U.S. patent application number 10/744152 was filed with the patent office on 2004-08-19 for apertured material for use in absorbent articles and method of making the same.
Invention is credited to Cree, James W., Iulianetti, Lino.
Application Number | 20040161586 10/744152 |
Document ID | / |
Family ID | 32682304 |
Filed Date | 2004-08-19 |
United States Patent
Application |
20040161586 |
Kind Code |
A1 |
Cree, James W. ; et
al. |
August 19, 2004 |
Apertured material for use in absorbent articles and method of
making the same
Abstract
A film for use in absorbent articles is first microscopically
textured and then macroscopically apertured while maintaining the
microscopic texture. The micro-texturing may be done by a variety
of means including vacuum forming, and may include micro-apertures.
The macroscopic texture may be done by a variety of means including
thermo-mechanical means with a heat shielding means. Where heated
pins are used, the heat shielding means protects the micro-texture
from the heat so that the heat does not deform the
micro-texture.
Inventors: |
Cree, James W.;
(Chesterfield, VA) ; Iulianetti, Lino; (Torre dei
Passeri, IT) |
Correspondence
Address: |
FISH & RICHARDSON P.C.
5000 BANK ONE CENTER
1717 MAIN STREET
DALLAS
TX
75201
US
|
Family ID: |
32682304 |
Appl. No.: |
10/744152 |
Filed: |
December 22, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60435942 |
Dec 20, 2002 |
|
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|
Current U.S.
Class: |
428/131 ;
156/209; 156/252; 264/156; 264/210.2; 264/555; 264/571;
428/137 |
Current CPC
Class: |
B32B 37/153 20130101;
B29C 51/145 20130101; B32B 3/26 20130101; B32B 2323/046 20130101;
B26F 1/26 20130101; B32B 2555/02 20130101; A61F 13/15707 20130101;
Y10T 428/249921 20150401; Y10T 156/1023 20150115; Y10T 428/24322
20150115; B29C 59/06 20130101; A61F 2013/51147 20130101; A61F
2013/15422 20130101; A61F 13/51104 20130101; B26F 1/24 20130101;
B32B 27/00 20130101; B29C 51/22 20130101; B32B 2305/20 20130101;
B29L 2031/4878 20130101; Y10T 428/24273 20150115; A61F 2013/53782
20130101; B29C 43/222 20130101; B32B 38/06 20130101; B32B 2305/026
20130101; A61F 13/512 20130101; A61F 13/5123 20130101; B32B 27/12
20130101; B32B 3/10 20130101; A61F 13/5122 20130101; Y10T 156/1056
20150115; B29C 59/04 20130101; B32B 2038/047 20130101; B32B 27/32
20130101; A61F 13/537 20130101; B29C 2059/023 20130101 |
Class at
Publication: |
428/131 ;
264/210.2; 264/156; 264/555; 264/571; 156/209; 156/252;
428/137 |
International
Class: |
B26F 001/10; B29C
047/00; B29C 059/04; B29C 059/06; B32B 003/10 |
Claims
What is claimed is:
1. A method for manufacturing a formed film, the method comprising:
extruding a thermoplastic material to form a film; forming
micro-textures soon after extrusion, while the thermoplastic
material is still in a maleable state; and forming
three-dimensional macro-apertures after micro-textures have been
formed.
2. The method of claim 1 wherein the micro-textures are formed with
a differential pressure means.
3. The method of claim 1 wherein the micro-textures are formed by
pulling the thermoplastic material onto a screen with a vacuum.
4. The method of claim 1 wherein the macro-apertures are formed
with a thermo-mechanical forming process.
5. The method of claim 4 wherein the thermo-mechanical forming
process includes use of a heat shielding material to maintain the
micro-textures in the film while the film is in a nip of the
thermo-mechanical means.
6. The method of claim 4 wherein the thermo-mechanical forming
process includes use of a layer of nonwoven fabric with a higher
melting point than the film as the heat shielding material.
7. The method of claim 1 wherein a nonwoven material is bonded to
the film concurrently with the forming of macro-textures.
8. An apertured thermoplastic film with a body facing surface and
an absorbent core facing surface that comprises: a micro-textured
surface comprising a high density of elongated micro-funnels
extending perpendicular to the surface's plane to form protrusions;
and three dimensional macro-apertures extending perpendicular to
its plane to form protrusions on the film's absorbent core facing
surface.
9. The film of claim 8 wherein the protrusions formed by the
micro-funnels protrude from the same surface as the protrusions
formed by the macro-apertures.
10. The film of claim 8 wherein the protrusions formed by the
micro-funnels is in the opposite direction as the protrusions
formed by the macro-apertures.
11. The film of claim 8 wherein the micro-funnels have a mesh of
about 30 to about 100 micro funnels per linear inch.
12. The film of claim 8 wherein the micro-funnels have a mesh of
about 40 to about 60 micro funnels per linear inch.
13. The film of claim 8 wherein the macro-apertures have a density
of between 4 holes per square centimeter and 15 holes per square
centimeter.
14. The film of claim 8 wherein the macro-apertures have a density
of between 5 holes per square centimeter and 12 holes per square
centimeter.
15. The film of claim 8 further comprising a nonwoven layer bonded
to the absorbent facing side of the film with apertures aligned
with the macro-protrusions on the absorbent facing side of the
film.
16. An absorbent article comprising: a topsheet; and an absorbent
core; wherein the topsheet is a film with apertures forming lands
on a surface, the apertures being three dimensional and extending
perpendicular to the surface, the lands having micro-apertures, the
micro-apertures being three dimensional and extending perpendicular
to the surface.
17. The absorbent article of claim 16 wherein the apertures and the
micro-apertures extend opposite one another.
18. The absorbent article of claim 16 wherein the apertures and the
micro-apertures extend in the same direction.
19. The absorbent article of claim 16 wherein the film is bonded to
a nonwoven layer having openings aligned with the apertures.
20. The film of claim 16 wherein the micro-apertures have a mesh of
about 30 to about 100 micro funnels per linear inch.
21. The film of claim 16 wherein the micro-apertures have a mesh of
about 40 to about 60 micro funnels per linear inch.
22. The film of claim 16 wherein the apertures have a density of
between 4 holes per square centimeter and 15 holes per square
centimeter.
23. The film of claim 16 wherein the apertures have a density of
between 5 holes per square centimeter and 12 holes per square
centimeter.
24. An absorbent article comprising: a topsheet; and an absorbent
core; wherein the topsheet is a film with apertures forming lands
on a surface, the apertures being three dimensional and extending
perpendicular to the surface, the lands having micro-textures, the
micro-textures being three dimensional and extending perpendicular
to the surface.
25. The absorbent article of claim 24 wherein the micro-textures
extend opposite the apertures.
26. The absorbent article of claim 24 wherein the micro-textures
are one of a group consisting of microdots, micro-ridges, random
matte, and micro-apertures.
27. The absorbent article of claim 24 wherein the film is bonded to
a nonwoven layer having openings aligned with the apertures.
28. The film of claim 24 wherein the apertures have a density of
between 4 holes per square centimeter and 15 holes per square
centimeter.
29. The film of claim 24 wherein the apertures have a density of
between 5 holes per square centimeter and 12 holes per square
centimeter.
30. A method for making a formed film comprising: extruding a resin
onto a forming screen imparted with a micro-texture so that the
resin forms to the screen and forms a film with the micro-texture;
aperturing the film with heated pins to create three dimensional
macro-apertures with lands between the macro-apertures; and
shielding the lands between the macro apertures during the
aperturing process with a protective layer to prevent the heating
of the lands to a point where the micro-texture loses its form.
31. The method of claim 30 wherein the protective layer is a
nonwoven material with a melting point higher than the resin.
32. The method of claim 30 further comprising: bonding a nonwoven
layer to the film during the aperturing process such that the
heated pins extend through the nonwoven layer so that the nonwoven
layer does not obstruct fluid flow through the apertures.
33. The method of claim 32 wherein a vacuum is applied to the
forming screen to create micro-apertures as the micro-texture in
the film.
34. An absorbent article comprising: a topsheet; an absorbent core;
and an intermediate layer between the topsheet and the absorbent
core; wherein the intermediate layer is a film with apertures
forming lands on a surface, the apertures being three dimensional
and extending perpendicular to the surface, the lands having
micro-textures, the micro-textures being three dimensional and
extending perpendicular to the surface.
35. The absorbent article of claim 34 wherein the micro-textures
extend opposite the apertures.
36. The absorbent article of claim 34 wherein the micro-textures
are one of a group consisting of microdots, micro-ridges, random
matte, and micro-apertures.
37. The absorbent article of claim 34 wherein the film is bonded to
a nonwoven layer having openings aligned with the apertures.
38. The film of claim 34 wherein the apertures have a density of
between 4 holes per square centimeter and 15 holes per square
centimeter.
39. The film of claim 34 wherein the apertures have a density of
between 5 holes per square centimeter and 12 holes per square
centimeter.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/435,942, filed Dec. 20, 2002. The disclosure of
the prior application is considered part of (and is incorporated by
reference in) the disclosure of this application.
TECHNICAL FIELD
[0002] This invention relates to the formation of three-dimensional
thermoplastic films, and more particularly those with both
micro-texture and macro-apertures.
BACKGROUND
DESCRIPTION OF RELATED ART
[0003] There has always been a need to create cloth-like textures
in poly-olefin films that can in turn become three-dimensionally
apertured fluid transporting structures. In the past this texturing
was achieved through the creation of a plurality of micro-apertures
that stick out from the surface of film. This fragile micro-texture
can be created through the use of water forming or vacuum forming
as described in the prior art. However, once micro-texturing is
completed, it is difficult to create the three-dimensional ("3D")
funnel-shaped aperture that allows the fluid to pass through the
film into the absorbent layer underneath without destroying the
micro-texture. Water or needle perforation has been attempted,
however, the water approach is not at a high enough temperature to
create a permanently deformed and stress annealed aperture. Thus, a
large 3D aperture formed using water perforation could have the
tendency to become flat again if subjected to stress or to pressure
at the time the aperture is formed. Use of a hot needle is not
effective either, because the heat from the hot needle will melt
the surrounding, very delicate micro-texture if the needle is hot
enough to impart any permanent deformation into the cone. If the
micro-texture is micro-apertures, the heat of the needle causes the
edges of the micro-apertures to "crisp" or become very stiff as a
result of the exposure to the heat. This sort of stiffening of the
edges makes the final product rough to the touch.
[0004] A novel method of using thermo-mechanical perforation with a
matching set of needles, grooves and protective surface to create
such product is disclosed herein. Further, this invention teaches
how, in one pass, a product can have large 3D fluid transport holes
imparted into a micro-textured film and how a fluid transport layer
may be attached under the fluid transport sheets to direct the
fluid away from the 3D funnel of the micro-textured film. The final
product produced via such process is primarily intended for use as
a body-contacting, textured formed film top sheet in an absorbent
hygienic product or wound dressing. Further, this product can be
used as a sub-layer in such an absorbent article or as a top layer
in a baby diaper.
SUMMARY
[0005] A film is first microscopically textured and then
macroscopically textured while maintaining the microscopic texture.
The micro-texturing may be done by a variety of means including
vacuum forming, and may include micro-apertures. The macroscopic
texture may be done by a variety of means including
thermo-mechanical means with a heat shielding means. Where heated
pins are used, the heat shielding means protects the micro-texture
from the heat so that the heat does not deform the
micro-texture.
[0006] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0007] FIG. 1 is a schematic view of a method of forming a
micro-texture in a film.
[0008] FIG. 2 is a cross sectional view of a film with
micro-texture formed by the process shown in FIG. 1.
[0009] FIG. 3 is a schematic view of a method of forming a
macro-texture in a film.
[0010] FIG. 4 is a cross sectional view of a film with both a
micro-texture and a macro-texture as formed by the processes of
FIG. 1 and FIG. 3.
[0011] FIG. 5 is a schematic view of a method of forming a
macro-texture in a film while combining a nonwoven layer with the
film.
[0012] FIG. 6 is a cross sectional view of a film adjacent to a
nonwoven layer and with both a microtexture and a macro-texture as
formed by the processes of FIG. 1 and FIG. 5.
[0013] FIG. 7 is a schematic view of a method of forming a
macro-texture in a film.
[0014] FIG. 8 is a cross sectional view of a film with both a
micro-texture and a macro-texture as formed by the processes of
FIG. 1 and FIG. 7.
[0015] FIG. 9 is a schematic view of a method of forming a
macro-texture in a film while combining a nonwoven layer with the
film.
[0016] FIG. 10 is a cross sectional view of a film adjacent to a
nonwoven layer and with both a microtexture and a macro-texture as
formed by the processes of FIG. 1 and FIG. 9.
[0017] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0018] As used herein, "micro" refers to individual features that
are not individually discernable when viewed by the human eye from
about 18 inches, although a change in texture on a whole may be
discernable, while "macro" refers to features that are individually
discernable when viewed by the human eye from about 18 inches. For
example, micro-apertures with a mesh of between about 30 apertures
per linear inch and 100 apertures per linear inch will change the
surface texture of a film, but the individual apertures will not be
individually discernable by the human eye from a distance of about
18 inches. Likewise, macro-apertures with a spacing of about 5 to
about 11 holes per square centimeter will be individually
discernable by the human eye from a distance of about 18
inches.
[0019] A film material 10, which is typically thermoplastic, is
extruded onto a forming screen 12. Forming screen 12 contains a
micro-texture. The forming screen 12 may have a variety of
micro-texture patterns. The film material 10 is thereby formed into
a microscopically three-dimensional film 14. The film material 10
may be apertured as part of the vacuum forming or may be allowed to
stay intact.
[0020] The film material 10 may be a thin film consisting of a
50/50 blend of LDPE and LLDPE extruded from a cast die 16 or a
blown die. While the film material 10 is still in a semi-molten,
malleable state a pressure is applied by differential pressure
means, such as a vacuum, blown air, etc., to the film material 10
to have the film material 10 form to a screen 12. The pressure may
be applied by known vacuum forming techniques as shown in FIG. 1,
although other means may be acceptable. The screen 12 imparts a
micro-texture 16 to the film material 10. The resultant
micro-textured film 14 will have a micro-texture 16, which may
include micro-apertures, micro-ridges, micro-dots, or other
micro-textures known in the art, as it is removed from the screen
12 as shown in FIG. 2. If the micro-texture 16 is micro-apertures,
the micro-apertures may have a density of between about 30 holes
per linear inch and about 100 holes per linear inch, also known as
about 30 mesh to about 100 mesh, and preferably between about 40
mesh and about 60 mesh. Where micro-textures 16 are formed of
micro-apertures, they may be three-dimensional micro-funnels to
increase their effect on tactile response as well as fluid handling
properties. Where micro-textures 16 are formed of micro-apertures
they may be round, elongated, octagonal, oval, hexagonal,
ellipsoid, rectangular, square, or any other shape or pattern
depending on the preferred texture or fluid handling
properties.
[0021] The film material 10 may contain surfactants in the resin,
or surfactants may be added to the micro-textured film 14.
Surfactants increase the philicity of the normally phobic film
material 10 and may affect the performance of the finished product
as discussed below. Alternatively, surfactants may not be added,
resulting in a phobic film material 10.
[0022] In a preferred embodiment, the micro-textured film 14 is
then thermo-mechanically perforated to produce a macroscopic
three-dimensional aperture 18. The macro-aperture 18 forms a
macroscopic texture on the film, and therefore the terms
macro-texture and macro-aperture 18 are used throughout. Heat
shielding 22 allows the use of heated pins 20 to perforate the
micro-textured film 14 without destroying the micro-texture 16.
Without heat shielding 22, the heated pins 20 may soften the
material of film 14 such that micro-texture 16 is destroyed or the
heated pins 20 may crisp the edges of the micro-texture 16 as
described above. If micro-textured film 14 is sufficiently heated
by heated pins 20, the micro-texture 16 will melt back to a film,
thus losing the texture created by screen 12. The heat shield 22,
shown in FIGS. 3, 5, 7, and 9, is a shielding material 26 having a
higher melting point than the film, such as a nonwoven
polypropylene, which passes through the perforating nip 30 between
the micro-textured film 14 and a drum 24 carrying heated
perforating pins 22. Two effective examples of shielding material
26 are nonwovens known in the art as Spun-Meltblown-Spun 19 gsm and
Thermo-bonded Carded 24 gsm. The selection of an appropriate
nonwoven material to be used as shielding material 26 should be
based on finding a nonwoven that has a melting point higher than
the film material 10. Other heat shields would include various
other materials, which may be able to run on a continuous loop with
a cooling cycle, a cooled drum/heated pin arrangement, and various
fluid-cooling means.
[0023] The thermo-mechanical perforating unit shown in FIG. 3 uses
heated pins 20 mated into an unheated female roll 28 to form a nip
30. The micro-textured film 14 and above-mentioned shielding
material 26 are fed into the nip 30 such that the heated pins 20
form macroscopic three-dimensional apertures 18 in the
micro-textured film 14. The shape of the apertures is determined by
the relationship between pins 20 and roll 28. The macro-apertures
18 of this preferred embodiment have a density of between about 4
holes per square centimeter and about 15 holes per square
centimeter, and preferably between about 5 holes per square
centimeter and about 12 holes per square centimeter. The
macro-apertures 18 may be formed into a cone that extends from an
upper surface of the film 14 to a lower surface spaced apart by a
distance greater than the initial thickness of film 14. The taper
of the cone will depend on the shape of female roll 28 and heated
pins 20. Depending on the relative speed at which the film 14,
heated pins 20, and female roll 28 are moving, the macro-apertures
18 may be round or elongated.
[0024] Female roll 28 may be temperature controlled to maintain a
consistency to the macro-apertures 18 formed at the nip 30. The
temperature control may include cooling or heating as needed for
the desired results. For example, an operating temperature of 30
degrees Celsius may require cooling in some environments, heating
in others.
[0025] The film 32 of the preferred embodiment will have a vacuum
formed micro-texture 16 and a thermo-mechanically formed
macro-texture 18, as shown in FIGS. 4 and 8. The micro-textured
film 14 of FIG. 2 has a caliper of about 25 microns while the
caliper of the film 32 of FIGS. 4 and 6 is about 400 microns to
about 1500 microns, preferably between about 800 microns and 1300
microns. The film 32 of this preferred embodiment will have a
desirable texture provided by the micro-texture 16 and a resilient
structure provided by the macro-texture 18.
[0026] As shown in FIGS. 5 and 9, a second material 34, such as a
wicking nonwoven, may be fed into the nip 30 of the
thermo-mechanical forming means to simultaneously bond the second
material 34 to the film layer 14 thus creating a composite material
36. The second material 34 may be positioned between the film layer
14 and female roll 28 so that the micro-texture 16 is still
exposed. Heated pins 20 would puncture second material 34 at
macro-apertures 18. In this manner, a composite material 36 may be
formed having the tactile impression and fluid handling abilities
of a micro-apertured film backed by a wicking material and the
fluid handling abilities of macro-apertures 18 unobstructed by the
second material 34 as shown in FIG. 6. The second material 34 is
effective in wicking moisture away from the film layer 14, thus
improving the wetback performance.
[0027] As can be seen by comparison of FIGS. 4 and 8 or FIGS. 6 and
10 where the micro-textures 16 are micro-apertures, the
micro-apertures may extend in the same direction as the
macro-apertures 18, FIGS. 8 and 10, or in the opposite direction as
the macro-apertures 18, FIGS. 4 and 6.
[0028] Absorbent articles typically have a body facing topsheet, a
backsheet opposite the topsheet, and an absorbent core between the
topsheet and backsheet. Additionally, modem absorbent articles may
contain an intermediate layer between the topsheet and the
absorbent core. The film 32 or composite material 36 may be used as
a topsheet or an intermediate layer in an absorbent article.
[0029] Performance Measures
[0030] Various materials were tested as topsheets against
comparative topsheet materials. One of the comparative materials is
a hydro-formed topsheet used in the Procter & Gamble sanitary
napkin product "Lines Petalo Blu" and referred to herein as "HFF".
Another of the comparative materials is the nonwoven phobic
topsheet used in the SCA sanitary napkin product "Nuvenia Libresse"
and referred to herein as "NW". The materials used for the
different examples are as follows:
[0031] Example 1: A micro-texture 16 of 60 mesh micro-apertures in
a philic film material 10 and macro-apertures 18 with a spacing of
about 5.6 apertures per square centimeter.
[0032] Example 2: Similar to Example 1, but with a micro-texture 16
of 40 mesh micro-apertures.
[0033] Example 3: Similar to Example 1, but with a phobic film
material 10.
[0034] Example 4: Similar to Example 2, but with a phobic film
material 10.
[0035] Example 5: Similar to Example 1, but with a second material
34 of 25 gsm air through bonded nonwoven (ATB 25 RAM).
[0036] Example 6: Similar to Example 2, but with a second material
34 of 25 gsm air through bonded nonwoven (ATB 25 RAM).
[0037] Example 7: Similar to Example 5, but with macro-apertures 18
with a spacing of about 11 apertures per square centimeter.
[0038] Example 8: Similar to Example 6, but with macro-apertures 18
with a spacing of about 11 apertures per square centimeter.
[0039] Strikethrough is a measure of the rate of absorption through
a topsheet into an absorbent article and was conducted on finished
articles as indicated below. In order to test strikethrough the
original topsheet material is removed from the article and replaced
with the topsheet material to be tested, except when testing the
sample of the original material. The article is then insulted with
a 10 ml sample of Menstrual Internal Synthetic Solution (MISS) and
the strikethrough time is recorded using a Lister apparatus as
described in EDANA Recommended Test Method ERT 150.5-02 Liquid
Strike Through Time Test Method. Lower strikethrough numbers
reflect a fast absorption and are desired in most absorbent
articles.
[0040] Wetback is measured on the same samples used in the
strikethrough test described above. After the strikethrough is
measured the samples are carefully removed from the test apparatus
and positioned on a flat surface. A 4 kg weight with a surface of
10 cm by 10 cm is placed on the insult area of the sample for three
minutes. At three minutes the weight is removed and 5 preweighed
pick up papers are placed over the insult area and the weight is
placed over the pickup paper. At two minutes the weight is removed
and the pickup paper is removed and reweighed. The weight gained by
the pickup paper is reported as the wetback. This method is based
on EDANA Recommended Test Method ERT 151.3-02 Wetback. Lower
wetback numbers reflect more complete absorption and less leakage
to the insult surface and are desired in most absorbent
articles.
[0041] The following data refers to the tests performed on "Lines
Petalo Blu" articles tested under the method described above:
1 Topsheet Strikethrough (seconds) Rewet (grams) HFF 49.0 0.93
Example 1 38.7 0.72 Example 2 13.0 0.36 Example 5 54.8 0.43 Example
6 27.8 0.27 Example 7 47.0 0.42 Example 8 32.0 0.26
[0042] The following data refers to the tests performed on
"Nuvenia" articles tested under the method described above:
2 Topsheet Strikethrough (seconds) Rewet (grams) NW >500 1.3
Example 1 143.6 1.2 Example 2 73.4 1.2 Example 3 325.3 1.1 Example
4 164.0 1.1 Example 7 91.78 0.465 Example 8 61.13 0.570
[0043] As can be seen from the above results, all of the Examples
showed improvement over the original topsheet material used in the
absorbent article.
[0044] 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. The appended claims are therefore intended to cover all
such changes and modifications that are within the scope of this
invention.
* * * * *