or dyes to achieve any color difference as provided herein. The fibers of the first layer and the fibers of the second layer may differ from each other in pigmentation. As used herein, to “differ in pigmentation” or “difference in pigmentation” means (a) the fibers of the first layer comprise a pigment which is different from the pigment of the second layer; or (b) the fibers of the first layer comprise a different combination of pigments; or (c) the fibers of the first layer comprise different amounts of the same pigment(s) versus the second layer; or (d) combinations of any of options a) to c). The pigment or colorant may be added uniformly throughout the fibers within each layer or may be added to one or both components in same or different type/amount within multicomponent fibers.
A pigment is a material, which can be organic or inorganic and may include activatable, structural and or special effects pigments. A pigment changes the color of reflected or transmitted light as the result of wavelength-selective absorption. This physical process differs from fluorescence, phosphorescence, and other forms of luminescence, in which a material emits light. A pigment is a generally insoluble powder, which differs from a dye, which either is itself a liquid or is soluble in a solvent (resulting in a solution). Dyes are often used to provide a print on the surface of a nonwoven web, such as graphics, pattern or images. Hence, these dyes do not form a part of the fibers of the nonwoven web but are rather applied on the web surface. In the present invention the pigments may be comprised within the fibers of the multilayered nonwoven web, which eliminates the risk of rub-off or wash-off of the color(s) imparted to the multilayered nonwoven web by the pigment.
For the present invention, the pigment will typically be mixed with the thermoplastic material, of which the fibers are made. Often, the pigment is added to the thermoplastic material in the form of a master batch or concentrate at the time of formation of the fibers. Colored master batches useful for the present invention include polypropylene based custom color master batches e.g. supplied by Ampacet; Lufilen and Luprofil supplied by BASF; Remafin for polyolefin fibers, Renol-AT for polyester fibers, Renol-AN for polyamide fibers and CESA for renewable polymers supplied by Clamant. Hence, the pigment will be suspended in the molten thermoplastic material prior to the thermoplastic material being forced through the spinnerets to form and lay down the fibers which form the nonwoven web.
To increase the whiteness and/or opacity of the fibers in either or both layers, titanium dioxide (TiO2) may be used. Different crystal forms are available, however most preferred are rutile or anatase TiO2. Other white pigments include zinc oxide, zinc sulfide, lead carbonate or calcium carbonate. To create a black color, carbon black or any other suitable colorant may be used. Various colored inorganic pigments may be used depending upon the desired color and may include metal oxides, hydroxides and sulfides or any other suitable material. Non-limiting examples of inorganic pigments include cadmium orange, iron oxide, ultramarine, chrome oxide green. One or more pigments may be combined to create the desired color. Non-limiting examples of organic colorants include anthraquinone pigments, azo pigments, benzimidazolone pigments, BONA Lakes, Dioxazine, Naphthol, Perylene, Perinone, Phthalocyanine, Pyranthrone, Quinacridones. Effects pigments including metal, pearlescent and fluorescent may also be used. Various colorants are described in Plastics Additives Handbook, 5th Edition.
The nonwoven materials suitable for use in the material webs of the present invention may be made from any suitable process. For example, as noted previously, the material web may comprise nonwoven layers or nonwoven strata produced via a spunbond process, or carded webs comprising staple fibers. Additional processes are contemplated, for example meltblown process. In some forms, the material web may comprise nonwovens which comprise spunbond filaments (“S”); meltblown fibers (“M”), finer fibers (fibers with average diameters less than one micron or 1000 nanometers (an “N-fiber”)). In some forms, the material webs of the present invention may comprise a combination of fibers/filaments. For example, SMS, SM, SMMS, SMSS, SNS, SN, SNM, or SMN.
Forms are contemplated where melt additive is provided in one or more of the fiber/filament types. For example, an SMS may comprise melt additive in the M filaments and no melt additive in one or both S filaments. Additional examples are provided herein.
Other suitable processes for the material webs of the present invention comprise dry-laid and wet-laid. Dry-laid technologies include carding and air-laying. These technologies may be combined with each other, e.g., dry-laid with melt-spun, to form multi-layer, functional nonwoven substrates.
The air-laid process also uses fibers of discrete length, though these fibers are often shorter than the staple fibers used for carding. The length of fibers used in air-laying typically ranges from 2 mm to 20 mm, though lengths beyond this range may also be used. Particles may also be deposited into the fibrous structure during the air-laying process. Some fibers for air-laying may be prepared similarly as for carding, i.e., opening and blending as described above. Other fibers, such as pulp, may use mills, such as hammer mills or disc mills, to individualize the fibers. The various fibers may be blended to improve the uniformity of properties of the finished nonwoven substrate. The air-laying forming device combines external air and the fibers and/or particles so that the fibers and/or particles are entrained in the airsteam. After entrainment, the fibers and/or particles are collected as a loose web upon a moving foraminous surface, such as a wire mesh conveyor belt, for example. The air-laying process may contain a single air-laying forming device or multiple air-laying forming devices in line with one another, where the fibers and/or particles of the subsequent air-laying forming device are deposited on top of the fibers and/or particles from a preceding air-laying forming device, thereby allowing manufacture of a multi-layered nonwoven substrate.
Wet-laid nonwovens are made with a modified papermaking process and typically use fibers in the range of 2 mm to 20 mm, though lengths beyond this range have also been used. Some fibers for wet-laying may be prepared similarly as for carding, i.e., opening and blending as described above. Other fibers, such as pulp, may use mills, such as hammer mills or disc mills, to individualize the fibers. The fibers are suspended in water, possibly with other additives like bonding agents, and this slurry is typically added to a headbox from where it flows onto a wet-laid forming device to create a sheet of material. After initial water removal, the web is bonded and dried.
Spunlace nonwovens are typically carded and hydroentangled. The fibers of the spunlace nonwoven are first carded. In order to provide the carded fibers with integrity in the Z-direction and in CD, the carded fibers are then subjected to hydroentangling. Instead of carded nonwovens, spunlace nonwovens may be air-laid or wet-laid and subsequently hydroentangled.
The constituent layers/strata of the material web may be provided with structural integrity via a variety of different processes. Some examples include thermal point bonding, air through bonding, hydroentangling, and needlepunching each of which is well known in the art. Similarly, the attachment of the material web layers/strata may be achieved by a variety of different processes. Examples of such processes are discussed hereafter. The constituent materials of the material webs of the present invention can be joined together by any suitable process. An example of a suitable process include calendar bonding. It is worth noting that for those material webs of the present invention for which filled tufts are desired, the percentage of bond area between constituent filaments of the material web should be carefully considered. The inventors have found that with crimped filaments, too low of a calendar bond area does not allow for good formation of filled tufts. And too low of a calendar bond area yields a material web with low strength and poor abrasion resistance. However, too high of a calendar bond area reduces the length of filaments between adjacent bonds which inhibits the amount of uncoiling and/or displacement possible. Specifically, too high of a calendar bond area inhibits the movement of the filaments such that when subjected to the localized Z-direction urging, described herein for the formation of filled tufts and outer tufts, the crimped filaments have very limited ability to uncoil. In such configurations, the crimped filaments must undergo plastic deformation or break once the amount of uncoiling surpasses the amount of applied process strain. The inventors have found that calendar bond area above about 10 percent and less than about 18 percent allows for a good balance of filament mobility and free filament length available for uncoiling but still provides sufficient strength in the nonwoven web for manipulations of the crimped filaments as well as abrasion and tearing resistance in use.
In some forms of the present invention, the nonwoven webs comprising crimped filaments may comprise a calendar bond area of between about 10 percent to about 18 percent or between about 12 percent and 16 percent, specifically including all values within these ranges or any range created thereby. Nonwoven webs of the present invention which do not include crimped filaments may comprise a calendar bond area of between about 5 percent to about 30 percent, between about 10 percent to about 20 percent, specifically including all values within these ranges and any ranges created thereby. The bonds can be shaped like dots, diamonds, ovals or any other suitable shape and may be arranged in any suitable pattern to provide the desired mechanical properties.
The basis weight of nonwoven materials is usually expressed in grams per square meter (gsm). The basis weight of a single layer nonwoven material can range from about 8 gsm to about 100 gsm, depending on the ultimate use of the material. For example, each layer of a laminate may have a basis weight from about 8 to about 40 gsm or from about 8 to about 30 gsm. The basis weight of a multi-layer material is the combined basis weight of the constituent layers and any other added components. The basis weight of multi-layer materials of interest herein can range from about 20 gsm to about 150 gsm, depending on the ultimate use of the material.
Where material webs of the present invention comprise a film layer, any suitable film may be utilized. Exemplary films are discussed in U.S. Pat. Nos. 7,410,683; 8,440,286 and 8,697,218.
Forms of the present invention are contemplated where fillers—having a higher thermal conductivity than the polymer material—are included to the polymer material. Exemplary fillers include inorganic fillers such as calcium carbonate, which can have a higher thermal conductivity than the polymer matrix (e.g., than polypropylene), allowing faster and more homogeneous transfer of heat within the fiber matrix. This can allow for more benefit from the heat already applied in the processing of the material web and, if any, may increase the effect of heat treatment after the production of the material web. The particle size of the filler may be important for the observed effect. In one embodiment, the average particle size of the filler is hence 10 μm or smaller, preferably 1 μm or smaller (ISO 14688). The material may also be chosen to exhibit a thermal conductivity at room temperature of 1 W·m−1·K−1 or greater or more, 2.0 W·m−1·K−1 or more (DIN EN 12664). In some forms, the thermal conductivity could be 2.7 W·m−1·K−1, which approximately corresponds to that of CaCO3. Suitable CaCO3 can in one example be either ground CaCO3 (GCC) or precipitated CaCO3, or a combination thereof. For example, the CaCO3 can be micro-CaCO3 (GCC) having a Plus 325 Mesh of 0.002% and/or mean particle size of 1.6 microns and/or specific surface area of 4.5 m2/g. Such material is, for example, contained in a masterbatch under the trade name “Fiberlink 201S” from A. Schulman. In another example, the CaCO3 can be nano-CaCO3 (PCC) having a residue on sieve 45 micron<250 ppm and/or mean particle diameter of 0.07-0.13 microns and/or specific surface area 16 m2/g. Such material is, for example, found under the tradename SOCAL® U1S2 from Imerys Group. The use of CaCO3 at around 10 percent by weight boosted blooming in materials tested. However, because of its size, CaCO3 may not be appropriate for other types of material processing, e.g. meltblowing.
Forms of the present invention are contemplated where a nucleating agent(s) is (are) included in the polymer matrix. A nucleating agent can increase the number of sites where crystallites begin to form, thereby decreasing the area the crystallites have to grow before they will impinge on each other. Accordingly, the crystallites will be dimensionally smaller and the additive will have a shorter distance to travel before it reaches the fiber surface. In general melt additives may only be able to migrate through the amorphous domains of the polymeric matrix at room temperature, but dependent on the degree of crystallinity (or degree of amorphousness), the geometry and size of the amorphous regions, as well as the conformation and size of the migratory additive, the additive may not be able to migrate effectively at all, as it can be too constricted to move. So it is believed that the less constricted the path composed of the amorphous phase, the more additive will be able to reach the surface before the polymer has recrystallized. Nucleating agents can help to drive more or faster blooming of a melt-additive. In the specific case of hydrophobic or hydrophilic melt additives, the nucleating agent can create a more intensive hydrophobic or hydrophilic effect from the respective melt-additives than without the nucleating agent. Additionally, the provision of a nucleating agent can reduce the level of melt additive needed for effective blooming. This can be cost beneficial as less melt additive may be utilized to potentially achieve the same blooming effect to that achievable with higher levels of melt additive sans the nucleating agent.
Suitable nucleating agents can be both inorganic or organic, and insoluble and soluble in the polymer matrix. In some forms, the nucleating agent comprises a nonitol, trisamide and/or a sorbitol based nucleating agent. Specific but non-limiting examples are: organic nucleation agents such as Millad NX 8000 or (in its new trade name) NX UltraClear GP110B from the Milliken company. Trisamide can be obtained, for example, from Irgaclear XT 386 or any masterbatches containing that active component. An example of an effective inorganic nucleating agent is CaCO3, or other and especially nano-clay or nano-scale mineral molecules.
Where finer fibers than spunbond are being produced, a suitable nucleating agent is NX UltraClear GP110B. The NX UltraClear GP110B may be used from between 2 weight percent to 4 weight percent of NX UltraClear GP110B masterbatch (containing 10 percent of the active). The nucleating agent can boost blooming of the melt additive. Weight percentages of 0.5 weight percent to about 1.0 weight percent may be utilized; however, it is believed that such concentrations would be less effective than the former range based upon testing of an equivalent nucleating agent NX10 also from Milliken.
Including branched polymers and/or random co-polymers to the polymer material may result in a polymeric matrix that inherently allows the additive to move more freely and less constricted and therefore faster. Diffusivity may be promoted, e.g., by using/adding branched polymers or random-copolymers as/to the polymer material. As an example, bi-component technology may be utilized where the additive is added to only (or predominantly) the polymer feeds eventually forming at least the predominant part of the outermost area of the fibers e.g. sheath in a core-sheath configuration.
Disposable Absorbent ArticlesThe material webs of the present invention may comprise any suitable portion of a disposable absorbent article. Some suitable examples, include a topsheet, backsheet, barrier cuff, intermediate layers between the topsheet and an absorbent core and/or intermediate layers between the backsheet and the absorbent core.
Referring to
Any suitable absorbent core known in the art may be utilized. The absorbent core 1718 may be any absorbent member which is generally compressible, conformable, non-irritating to the wearer's skin, and capable of absorbing and retaining liquids such as urine, menses, and/or other body exudates. The absorbent core 1718 may be manufactured from a wide variety of liquid-absorbent materials commonly used in disposable absorbent articles such as comminuted wood pulp which is generally referred to as airfelt. The absorbent core 1718 may comprise superabsorbent polymers (SAP) and less than 15%, less than 10%, less than 5%, less than 3%, or less than 1% of airfelt, or be completely free of airfelt. Examples of other suitable absorbent materials comprise creped cellulose wadding, meltblown polymers including coform, chemically stiffened, modified or cross-linked cellulosic fibers, tissue including tissue wraps and tissue laminates, absorbent foams, absorbent sponges, superabsorbent polymers, absorbent gelling materials, or any equivalent material or combinations of materials.
The configuration and construction of the absorbent core 1718 may vary (e.g., the absorbent core may have varying caliper zones, a hydrophilic gradient, a superabsorbent gradient, or lower average density and lower average basis weight acquisition zones; or may comprise one or more layers or structures). In some forms, the absorbent core 1718 may comprise one or more channels, such as two, three, four, five, or six channels.
The absorbent core 1718 of the present disclosure may comprise one or more adhesives, for example, to help immobilize the SAP or other absorbent materials within a core wrap and/or to ensure integrity of the core wrap, in particular when the core wrap is made of two or more substrates. The core wrap may extend to a larger area than required for containing the absorbent material(s) within.
Absorbent cores comprising relatively high amounts of SAP with various core designs are disclosed in U.S. Pat. No. 5,599,335 to Goldman et al., EP 1,447,066 to Busam et al., WO 95/11652 to Tanzer et al., U.S. Pat. Publ. No. 2008/0312622A1 to Hundorf et al., and WO 2012/052172 to Van Malderen.
Other forms and more details regarding channels and pockets that are free of, or substantially free of absorbent materials, such as SAP, within absorbent cores are discussed in greater detail in U.S. Patent Application Publication Nos. 2014/0163500, 2014/0163506, and 2014/0163511, all published on Jun. 12, 2014.
The absorbent article 1710 may comprise additional layers between the top sheet 1714 and the absorbent core 1718. For example, the absorbent article 1710 may comprise a secondary topsheet and/or an acquisition layer positioned between the topsheet 1714 and the absorbent core 1718.
The backsheet can comprise a liquid impervious film. The backsheet can be impervious to liquids (e.g., body fluids) and can be typically manufactured from a thin plastic film. However, typically the backsheet can permit vapours to escape from the disposable article. In an embodiment, a microporous polyethylene film can be used for the backsheet. A suitable microporous polyethylene film is manufactured by Mitsui Toatsu Chemicals, Inc., Nagoya, Japan and marketed in the trade as PG-P.
One suitable material for the backsheet can be a liquid impervious thermoplastic film having a thickness of from about 0.012 mm (0.50 mil) to about 0.051 mm (2.0 mils), for example including polyethylene or polypropylene. Typically, the backsheet can have a basis weight of from about 5 g/m2 to about 35 g/m2. However, it should be noted that other flexible liquid impervious materials may be used as the backsheet. Herein, “flexible” refers to materials which are compliant and which will readily conform to the general shape and contours of the wearer's body.
The backsheet can be typically positioned adjacent an outer-facing surface of the absorbent core and can be joined thereto by any suitable attachment device known in the art. For example, the backsheet may be secured to the absorbent core by a uniform continuous layer of adhesive, a patterned layer of adhesive, or an array of separate lines, spirals, or spots of adhesive. Illustrative, but non-limiting adhesives, include adhesives manufactured by H. B. Fuller Company of St. Paul, Minn., U.S.A., and marketed as HL-1358J. An example of a suitable attachment device including an open pattern network of filaments of adhesive is disclosed in U.S. Pat. No. 4,573,986 entitled “Disposable Waste-Containment Garment”, which issued to Minetola et al. on Mar. 4, 1986. Another suitable attachment device including several lines of adhesive filaments swirled into a spiral pattern is illustrated by the apparatus and methods shown in U.S. Pat. No. 3,911,173 issued to Sprague, Jr. on Oct. 7, 1975; U.S. Pat. No. 4,785,996 issued to Ziecker, et al. on Nov. 22, 1978; and U.S. Pat. No. 4,842,666 issued to Werenicz on Jun. 27, 1989. Alternatively, the attachment device may include heat bonds, thermal fusion bonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitable attachment device or combinations of these attachment devices. The backsheet may be additionally secured to the topsheet by any of the above-cited attachment devices/methods.
Still another example of a disposable absorbent article which may utilize the material webs of the present invention are diapers which include non-refastenable pants, re-fastenable pants and/or re-fastenable diapers. Diapers have can have a similar construction to that of sanitary napkins. An exemplary diaper is described below.
Referring to
The absorbent article may comprise a liquid permeable topsheet 1924, a liquid impermeable backsheet 1925, an absorbent core 1928 positioned at least partially intermediate the topsheet 1924 and the backsheet 1925, and barrier leg cuffs 1934. The absorbent article may also comprise a liquid management system (“LMS”) 1950 (shown in
The Figures also show typical taped diaper components such as a fastening system comprising adhesive tabs 1942 or other mechanical fasteners attached towards the rear edge of the absorbent article 1900 and cooperating with a landing zone on the front of the absorbent article 1900. The absorbent article may also comprise other typical elements, which are not represented, such as a rear elastic waist feature and a front elastic waist feature, for example.
The absorbent article 1900 may comprise a front waist edge 1910, a rear waist edge 1912 longitudinally opposing the front waist edge 1910, a first side edge 1903, and a second side edge 1904 laterally opposing the first side edge 1903. The front waist edge 1910 is the edge of the absorbent article 1900 which is intended to be placed towards the front of the user when worn, and the rear waist edge 1912 is the opposite edge. Together the front waist edge 1910 and the rear waist edge form waist opening when the absorbent article 1900 is donned on a wearer. The absorbent article 1900 may have a longitudinal axis 1980 extending from the lateral midpoint of the front waist edge 1910 to a lateral midpoint of the rear waist edge 1912 of the absorbent article 1900 and dividing the absorbent article 1900 in two substantially symmetrical halves relative to the longitudinal axis 1980, with article placed flat and viewed from the wearer-facing surface as illustrated
The topsheet 1924, the backsheet 1925, the absorbent core 1928, and the other article components may be assembled in a variety of configurations, in particular by gluing or heat embossing, for example. Example diaper configurations are described generally in U.S. Pat. Nos. 3,860,003, 5,221,274, 5,554,145, 5,569,234, 5,580,411, and 6,004,306.
The absorbent core 1928 may comprise an absorbent material comprising 75% to 100%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99%, all by weight, of the absorbent material, specifically reciting all 0.1% increments within the above-specified ranges and all ranges formed therein or thereby, and a core wrap enclosing the absorbent material. The core wrap may typically comprise two materials, substrates, or nonwoven materials 16 and 16′ for the top side and bottom side of the core.
The absorbent core 1928 may comprises one or more channels, represented in
The topsheet 1924 is the part of the absorbent article that is directly in contact with the wearer's skin. The topsheet 1924 may be joined to the backsheet 1925, the core 1928 and/or any other layers as is known to those of skill in the art. Usually, the topsheet 1924 and the backsheet 1925 are joined directly to each other in some locations (e.g., on or close to the periphery of the article) and are indirectly joined together in other locations by directly joining them to one or more other elements of the absorbent article 1900.
The backsheet 1925 is generally that portion of the absorbent article 1900 positioned adjacent the garment-facing surface of the absorbent core 1928 and which prevents, or at least inhibits, the bodily exudates absorbed and contained therein from soiling articles such as bedsheets and undergarments. The backsheet 1925 is typically impermeable, or at least substantially impermeable, to liquids (e.g., urine, running BM), but permeable to vapors to allow the diaper to “breath”. The backsheet may, for 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. Example backsheet films include those manufactured by Tredegar Corporation, based in Richmond, Va., and sold under the trade name CPC2 film. Other suitable backsheet materials may include breathable materials which permit vapors to escape from the absorbent article 1900 while still preventing, or at least inhibiting, bodily exudates from passing through the backsheet 1925. Example breathable materials may include materials such as woven webs, nonwoven webs, and composite materials such as film-coated nonwoven webs, microporous films, and monolithic films.
The backsheet 1925 may be joined to the topsheet 1924, the absorbent core 1928, and/or any other element of the absorbent article 1900 by any attachment methods known to those of skill in the art. Suitable attachment methods are described above with respect to methods for joining the topsheet 1924 to other elements of the absorbent article 1900.
As used herein, the term “absorbent core” refers to the individual component of the absorbent article having the most absorbent capacity and that comprises an absorbent material. The absorbent core may comprise a core wrap or core bag (hereafter “core wrap”) enclosing the absorbent material. The term “absorbent core” does not include the LMS or any other component of the absorbent article which is not either integral part of the core wrap or placed within the core wrap. The absorbent core may comprise, consist essentially of, or consist of, a core wrap, absorbent material as defined below, and glue enclosed within the core wrap. Pulp or air-felt may also be present within the core wrap and may form a portion of the absorbent material. The absorbent core periphery, which may be the periphery of the core wrap, may define any suitable shape, such as a “T,” “Y,” “hour-glass,” or “dog-bone” shape, for example. An absorbent core periphery having a generally “dog bone” or “hour-glass” shape may taper along its width towards the middle or “crotch” region of the core. In this way, the absorbent core may have a relatively narrow width in an area of the absorbent core intended to be placed in the crotch region of an absorbent article.
The absorbent core 1928 of the present disclosure may comprise an absorbent material with a high amount of superabsorbent polymers (herein abbreviated as “SAP”) enclosed within a core wrap. The SAP content may represent 70% to 100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99%, or 100% by weight of the absorbent material contained in the core wrap. The SAP useful with the present disclosure may include a variety of water-insoluble, but water-swellable polymers capable of absorbing large quantities of fluids. The core wrap is not considered as absorbent material for the purpose of assessing the percentage of SAP in the absorbent core. The remainder of the absorbent material in the core 1928 may be air-felt.
“Absorbent material” means a material which has some absorbency property or liquid retaining properties, such as SAP, cellulosic fibers as well as synthetic fibers. Typically, glues used in making absorbent cores have no absorbency properties and are not considered as absorbent material. The SAP content may be higher than 80%, for example at least 85%, at least 90%, at least 95%, at least 99%, and even up to and including 100% of the weight of the absorbent material contained within the core wrap, as stated above. This provides a relatively thin core compared to conventional cores typically comprising between 40-60% SAP, for example, and high content of cellulose fibers or airfelt. The absorbent material may comprise less than 15% or less than 10% weight percent of natural or synthetic fibers, less than 5% weight percent, less than 3% weight percent, less than 2% weight percent, less than 1% weight percent, or may even be substantially free of, or free of, natural and/or synthetic fibers, specifically reciting all 0.1% increments within the specified ranges and all ranges formed therein or thereby. The absorbent material may comprise little or no airfelt (cellulose) fibers, in particular the absorbent core may comprise less than 15%, 10%, 5%, 3%, 2%, 1% airfelt (cellulose) fibers by weight, or may even be substantially free of, or free of, cellulose fibers, specifically reciting all 0.1% increments within the specified ranges and all ranges formed therein or thereby.
The absorbent core 1928 may also comprise a generally planar top side and a generally planar bottom side. The core 1928 may have a longitudinal axis 80′ corresponding substantially to the longitudinal axis 80 of the absorbent article, as seen from the top in a planar view as in
Cores comprising relatively high amount of SAP with various core designs are disclosed in U.S. Pat. No. 5,599,335 (Goldman), EP 1,447,066 (Busam), WO 95/11652 (Tanzer), U.S. Pat. Publ. No. 2008/0312622A1 (Hundorf), and WO 2012/052172 (Van Malderen).
The absorbent material may be one or more continuous layers present within the core wrap. Alternatively, the absorbent material may be comprised of individual pockets or stripes of absorbent material enclosed within the core wrap. In the first case, the absorbent material may be, for example, obtained by the application of a single continuous layer of absorbent material. The continuous layer of absorbent material, in particular of SAP, may also be obtained by combining two or more absorbent layers having discontinuous absorbent material application pattern, wherein the resulting layer is substantially continuously distributed across the absorbent particulate polymer material area, as disclosed in U.S. Pat. Appl. Publ. No. 2008/0312622A1 (Hundorf), for example. The absorbent core 1928 may comprise a first absorbent layer and a second absorbent layer. The first absorbent layer may comprise the first material 1916 and a first layer of absorbent material 1960, which may be 100% or less of SAP. The second absorbent layer may comprise the second material 1916′ and a second layer of absorbent material 1960, which may also be 100% or less of SAP.
The fibrous thermoplastic adhesive material may be at least partially in contact with the absorbent material 1960 in the land areas and at least partially in contact with the materials 1916 and 1916′ in the junction areas. This imparts an essentially three-dimensional structure to the fibrous layer of thermoplastic adhesive material, which in itself is essentially a two-dimensional structure of relatively small thickness, as compared to the dimension in length and width directions. Thereby, the fibrous thermoplastic adhesive material may provide cavities to cover the absorbent material in the land area, and thereby immobilizes this absorbent material, which may be 100% or less of SAP.
The core wrap may be made of a single substrate, material, or nonwoven folded around the absorbent material, or may comprise two (or more) substrates, materials, or nonwovens which are attached to another. Typical attachments are the so-called C-wrap and/or sandwich wrap. In a C-wrap, the longitudinal and/or transversal edges of one of the substrates are folded over the other substrate to form flaps. These flaps are then bonded to the external surface of the other substrate, typically by gluing. Other techniques may be used to form a core wrap. For example, the longitudinal and/or transversal edges of the substrates may be bonded together and then folded underneath the absorbent core 1928 and bonded in that position.
The core wrap may be at least partially sealed along all the sides of the absorbent core so that substantially no absorbent material leaks out of the core. By “substantially no absorbent material” it is meant that less than 5%, less than 2%, less than 1%, or about 0% by weight of absorbent material escape the core wrap. The term “seal” is to be understood in a broad sense. The seal does not need to be continuous along the whole periphery of the core wrap but may be discontinuous along part or the whole of it, such as formed by a series of seal points spaced on a line. A seal may be formed by gluing and/or thermal bonding.
The core wrap may also be formed by a single substrate which may enclose as in a parcel wrap the absorbent material and be sealed along the front side and rear side of the core and one longitudinal seal.
The absorbent article 1900 may comprise a pair of barrier leg cuffs 1934. Each barrier leg cuff may be formed by a piece of material which is bonded to the absorbent article so it can extend upwards from the inner surface of the absorbent article and provide improved containment of liquids and other bodily exudates approximately at the junction of the torso and legs of the wearer. The barrier leg cuffs 1934 are delimited by a proximal edge 1964 joined directly or indirectly to the topsheet 1924 and/or the backsheet 1925 and a free terminal edge 1966, which is intended to contact and form a seal with the wearer's skin. The barrier leg cuffs 1934 extend at least partially between the front waist edge 1910 and the rear waist edge 1912 of the absorbent article on opposite sides of the longitudinal axis 1980 and are at least present in the crotch region 1907. The barrier leg cuffs 1934 may be joined at the proximal edge 1964 with the chassis of the absorbent article by a bond 1965 which may be made by gluing, fusion bonding, or combination of other suitable bonding processes. The bond 1965 at the proximal edge 64 may be continuous or intermittent. The bond 1965 closest to the raised section of the leg cuffs 1934 delimits the proximal edge 1964 of the standing up section of the leg cuffs 1934.
The barrier leg cuffs 1934 may be integral with the topsheet 1924 or the backsheet 1925 or may be a separate material joined to the absorbent article's chassis. The material of the barrier leg cuffs 1934 may extend through the whole length of the diapers but may be “tack bonded” to the topsheet 1924 towards the front waist edge 1910 and rear waist edge 1912 of the absorbent article so that in these sections the barrier leg cuff material remains flush with the topsheet 1924.
Each barrier leg cuff 1934 may comprise one, two or more elastic strands or strips of film 1935 close to this free terminal edge 1966 to provide a better seal.
In addition to the barrier leg cuffs 1934, the absorbent article may comprise gasketing cuffs 1932, which are joined to the chassis of the absorbent article, in particular to the topsheet 1924 and/or the backsheet 1925 and are placed externally relative to the barrier leg cuffs 1934. The gasketing cuffs 1932 may provide a better seal around the thighs of the wearer. Each gasketing leg cuff may comprise one or more elastic strings 1933 or elastic elements in the chassis of the absorbent article between the topsheet 1924 and backsheet 1925 in the area of the leg openings. All or a portion of the barrier leg and/or gasketing cuffs may be treated with a lotion or skin care composition. The barrier leg cuffs may be constructed in a number of different configurations, including those described in U.S. Pat. App. Publ. No. 2012/0277713.
In a form, the absorbent article may comprise front ears 1946 and rear ears 1940. The ears may be an integral part of the chassis, such as formed from the topsheet 1924 and/or backsheet 1925 as side panel. Alternatively, as represented on
One function of the LMS 1950 is to quickly acquire the fluid and distribute it to the absorbent core 1928 in an efficient manner. The LMS 1950 may comprise one or more layers, which may form a unitary layer or may remain as discrete layers which may be attached to each other. The LMS 1950 may comprise additional layers: a distribution layer 1954 and/or an acquisition layer 1952 disposed between the absorbent core and the topsheet, but the present disclosure is not limited to such a configuration.
The LMS 1950 may comprise SAP as this may slow the acquisition and distribution of the fluid. In other forms, the LMS may be substantially free (e.g., 80%, 85%, 90%, 95%, or 99% free of) or completely free of SAP. The LMS may also comprise one or more of a variety of other suitable types of materials, such as opened-cell foam, air-laid fibers, or carded, resin bonded nonwoven materials, for example. Suitable example LMSs are described in WO 2000/59430 (Daley), WO 95/10996 (Richards), U.S. Pat. No. 5,700,254 (McDowall), and WO 02/067809 (Graef), for example. The distribution layer 1954 may comprise at least 50% or more by weight of cross-linked cellulose fibers, for example. The cross-linked cellulosic fibers may be crimped, twisted, or curled, or a combination thereof including crimped, twisted, and curled. This type of material is disclosed in U.S. Pat. Publ. No. 2008/0312622 A1 (Hundorf).
The acquisition layer 1952 may be disposed, for example, between the distribution layer 1954 and the topsheet 1924. The acquisition layer 1952 may be or may comprise a non-woven material, such as an SMS or SMMS material, comprising a spunbonded, a melt-blown and a further spunbonded layer or alternatively a carded chemical-bonded nonwoven. The acquisition layer 1952 may comprise air or wet-laid cellulosic, cross-linked cellulosic, or synthetic fibers, or blends thereof. The acquisition layer 1952 may comprise a roll-stock web of synthetic fibers (which may be processed to increase void space, such as by solid state formation), or a combination of synthetic and cellulosic fibers, bonded together to form a highloft material. Alternatively, the acquisition layer 1952 may comprise absorbent open cell foam. The nonwoven material may be latex bonded.
The LMS 1950 of the absorbent article 1900 may comprise channels that may generally enable better conformation of the absorbent article to the wearer's anatomy, leading to increased freedom-of-movement and reduced gapping. One or more of the channels of the LMS 1950 may be configured to work in concert with various channels in the absorbent core 1928, as discussed above. Furthermore, channels in the LMS 1950 may also provide increased void space to hold and distribute urine, BM or other bodily exudates within the absorbent article, leading to reduced leakage and skin contact. Channels in the LMS 1950 may also provide internal serviceable indicia, especially when highlighted via physical differences in texture, color, and/or pattern, to facilitate achieving the correct alignment of the absorbent article on a wearer. Thus, such physical differences may be, for example, visually and/or tactilely noticeable.
As stated previously, the material webs of the present invention may be utilized as a topsheet for a disposable absorbent article, examples of which include the sanitary napkin 1710 and diaper 1900 discussed heretofore.
The material webs of the present disclosure may be used as components of absorbent articles. More than one material web may be used in a single absorbent article. In such a context, the material webs may form at least a portion of: a topsheet; a topsheet and an acquisition layer; a topsheet and a distribution layer; an acquisition layer and a distribution layer; a topsheet, an acquisition layer, and a distribution layer; an outer cover; a backsheet; an outer cover and a backsheet, wherein a film (non-apertured layer) forms the backsheet and a nonwoven web forms the outer cover; a leg cuff; an ear or side panel; a fastener; a waist band; belt or any other suitable portion of an absorbent article. The number of strata in a nonwoven web may also be determined by the nonwoven laminates' particular use.
In some forms, additional layers may be positioned between the topsheet and the absorbent core. For example, a secondary topsheet, acquisition layer, and/or distribution layer, each of which are known in the art, may be positioned between the topsheet and the absorbent core of the absorbent article.
Arrays of Absorbent ArticlesAs mentioned heretofore, material webs of the present invention may be utilized in a plurality of absorbent articles. Forms of the present invention are contemplated where an array of absorbent articles, each comprising a topsheet, backsheet, and an absorbent core disposed therebetween comprise material webs of the present invention. The array comprises a first plurality of absorbent articles comprising a first material web. The first material web comprises a first plurality of melt additive bloom areas. The first material web may form at least a portion of each of the first plurality of absorbent articles, e.g. topsheet, backsheet, absorbent core.
The array further comprises a second plurality of absorbent articles. Each of the second plurality of absorbent articles comprises a second material web which forms a portion of at least one of the topsheet, backsheet and/or absorbent core. The second material web may comprise a second plurality of melt additive bloom areas. The first plurality of melt additive bloom areas and the second plurality of bloom areas may be different. For example, the first plurality of melt additive areas may comprise a hydrophobic composition while the second plurality of melt additive areas comprise a hydrophilic composition. In such forms, the first material web may form a portion of the topsheet of the first plurality of absorbent articles, and the second material web may form a portion of the topsheet of the second plurality of absorbent articles. In some forms, the first plurality of absorbent articles may be the same type of article as the second plurality of absorbent articles, e.g. sanitary pads. In other forms, the first plurality of absorbent articles may be different than the second plurality of absorbent articles, e.g. diapers versus sanitary pads. Still in other forms, the first material web may form a portion of the first plurality of absorbent articles which is different than what the second material web forms for the second plurality of absorbent articles, e.g. backsheet versus topsheet.
In some forms of the present invention, the first material web may comprise a different combination of discontinuities than the second material web. For example, the first material may comprise a combination of apertures and tunnel tufts while the second material web comprises a nested tufts and apertures. In some forms, the first plurality of absorbent articles may comprise a different discontinuity or combination thereof than the second plurality of absorbent articles. In such forms, the melt additive bloom areas for the first plurality of absorbent articles may comprise a different composition than the melt additive bloom areas for the second plurality of absorbent articles. Additionally, in such forms, the first plurality of absorbent articles may be different than the second plurality of absorbent articles, e.g. diaper versus sanitary pad.
Forms of the present invention are contemplated where the array comprises additional pluralities of absorbent articles. Such additional pluralities may comprise material webs of the present invention. These material webs may be different than the first material web and/or second material web.
As another example, forms of the present invention are contemplated where a nonwoven comprises a hydrophobic melt additive. The nonwoven comprises a hydrophilic fiber composition or a fiber composition which is more hydrophilic than the melt additive. In such forms, the nonwoven may be processed such that a plurality of discrete melt additive bloom areas are provided on the nonwoven. The melt additive bloom areas may correspond to the distal ends of at least one of tufts or corrugations. The nonwoven, in some forms, may further comprise apertures, embossments, and/or fusion bonds. In some forms, the apertures may be provided in an intermediate zone, while the tufts are provided in laterally outboard zones from the intermediate zone. The fusion bonds and/or embossments may be in the intermediate zone and/or in the laterally outboard zones. In some forms, the embossments may be limited to the intermediate zone while the fusion bonds are in the intermediate zone and in the lateral zones.
As yet another example, forms of the present invention are contemplated where a nonwoven comprises a hydrophilic melt additive. The nonwoven comprises a hydrophobic fiber composition or a fiber composition which is more hydrophobic than the melt additive. In such forms, the nonwoven may be processed such that a plurality of discrete melt additive bloom areas are provided on the nonwoven. The melt additive bloom areas may correspond to the undeformed regions of the material web. The nonwoven web may further comprise a plurality of tufts and/or corrugations. The nonwoven web may further comprise at least one of fusion bonds, embossments, and/or apertures.
As yet another example, forms of the present invention are contemplated where a film comprises a melt additive. The film may be subjected to processing which applies thermal energy across the film thereby creating promoting the creation of melt additive bloom areas. The melt additive bloom area may comprise a hydrophobic composition. Forms of this invention are contemplated where the film further comprises at least one of apertures, embossments, tufts, corrugations, fusion bonds, and/or distal end/land area bonds. Additionally, such films may be utilized in the context of a portion of a backsheet which is air permeable but impervious to liquid.
As yet another example, forms of the present invention are contemplated where a material web comprising a melt additive is subjected to thermal energy application across the entirety of the web. The material web may be a nonwoven and the melt additive may comprise a hydrophobic composition. The nonwoven web may further comprise apertures. Additionally, the nonwoven web may further comprise at least one of embossments, tufts, corrugations, or fusion bonds. The apertures, embossments, tufts, corrugations and/or fusion bonds may be arranged in zones as described herein.
PackagingIn some forms of the present invention, the material webs of the present invention may be utilized as packaging. For example, as packaging of disposable absorbent articles. In such forms, the material web may be provided with discrete melt additive bloom areas as described herein. The melt additive bloom areas may alter the coefficient of friction in a plurality of localized areas. In some forms, the melt additive bloom areas may increase the coefficient of friction to provide for better grip of the packaging. In some forms, the melt additive bloom areas may form anti-stick regions to control fluid dispensing. In such forms, hydrophobic compositions may be leveraged due to its liquid repelling effect that gives a cleanliness benefit in “critical areas”, e.g. close to an opening for fluid dispensing aperture.
In some forms, the melt additive bloom areas may alter the coefficient of friction of discrete portions of packaging, e.g. by providing softness, to reinforce the haptic perception of a 3D structure on the package. In some forms the haptic perception on the package may correspond to a haptic perception of the product within the package. In such forms, a consumer may more easily recognize the package and may associate the “special feel” with the product.
In some forms, the melt additive bloom areas can be utilized to improve the adhesion of ink and/or of glues to the material web, which as noted above can be packaging for articles. For example melt additive bloom areas comprising hydrophilic compositions can increase the surface energy of the material web at the location of the melt additive bloom areas. The increased surface energy can increase the adhesion of inks and glues. In contrast, where the melt additive bloom areas comprise a hydrophobic composition, the melt additive bloom areas may be selected to occur where ink and/or glues will not be present. In general, inks and/or glues tend to wash off of hydrophobic compositions/substrates.
Forms of the present invention are contemplated where the packaging comprises a composition having a higher Tg, e.g. polystyrene—100 degrees C., polycarbonate—145 degrees C. In such forms, as noted previously, it is believed that suitable melt additives are much easier to find given the high Tg.
Tests Glass Transition Temperature and Melting TemperatureTg and melting point are determined in accordance with ASTM D3418-15 for both the base matrix polymer and the neat melt-additive. When melt additive is not directly available, it can be collected from heat treated substrate using the extraction described in “Solvent Wash Procedure”.
Surface Tension of a LiquidThe surface tension of a liquid is determined by measuring the force exerted on a platinum Wilhelmy plate at the air-liquid interface. A Krüss tensiometer K11 or equivalent is used. (Available by Krüss USA (www.kruss.de)). The test is operated in a laboratory environment at 23±2° C. and 50±5% relative humidity. The test liquid is placed into the container given by the manufacturer and the surface tension is recorded by the instrument and its software.
Surface Tension of a Fiber Basis Weight TestA 9.00 cm2 large piece of web, i.e. 1.0 cm wide by 9.0 cm long, is cut out of the product, and it needs to be dry and free from other materials like glue or dust. Samples are conditioned at 23° Celsius (±2° C.) and at a relative humidity of about 50% (±5%) for 2 hours to reach equilibrium. The weight of the cut web pieces is measured on a scale with accuracy to 0.0001 g. The resulting mass is divided by the specimen area to give a result in g/m2 (gsm). Repeat for at least 20 specimens for a particular sample from 20 identical products, if the product and component is large enough, more than one specimen can be obtained from each product. An example of a sample is the left diaper cuff in a bag of diapers, and 10 identical diapers are used to cut out two 9.00 cm2 large specimens of cuff web from the left side of each diaper for a total of 20 specimens of “left-side cuff nonwoven.” If the local basis weight variation test is done, those same samples and data are used for calculating and reporting the average basis weight.
Low Surface Tension Fluid Strikethrough Time TestThe low surface tension fluid strikethrough time test is used to determine the amount of time it takes a specified quantity of a low surface tension fluid, discharged at a prescribed rate, to fully penetrate a sample of a web (and other comparable barrier materials) which is placed on a reference absorbent pad. As a default, this is also called the 32 mN/m Low Surface Tension Fluid Strikethrough Test because of the surface tension of the test fluid and each test is done on two layers of the nonwoven sample simply laid on top of each other.
For this test, the reference absorbent pad is 5 plies of Ahlstrom grade 989 filter paper (10 cm×10 cm) and the test fluid is a 32 mN/m low surface tension fluid.
ScopeThis test is designed to characterize the low surface tension fluid strikethrough performance (in seconds) of webs intended to provide a barrier to low surface tension fluids, such as runny BM, for example.
EquipmentLister Strikethrough Tester: The instrumentation is like described in EDANA ERT 153.0-02 section 6 with the following exception: the strike-through plate has a star-shaped orifice of 3 slots angled at 60 degrees with the narrow slots having a 10.0 mm length and a 1.2 mm slot width. This equipment is available from Lenzing Instruments (Austria) and from W. Fritz Metzger Corp (USA). The unit needs to be set up such that it does not time out after 100 seconds.
Reference Absorbent Pad: Ahlstrom Grade 989 filter paper, in 10 cm×10 cm areas, is used. The average strikethrough time is 3.3+0.5 seconds for 5 plies of filter paper using the 32 mN/m test fluid and without the web sample. The filter paper may be purchased from Empirical Manufacturing Company, Inc. (EMC) 7616 Reinhold Drive Cincinnati, Ohio 45237.
Test Fluid: The 32 mN/m surface tension fluid is prepared with distilled water and 0.42+/−0.001 g/liter Triton-X 100. All fluids are kept at ambient conditions.
Electrode-Rinsing Liquid: 0.9% sodium chloride (CAS 7647-14-5) aqueous solution (9 g NaCl per 1 L of distilled water) is used.
Test Procedure
-
- Ensure that the surface tension is 32 mN/m+/−1 mN/m. Otherwise remake the test fluid.
- Prepare the 0.9% NaCl aqueous electrode rinsing liquid.
- Ensure that the strikethrough target (3.3+/−0.5 seconds) for the Reference Absorbent Pad is met by testing 5 plies with the 32 mN/m test fluid as follows:
- Neatly stack 5 plies of the Reference Absorbent Pad onto the base plate of the strikethrough tester.
- Place the strikethrough plate over the 5 plies and ensure that the center of the plate is over the center of the paper. Center this assembly under the dispensing funnel.
- Ensure that the upper assembly of the strikethrough tester is lowered to the pre-set stop point.
- Ensure that the electrodes are connected to the timer.
- Turn the strikethrough tester “on” and zero the timer.
- Using the 5 mL fixed volume pipette and tip, dispense 5 mL of the 32 mN/m test fluid into the funnel.
- Open the magnetic valve of the funnel (by depressing a button on the unit, for example) to discharge the 5 mL of test fluid. The initial flow of the fluid will complete the electrical circuit and start the timer. The timer will stop when the fluid has penetrated into the Reference Absorbent Pad and fallen below the level of the electrodes in the strikethrough plate.
- Record the time indicated on the electronic timer.
- Remove the test assembly and discard the used Reference Absorbent Pad. Rinse the electrodes with the 0.9% NaCl aqueous solution to “prime” them for the next test. Dry the depression above the electrodes and the back of the strikethrough plate, as well as wipe off the dispenser exit orifice and the bottom plate or table surface upon which the filter paper is laid.
- Repeat this test procedure for a minimum of 3 replicates to ensure the strikethrough target of the Reference Absorbent Pad is met. If the target is not met, the Reference Absorbent Pad may be out of spec and should not be used.
- After the Reference Absorbent Pad performance has been verified, nonwoven web samples may be tested.
- Cut the required number of nonwoven web specimens. For web sampled off a roll, cut the samples into 10 cm by 10 cm sized square specimens. For web sampled off of a product, cut the samples into 15 by 15 mm square specimens. The fluid flows onto the nonwoven web specimen from the strike through plate. Touch the nonwoven web specimen only at the edge.
- Neatly stack 5 plies of the Reference Absorbent Pad onto the base plate of the strikethrough tester.
- Place the nonwoven web specimen on top of the 5 plies of filter paper. Two plies of the nonwoven web specimen are used in this test method. If the nonwoven web sample is sided (i.e., has a different layer configuration based on which side is facing in a particular direction), the side facing the wearer (for an absorbent product) faces upwards in the test.
- Place the strikethrough plate over the nonwoven web specimen and ensure that the center of the strikethrough plate is over the center of the nonwoven web specimen. Center this assembly under the dispensing funnel.
- Ensure that the upper assembly of the strikethrough tester is lowered to the pre-set stop point.
- Ensure that the electrodes are connected to the timer. Turn the strikethrough tester “on” and zero the timer.
- Run as described above.
- Repeat this procedure for the required number of nonwoven web specimens. A minimum of 5 specimens of each different nonwoven web sample is required. The average value is the 32 mN/m low surface tension strikethrough time in seconds.
The diameter of filaments in a sample of a nonwoven substrate is determined by using a Scanning Electron Microscope (SEM) and image analysis software. A magnification of 500 to 10,000 times is chosen such that the filaments are suitably enlarged for measurement. The samples are sputtered with gold or a palladium compound to avoid electric charging and vibrations of the filaments in the electron beam. A manual procedure for determining the filament diameters is used. Using a mouse and a cursor tool, the edge of a randomly selected filament is sought and then measured across its width (i.e., perpendicular to filament direction at that point) to the other edge of the filament. For non-circular filaments, the area of the cross-section is measured using the image analysis software. The effective diameter is then calculated by calculating the diameter as if the found area was that of a circle. A scaled and calibrated image analysis tool provides the scaling to get actual reading in micrometers (μm). Several filaments are thus randomly selected across the sample of the nonwoven substrate using the SEM. At least two specimens from the nonwoven substrate are cut and tested in this manner. Altogether, at least 100 such measurements are made and then all data is recorded for statistical analysis. The recorded data is used to calculate average (mean) of the filament diameters, standard deviation of the filament diameters, and median of the filament diameters. Another useful statistic is the calculation of the amount of the population of filaments that is below a certain upper limit. To determine this statistic, the software is programmed to count how many results of the filament diameters are below an upper limit and that count (divided by total number of data and multiplied by 100%) is reported in percent as percent below the upper limit, such as percent below 1 micrometer diameter or %-submicron, for example.
If the results are to be reported in denier, then the following calculations are made.
Filament Diameter in denier=Cross-sectional area (in m2)*density (in kg/m3)*9000 m*1000 g/kg.
For round filaments, the cross-sectional area is defined by the equation:
A=π*(D/2){circumflex over ( )}2.
The density for polypropylene, for example, may be taken as 910 kg/m3.
Given the filament diameter in denier, the physical circular filament diameter in meters (or micrometers) is calculated from these relationships and vice versa. We denote the measured diameter (in microns) of an individual circular filament as D.
In case the filaments have non-circular cross-sections, the measurement of the filament diameter is determined as and set equal to the hydraulic diameter, as discussed above.
Mass-Average DiameterThe mass-average diameter of filaments is calculated as follows:
mass average diameter,
where
filaments in the sample are assumed to be circular/cylindrical,
di=measured diameter of the ith filament in the sample,
∂x=infinitesimal longitudinal section of filament where its diameter is measured, same for all the filaments in the sample,
mi=mass of the ith filament in the sample,
n=number of filaments whose diameter is measured in the sample
ρ=density of filaments in the sample, same for all the filaments in the sample
Vi=volume of the ith filament in the sample.
The mass-average filament diameter should be reported in μm.
Gravimetric Weight Loss TestThe Gravimetric Weight Loss Test can be used to determine the amount of lipid ester (e.g., GTS) in a nonwoven substrate of the present disclosure. One or more samples of the nonwoven substrate are placed, with the narrowest sample dimension no greater than 1 mm, into acetone at a ratio of 1 g nonwoven substrate sample per 100 g of acetone using a refluxing flask system. First, the sample is weighed before being placed into the reflux flask, and then the mixture of the sample and the acetone is heated to 60° C. for 20 hours. The sample is then removed and air dried for 60 minutes and a final weight of the sample is determined. The equation for calculating the weight percent lipid ester in the sample is:
weight % lipid ester=([initial mass of the sample−final mass of the sample]/[initial mass of the sample])×100%.
Presence of a melt additive (as opposed to a surface coating) is determined by comparison of non-heat activated substrate with and without solvent wash. Non activated regions can be identified using the “Determination of Activated Zones by FTIR/ATR” method as described previously and excised from the substrate for analysis. Approximately 2.0 grams needs to be collected.
An appropriate solvent is identified which is effective to dissolve the additive but will not swell the matrix or dissolve any further additive from the matrix. For GTS in PP, acetone is an appropriate solvent.
1.00 g±0.01 g of the non-heat activated substrate is weighed into a 500 mL flask and 100 mL of a solvent is added. The substrate with solvent is then stirred for 30 minutes at 900 rpm at 20° C. The solvent is decanted and the flask is refilled with a second 100 mL of solvent. The mixture is stirred again for 30 minutes at 900 rpm at 20° C. The solvent is decanted and the nonwoven is dried overnight at 40° C.
Two melt films are prepared, the first of the non-activated area unwashed, and a second of the non-activated substrate after solvent wash, for analysis. Melt film were prepare and analyzed as described in “Quantification of Total Melt-Additive Concentration by FTIR”. FTIR transmission measurements are made on three (3) randomly selected sites from each of the washed and non-washed films to calculate the total concentration. Calculate and record the arithmetic mean of the triplicates separately, and record as Concentration Washed and Concentration Unwashed to the nearest 0.1%. Report the ratio of the Unwashed Concentration divided by the Washed Concentration. A ratio greater than 20 indicates a surface coating instead of a melt additive was used.
The FTIR (reflectance and ATR) measurements of melt additives in a polymer matrix are quantified by peak normalization. One absorption band is selected which is attributed exclusively to the melt additive and must be free of interference from other components or impurities in the sample mixture. This signal is denoted as E1. An example is the peak between 1806 cm−1 and 1660 cm−1 for the GTS. A second band is selected that which is attributed exclusively to the polymer matrix and must be free of interferences from the sample matrix or other impurities in the sample mixture. The signal is used to normalize for path length of the specific specimen. This signal is denoted as E2. An example is the peak between 985 cm−1 and 950 cm−1 for polypropylene (PP). The FTIR methods described herein are written directed specifically toward these examples, GTS in PP, but one skilled in the art, can select analogous peaks to facilitate analysis of other melt additives and matrixes.
Quantification of Total Melt-Additive Concentration by FTIRTotal GTS in fibers, is measured using transmission FTIR (a suitable instrument is the Nicolet 6700, Thermo Scientific, or equivalent). Calibration was performed using standard films prepared from known mixtures of GTS in PP and can be used to quantify the total concentration of GTS on and within a fiber. All testing is performed in a conditioned room maintained at 23° C.±2C° and 50%±2% relative humidity. Samples are conditioned under the same conditions for 2 hours prior to testing.
Calibration Standards are prepared by mixing the base polymer (e.g. polypropylene) with the active GTS. A volume of 55 cm3 of each standard was prepared at a concentration of 0.0%, 0.4%, 1.2%, 2.0%, 4.0%, 12.0% and 20.0% wt/wt of GTS in PP. First the components were accurately weighed and then placed into a laboratory tumble mixer (a suitable mixer is the Turbula T2C available from Willy A. Bachofen AG Maschinenfabrik, or equivalent) and mixed for 10 min. Next the mixture was added to a laboratory kneader (a suitable instrument is a Haake Polydrive Mixer, Thermo Electron GmbH, or equivalent) and kneaded at 180° C. at 10 rpm for 2 min and then again at 60 rpm for an additional 8 min. After kneading, each mixture is ground (a suitable grinder is the Wanner C13.20sv or equivalent) before being pressed into a film.
One melt film was prepared for each concentration using a hot press (a suitable press is the Graseby Specac Hot Press, or equivalent). A standard mixture of 25 mg was placed between two aluminum foils and melted until the pressing form reached 175° C., pressed for 2.0 min with a 5000 kg weight and then cooled for 20 min in a water cooled form under no pressure. The resulting film should have a uniform thickness from 59 μm to 62 μm.
Transmission FTIR is performed on three different locations on each calibration film under the following conditions: 64 scans at a resolution of 1.0 and amplification of 1.0 from 550 to 4000 cm−1. Background scans are performed before every new specimen. Two peaks were measured for quantification, one associated with the PP and the second associated with the GTS. Using an appropriate software, draw a baseline between 1025 cm−1 and 950 cm−1 and measure the vertical drop from highest peak between 985 cm−1 and 950 cm−1 wavenumbers. Secondly, draw a baseline between 1806 cm−1 and 1660 cm−1 and measure the vertical drop from highest peak between those two wavenumbers.
Calibration is performed using peak ratio normalization. Extinction E at a specific wave length λ is defined as:
E(λ)=ϵ·c·d
with c=weight fraction of the absorbing substance; d=thickness of the radiated sample path length and ϵ=coefficient of absorption. For a two-component-system from substance A and substance B, the equation would be expressed as:
E(λ)=ϵEA(A)·cA·d+ϵB(λ)·cB·d
To eliminate contribution from the path length, a ratio of the area of two peaks can be used:
Here E1 refers to the peak between 1660 and 1806 cm−1 and E2 refers to the peak between 950 and 985 cm−1. Taking into account that in a two component system, the single weight fractions χ add up to 1, this gives:
Here the weight fraction of the component is independent of the path length. Plot the ratio of E1/E2 versus the concentration of the calibration sample and perform a least square linear fit. The calibration is defined as:
with x corresponding to a calibration coefficient used to relate the peak ratio to concentration as % GTS.
Analysis of a sample nonwoven is performed on 25 mg of nonwoven excised from the site of interest. Once again a film is prepared using a hot press with the specimen placed between two aluminum foils and melted until the pressing form reached 175° C., pressed for 2.0 min with a 5000 kg weight and then cooled for 20 min in a water cooled form under no pressure. The resulting film should have a uniform thickness from 59 μm to 62 μm.
Transmission FTIR is performed on three different locations on each specimen film using the identical conditions as the standards. Peak heights in the 1025 cm−1 and 950 cm−1 region and 1806 cm−1 and 1660 cm−1 region are collected in like fashion as the standards. The % GTS is calculated using the calibration coefficient derived above for the three replicates and reported as the arithmetic average to the nearest 0.1%.
Quantification of Heat Activated Zones Via FTIR/ATRGTS surface enrichment on fibers, is measured using Attenuated Total Reflection (ATR) FTIR (a suitable instrument is the Nicholet 6700, Thermo Scientific, or equivalent) utilizing both a Germanium and Diamond crystal. The instrument should be capable of correcting the ATR signal to match transmission FTIR signal in accordance with the Advanced ATR Correction Algorithm as described in Thermo Scientific Application Note 50581. The correction is applied as specified by the manufactures operating procedures. All testing is performed in a conditioned room maintained at 23° C.±2C° and 50%±2% relative humidity. Samples are conditioned under the same conditions for 2 hours prior to testing.
Surface enrichment of GTS is measured using FTIR ATR with both a germanium crystal and diamond crystal. Selecting the germanium crystal, the specimen is placed on the ATR stage with the site of interest centered beneath the crystal. The crystal is pressed against the specimen using the probe to a pressure of 68.9 N/mm2. 64 scans are collected at a resolution of one data point per every 0.482 cm−1, amplification of 1.0, 64 scans are collected at a resolution of one data point per every 0.482 cm−1, amplification of 1.0, and 1 bounce measurement type, between a wave number of 550 cm−1 to 4000 cm−1. Between each measurement the crystal and plunger must be cleaned thoroughly with isopropanol to prevent carry-over from the previous analyses. After cleaning wait at least 10 min before starting a new measurement to ensure no residual isopropanol is present on the stage and crystal. Background spectra, using the parameters specified above, were collected every 15 minutes. This background spectrum is subtracted from each measured sample spectra. A spectrum is collected on three different but equivalent sites for a total of 3 spectra. Spectra were repeated using this protocol for both the germanium and diamond crystals. Two peaks were measured for quantification, one associated with the PP and the second associated with the GTS.
The ATR signal can be corrected to match transmission FTIR signal by application of the following equation (equation was derived from Thermo Scientific Application note 50581):
where:
A=ATR intensity
E0=electric fields of the evanescent wave at the boundary
α=absorption coefficient per unit thickness of sample
dp=penetration depth
n1=refractive index of the crystal
n2=refractive index of the sample
Ø=incident angle
The penetration depth (dp) for each crystal is calculated using the following equation:
with n is the refractive index, θ is the incident angle, and A is the incident wave length. The refractive index of the sample is taken as 1.49 for PP and PE. For example, a germanium crystal (refractive index=4.0 and incident angle=42°) would give 0.41 μm penetration and a diamond crystal (refractive index=2.4 and incident angle=42°) would give 1.51 μm penetration. Values must be calculated based on the specific configuration of the instrument used.
Using an appropriate software draw a baseline between 1806 cm−1 and 1660 cm−1 and measure the vertical drop from highest peak between those two wave numbers. This is E1. Secondly, draw a baseline between 1025 cm−1 and 950 cm−1 and measure the vertical drop from highest peak between 985 cm−1 and 950 cm−1 wave numbers. This is E2. Quantification is performed with the calibration coefficient x as determined herein from the “Quantification of Total Melt-Additive Concentration by FTIR” method using the equation:
The % GTS is calculated for the three replicates and reported as the arithmetic average to the nearest 0.1%.
Determination of Activated Zones by FTIR/ATRHeat activation zones are determined using FTIR with Attenuated Total Reflection (ATR) (a suitable instrument is the Nicholet 6700, Thermo Scientific, or equivalent) utilizing both a Germanium and Diamond crystal. Peak ratios internal to the same spectrum are proportional to the additive concentration and therefore can be utilized as a measure to describe the additive concentration without any further calibration. All testing is performed in a conditioned room maintained at 23° C.±2C° and 50%±2% relative humidity. Samples are conditioned under the same conditions for 2 hours prior to testing.
Measurements are made by placing the specimen on the ATR stage with the site of interest centered beneath the crystal. The crystal is pressed against the specimen using the probe to a pressure of 68.9 N/mm2. 64 scans are collected at a resolution of one data point per every 0.482 cm−1, amplification of 1.0, and 1 bounce measurement type, between a wave number of 550 cm−1 to 4000 cm−1. Between each measurement the crystal and plunger must be cleaned thoroughly with isopropanol to prevent carry-over from the previous analyses. After cleaning wait at least 10 min before starting a new measurement to ensure no residual isopropanol is present on the stage and crystal. Background spectra, using the parameters specified above, were collected every 15 minutes. This background spectrum is subtracted from each measured sample spectra. Using an appropriate software draw a baseline between 1806 cm−1 and 1660 cm−1 and measure the vertical drop from highest peak between those two wave numbers. This is E1. Secondly, draw a baseline between 1025 cm−1 and 950 cm−1 and measure the vertical drop from highest peak between 985 cm−1 and 950 cm−1 wave numbers. Measurements are made at the same site using both the Germanium and Diamond crystals.
When the location of heat treated regions and non-heat treated regions are known a Migration Coefficient (MC) can be calculated for activated and non-activated areas as follows:
With an activated area having an MC equal to or greater than twice the MC of a non-activated area. But in most cases with respect to a product heat activated and non-activated areas are not known, so they need to be determined empirically.
Select a region of the sample substrate to analyze for heat activated zones. An x-y test grid 50.0 mm in the machine direction and 50.0 mm in the cross direction is constructed. Using the Germanium crystal, an FTIR/ATR spectrum is measured every 5.0 mm within the test grid from x,y coordinates 1,1 (upper left position) to coordinate 50,50 (lower right position) for a total of 250 spectra indexed by coordinate. Measure the peak signal for E1 and E2 for each spectrum and calculate the ratio of E1/E2 and tabulate into a 50×50 Geranium Peak Ratio (PR) Grid. A 3×3 mean filter is applied to the Geranium PR Grid using the following equation:
A Germanium Results Grid is tabulated, starting at x,y coordinate 2,2 calculate PR2,2 then increment x by 1 and calculate PR3,2 and so forth until coordinate 49,2. Next increment y by 1 and calculate PR2,3 through PR49,3 and so forth until all coordinates between 2,2 and 49,49 have been calculated and recorded.
These measurements and calculations are repeated in like fashion at the same physical test sites using the diamond crystal to tabulate a Diamond Results Grid.
Survey the Diamond Results Grid and identify the lowest value for PRx,y. This value is PRDia,min. Survey the Germanium Results Grid and identify the lowest value for PRx,y. This value is PRGer,min. From these values, calculate a Migration Coefficient (MC) for a non-activated region as:
Using PRDia,min, calculate a MC for each value in the Germanium Results Grid as:
to tabulate a MC Results Grid. To be identified as a heat activated zone MCactivated, a MCx,y must be at least 2× the MCnon-activated:
2·MCnon-activated≤MCactivated
Using this criteria, assign all coordinate sites in the physical test grid as either Activated or Non-activated.
SEM Method for Determining Contact Angle on FibersA rectangular specimen measuring 1 cm×2 cm is cut from the topsheet of a disposable absorbent product taking care not to touch the surface of the specimen or to disturb the structure of the material. The specimen shall be inclusive of any heat activated zones identified via the Determination of Activated Zones by FTIR/ATR test method described heretofore. To the extent that additional heat activated zones lie outside of the specimen, additional specimens shall be obtained to accommodate all of the identified heat activated zones. The length of the specimen (2 cm) is aligned with a longitudinal centerline of the article. The specimen is handled gently by the edges using forceps and is mounted flat with the skin-facing side up on an SEM specimen holder using double-sided tape. The specimen is sprayed with a fine mist of water droplets generated using a small hobby air-brush apparatus. The water used to generate the droplets is distilled deionized water with a resistivity of at least 18 MΩ-cm. The airbrush is adjusted so that the droplets each have a volume of about 2 pL. Approximately 0.5 mg of water droplets are evenly and gently deposited onto the specimen. Immediately after applying the water droplets, the mounted specimen is frozen by plunging it into liquid nitrogen. After freezing, the sample is transferred to a Cryo-SEM prep chamber at −150° C., coated with Au/Pd, and transferred into Cryo-SEM chamber at −150° C. A Hitachi S-4700 Cry-SEM or equivalent instrument is used to obtain high-resolution images of the droplets on the fibers. Droplets are randomly selected, though a droplet is suitable to be imaged only if it is oriented in the microscope such that the projection of the droplet extending from the fiber surface is approximately maximized. This is further discussed with regard to
Examples of images are provided with regard to
X-Ray Photoelectron Spectroscopy (XPS) and Time-of-Flight Secondary Ion Mass Spectroscopy (TOF-SIMS) Imaging techniques are very surface sensitive (penetration depth below 0.5 μm) with a lateral reslution of <10 μm which can be used to visualize the distribution of the melt additive on the surface of the polymer after the activation.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with 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 shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious 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 therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
Claims
1-20. (canceled)
21. An absorbent article comprising:
- a topsheet;
- a backsheet;
- an absorbent core disposed between the topsheet and the backsheet; and
- a material web forming a portion of the absorbent article, the material web having a first surface and an opposing second surface, and wherein the material web comprises a thermoplastic polymeric material and a melt additive homogeneously mixed with the thermoplastic polymeric material and melt additive bloom areas disposed on the first surface, and wherein the thermoplastic polymeric material and the melt additive are matched to discourage auto blooming of the melt additive at room temperature;
- wherein the material web further comprises a plurality of apertures; and
- wherein said melt additive bloom areas comprise a first portion surrounding said apertures and a second portion defined by melt lips of said apertures, wherein said first portion comprises a higher percentage of melt blooming than said second portion.
22. The absorbent article of claim 21, wherein the material web forms a portion of the topsheet.
23. The absorbent article of claim 21, wherein the melt additive bloom areas are more hydrophobic than the thermoplastic polymeric material as determined by the Scanning Electron Microscope (SEM) Method for determining contact angle on fibers.
24. The absorbent article of claim 21, wherein the material web is a nonwoven material comprising a plurality of staple length fibers.
25. The absorbent article of claim 24, wherein a first plurality of staple length fibers comprise the melt additive and a second plurality of staple length fibers do not comprise the melt additive of the first plurality of staple length fibers.
26. The absorbent article according to claim 21, wherein the material web is a nonwoven material comprising continuous filaments.
27. The absorbent article of claim 21, wherein a first migration coefficient of the melt additive bloom areas is at least two times a second migration coefficient of a non-activated area of the thermoplastic polymeric material.
28. The absorbent article of claim 21, wherein the material web comprises the thermoplastic polymeric material, the melt additive, and an additive which influences crystallinity of the thermoplastic polymeric material, the additive being selected from at least one of a nucleating agent, branched polymers, or random co-polymers.
29. The absorbent article of claim 21, wherein said melt additive bloom areas are in the form of a film, flakes, fibrils, or combinations thereof.
Type: Application
Filed: Aug 26, 2021
Publication Date: Dec 16, 2021
Inventors: Torsten LINDNER (Kronberg), Olaf Erik Alexander ISELE (Wester Chester, OH), Gueltekin ERDEM (Hessen), Misael Omar AVILES (Hamilton, OH), Holger BERUDA (Schwalbach am Taunus), Jan CLAUSSEN (Wiesbaden), Kelyn Anne ARORA (Cincinnati, OH), Nathan Ray WHITELY (Liberty Township, OH), Franz Josef LANYI (Erlangen), Dirk Wolfram SCHUBERT (Eggolsheim), Barbara Harling HEDE (Aalborg), Thomas BROCH (Gistrup), Morten Rise HANSEN (Aalborg), Brian UDENGAARD (Lystrup)
Application Number: 17/412,805
