U.S. patent application number 15/587894 was filed with the patent office on 2017-11-09 for topsheets integrated with heterogenous mass layer.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Christopher Philip Bewick-Sonntag, Dean Larry DuVal, John Lee Hammons, Clint Adam Morrow.
Application Number | 20170319402 15/587894 |
Document ID | / |
Family ID | 58709633 |
Filed Date | 2017-11-09 |
United States Patent
Application |
20170319402 |
Kind Code |
A1 |
Morrow; Clint Adam ; et
al. |
November 9, 2017 |
TOPSHEETS INTEGRATED WITH HETEROGENOUS MASS LAYER
Abstract
An absorbent article and method of making the absorbent article
are disclosed. The absorbent article having a topsheet, a
backsheet, and an absorbent core structure having one or more
layers wherein at least one layer is a heterogeneous mass layer,
wherein the topsheet and the heterogeneous mass are integrated such
that they reside in the same X-Y plane.
Inventors: |
Morrow; Clint Adam; (Union,
KY) ; Bewick-Sonntag; Christopher Philip;
(Cincinnati, OH) ; Hammons; John Lee; (Hamilton,
OH) ; DuVal; Dean Larry; (Lebanon, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
58709633 |
Appl. No.: |
15/587894 |
Filed: |
May 5, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62332549 |
May 6, 2016 |
|
|
|
62332472 |
May 5, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F 13/15 20130101;
A61F 13/47 20130101; A61F 13/532 20130101; A61F 13/53708 20130101;
A61F 13/15699 20130101; A61F 13/15707 20130101; B29L 2031/4878
20130101; A61F 13/535 20130101; A61F 13/534 20130101; A61F
2013/15406 20130101; A61F 13/00042 20130101; A61F 13/15203
20130101; A61F 2013/530802 20130101; B29C 43/222 20130101; A61F
13/00987 20130101; B29K 2105/04 20130101; A61F 13/00038 20130101;
A61F 13/15634 20130101; B29K 2313/00 20130101; A61F 13/51104
20130101; A61F 2013/530481 20130101; A61F 2013/53721 20130101; A61F
2013/15536 20130101; B29C 59/046 20130101 |
International
Class: |
A61F 13/535 20060101
A61F013/535; A61F 13/47 20060101 A61F013/47; A61F 13/15 20060101
A61F013/15; A61F 13/15 20060101 A61F013/15 |
Claims
1. An absorbent article comprising a topsheet, a backsheet, and an
absorbent structure comprising one or more layers, wherein the
absorbent structure exhibits an average first cycle Peak Force
compression between about 30 gram force and about 1,000 gram force;
wherein the absorbent structure further exhibits an average fifth
cycle dry recovery energy between 0.1 mJ and 2.8 mJ and wherein a
portion of the topsheet is integrated into the absorbent core
structure.
2. The absorbent article of claim 1, wherein the absorbent
structure exhibits a fifth cycle wet recovery energy between 0.6
mJ/m.sup.2 and 5.0 mJ/m.sup.2.
3. The absorbent article of claim 1, wherein the absorbent
structure caliper change from Dry to Wet is between 0% and
175%.
4. The absorbent article of claim 1, wherein the absorbent
structure exhibits an increase in Peak Force during a first cycle
when measured from dry to wet.
5. The absorbent article of claim 1, wherein the absorbent
structure exhibits an average wet fifth cycle recovery energy
between 0.8 mJ/m.sup.2 and 2.8 mJ/m.sup.2.
6. The absorbent article of claim 1, wherein the absorbent
structure comprises less than 50% fibers by volume.
7. The absorbent article according to claim 1, wherein the
absorbent structure comprises a layer of absorbent polymer
material.
8. The absorbent article according to claim 7, wherein the layer of
absorbent polymer material has a basis weight of less than 250
g/m.sup.2.
9. The absorbent article of claim 1, wherein one or more layers of
the absorbent structure are substantially free of cellulose
fibers.
10. The absorbent article of claim 1, wherein the absorbent
structure comprises a heterogeneous mass.
11. The absorbent article of claim 10, wherein the heterogeneous
mass comprises at least 5% of discrete open cell foam pieces for a
fixed volume.
12. The absorbent article of claim 10, wherein the heterogeneous
mass comprises enrobeable fibers.
13. An absorbent article comprising a topsheet, a backsheet, and an
absorbent structure comprising one or more layers, wherein the
absorbent structure exhibits an average first cycle Peak Force
compression between about 30 gram force and about 1,000 gram force;
wherein the absorbent structure further exhibits an average fifth
cycle dry recovery energy between 0.1 mJ and 2.8 mJ, and wherein
the absorbent article comprises wells.
14. The absorbent article of claim 13, wherein the absorbent
structure exhibits a fifth cycle wet recovery energy between 0.6
mJ/m.sup.2 and 5.0 mJ/m.sup.2.
15. The absorbent article of claim 13, wherein the absorbent
structure caliper change from Dry to Wet is between 0% and
175%.
16. The absorbent article of claim 13, wherein the absorbent
structure exhibits an increase in Peak Force during a first cycle
when measured from dry to wet.
17. The absorbent article of claim 13, wherein the absorbent
structure exhibits an average wet fifth cycle recovery energy
between 0.8 mJ/m.sup.2 and 2.8 mJ/m.sup.2.
18. The absorbent article of claim 13, wherein the absorbent
structure comprises less than 50% fibers by volume.
19. The absorbent article according to claim 13, wherein the
absorbent structure comprises a layer of absorbent polymer
material.
20. The absorbent article according to claim 19, wherein the layer
of absorbent polymer material has a basis weight of less than 250
g/m.sup.2.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an absorbent structure
utilizing a plurality of absorbent core layers that are integrated
together in a manner that leads to beneficial physical and
performance properties. The absorbent core structure is useful in
absorbent articles such as diapers, incontinent briefs, training
pants, diaper holders and liners, sanitary hygiene garments, and
the like.
BACKGROUND OF THE INVENTION
[0002] One of the goals of an absorbent article is to absorb fluid
without being noticeable to the user or others. Ideally, an article
would be created that has the flexibility of a cloth undergarment
while being capable of absorbing fluid rapidly into the core.
However, there is often a tradeoff between comfort and rate of
absorption. Further, there is often a tradeoff between the
permeability of the absorbent article and the suction provided by
the absorbent article. In essence, as a core becomes more
permeable, it traditionally loses some of the ability to create
suction within the absorbent core.
[0003] Further, there is a tradeoff made regarding flexibility and
comfort inclusive of fit to body. For example, traditional
cellulose based thick products focuses on high initial stiffness,
recognizing that they will deform, bunch and degrade while wearing
but they nevertheless offer high bulk volume in an effort to
attempt to ensure sufficient body coverage is available throughout
pad wear. Traditional in market products often composed of airlaid
absorbent materials are thinner and more comfortable, with less
initial stiffness, but are designed to better retain their shape
and fit to body during wear by the use of binders such as
bi-component fibers and latex to attempt to reduce structural
collapse as the products are worn and loaded by the wearer.
[0004] Yet another approach for improved fit to body has been to
create specific humps and valleys, so specific 3 dimensional
topographies on a product to better macroscopically conform to the
intimate geometries. The drawback of such approaches is such
topography is `macroscopic` in dimensions compared to the scale and
complex topography present in the intimate area and at the same
time, with the wide range of anatomies and body sizes, shapes the
ability to deliver a preferred product geometry to the body is
limited.
[0005] Another historical tradeoff that is well known is the need
to provide a close to body fit in order to remove complex liquids
such as menstrual fluid closer to the source and yet preserve
sufficient panty coverage in case fluid is not captured at the
source and the panty is exposed to fluid moving on the body or in
body folds that often leads to leakage.
[0006] A variety of approaches have been leveraged to balance this
competing set of mechanical requirements. On the one end typical
approaches have included discrete absorbent elements contained in a
tube or highly fragmented, deformable and stretchable absorbent
materials able to conform to a wide variety of complex body shapes.
The main limitation of such discrete or decoupled absorbent
components is a fundamental inability to sustain a preferred
product to body shape and, or to dynamically conform back to a
preferred shape following bodily deformation. The ability to
overcome the severe bunching, product bending and buckling of these
discrete or decoupled approaches has not been demonstrated.
[0007] Another series of approaches to solve this complex
mechanical-structural set of requirements has been to design an
absorbent system with a series of preferred bending locations to
force a specific bending mode in the product or to leveraging a
small number of discrete core pieces or core cutouts to drive
specific product shapes. The fundamental challenge that limits such
approaches (including the one listed above) is three fold, first,
breaking the absorbent core into pieces, however small, breaks the
fluid continuity thereby limiting the ability to wick fluid and
reduce saturation at the loading point. Second, women's intimate
anatomy and body shapes are extremely varied and while creating
specific bending or fold lines and core segments can help create a
specific shape, there is no guarantee that this `programmed shape`
can fit such a wide range of intimate topography and body shapes.
So its effectiveness is limited. A third limitation is that in
programing specific bending or folding modes the struggle is to
sustain these programed shapes during dynamic body movements in a
way that is both comfortable and resilient.
[0008] One possible material that has improved comfort are
absorbent cores that utilize absorbent foams. However, because
absorbent products that use foam traditionally have the foam in
layers, it cannot be integrated by mechanical means with other
layers because the foam will fracture and break.
[0009] Prior fibrous topsheets require a trade-off between
capillarity, permeability, wetting, and rewet or fluid retention
properties. If you want high permeability, you can either make the
topsheet philic so that fluid passes through it fast, but then you
are left with a wet topsheet with either poor rewet values or
retention of fluid in the topsheet that the wearer (or care giver)
can be sensitive to.
[0010] Alternatively, you can use a phobic topsheet which may give
good rewet values but poor wettability or permeability. The poor
wettability or permeability can partially be overcome by using
apertures. However, with viscous liquids the apertures may still
drain poorly due to the Bond viscosity void gap, i.e., the fluid
bridges the aperture rather than draining through the aperture.
[0011] Another alternative to address skin wetness issues is a
topsheet with a higher density, thus yielding higher capillarity
pressures to better compete for complex and viscous liquids trapped
or remaining on the body. However, unless the secondary topsheet
and core layers below the topsheet have even higher capillarity,
the product cannot generate enough capillary suction to properly
drain the topsheet. Further, attempts to create a capillarity
gradient via densification of the topsheet through embossing,
channels, etc. are also problematic as the denser topsheet is
stiffer to the consumer (comfort issues) and does not drain
efficiently due to the disruption of a capillarity cascade, i.e.
each sub layer needs to have higher capillarity that the layer
above it.
[0012] As such, there exists the need to develop an absorbent
structure that can, conform to a wide range of intimate
topographies and overall body shapes and sizes, both statically and
dynamically, that is able to follow her complex body geometry
during motion and nevertheless recover to a preferred geometric
shape following motion and be ready to capture fluid closer to the
source in a sustained way. Further there remains the need to be
able to deliver this dynamic conforming shape resiliently and
comfortably all without disrupting the critical need to ensure
fluid connectivity so that the primary loading area is adequately
drained and suction at the primary or other loading area(s) is
regenerated.
SUMMARY OF THE INVENTION
[0013] An absorbent article is disclosed. The absorbent article has
a topsheet, a backsheet, and an absorbent core structure comprising
one or more layers. The absorbent structure exhibits an average
first cycle Peak Force compression between about 30 gram force and
about 1,000 gram force and an average fifth cycle dry recovery
energy between 0.1 mJ and 2.8 mJ. A portion of the topsheet is
integrated into the absorbent core structure.
[0014] An absorbent article is disclosed. The absorbent article has
a topsheet, a backsheet, and an absorbent core structure comprising
one or more layers. The absorbent structure exhibits an average
first cycle Peak Force compression between about 30 gram force and
about 1,000 gram force and an average fifth cycle dry recovery
energy between 0.1 mJ and 2.8 mJ. The absorbent article comprises
wells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] 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:
[0016] FIG. 1 is a perspective view of an apparatus for forming the
web for use in the present invention.
[0017] FIG. 2 is a cross-sectional depiction of a portion of the
apparatus shown in FIG. 1.
[0018] FIG. 3 is a perspective view of a web suitable for use in an
article.
[0019] FIG. 4 is an enlarged view of a portion of the web shown in
FIG. 3.
[0020] FIG. 5 is a perspective view of a portion of the apparatus
for forming one embodiment of a web suitable for use in an
article.
[0021] FIG. 6 is an enlarged perspective view of a portion of the
apparatus for forming a web suitable for use in an article.
[0022] FIG. 7 is an enlarged view of a portion of another
embodiment of a web suitable for use in an article.
[0023] FIG. 8 is a schematic representation of an apparatus for
making a web.
[0024] FIG. 9 is a perspective view of one example of an apparatus
for forming the nonwoven material described herein.
[0025] FIG. 10 is an enlarged perspective view of a portion of the
male roll shown in FIG. 9.
[0026] FIG. 10A is an enlarged schematic side view showing an
example of a surface texture formed by knurling a forming
member.
[0027] FIG. 10A is a schematic side view of a male element with
tapered side walls.
[0028] FIG. 10B is a schematic side view of a male element with
undercut side walls.
[0029] FIG. 10C is an enlarged perspective view of a portion of a
male roll having an alternative configuration.
[0030] FIG. 10D is a schematic side view of a male element with a
rounded top.
[0031] FIG. 10E is a magnified photograph of the top surface of a
male element that has been roughened by sandblasting.
[0032] FIG. 10F is a magnified photograph of the top surface of a
male element that has a relatively smooth surface formed by
machining the same.
[0033] FIG. 10G is a schematic side view showing an example of
macro texture and micro texture that can be created by knurling the
surface of a male or female forming member.
[0034] FIG. 11 is an enlarged perspective view showing the nip
between the rolls shown in FIG. 9.
[0035] FIG. 11A is a schematic side view of a recess in a female
forming member with a rounded top edge or rim.
[0036] FIG. 11B is a photograph of a second forming member having a
surface that has been roughened with diamond type knurling.
[0037] FIG. 12 is a perspective view of one embodiment of a
sanitary napkin.
[0038] FIG. 13 is a cross-sectional view of the sanitary napkin of
FIG. 1, taken through line 2-2.
[0039] FIG. 14 is an enlarged section of FIG. 13.
[0040] FIG. 15 is an SEM micrograph of a heterogeneous mass.
[0041] FIG. 16 is an SEM micrograph of a heterogeneous mass.
[0042] FIG. 17 shows a top view of a topsheet.
[0043] FIG. 18 shows a second top view of the topsheet of FIG.
17.
[0044] FIG. 19 shows a cross section of FIG. 18.
[0045] FIG. 20 shows a top view of a topsheet.
[0046] FIG. 21 shows a second top view of the topsheet of FIG.
20.
[0047] FIG. 22 shows a cross section of FIG. 21.
[0048] FIG. 23 zoomed in portion of the cross section of FIG.
22.
[0049] FIG. 24 shows a top view of a topsheet.
[0050] FIG. 25 shows a cross section of FIG. 24.
[0051] FIG. 26 zoomed in portion of the cross section of FIG.
25.
[0052] FIG. 27 is a top view of an alternative pattern.
[0053] FIG. 28 shows a top view of alternative patterns.
[0054] FIG. 29 shows a top view of alternative patterns.
[0055] FIG. 30 shows the apparatus for a test method.
[0056] FIG. 31A-B relate to the test method of FIG. 30.
[0057] FIG. 32A-B relate to the test method of FIG. 30.
[0058] FIG. 33 shows an apparatus for a test method.
[0059] FIG. 34 shows an apparatus for a test method.
[0060] FIG. 35 shows an apparatus for a test method.
[0061] FIG. 36a shows a plot of an NMR profile.
[0062] FIG. 36b shows a plot of an NMR profile.
[0063] FIG. 37 shows a kinetic plot of an NMR profile.
DETAILED DESCRIPTION OF THE INVENTION
[0064] As used herein, the term "absorbent core structure" refers
to an absorbent core that is has two or more absorbent core layers.
Each absorbent core layer is capable acquiring and transporting or
retaining fluid.
[0065] As used herein, the term "bicomponent 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. Bicomponent 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 bicomponent fibers and extend
continuously along the length of the bicomponent fibers. The
configuration of such a bicomponent 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.
[0066] As used herein, the term "biconstituent fibers" refers to
fibers which have been formed from at least two polymers extruded
from the same extruder as a blend. Biconstituent 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. Biconstituent fibers are sometimes also
referred to as multiconstituent fibers.
[0067] As used herein, "complex liquids" are defined as fluids that
are non-Newtonian, whose rheological properties are complex that
change with shear and commonly shear thin. Such liquids commonly
contain more than one phase (red blood cells plus vaginal mucous)
that may phase separate on contact with topsheets and absorbent
materials. In addition, complex liquids such as menstrual fluid may
contain long chain proteins exhibiting stringy properties, high
cohesive force within a droplet allowing for droplet elongation
without breaking. Complex liquids may have solids (menstrual and
runny feces).
[0068] The term "disposable" is used herein to describe articles,
which are not intended to be laundered or otherwise restored or
reused as an article (i.e. they are intended to be discarded after
a single use and possibly to be recycled, composted or otherwise
disposed of in an environmentally compatible manner). The absorbent
article comprising an absorbent structure according to the present
invention can be for example a sanitary napkin or a panty liner or
an adult incontinence article or a baby diaper or a wound dressing.
The absorbent structure of the present invention will be herein
described in the context of a typical absorbent article, such as,
for example, a sanitary napkin. Typically, such articles can
comprise a liquid pervious topsheet, a backsheet and an absorbent
core intermediate the topsheet and the backsheet.
[0069] As used herein, an "enrobeable element" refers to an element
that may be enrobed by the foam. The enrobeable element may be, for
example, a fiber, a group of fibers, a tuft, or a section of a film
between two apertures. It is understood that other elements are
contemplated by the present invention.
[0070] A "fiber" as used herein, refers to any material that can be
part of a fibrous structure. Fibers can be natural or synthetic.
Fibers can be absorbent or non-absorbent.
[0071] A "fibrous structure" as used herein, refers to materials
which can be broken into one or more fibers. A fibrous structure
can be absorbent or adsorbent. A fibrous structure can exhibit
capillary action as well as porosity and permeability.
[0072] As used herein, the term "meltblowing" refers to a process
in which fibers are formed by extruding a molten thermoplastic
material through a plurality of fine, usually circular, die
capillaries as molten threads or filaments into converging high
velocity, usually heated, gas (for example air) streams which
attenuate the filaments of molten thermoplastic material to reduce
their diameter. Thereafter, the meltblown fibers are carried by the
high velocity gas stream and are deposited on a collecting surface,
often while still tacky, to form a web of randomly dispersed
meltblown fibers.
[0073] As used herein, the term "monocomponent" fiber refers to a
fiber formed from one or more extruders using only one polymer.
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. These
additives, for example titanium dioxide for coloration, are
generally present in an amount less than about 5 weight percent and
more typically about 2 weight percent.
[0074] 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 are preferably 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).
[0075] As used herein, the term "nonwoven web" refers to a web
having a structure of individual fibers or threads which are
interlaid, but not in a repeating pattern as in a woven or knitted
fabric, which do not typically have randomly oriented fibers.
Nonwoven webs or fabrics have been formed from many processes, such
as, for example, meltblowing processes, spunbonding processes,
spunlacing processes, hydroentangling, airlaying, and bonded carded
web processes, including carded thermal bonding. The basis weight
of nonwoven fabrics is usually expressed in grams per square meter
(gsm). The basis weight of the laminate web is the combined basis
weight of the constituent layers and any other added components.
Fiber diameters are usually expressed in microns; fiber size can
also be expressed in denier, which is a unit of weight per length
of fiber. The basis weight of laminate webs suitable for use in an
article of the present invention can range from 10 gsm to 100 gsm,
depending on the ultimate use of the web.
[0076] As used herein, the term "polymer" generally includes, but
is not limited to, homopolymers, copolymers, such as for example,
block, graft, random and alternating copolymers, terpolymers, etc.,
and blends and modifications thereof. In addition, unless otherwise
specifically limited, the term "polymer" includes all possible
geometric configurations of the material. The configurations
include, but are not limited to, isotactic, atactic, syndiotactic,
and random symmetries.
[0077] As used herein, "spunbond fibers" refers to small diameter
fibers which are formed by extruding molten thermoplastic material
as filaments from a plurality of fine, usually circular capillaries
of a spinneret with the diameter of the extruded filaments then
being rapidly reduced. Spunbond fibers are generally not tacky when
they are deposited on a collecting surface. Spunbond fibers are
generally continuous and have average diameters (from a sample size
of at least 10 fibers) larger than 7 microns, and more
particularly, between about 10 and 40 microns.
[0078] As used herein, a "strata" or "stratum" relates to one or
more layers wherein the components within the stratum are
intimately combined without the necessity of an adhesive, pressure
bonds, heat welds, a combination of pressure and heat bonding,
hydro-entangling, needlepunching, ultrasonic bonding, or similar
methods of bonding known in the art such that individual components
may not be wholly separated from the stratum without affecting the
physical structure of the other components. The skilled artisan
should understand that while separate bonding is unnecessary
between the strata, bonding techniques could be employed to provide
additional integrity depending on the intended use.
[0079] As used herein, a "tuft" or chad relates to discrete
integral extensions of the fibers of a nonwoven web. Each tuft can
comprise a plurality of looped, aligned fibers extending outwardly
from the surface of the web. In another embodiment each tuft can
comprise a plurality of non-looped fibers that extend outwardly
from the surface of the web. In another embodiment, each tuft can
comprise a plurality of fibers which are integral extensions of the
fibers of two or more integrated nonwoven webs.
[0080] As used herein, a "well" or "wells" relates to one or more
funnel shaped volumetric spaces wherein a portion of a fibrous
layer has been integrated into a second fibrous layer without
creating a higher density zone. The wells may be circular or
elongated circular patterns where there is a smooth transition from
a horizontal plane to a vertical plane along the surface of the
well. Wells are further defined in that one or more fibers from the
first fibrous layer and one or more fibers from the second fibrous
layer create the outer surface of the well within the same x-y
plane. The second fibrous layer is either a fluid transfer or a
fluid storage layer. A well may exhibit variations in the density
of the side wall or the distal end, however the density of the
distal end is not greater than the average density of the original
first fibrous layer. Additionally, a well may be defined as a point
of discontinuity in the topsheet wherein one or more fibers of the
topsheet or one or more portions of the topsheet have been changed
in orientation from an X-Y plane to a Z direction plane entering an
X-Y plane of the absorbent core structure.
[0081] 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.
General Summary
[0082] An absorbent article structure is disclosed. The absorbent
article has one of a topsheet, a secondary topsheet, or both
combined with a fibrous web having a high capacity absorbent.
[0083] The fibrous web may be a heterogeneous mass comprising a
fibrous web and one or more pieces of open cell foam intermixed
within the fibrous web and/or enrobing one or more fibers within
the fibrous web.
[0084] The fibrous web may be the upper layer of an absorbent core.
The absorbent core may be a two layer system wherein the upper
layer is heterogeneous mass layer comprising one or more enrobeable
elements and one or more discrete open-cell foam pieces. The upper
layer heterogeneous mass layer may be a stratum as defined above.
The lower layer may be an absorbent layer that comprises
superabsorbent polymer. The absorbent core structure may comprise
additional layers below the absorbent layer that comprises
superabsorbent polymer. The upper layer heterogeneous mass layer
may be integrated with a topsheet using formation means.
[0085] The absorbent core structure may comprise a heterogeneous
mass layer or may utilize methods or parameters such as those
described in US Patent Publication No. 2015-0335498, filed May 19,
2015; US Patent Publication No. 2015-0374560, Jun. 25, 2015; US
Patent Publication No. 2015-0374561 filed Jun. 26, 2015; US Patent
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U.S. Provisional Patent Application No. 62/332,472 filed May 5,
2016; U.S. Provisional Patent Application No. 62/437,208 filed Dec.
21, 2016; U.S. Provisional Patent Application No. 62/437,225 filed
Dec. 21, 2016; U.S. Provisional Patent Application No. 62/437,241
filed Dec. 21, 2016; U.S. Provisional Patent Application No.
62/437,259 filed Dec. 21, 2016, or U.S. Provisional Patent
Application No. 62/500,920 filed May 3, 2017. The heterogeneous
mass layer has a depth, a width, and a height.
[0086] The absorbent core structure may comprise a substrate and
superabsorbent polymer layer as those described in U.S. Pat. No.
8,124,827 filed on Dec. 2, 2008 (Tamburro); U.S. application Ser.
No. 12/718,244 published on Sep. 9, 2010; U.S. application Ser. No.
12/754,935 published on Oct. 14, 2010; or U.S. Pat. No. 8,674,169
issued on Mar. 18, 2014.
[0087] The one or more discrete portions of foam pieces enrobe the
enrobeable elements. The discrete portions of foam pieces are
open-celled foam. In an embodiment, the foam is a High Internal
Phase Emulsion (HIPE) foam. In an embodiment, one continuous piece
of open cell foam may enrobe multiple enrobeable elements, such as,
for example, the fibers that make up the upper layer of a nonwoven
web.
[0088] In the following description of the invention, the surface
of the article, or of each component thereof, which in use faces in
the direction of the wearer is called wearer-facing surface.
Conversely, the surface facing in use in the direction of the
garment is called garment-facing surface. The absorbent article of
the present invention, as well as any element thereof, such as, for
example the absorbent core, has therefore a wearer-facing surface
and a garment-facing surface.
[0089] The heterogeneous mass layer contains one or more discrete
open-cell foam pieces foams that are integrated into the
heterogeneous mass comprising one or more enrobeable elements
integrated into the one or more open-cell foams such that the two
may be intertwined.
[0090] The open-cell foam pieces may comprise between 1% of the
heterogeneous mass by volume to 99% of the heterogeneous mass by
volume, such as, for example, 5% by volume, 10% by volume, 15% by
volume, 20% by volume, 25% by volume, 30% by volume, 35% by volume,
40% by volume, 45% by volume, 50% by volume, 55% by volume, 60% by
volume, 65% by volume, 70% by volume, 75% by volume, 80% by volume,
85% by volume, 90% by volume, or 95% by volume.
[0091] The heterogeneous mass layer may have void space found
between the enrobeable elements (e.g. fibers), between the
enrobeable elements and the enrobed enrobeable elements (e.g.
fibers enrobed by open cell foam), and between enrobed enrobeable
elements. The void space may contain gas. The void space may
represent between 1% and 95% of the total volume for a fixed amount
of volume of the heterogeneous mass, such as, for example, 5%, 10%,
15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%,
80%, 85%, 90% of the total volume for a fixed amount of volume of
the heterogeneous mass.
[0092] The combination of open-cell foam pieces and void space
within the heterogeneous mass may exhibit an absorbency of between
10 g/g to 200 g/g of the heterogeneous mass, such as for example,
40 g/g, 60 g/g, 80 g/g, 100 g/g, 120 g/g, 140 g/g 160 g/g 180 g/g
or 190 g/g of the heterogeneous mass. Absorbency may be quantified
according to the EDANA Nonwoven Absorption method 10.4-02.
[0093] The open-cell foam pieces are discrete foam pieces
intertwined within and throughout a heterogeneous mass such that
the open-cell foam enrobes one or more of the enrobeable elements
such as, for example, fibers within the mass. The open-cell foam
may be polymerized around the enrobeable elements.
[0094] In an embodiment, a discrete open-cell foam piece may enrobe
more than one enrobeable element. The enrobeable elements may be
enrobed together as a bunch. Alternatively, more than one
enrobeable element may be enrobed by the discrete open-cell foam
piece without contacting another enrobeable element.
[0095] In an embodiment, the open-cell foam pieces may enrobe an
enrobeable element such that the enrobeable element is enrobed
along the enrobeable elements axis for between 5% and 95% of the
length along the enrobeable element's axis. For example, a single
fiber may be enrobed along the length of the fiber for a distance
greater than 50% of the entire length of the fiber. In an
embodiment, an enrobeable element may have between 5% and 100% of
its surface area enrobed by one or more open-cell foam pieces.
[0096] In an embodiment, two or more open-cell foam pieces may
enrobe the same enrobeable element such that the enrobeable element
is enrobed along the enrobeable elements axis for between 5% and
100% of the length along the enrobeable element's axis.
[0097] The open-cell foam pieces enrobe the enrobeable elements
such that a layer surrounds the enrobeable element at a given cross
section. The layer surrounding the enrobeable element at a given
cross section may be between 0.01 mm to 100 mm such as, for
example, 0.1 mm, 0 2 mm, 0.3 mm, 0 4 mm, 0.5 mm, 0 6 mm, 0.7 mm,
0.8 mm, 0.9 mm, 1.0 mm, 1.2 mm, 1.4 mm, 1.6 mm, 1.8 mm, 2.0 mm, 2.2
mm, 2.4 mm, 2.6 mm, 2.8 mm, or 3 mm. The layer may not be
equivalent in dimension at all points along the cross section of
the enrobeable element. For example, in an embodiment, an
enrobeable element may be enrobed by 0.5 mm at one point along the
cross section and by 1.0 mm at a different point along the same
cross section.
[0098] The open-cell foam pieces are considered discrete in that
they are not continuous throughout the entire heterogeneous mass
layer. Not continuous throughout the entire heterogeneous mass
layer represents that at any given point in the heterogeneous mass
layer, the open-cell absorbent foam is not continuous in at least
one of the cross sections of a longitudinal, a vertical, and a
lateral plane of the heterogeneous mass layer. In a non-limiting
embodiment, the absorbent foam is not continuous in the lateral and
the vertical planes of the cross section for a given point in the
heterogeneous mass layer. In a non-limiting embodiment, the
absorbent foam is not continuous in the longitudinal and the
vertical planes of the cross section for a given point in the
heterogeneous mass layer. In a non-limiting embodiment, the
absorbent foam is not continuous in the longitudinal and the
lateral planes of the cross section for a given point in the
heterogeneous mass layer.
[0099] In an embodiment wherein the open-cell foam is not
continuous in at least one of the cross sections of the
longitudinal, the vertical, and the lateral plane of the
heterogeneous mass, one or both of either the enrobeable elements
or the open-cell foam pieces may be bi-continuous throughout the
heterogeneous mass.
[0100] The open-cell foam pieces may be located at any point in the
heterogeneous mass. In a non-limiting embodiment, a foam piece may
be surrounded by the elements that make up the enrobeable elements.
In a non-limiting embodiment a foam piece may be located on the
outer perimeter of the heterogeneous mass such that only a portion
of the foam piece is entangled with the elements of the
heterogeneous mass.
[0101] In a non-limiting embodiment, the open-cell foam pieces may
expand upon being contacted by a fluid to form a channel of
discrete open-cell foam pieces. The open-cell foam pieces may or
may not be in contact prior to being expanded by a fluid.
[0102] An open-celled foam may be integrated onto the enrobeable
elements prior to being polymerized. In a non-limiting embodiment
the open-cell foam pieces may be partially polymerized prior to
being impregnated into or onto the enrobeable elements such that
they become intertwined. After being impregnated into or onto the
enrobeable elements, the open-celled foam in either a liquid or
solid state are polymerized to form one or more open-cell foam
pieces.
[0103] The open cell foam pieces may be impregnated prior to
polymerization into or onto two or more different enrobeable
elements that are combined to create a heterogeneous mixture of
enrobeable elements. The two or more different enrobeable elements
may be intertwined such that one enrobeable element may be
surrounded by multiples of the second enrobeable element, such as,
for example by using more than one type of fiber in a mixture of
fibers or by coating one or more fibers with surfactant. The two or
more different enrobeable elements may be layered within the
heterogeneous mass along any of the vertical, longitudinal, and/or
lateral planes such that the enrobeable elements are profiled
within the heterogeneous mass for an enrobeable element inherent
property or physical property, such as, for example,
hydrophobicity, fiber diameter, fiber or composition. It is
understood that any inherent property or physical property of the
enrobeable elements listed is contemplated herein.
[0104] The open-celled foam may be polymerized using any known
method including, for example, heat, UV, and infrared. Following
the polymerization of a water in oil open-cell foam emulsion, the
resulting open-cell foam is saturated with aqueous phase that needs
to be removed to obtain a substantially dry open-cell foam. Removal
of the saturated aqueous phase or dewatering may occur using nip
rollers, and vacuum. Utilizing a nip roller may also reduce the
thickness of the heterogeneous mass such that the heterogeneous
mass will remain thin until the open-cell foam pieces entwined in
the heterogeneous mass are exposed to fluid.
[0105] Dependent upon the desired foam density, polymer
composition, specific surface area, or pore size (also referred to
as cell size), the open-celled foam may be made with different
chemical composition, physical properties, or both. For instance,
dependent upon the chemical composition, an open-celled foam may
have a density of 0.0010 g/cc to about 0.25 g/cc. Preferred 0.04
g/cc.
[0106] Open-cell foam pore sizes may range in average diameter of
from 1 to 800 .mu.m, such as, for example, between 50 and 700
.mu.m, between 100 and 600 .mu.m, between 200 and 500 .mu.m,
between 300 and 400 .mu.m.
[0107] In some embodiments, the foam pieces have a relatively
uniform cell size. For example, the average cell size on one major
surface may be about the same or vary by no greater than 10% as
compared to the opposing major surface. In other embodiments, the
average cell size of one major surface of the foam may differ from
the opposing surface. For example, in the foaming of a
thermosetting material it is not uncommon for a portion of the
cells at the bottom of the cell structure to collapse resulting in
a lower average cell size on one surface.
[0108] The foams produced from the present invention are relatively
open-celled. This refers to the individual cells or pores of the
foam being in substantially unobstructed communication with
adjoining cells. The cells in such substantially open-celled foam
structures have intercellular openings or windows that are large
enough to permit ready fluid transfer from one cell to another
within the foam structure. For purpose of the present invention, a
foam is considered "open-celled" if at least about 80% of the cells
in the foam that are at least 1 .mu.m in average diameter size are
in fluid communication with at least one adjoining cell.
[0109] In addition to being open-celled, in certain embodiments
foams are sufficiently hydrophilic to permit the foam to absorb
aqueous fluids, for example the internal surfaces of a foam may be
rendered hydrophilic by residual hydrophilizing surfactants or
salts left in the foam following polymerization, by selected
post-polymerization foam treatment procedures (as described
hereafter), or combinations of both.
[0110] In certain embodiments, for example when used in certain
absorbent articles, an open-cell foam may be flexible and exhibit
an appropriate glass transition temperature (Tg). The Tg represents
the midpoint of the transition between the glassy and rubbery
states of the polymer.
[0111] In certain embodiments, the Tg of this region will be less
than about 200.degree. C. for foams used at about ambient
temperature conditions, in certain other embodiments less than
about 90.degree. C. The Tg may be less than 50.degree. C.
[0112] The open-cell foam pieces may be distributed in any suitable
manner throughout the heterogeneous mass. In an embodiment, the
open-cell foam pieces may be profiled along the vertical axis such
that smaller pieces are located above larger pieces. Alternatively,
the pieces may be profiled such that smaller pieces are below
larger pieces. In another embodiment, the open-cell pieces may be
profiled along a vertical axis such that they alternate in size
along the axis.
[0113] In an embodiment the open-cell foam pieces may be profiled
along any one of the longitudinal, lateral, or vertical axis based
on one or more characteristics of the open-cell foam pieces.
Characteristics by which the open-cell foam pieces may be profiled
within the heterogeneous mass may include, for example, absorbency,
density, cell size, and combinations thereof.
[0114] In an embodiment, the open-cell foam pieces may be profiled
along any one of the longitudinal, lateral, or vertical axis based
on the composition of the open-cell foam. The open-cell foam pieces
may have one composition exhibiting desirable characteristics in
the front of the heterogeneous mass and a different composition in
the back of the heterogeneous mass designed to exhibit different
characteristics. The profiling of the open-cell foam pieces may be
either symmetric or asymmetric about any of the prior mentioned
axes or orientations.
[0115] The open-cell foam pieces may be distributed along the
longitudinal and lateral axis of the heterogeneous mass in any
suitable form. In an embodiment, the open-cell foam pieces may be
distributed in a manner that forms a design or shape when viewed
from a top planar view. The open-cell foam pieces may be
distributed in a manner that forms stripes, ellipticals, squares,
or any other known shape or pattern.
[0116] In an embodiment, different types of foams may be used in
one heterogeneous mass. For example, some of the foam pieces may be
polymerized HIPE while other pieces may be made from polyurethane.
The pieces may be located at specific locations within the mass
based on their properties to optimize the performance of the
heterogeneous mass.
[0117] In an embodiment, the open-celled foam is a thermoset
polymeric foam made from the polymerization of a High Internal
Phase Emulsion (HIPE), also referred to as a polyHIPE. To form a
HIPE, an aqueous phase and an oil phase are combined in a ratio
between about 8:1 and 140:1. In certain embodiments, the aqueous
phase to oil phase ratio is between about 10:1 and about 75:1, and
in certain other embodiments the aqueous phase to oil phase ratio
is between about 13:1 and about 65:1. This is termed the
"water-to-oil" or W:O ratio and can be used to determine the
density of the resulting polyHIPE foam. As discussed, the oil phase
may contain one or more of monomers, co-monomers, photo-initiators,
cross-linkers, and emulsifiers, as well as optional components. The
water phase will contain water and in certain embodiments one or
more components such as electrolyte, initiator, or optional
components.
[0118] The open-cell foam can be formed from the combined aqueous
and oil phases by subjecting these combined phases to shear
agitation in a mixing chamber or mixing zone. The combined aqueous
and oil phases are subjected to shear agitation to produce a stable
HIPE having aqueous droplets of the desired size. An initiator may
be present in the aqueous phase, or an initiator may be introduced
during the foam making process, and in certain embodiments, after
the HIPE has been formed. The emulsion making process produces a
HIPE where the aqueous phase droplets are dispersed to such an
extent that the resulting HIPE foam will have the desired
structural characteristics. Emulsification of the aqueous and oil
phase combination in the mixing zone may involve the use of a
mixing or agitation device such as an impeller, by passing the
combined aqueous and oil phases through a series of static mixers
at a rate necessary to impart the requisite shear, or combinations
of both. Once formed, the HIPE can then be withdrawn or pumped from
the mixing zone. One method for forming HIPEs using a continuous
process is described in U.S. Pat. No. 5,149,720 (DesMarais et al),
issued Sep. 22, 1992; U.S. Pat. No. 5,827,909 (DesMarais) issued
Oct. 27, 1998; and U.S. Pat. No. 6,369,121 (Catalfamo et al.)
issued Apr. 9, 2002.
[0119] The emulsion can be withdrawn or pumped from the mixing zone
and impregnated into or onto a mass prior to being fully
polymerized. Once fully polymerized, the foam pieces and the
elements are intertwined such that discrete foam pieces are
bisected by the elements comprising the mass and such that parts of
discrete foam pieces enrobe portions of one or more of the elements
comprising the heterogeneous mass.
[0120] Following polymerization, the resulting foam pieces are
saturated with aqueous phase that needs to be removed to obtain
substantially dry foam pieces. In certain embodiments, foam pieces
can be squeezed free of most of the aqueous phase by using
compression, for example by running the heterogeneous mass
comprising the foam pieces through one or more pairs of nip
rollers. The nip rollers can be positioned such that they squeeze
the aqueous phase out of the foam pieces. The nip rollers can be
porous and have a vacuum applied from the inside such that they
assist in drawing aqueous phase out of the foam pieces. In certain
embodiments, nip rollers can be positioned in pairs, such that a
first nip roller is located above a liquid permeable belt, such as
a belt having pores or composed of a mesh-like material and a
second opposing nip roller facing the first nip roller and located
below the liquid permeable belt. One of the pair, for example the
first nip roller can be pressurized while the other, for example
the second nip roller, can be evacuated, so as to both blow and
draw the aqueous phase out the of the foam. The nip rollers may
also be heated to assist in removing the aqueous phase. In certain
embodiments, nip rollers are only applied to non-rigid foams, that
is, foams whose walls would not be destroyed by compressing the
foam pieces.
[0121] In certain embodiments, in place of or in combination with
nip rollers, the aqueous phase may be removed by sending the foam
pieces through a drying zone where it is heated, exposed to a
vacuum, or a combination of heat and vacuum exposure. Heat can be
applied, for example, by running the foam though a forced air oven,
IR oven, microwave oven or radiowave oven. The extent to which a
foam is dried depends on the application. In certain embodiments,
greater than 50% of the aqueous phase is removed. In certain other
embodiments greater than 90%, and in still other embodiments
greater than 95% of the aqueous phase is removed during the drying
process.
[0122] In an embodiment, open-cell foam is produced from the
polymerization of the monomers having a continuous oil phase of a
High Internal Phase Emulsion (HIPE). The HIPE may have two phases.
One phase is a continuous oil phase having monomers that are
polymerized to form a HIPE foam and an emulsifier to help stabilize
the HIPE. The oil phase may also include one or more
photo-initiators. The monomer component may be present in an amount
of from about 80% to about 99%, and in certain embodiments from
about 85% to about 95% by weight of the oil phase. The emulsifier
component, which is soluble in the oil phase and suitable for
forming a stable water-in-oil emulsion may be present in the oil
phase in an amount of from about 1% to about 20% by weight of the
oil phase. The emulsion may be formed at an emulsification
temperature of from about 10.degree. C. to about 130.degree. C. and
in certain embodiments from about 50.degree. C. to about
100.degree. C.
[0123] In general, the monomers will include from about 20% to
about 97% by weight of the oil phase at least one substantially
water-insoluble monofunctional alkyl acrylate or alkyl
methacrylate. For example, monomers of this type may include
C.sub.4-C.sub.18 alkyl acrylates and C.sub.2-C.sub.18
methacrylates, such as ethylhexyl acrylate, butyl acrylate, hexyl
acrylate, octyl acrylate, nonyl acrylate, decyl acrylate, isodecyl
acrylate, tetradecyl acrylate, benzyl acrylate, nonyl phenyl
acrylate, hexyl methacrylate, 2-ethylhexyl methacrylate, octyl
methacrylate, nonyl methacrylate, decyl methacrylate, isodecyl
methacrylate, dodecyl methacrylate, tetradecyl methacrylate, and
octadecyl methacrylate.
[0124] The oil phase may also have from about 2% to about 40%, and
in certain embodiments from about 10% to about 30%, by weight of
the oil phase, a substantially water-insoluble, polyfunctional
crosslinking alkyl acrylate or methacrylate. This crosslinking
co-monomer, or cross-linker, is added to confer strength and
resilience to the resulting HIPE foam. Examples of crosslinking
monomers of this type may have monomers containing two or more
activated acrylate, methacrylate groups, or combinations thereof.
Nonlimiting examples of this group include
1,6-hexanedioldiacrylate, 1,4-butanedioldimethacrylate,
trimethylolpropane triacrylate, trimethylolpropane trimethacrylate,
1,12-dodecyldimethacrylate, 1,14-tetradecanedioldimethacrylate,
ethylene glycol dimethacrylate, neopentyl glycol diacrylate
(2,2-dimethylpropanediol diacrylate), hexanediol acrylate
methacrylate, glucose pentaacrylate, sorbitan pentaacrylate, and
the like. Other examples of cross-linkers contain a mixture of
acrylate and methacrylate moieties, such as ethylene glycol
acrylate-methacrylate and neopentyl glycol acrylate-methacrylate.
The ratio of methacrylate:acrylate group in the mixed cross-linker
may be varied from 50:50 to any other ratio as needed.
[0125] Any third substantially water-insoluble co-monomer may be
added to the oil phase in weight percentages of from about 0% to
about 15% by weight of the oil phase, in certain embodiments from
about 2% to about 8%, to modify properties of the HIPE foams. In
certain embodiments, "toughening" monomers may be desired which
impart toughness to the resulting HIPE foam. These include monomers
such as styrene, vinyl chloride, vinylidene chloride, isoprene, and
chloroprene. Without being bound by theory, it is believed that
such monomers aid in stabilizing the HIPE during polymerization
(also known as "curing") to provide a more homogeneous and better
formed HIPE foam which results in better toughness, tensile
strength, abrasion resistance, and the like. Monomers may also be
added to confer flame retardancy as disclosed in U.S. Pat. No.
6,160,028 (Dyer) issued Dec. 12, 2000. Monomers may be added to
confer color, for example vinyl ferrocene, fluorescent properties,
radiation resistance, opacity to radiation, for example lead
tetraacrylate, to disperse charge, to reflect incident infrared
light, to absorb radio waves, to form a wettable surface on the
HIPE foam struts, or for any other desired property in a HIPE foam.
In some cases, these additional monomers may slow the overall
process of conversion of HIPE to HIPE foam, the tradeoff being
necessary if the desired property is to be conferred. Thus, such
monomers can be used to slow down the polymerization rate of a
HIPE. Examples of monomers of this type can have styrene and vinyl
chloride.
[0126] The oil phase may further contain an emulsifier used for
stabilizing the HIPE. Emulsifiers used in a HIPE can include: (a)
sorbitan monoesters of branched C.sub.16-C.sub.24 fatty acids;
linear unsaturated C.sub.16-C.sub.22 fatty acids; and linear
saturated C.sub.12-C.sub.14 fatty acids, such as sorbitan
monooleate, sorbitan monomyristate, and sorbitan monoesters,
sorbitan monolaurate diglycerol monooleate (DGMO), polyglycerol
monoisostearate (PGMIS), and polyglycerol monomyristate (PGMM); (b)
polyglycerol monoesters of -branched C.sub.16-C.sub.24 fatty acids,
linear unsaturated C.sub.16-C.sub.22 fatty acids, or linear
saturated C.sub.12-C.sub.14 fatty acids, such as diglycerol
monooleate (for example diglycerol monoesters of C18:1 fatty
acids), diglycerol monomyristate, diglycerol monoisostearate, and
diglycerol monoesters; (c) diglycerol monoaliphatic ethers of
-branched C.sub.16-C.sub.24 alcohols, linear unsaturated
C.sub.16-C.sub.22 alcohols, and linear saturated C.sub.12-C.sub.14
alcohols, and mixtures of these emulsifiers. See U.S. Pat. No.
5,287,207 (Dyer et al.), issued Feb. 7, 1995 and U.S. Pat. No.
5,500,451 (Goldman et al.) issued Mar. 19, 1996. Another emulsifier
that may be used is polyglycerol succinate (PGS), which is formed
from an alkyl succinate, glycerol, and triglycerol.
[0127] Such emulsifiers, and combinations thereof, may be added to
the oil phase so that they can have between about 1% and about 20%,
in certain embodiments from about 2% to about 15%, and in certain
other embodiments from about 3% to about 12% by weight of the oil
phase. In certain embodiments, co-emulsifiers may also be used to
provide additional control of cell size, cell size distribution,
and emulsion stability, particularly at higher temperatures, for
example greater than about 65.degree. C. Examples of co-emulsifiers
include phosphatidyl cholines and phosphatidyl choline-containing
compositions, aliphatic betaines, long chain C.sub.12-C.sub.22
dialiphatic quaternary ammonium salts, short chain C.sub.1-C.sub.4
dialiphatic quaternary ammonium salts, long chain C.sub.12-C.sub.22
dialkoyl(alkenoyl)-2-hydroxyethyl, short chain C.sub.1-C.sub.4
dialiphatic quaternary ammonium salts, long chain C.sub.12-C.sub.22
dialiphatic imidazolinium quaternary ammonium salts, short chain
C.sub.1-C.sub.4 dialiphatic imidazolinium quaternary ammonium
salts, long chain C.sub.12-C.sub.22 monoaliphatic benzyl quaternary
ammonium salts, long chain C.sub.12-C.sub.22
dialkoyl(alkenoyl)-2-aminoethyl, short chain C.sub.1-C.sub.4
monoaliphatic benzyl quaternary ammonium salts, short chain
C.sub.1-C.sub.4 monohydroxyaliphatic quaternary ammonium salts. In
certain embodiments, ditallow dimethyl ammonium methyl sulfate
(DTDMAMS) may be used as a co-emulsifier.
[0128] The oil phase may comprise a photo-initiator at between
about 0.05% and about 10%, and in certain embodiments between about
0.2% and about 10% by weight of the oil phase. Lower amounts of
photo-initiator allow light to better penetrate the HIPE foam,
which can provide for polymerization deeper into the HIPE foam.
However, if polymerization is done in an oxygen-containing
environment, there should be enough photo-initiator to initiate the
polymerization and overcome oxygen inhibition. Photo-initiators can
respond rapidly and efficiently to a light source with the
production of radicals, cations, and other species that are capable
of initiating a polymerization reaction. The photo-initiators used
in the present invention may absorb UV light at wavelengths of
about 200 nanometers (nm) to about 800 nm, in certain embodiments
about 200 nm to about 350 nm. If the photo-initiator is in the oil
phase, suitable types of oil-soluble photo-initiators include
benzyl ketals, .alpha.-hydroxyalkyl phenones, .alpha.-amino alkyl
phenones, and acylphospine oxides. Examples of photo-initiators
include 2,4,6-[trimethylbenzoyldiphosphine] oxide in combination
with 2-hydroxy-2-methyl-1-phenylpropan-1-one (50:50 blend of the
two is sold by Ciba Speciality Chemicals, Ludwigshafen, Germany as
DAROCUR.RTM. 4265); benzyl dimethyl ketal (sold by Ciba Geigy as
IRGACURE 651); .alpha.-,.alpha.-dimethoxy-.alpha.-hydroxy
acetophenone (sold by Ciba Speciality Chemicals as DAROCUR.RTM.
1173); 2-methyl-1-[4-(methyl thio)
phenyl]-2-morpholino-propan-1-one (sold by Ciba Speciality
Chemicals as IRGACURE.RTM. 907); 1-hydroxycyclohexyl-phenyl ketone
(sold by Ciba Speciality Chemicals as IRGACURE.RTM. 184);
bis(2,4,6-trimethylbenzoyl)-phenylphosphineoxide (sold by Ciba
Speciality Chemicals as IRGACURE 819); diethoxyacetophenone, and
4-(2-hydroxyethoxy)phenyl-(2-hydroxy-2-methylpropyl) ketone (sold
by Ciba Speciality Chemicals as IRGACURE.RTM. 2959); and Oligo
[2-hydroxy-2-methyl-1-[4-(1-methylvinyl) phenyl]propanone] (sold by
Lamberti spa, Gallarate, Italy as ESACURE.RTM. KIP EM.
[0129] The dispersed aqueous phase of a HIPE can have water, and
may also have one or more components, such as initiator,
photo-initiator, or electrolyte, wherein in certain embodiments,
the one or more components are at least partially water
soluble.
[0130] One component of the aqueous phase may be a water-soluble
electrolyte. The water phase may contain from about 0.2% to about
40%, in certain embodiments from about 2% to about 20%, by weight
of the aqueous phase of a water-soluble electrolyte. The
electrolyte minimizes the tendency of monomers, co-monomers, and
cross-linkers that are primarily oil soluble to also dissolve in
the aqueous phase. Examples of electrolytes include chlorides or
sulfates of alkaline earth metals such as calcium or magnesium and
chlorides or sulfates of alkali earth metals such as sodium. Such
electrolyte can include a buffering agent for the control of pH
during the polymerization, including such inorganic counter-ions as
phosphate, borate, and carbonate, and mixtures thereof. Water
soluble monomers may also be used in the aqueous phase, examples
being acrylic acid and vinyl acetate.
[0131] Another component that may be present in the aqueous phase
is a water-soluble free-radical initiator. The initiator can be
present at up to about 20 mole percent based on the total moles of
polymerizable monomers present in the oil phase. In certain
embodiments, the initiator is present in an amount of from about
0.001 to about 10 mole percent based on the total moles of
polymerizable monomers in the oil phase. Suitable initiators
include ammonium persulfate, sodium persulfate, potassium
persulfate, 2,2'-azobis(N,N'-dimethyleneisobutyramidine)
dihydrochloride, and other suitable azo initiators. In certain
embodiments, to reduce the potential for premature polymerization
which may clog the emulsification system, addition of the initiator
to the monomer phase may be just after or near the end of
emulsification.
[0132] Photo-initiators present in the aqueous phase may be at
least partially water soluble and can have between about 0.05% and
about 10%, and in certain embodiments between about 0.2% and about
10% by weight of the aqueous phase. Lower amounts of
photo-initiator allow light to better penetrate the HIPE foam,
which can provide for polymerization deeper into the HIPE foam.
However, if polymerization is done in an oxygen-containing
environment, there should be enough photo-initiator to initiate the
polymerization and overcome oxygen inhibition. Photo-initiators can
respond rapidly and efficiently to a light source with the
production of radicals, cations, and other species that are capable
of initiating a polymerization reaction. The photo-initiators used
in the present invention may absorb UV light at wavelengths of from
about 200 nanometers (nm) to about 800 nm, in certain embodiments
from about 200 nm to about 350 nm, and in certain embodiments from
about 350 nm to about 450 nm. If the photo-initiator is in the
aqueous phase, suitable types of water-soluble photo-initiators
include benzophenones, benzils, and thioxanthones. Examples of
photo-initiators include
2,2'-Azobis[2-(2-imidazolin-2-yl)propane]dihydrochloride;
2,2'-Azobis[2-(2-imidazolin-2-yl)propane]disulfate dehydrate;
2,2'-Azobis(1-imino-1-pyrrolidino-2-ethylpropane) dihydrochloride;
2,2'-Azobis[2-methyl-N-(2-hydroxyethyl)propionamide];
2,2'-Azobis(2-methylpropionamidine) dihydrochloride;
2,2'-dicarboxymethoxydibenzalacetone,
4,4'-dicarboxymethoxydibenzalacetone,
4,4'-dicarboxymethoxydibenzalcyclohexanone,4-dimethylamino-4'-carboxymeth-
oxydibenzalacetone; and 4,4'-disulphoxymethoxydibenzalacetone.
Other suitable photo-initiators that can be used in the present
invention are listed in U.S. Pat. No. 4,824,765 (Sperry et al.)
issued Apr. 25, 1989.
[0133] In addition to the previously described components other
components may be included in either the aqueous or oil phase of a
HIPE. Examples include antioxidants, for example hindered
phenolics, hindered amine light stabilizers; plasticizers, for
example dioctyl phthalate, dinonyl sebacate; flame retardants, for
example halogenated hydrocarbons, phosphates, borates, inorganic
salts such as antimony trioxide or ammonium phosphate or magnesium
hydroxide; dyes and pigments; fluorescers; filler pieces, for
example starch, titanium dioxide, carbon black, or calcium
carbonate; fibers; chain transfer agents; odor absorbers, for
example activated carbon particulates; dissolved polymers;
dissolved oligomers; and the like.
[0134] The heterogeneous mass comprises enrobeable elements and
discrete pieces of foam. The enrobeable elements may be a web or a
portion of a web such as, for example, nonwoven, a fibrous
structure, an air-laid web, a wet laid web, a high loft nonwoven, a
needlepunched web, a hydroentangled web, a fiber tow, a woven web,
a knitted web, a flocked web, a spunbond web, a layered
spunbond/melt blown web, a carded fiber web, a coform web of
cellulose fiber and melt blown fibers, a coform web of staple
fibers and melt blown fibers, and layered webs that are layered
combinations thereof.
[0135] The enrobeable elements may be, for example, conventional
absorbent materials such as creped cellulose wadding, fluffed
cellulose fibers, wood pulp fibers also known as airfelt, and
textile fibers. The enrobeable elements may also be fibers such as,
for example, synthetic fibers, thermoplastic particulates or
fibers, tricomponent fibers, and bicomponent fibers such as, for
example, sheath/core fibers having the following polymer
combinations: polyethylene/polypropylene, polyethylvinyl
acetate/polypropylene, polyethylene/polyester,
polypropylene/polyester, copolyester/polyester, and the like. The
enrobeable elements may be any combination of the materials listed
above and/or a plurality of the materials listed above, alone or in
combination.
[0136] The enrobeable elements may be hydrophobic or hydrophilic.
In an embodiment, the enrobeable elements may be treated to be made
hydrophobic. In an embodiment, the enrobeable elements may be
treated to become hydrophilic.
[0137] The constituent fibers of the heterogeneous mass can be
comprised of polymers such as polyethylene, polypropylene,
polyester, and blends thereof. The fibers can be spunbond fibers.
The fibers can be meltblown fibers. The fibers can comprise
cellulose, rayon, cotton, or other natural materials or blends of
polymer and natural materials. The fibers can also comprise a super
absorbent material such as polyacrylate or any combination of
suitable materials. The fibers can be monocomponent, bicomponent,
and/or biconstituent, 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 >20 denier), shape (i.e. capillary and round)
and the like. The constituent fibers can range from about 0.1
denier to about 100 denier.
[0138] The heterogeneous mass can be comprised of more than one
nonwoven precursor web. For example, the high internal phase
emulsion is applied to the top surface of the first nonwoven web by
means of an extrusion die in a horizontal configuration. A second
nonwoven web can be applied to the top surface of the previously
extruded high internal phase emulsion while in a horizontal
configuration prior to the onset of solidification of the HIPE into
a HIPE foam.
[0139] The above described structure creates a two nonwoven
structure with HIPE foam in between the nonwovens and enrobed
elements at the interface of HIPE foam and nonwoven, e.g. an
absorbent stratum that is a heterogeneous mass comprising a first
nonwoven having a first surface and a second surface and a second
nonwoven. An open cell foam piece enrobes a portion of the first
nonwoven and a portion of the second nonwoven. Alternatively, the
second precursor web may be glued to the stratum heterogeneous mass
after polymerization of the stratum.
[0140] It has been surprisingly found that by creating a
heterogenous mass layer comprising open cell foam wherein at least
a portion of one or more open cell foam pieces is in contact with a
substrate or layer of enrobeable elements such as nonwoven fibers
at both the top and bottom surface of the piece along a vertical
axis allows for the heterogeneous mass to be submitted through a
formation means while maintaining the fluid connectivity of the
heterogeneous mass layer and without leaving a meaningful buildup
or residue on the formation means.
[0141] In one aspect, known absorbent web materials in an as-made
state can be considered as being homogeneous throughout. Being
homogeneous, the fluid handling properties of the absorbent web
material are not location dependent, but are substantially uniform
at any area of the web. Homogeneity can be characterized by
density, basis weight, for example, such that the density or basis
weight of any particular part of the web is substantially the same
as an average density or basis weight for the web. By the apparatus
and method of the present invention, homogeneous fibrous absorbent
web materials are modified such that they are no longer
homogeneous, but are heterogeneous, such that the fluid handling
and or mechanical properties of the web material are location
dependent. Therefore, for the heterogeneous absorbent materials of
the present invention, at discrete locations the density or basis
weight of the web may be substantially different than the average
density or basis weight for the web. The heterogeneous nature of
the absorbent web of the present invention permits the negative
aspects of either of permeability or capillarity to be minimized by
rendering discrete portions highly permeable and other discrete
portions to have high capillarity. Likewise, the tradeoff between
permeability and capillarity is managed such that delivering
relatively higher permeability can be accomplished without a
decrease in capillarity. Likewise the heterogeneous nature of the
absorbent web may also enable discrete bending, compression or
stretch zones within the web.
[0142] In an embodiment, the heterogeneous mass may also include
superabsorbent material that imbibe fluids and form hydrogels.
These materials are typically capable of absorbing large quantities
of body fluids and retaining them under moderate pressures and can
be in either a fibrous, particulate or other physical form. The
heterogeneous mass can include such materials dispersed in a
suitable carrier such as cellulose fibers in the form of fluff or
stiffened fibers or integrated within an AGM containing
laminate.
[0143] The heterogeneous mass may include one or more types of
fibers. Fibers included in the fibrous web may be thermoplastic
particulates or fibers. The materials, and in particular
thermoplastic fibers, can be made from a variety of thermoplastic
polymers including polyolefins such as polyethylene (e.g.,
PULPEX.RTM.) and polypropylene, polyesters, copolyesters, and
copolymers of any of the foregoing.
[0144] Depending upon the desired characteristics, suitable
thermoplastic materials include hydrophobic fibers that have been
made hydrophilic, such as surfactant-treated or silica-treated
thermoplastic fibers derived from, for example, polyolefins such as
polyethylene or polypropylene, polyacrylics, polyamides,
polystyrenes, and the like. The surface of the hydrophobic
thermoplastic fiber can be rendered hydrophilic by treatment with a
surfactant, such as a nonionic or anionic surfactant, e.g., by
spraying the fiber with a surfactant, by dipping the fiber into a
surfactant or by including the surfactant as part of the polymer
melt in producing the thermoplastic fiber. Upon melting and
resolidification, the surfactant will tend to remain at the
surfaces of the thermoplastic fiber. Suitable surfactants include
nonionic surfactants such as Brij 76 manufactured by ICI Americas,
Inc. of Wilmington, Del., and various surfactants sold under the
Pegosperse.RTM. trademark by Glyco Chemical, Inc. of Greenwich,
Conn. Besides nonionic surfactants, anionic surfactants can also be
used. These surfactants can be applied to the thermoplastic fibers
at levels of, for example, from about 0.2 to about 1 g. per sq. of
centimeter of thermoplastic fiber.
[0145] Suitable thermoplastic fibers can be made from a single
polymer (monocomponent fibers), or can be made from more than one
polymer (e.g., bicomponent fibers). The polymer comprising the
sheath often melts at a different, typically lower, temperature
than the polymer comprising the core. As a result, these
bicomponent fibers provide thermal bonding due to melting of the
sheath polymer, while retaining the desirable strength
characteristics of the core polymer.
[0146] Suitable bicomponent fibers for use in the present invention
can include sheath/core fibers having the following polymer
combinations: polyethylene/polypropylene, polyethylvinyl
acetate/polypropylene, polyethylene/polyester,
polypropylene/polyester, copolyester/polyester, and the like.
Particularly suitable bicomponent thermoplastic fibers for use
herein are those having a polypropylene or polyester core, and a
lower melting copolyester, polyethylvinyl acetate or polyethylene
sheath (e.g., DANAKLON.RTM., CELBOND.RTM. or CHISSO.RTM.
bicomponent fibers). These bicomponent fibers can be concentric or
eccentric. As used herein, the terms "concentric" and "eccentric"
refer to whether the sheath has a thickness that is even, or
uneven, through the cross-sectional area of the bicomponent fiber.
Eccentric bicomponent fibers can be desirable in providing more
compressive strength at lower fiber thicknesses. Suitable
bicomponent fibers for use herein can be either uncrimped (i.e.
unbent) or crimped (i.e. bent). Bicomponent fibers can be crimped
by typical textile means such as, for example, a stuffer box method
or the gear crimp method to achieve a predominantly two-dimensional
or "flat" crimp.
[0147] The length of bicomponent fibers can vary depending upon the
particular properties desired for the fibers and the web formation
process. Typically, in an airlaid web, these thermoplastic fibers
have a length from about 2 mm to about 12 mm long, preferably from
about 2.5 mm to about 7.5 mm long, and most preferably from about
3.0 mm to about 6.0 mm long. The properties-of these thermoplastic
fibers can also be adjusted by varying the diameter (caliper) of
the fibers. The diameter of these thermoplastic fibers is typically
defined in terms of either denier (grams per 9000 meters) or
decitex (grams per 10,000 meters). Suitable bicomponent
thermoplastic fibers as used in an airlaid making machine can have
a decitex in the range from about 1.0 to about 20, preferably from
about 1.4 to about 10, and most preferably from about 1.7 to about
7 decitex.
[0148] The compressive modulus of these thermoplastic materials,
and especially that of the thermoplastic fibers, can also be
important. The compressive modulus of thermoplastic fibers is
affected not only by their length and diameter, but also by the
composition and properties of the polymer or polymers from which
they are made, the shape and configuration of the fibers (e.g.,
concentric or eccentric, crimped or uncrimped), and like factors.
Differences in the compressive modulus of these thermoplastic
fibers can be used to alter the properties, and especially the
density characteristics, of the respective thermally bonded fibrous
matrix.
[0149] The heterogeneous mass can also include synthetic fibers
that typically do not function as binder fibers but alter the
mechanical properties of the fibrous webs. Synthetic fibers include
cellulose acetate, polyvinyl fluoride, polyvinylidene chloride,
acrylics (such as Orlon), polyvinyl acetate, non-soluble polyvinyl
alcohol, polyethylene, polypropylene, polyamides (such as nylon),
polyesters, bicomponent fibers, tricomponent fibers, mixtures
thereof and the like. These might include, for example, polyester
fibers such as polyethylene terephthalate (e.g., DACRON.RTM. and
KODEL.RTM.), high melting crimped polyester fibers (e.g.,
KODEL.RTM. 431 made by Eastman Chemical Co.) hydrophilic nylon
(HYDROFIL.RTM.), and the like. Suitable fibers can also
hydrophilized hydrophobic fibers, such as surfactant-treated or
silica-treated thermoplastic fibers derived from, for example,
polyolefins such as polyethylene or polypropylene, polyacrylics,
polyamides, polystyrenes, polyurethanes and the like. In the case
of nonbonding thermoplastic fibers, their length can vary depending
upon the particular properties desired for these fibers. Typically
they have a length from about 0.3 to 7.5 cm, preferably from about
0.9 to about 1.5 cm. Suitable nonbonding thermoplastic fibers can
have a decitex in the range of about 1.5 to about 35 decitex, more
preferably from about 14 to about 20 decitex.
[0150] However structured, the total absorbent capacity of the
absorbent core should be compatible with the design loading and the
intended use of the mass. For example, when used in an absorbent
article, the size and absorbent capacity of the heterogeneous mass
may be varied to accommodate different uses such as incontinence
pads, pantiliners, regular sanitary napkins, or overnight sanitary
napkins.
[0151] The heterogeneous mass can also include other optional
components sometimes used in absorbent webs. For example, a
reinforcing scrim can be positioned within the respective layers,
or between the respective layers, of the heterogeneous mass.
[0152] The heterogeneous mass comprising open-cell foam pieces
produced from the present invention may be used as an absorbent
core or a portion of an absorbent core in absorbent articles, such
as feminine hygiene articles, for example pads, pantiliners, and
tampons; wound dressing; disposable diapers; incontinence articles,
for example pads, adult diapers; homecare articles, for example
wipes, pads, towels; and beauty care articles, for example pads,
wipes, and skin care articles, such as used for pore cleaning. The
absorbent structure having a topsheet and/or a secondary topsheet
integrated into a heterogeneous mass layer having open-cell foam
pieces may be used in absorbent articles such as feminine hygiene
articles, for example pads, pantiliners, and tampons; wound
dressings; disposable diapers; incontinence articles, for example
pads, adult diapers; homecare articles, for example wipes, pads,
towels; and beauty care articles, for example pads, wipes, and skin
care articles, such as used for pore cleaning. A diaper may be an
absorbent article as disclosed in U.S. patent application Ser. No.
13/428,404, filed on Mar. 23, 2012.
[0153] The absorbent core structure may be used as an absorbent
core for an absorbent article. In such an embodiment, the absorbent
core can be relatively thin, less than about 5 mm in thickness, or
less than about 3 mm, or less than about 1 mm in thickness. Cores
having a thickness of greater than 5 mm are also contemplated
herein. Thickness can be determined by measuring the thickness at
the midpoint along the longitudinal centerline of the pad by any
means known in the art for doing while under a uniform pressure of
0.25 psi. The absorbent core can comprise absorbent gelling
materials (AGM), including AGM fibers, blood gelling agents (e.g.
chitosan), quaternary salts or combinations thereof as is known in
the art.
[0154] The heterogeneous mass layer may be formed or cut to a
shape, the outer edges of which define a periphery.
[0155] In an embodiment, the heterogeneous mass may be used as a
topsheet for an absorbent article. The heterogeneous mass may be
combined with an absorbent core or may only be combined with a
backsheet.
[0156] In an embodiment, the heterogeneous mass may be combined
with any other type of absorbent layer or non-absorbent layer such
as, for example, a layer of cellulose, a layer comprising
superabsorbent gelling materials, a layer of absorbent airlaid
fibers, a nonwoven layer, or a layer of absorbent foam, or
combinations thereof. Other absorbent layers not listed are
contemplated herein.
[0157] In an embodiment, the open-cell foam pieces are in the form
of stripes. The stripes may be formed during the formation of the
heterogeneous mass or by formation means after polymerization. The
stripes may run along the longitudinal length of the heterogeneous
mass layer, along the lateral length of the heterogeneous mass
layer, or a combination of both the longitudinal length and the
lateral length. The stripes may run along a diagonal to either the
longitudinal length or the lateral length of the heterogeneous mass
layer. The stripes are separated by canals.
[0158] Formation means known for deforming a generally planar
fibrous web into a three-dimensional structure are utilized in the
present invention to modify as-made absorbent materials into
absorbent materials having relatively higher permeability without a
significant corresponding decrease in capillary pressure. Using
formation means, one may create an absorbent structure by providing
a first fibrous web material, wherein the first fibrous web
material is a heterogeneous mass comprising one or more open cell
foam pieces; providing a second fibrous web material; providing a
pair of rolls forming a nip through which said first fibrous web
material and second fibrous web material can be processed, said
pair of rolls being selected from the processes consisting of ring
rolling, SELF, micro-SELF, nested SELF, rotary knife aperturing,
hot pin, 3D embossing, SAN, and embossed stabilized formation; and
deforming both the first fibrous web material and the second
fibrous web. The second fibrous web may be absorbent.
[0159] Formation means may comprise a pair of inter-meshing rolls,
typically steel rolls having inter-engaging ridges or teeth and
grooves. However, it is contemplated that other means for achieving
formation can be utilized, such as the deforming roller and cord
arrangement disclosed in US 2005/0140057 published Jun. 30, 2005.
Therefore, all disclosure of a pair of rolls herein is considered
equivalent to a roll and cord, and a claimed arrangement reciting
two inter-meshing rolls is considered equivalent to an
inter-meshing roll and cord where a cord functions as the ridges of
a mating inter-engaging roll. In one embodiment, the pair of
intermeshing rolls of the instant invention can be considered as
equivalent to a roll and an inter-meshing element, wherein the
inter-meshing element can be another roll, a cord, a plurality of
cords, a belt, a pliable web, or straps. Likewise, other known
formation technologies, such as creping, necking/consolidation,
corrugating, embossing, button break, hot pin punching, and the
like are believed to be able to produce absorbent materials having
some degree of relatively higher permeability without a significant
corresponding decrease in capillary pressure. Formation means
utilizing rolls include "ring rolling", a "SELF" or "SELF'ing"
process, in which SELF stands for Structural Elastic Like Film, as
"micro-SELF", and "rotary knife aperturing" (RKA); as described in
U.S. Pat. No. 7,935,207 Zhao et al., granted May 3, 2011. The
formation means may be one of the formation means described in U.S.
Pat. No. 7,682,686 (Curro et al.) granted on Mar. 23, 2010 or U.S.
Pat. No. 7,648,752 (Hoying et al.) granted on Jan. 19, 2010.
Suitable processes for constructing tufts are described 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. Formation means may also include Nested
"SELF" as described below and in U.S. patent application Ser. No.
14/844,459 filed on Sep. 3, 2015. Formation means may also include
hot pin, Selective Aperturing a Nonwoven (SAN) described in U.S.
Pat. No. 5,628,097, 3D embossing and embossed stabilized formation
as described in U.S. Patent Application No. 62/458,051 filed Feb.
13, 2017.
[0160] Referring to FIG. 1 there is shown in an apparatus and
method for making web 1. The apparatus 100 comprises a pair of
intermeshing rolls 174 and 176, each rotating about an axis A, the
axes A being parallel in the same plane. Roll 174 comprises a
plurality of ridges 172 and corresponding grooves 108 which extend
unbroken about the entire circumference of roll 174. Roll 176 is
similar to roll 174, but rather than having ridges that extend
unbroken about the entire circumference, roll 176 comprises a
plurality of rows of circumferentially-extending ridges that have
been modified to be rows of circumferentially-spaced teeth 110 that
extend in spaced relationship about at least a portion of roll 176.
The individual rows of teeth 110 of roll 176 are separated by
corresponding grooves 112. In operation, rolls 174 and 176
intermesh such that the ridges 172 of roll 174 extend into the
grooves 112 of roll 176 and the teeth 110 of roll 176 extend into
the grooves 108 of roll 174. The intermeshing is shown in greater
detail in the cross sectional representation of FIG. 2, discussed
below. Both or either of rolls 174 and 176 can be heated by means
known in the art such as by using hot oil filled rollers or
electrically-heated rollers.
[0161] In FIG. 1, the apparatus 100 is shown in a preferred
configuration having one patterned roll, e.g., roll 176, and one
non-patterned grooved roll 174. However, in certain embodiments it
may be preferable to use two patterned rolls 176 having either the
same or differing patterns, in the same or different corresponding
regions of the respective rolls. Such an apparatus can produce webs
with tufts 6 protruding from both sides of the web 1.
[0162] The method of making a web 1 in a commercially viable
continuous process is depicted in FIG. 1. Web 1 is made by
mechanically deforming precursor webs, such as first and second
precursor webs, 180 and 21 that can each be described as generally
planar and two dimensional prior to processing by the apparatus
shown in FIG. 1. By "planar" and "two dimensional" is meant simply
that the webs start the process in a generally flat condition
relative to the finished web 1 that has distinct, out-of-plane,
Z-direction three-dimensionality due to the formation of tufts 6.
"Planar" and "two-dimensional" are not meant to imply any
particular flatness, smoothness or dimensionality.
[0163] The process and apparatus of the present invention is
similar in many respects to a process described in U.S. Pat. No.
5,518,801 entitled "Web Materials Exhibiting Elastic-Like Behavior"
and referred to in subsequent patent literature as "SELF" webs,
which stands for "Structural Elastic-like Film". However, there are
significant differences between the apparatus and process of the
present invention and the apparatus and process disclosed in the
'801 patent, and the differences are apparent in the respective
webs produced thereby. As described below, the teeth 110 of roll
176 have a specific geometry associated with the leading and
trailing edges that permit the teeth to essentially "punch" through
the precursor webs 180, 21 as opposed to, in essence, deforming the
web. In a two layer laminate web 1 the teeth 110 urge fibers from
precursor webs 180 and 21 out-of-plane by the teeth 110 pushing the
fibers 8 through to form tufts 6. Therefore, a web 1 can have tufts
6 comprising loose fiber ends 18 and/or "tunnel-like" tufts 6 of
looped, aligned fibers 8 extending away from the surface 13 of side
3, unlike the "tent-like" rib-like elements of SELF webs which each
have continuous side walls associated therewith, i.e., a continuous
"transition zone," and which do not exhibit interpenetration of one
layer through another layer.
[0164] Precursor webs 180 and 21 are provided either directly from
their respective web making processes or indirectly from supply
rolls (neither shown) and moved in the machine direction to the nip
116 of counter-rotating intermeshing rolls 174 and 176. The
precursor webs are preferably held in a sufficient web tension so
as to enter the nip 16 in a generally flattened condition by means
well known in the art of web handling. As each precursor web 180,
21 goes through the nip 116 the teeth 110 of roll 176 which are
intermeshed with grooves 108 of roll 174 simultaneously urge
portions of precursor webs 180 and 21 out of the plane to form
tufts 6. In one embodiment, teeth 110 in effect "push" or "punch"
fibers of first precursor web 180 through second precursor web 21.
In another embodiment teeth 110 in effect "push" or "punch" fibers
of both first and second precursor webs 180 and 21 out of plane to
form tufts 6.
[0165] As the tip of teeth 110 push through first and second
precursor webs 180, 21 the portions of the fibers of first
precursor web 180 (and, in some embodiments, second precursor web
21) that are oriented predominantly in the CD across teeth 110 are
urged by the teeth 110 out of the plane of first precursor web 180.
Fibers can be urged out of plane due to fiber mobility, or they can
be urged out of plane by being stretched and/or plastically
deformed in the Z-direction. Portions of the precursor webs urged
out of plane by teeth 110 results in formation of tufts 6 on first
side 3 of web 1. Fibers of precursor webs 180 and 21 that are
predominantly oriented generally parallel to the longitudinal axis
L, i.e., in the MD as shown in FIG. 3, are simply spread apart by
teeth 110 and remain substantially in their original,
randomly-oriented condition. This is why the looped fibers 8 can
exhibit the unique fiber orientation in embodiments such as the one
shown in FIGS. 3-4, which is a high percentage of fibers of each
tuft 6 having a significant or major vector component parallel to
the transverse axis T of tuft 6.
[0166] It can be appreciated by the forgoing description that when
web 1 is made by the apparatus and method of the present invention
that the precursor webs 180, 21 can possess differing material
properties with respect to the ability of the precursor webs to
elongate before failure, e.g., failure due to tensile stresses. In
one embodiment, a nonwoven first precursor web 180 can have greater
fiber mobility and/or greater fiber elongation characteristics
relative to second precursor web 21, such that the fibers thereof
can move or stretch sufficiently to form tufts 6 while the second
precursor web 21 ruptures, i.e., does not stretch to the extent
necessary to form tufts. In another embodiment, second precursor
web 21 can have greater fiber mobility and/or greater fiber
elongation characteristics relative to first precursor web 180,
such that both first and second precursor webs 180 and 21 form
tufts 6. In another embodiment, second precursor web 21 can have
greater fiber mobility and/or greater fiber elongation
characteristics relative to first precursor web 180, such that the
fibers of second precursor web 21 can move or stretch sufficiently
to form tufts 6 while the first precursor web 180 ruptures, i.e.,
does not stretch to the extent necessary to form tufts.
[0167] The degree to which the fibers of nonwoven precursor webs
are able to extend out of plane without plastic deformation can
depend upon the degree of inter-fiber bonding of the precursor web.
For example, if the fibers of a nonwoven precursor web are only
very loosely entangled to each other, they will be more able to
slip by each other (i.e., to move relative to adjacent fibers by
reptation) and therefore be more easily extended out of plane to
form tufts. On the other hand, fibers of a nonwoven precursor web
that are more strongly bonded, for example by high levels of
thermal point bonding, hydroentanglement, or the like, will more
likely require greater degrees of plastic deformation in extended
out-of-plane tufts. Therefore, in one embodiment, one precursor web
180 or 21 can be a nonwoven web having relatively low inter-fiber
bonding, and the other precursor web 180 or 21 can be a nonwoven
web having relatively high inter-fiber bonding, such that the
fibers of one precursor web can extend out of plane, while the
fibers of the other precursor web cannot.
[0168] In one embodiment, for a given maximum strain (e.g., the
strain imposed by teeth 110 of apparatus 100), it is beneficial
that second precursor web 21 actually fail under the tensile
loading produced by the imposed strain. That is, for the tufts 6
comprising only, or primarily, fibers from first precursor web 180
to be disposed on the first side 3 of web 1, second precursor web
21 must have sufficiently low fiber mobility (if any) and/or
relatively low elongation-to-break such that it locally (i.e., in
the area of strain) fails in tension, thereby producing openings 4
through which tufts 6 can extend.
[0169] In another embodiment it is beneficial that second precursor
web 21 deform or stretch in the region of induced strain, and does
not fail, such that tuft 6 includes portions of second precursor
web 21.
[0170] In one embodiment second precursor web 21 has an elongation
to break in the range of 1%-5%. While the actual required
elongation to break depends on the strain to be induced to form
web. 1, it is recognized that for most embodiments, second
precursor web 21 can exhibit a web elongation-to-break of 6%, 7%,
8%, 9%, 10%, or more. It is also recognized that actual
elongation-to-break can depend on the strain rate, which, for the
apparatus shown in FIG. 1 is a function of line speed. Elongation
to break of webs used in the present invention can be measured by
means known in the art, such as by standard tensile testing methods
using standard tensile testing apparatuses, such as those
manufactured by Instron, MTS, Thwing-Albert, and the like.
[0171] Relative to first precursor web 180, second precursor web 21
can have lower fiber mobility (if any) and/or lower
elongation-to-break (i.e., elongation-to-break of individual
fibers, or, if a film, elongation-to-break of the film) such that,
rather than extending out-of-plane to the extent of the tufts 6,
second precursor web 21 fails in tension under the strain produced
by the formation of tufts 6, e.g., by the teeth 110 of apparatus
100. In one embodiment, second precursor web 21 exhibits
sufficiently low elongation-to-break relative to first precursor
web 180 such that flaps 7 of opening 4 only extend slightly
out-of-plane, if at all, relative to tufts 6. In general, for
embodiments in which tufts 6 comprise primarily fibers from first
precursor web 180, it is believed that second precursor web 21
should have an elongation to break of at least 10% less than the
first precursor web 180, preferably at least 30% less, more
preferably at least 50% less, and even more preferably at least
about 100% less than that of first precursor web 180. Relative
elongation to break values of webs used in the present invention
can be measured by means known in the art, such as by standard
tensile testing methods using standard tensile testing apparatuses,
such as those manufactured by Instron, MTS, Thwing-Albert, and the
like.
[0172] In one embodiment second precursor web 21 can comprise
substantially all MD-oriented fibers, e.g., tow fibers, such that
there are substantially no fibers oriented in the CD. For such an
embodiment of web 1 the fibers of second precursor web 21 can
simply separate at the opening 4 through which tufts 6 extend. In
this embodiment, therefore, second precursor web 21 need not have
any minimum elongation to break, since failure or rupture of the
material is not the mode of forming opening 4.
[0173] The number, spacing, and size of tufts 6 can be varied by
changing the number, spacing, and size of teeth 110 and making
corresponding dimensional changes as necessary to roll 176 and/or
roll 174. This variation, together with the variation possible in
precursor webs 180, 21 permits many varied webs 1 having varied
fluid handling properties for use in a disposable absorbent
article. As described more fully below, a web 1 comprising a
nonwoven/film first precursor web/second precursor web combination
can also be used as a component in disposable absorbent articles.
However, even better results are obtained in a nonwoven/nonwoven
precursor web/second precursor web combination wherein fibers from
both webs contribute to tufts 6.
[0174] FIG. 2 shows in cross section a portion of the intermeshing
rolls 174 and 176 and ridges 172 and teeth 110. As shown teeth 110
have a tooth height TH (note that TH can also be applied to ridge
height; in a preferred embodiment tooth height and ridge height are
equal), and a tooth-to-tooth spacing (or ridge-to-ridge spacing)
referred to as the pitch P. As shown, depth of engagement E is a
measure of the level of intermeshing of rolls 174 and 176 and is
measured from tip of ridge 172 to tip of tooth 110. The depth of
engagement E, tooth height TH, and pitch P can be varied as desired
depending on the properties of precursor webs 180, 21 and the
desired characteristics of web 1. For example, in general, the
greater the level of engagement E, the greater the necessary
elongation or fiber-to-fiber mobility characteristics the fibers of
portions of the precursor webs intended to form tufts must possess.
Also, the greater the density of tufts 6 desired (tufts 6 per unit
area of web 1), the smaller the pitch should be, and the smaller
the tooth length TL and tooth distance TD should be, as described
below.
[0175] FIG. 5 shows one embodiment of a roll 176 having a plurality
of teeth 110 useful for making a web 1 from a nonwoven first
precursor web 180 having a basis weight of between about 60 gsm and
100 gsm, preferably about 80 gsm and a polyolefinic film (e.g.,
polyethylene or polypropylene) second precursor web 21 having a
density of about 0.91-0.94 and a basis weight of about 180 gsm.
[0176] An enlarged view of teeth 110 is shown in FIG. 6. In this
embodiment of roll 176 teeth 110 have a uniform circumferential
length dimension TL measured generally from the leading edge LE to
the trailing edge TE at the tooth tip 111 of about 1.25 mm and are
uniformly spaced from one another circumferentially by a distance
TD of about 1.5 mm For making a terry-cloth web 1 from web 1 having
a total basis weight in the range of about 60 to about 100 gsm,
teeth 110 of roll 176 can have a length TL ranging from about 0.5
mm to about 10 mm and a spacing TD from about 0.5 mm to about 10
mm, a tooth height TH ranging from about 0.5 mm to about 10 mm, and
a pitch P between about 1 mm (0.040 inches) and about 5 mm (0.1800
inches). Depth of engagement E can be from about 0.5 mm to about 10
mm (up to a maximum equal to tooth height TH). Of course, E, P, TH,
TD and TL can be varied independently of each other to achieve a
desired size, spacing, and area density of tufts 6 (number of tufts
6 per unit area of web 1).
[0177] As shown in FIG. 6, each tooth 110 has a tip 111, a leading
edge LE and a trailing edge TE. The tooth tip 111 is elongated and
has a generally longitudinal orientation, corresponding to the
longitudinal axes L of tufts 6 and discontinuities 16. It is
believed that to get the tufted, looped tufts 6 of the web 1 that
can be described as being terry cloth-like, the LE and TE should be
very nearly orthogonal to the local peripheral surface 1180 of roll
176. As well, the transition from the tip 111 and LE or TE should
be a sharp angle, such as a right angle, having a sufficiently
small radius of curvature such that teeth 110 push through second
precursor web 21 at the LE and TE. Without being bound by theory,
it is believed that having relatively sharply angled tip
transitions between the tip of tooth 110 and the LE and TE permits
the teeth 110 to punch through precursor webs 180, 21 "cleanly",
that is, locally and distinctly, so that the first side 3 of the
resulting web 1 can be described as "tufted" rather than
"deformed." When so processed, the web 1 is not imparted with any
particular elasticity, beyond what the precursor webs 180 and 21
may have possessed originally.
[0178] At higher line speeds, i.e., relatively higher rates of
processing of the web through the nip of rotating rolls 174 and
176, like materials can exhibit very different structures for tufts
6. The tuft 6 shown in FIG. 7 is similar in structure to the tuft
shown in FIG. 4 but exhibits a very different structure, a
structure that appears to be typical of spunbond nonwoven first
precursor webs 180 processed to form tufts 6 at relatively high
speeds, i.e., at high strain rates. Typical of this structure is
broken fibers between the proximal portion, i.e., base 7, of tufts
6 and the distal portion, i.e., the top 31, of tuft 6, and what
appears to be a "mat" 19 of fibers at the top of the tuft 6. Mat 19
comprises and is supported at the top of tufts 6 by unbroken,
looped fibers 8, and also comprises portions of broken fibers 11
that are no longer integral with first precursor web 180. That is,
mat 19 comprises fiber portions which were formerly integral with
precursor web 180 but which are completely detached from precursor
web 180 after processing at sufficiently high line speeds, e.g., 30
meters per minute line speed in the process described with
reference to FIG. 1.
[0179] Therefore, from the above description, it is understood that
in one embodiment web 1 can be described as being a laminate web
formed by selective mechanical deformation of at least a first and
second precursor webs, at least the first precursor web being a
nonwoven web, the laminate web having a first garment-facing, side,
the first garment-facing side comprising the second precursor web
and a plurality of discrete tufts, each of the discrete tufts
comprising fibers integral with but extending from the first
precursor web and fibers neither integral with nor extending from
the first precursor web.
[0180] As shown in FIG. 8, after tufts 6 are formed, tufted
precursor web 21 travels on rotating roll 104 to nip 117 between
roll 104 and a first bonding roll 156. Bonding roll 156 can
facilitate a number of bonding techniques. For example, bonding
roll 156 can be a heated steel roller for imparting thermal energy
in nip 117, thereby melt-bonding adjacent fibers of tufted web 21
at the distal ends (tips) of tufts 6. Bonding roll 156 can also
facilitate thermal bonding by means of pressure only, or use of
heat and pressure. In one embodiment, for example, nip 117 can be
set at a width sufficient to compress the distal ends of tufts 6,
which at high rates of processing can cause thermal energy transfer
to the fibers, which can then reflow and bond.
[0181] Depending on the type of bonding being facilitated, bonding
roll 156 can be a smooth, steel surface, or a relatively soft,
flexible surface. In a preferred embodiment, as discussed in the
context of a preferred web below, bonding roll 156 is a heated roll
designed to impart sufficient thermal energy to tufted web 21 so as
to thermally bond adjacent fibers of the distal ends of tufts 6.
Thermal bonding can be by melt-bonding adjacent fibers directly, or
by melting an intermediate thermoplastic agent, such as
polyethylene powder, which in turn, adheres adjacent fibers.
Polyethylene powder can be added to precursor web 20 for such
purposes.
[0182] First bonding roll 156 can be heated sufficiently to melt or
partially melt fibers 8 or 18 at the distal ends 3 of tufts 6. The
amount of heat or heat capacity necessary in first bonding roll 156
depends on the melt properties of the fibers of tufts 6 and the
speed of rotation of roll 104. The amount of heat necessary in
first bonding roll 156 also depends on the pressure induced between
first bonding roll 156 and tips of teeth 110 on roll 104, as well
as the degree of melting desired at distal ends 3 of tufts 6. In
one embodiment, bonding roll 156 can provide sufficient heat and
pressure to not only melt bond fibers at the distal ends 3 of tufts
6, but also cut through the bonded portion so as to, in effect, cut
through the end of tuft 6. In such an embodiment, the tuft is
divided into two portions, but is not longer looped. In one
embodiment, pressure alone can cause the looped portion of the tuft
to be cut through, thereby rendering the tufts 6 to be un-looped
tufts of fiber free ends. Other methods known in the art, such as
use of a spinning wire brush wheel can also be utilized to cut the
loops of looped fibers to form un-looped tufts.
[0183] In one embodiment, first bonding roll 156 is a heated steel
cylindrical roll, heated to have a surface temperature sufficient
to melt-bond adjacent fibers of tufts 6. First bonding roll can be
heated by internal electrical resistance heaters, by hot oil, or by
any other means known in the art for making heated rolls. First
bonding roll 156 can be driven by suitable motors and linkages as
known in the art. Likewise, first bonding roll can be mounted on an
adjustable support such that nip 117 can be accurately adjusted and
set.
[0184] Nested "SELF" relates to a method that includes making a
fibrous materials by a method comprising the steps of: a) providing
at least one precursor nonwoven web; b) providing an apparatus
comprising a pair of forming members comprising a first forming
member (a "male" forming member) and a second forming member (a
"female" forming member); and c) placing the precursor nonwoven
web(s) between the forming members and mechanically deforming the
precursor nonwoven web(s) with the forming members. The forming
members have a machine direction (MD) orientation and a
cross-machine direction (CD) orientation.
[0185] The first and second forming members can be plates, rolls,
belts, or any other suitable types of forming members. In the
embodiment of the apparatus 200 shown in FIG. 9, the first and
second forming members 182 and 190 are in the form of
non-deformable, meshing, counter-rotating rolls that form a nip 188
therebetween. The precursor web(s) is/are fed into the nip 188
between the rolls 182 and 190. Although the space between the rolls
182 and 190 is described herein as a nip, as discussed in greater
detail below, in some cases, it may be desirable to avoid
compressing the precursor web(s) to the extent possible.
[0186] First Forming Member.
[0187] The first forming member (such as "male roll") 182 has a
surface comprising a plurality of first forming elements which
comprise discrete, spaced apart male forming elements 112. The male
forming elements are spaced apart in the machine direction and in
the cross-machine direction.
[0188] As shown in FIG. 10, the male forming elements 112 have a
base 186 that is joined to (in this case is integral with) the
first forming member 182, a top 184 that is spaced away from the
base, and side walls (or "sides") 120 that extend between the base
186 and the top 184 of the male forming elements. The male elements
112 may also have a transition portion or region 122 between the
top 184 and the side walls 120. The male elements 112 also have a
plan view periphery, and a height H.sub.1 (the latter being
measured from the base 186 to the top 184). The discrete elements
on the male roll may have a top 184 with a relatively large surface
area (e.g., from about 1 mm to about 10 mm in width, and from about
1 mm to about 20 mm in length) for creating a wide deformation. The
male elements 112 may, thus, have a plan view aspect ratio (ratio
of length to width) that ranges from about 1:1 to about 10:1. For
the purpose of determining the aspect ratio, the larger dimension
of the male elements 112 will be consider the length, and the
dimension perpendicular thereto will be considered to be the width
of the male element. The male elements 112 may have any suitable
configuration.
[0189] The base 186 and the top 184 of the male elements 112 may
have any suitable plan view configuration, including but not
limited to: a rounded diamond configuration as shown in FIGS. 9 and
10, an American football-like shape, triangle, circle, clover, a
heart-shape, teardrop, oval, or an elliptical shape. The
configuration of the base 186 and the configuration of the top 184
of the male elements 112 may be in any of the following
relationships to each other: the same, similar, or different. The
top 184 of the male elements 112 can be flat, rounded, or any
configuration therebetween.
[0190] The transition region or "transition " 122 between the top
184 and the side walls 120 of the male elements 112 may also be of
any suitable configuration. The transition 122 can be in the form
of a sharp edge (as shown in FIG. 10C) in which case there is zero,
or a minimal radius where the side walls 120 and the top 184 of the
male elements meet. That is, the transition 122 may be
substantially angular, sharp, non-radiused, or non-rounded. In
other embodiments, such as shown in FIG. 10, the transition 122
between the top 184 and the side walls 120 of the male elements 112
can be radiused, or alternatively beveled. Suitable radiuses
include, but are not limited to: zero (that is, the transition
forms a sharp edge), 0.01 inch (about 0.25 mm), 0.02 inch (about
0.5 mm), 0.03 inch (about 0.76 mm), 0.04 inch (about 1 mm) (or any
0.01 inch increment above 0.01 inch), up to a fully rounded male
element as shown in FIG. 10D.
[0191] In some cases, it may be desired to roughen the surface of
all, or a portion, of the male elements 112. The surface of the
male elements 112 can be roughened in any suitable manner The
surface of the male elements 112 can be roughened, for example, by:
media blasting (that is, roughened with shot or "shot blasted");
wet blasting (roughed with water jets); plasma coating, machining,
or knurling (i.e., pressure embossing of surface of first forming
member); or combinations of the same. The roughened configuration
and characteristics of the male elements 112 will depend on the
type of process used to roughen the same. The roughening will
typically provide at least the top 184 of at least some of the male
elements 112 with greater than or equal to two discrete first
surface texture elements protruding therefrom.
[0192] Second Forming Member.
[0193] As shown in FIG. 9, the second forming member (such as
"female roll") 190 has a surface 124 having a plurality of cavities
or recesses 114 therein. The recesses 114 are aligned and
configured to receive the male forming elements 112 therein. Thus,
the male forming elements 112 mate with the recesses 114 so that a
single male forming element 112 fits within the periphery of a
single recess 114, and at least partially within the recess 114 in
the z-direction. The recesses 114 have a plan view periphery 126
that is larger than the plan view periphery of the male elements
112. As a result, the recess 114 on the female roll may completely
encompass the discrete male element 112 when the rolls 182 and 190
are intermeshed. The recesses 114 have a depth D.sub.1 shown in
FIG. 11. In some cases, the depth D.sub.1 of the recesses may be
greater than the height H.sub.1 of the male forming elements
112.
[0194] The recesses 114 have a plan view configuration, side walls
128, a top edge or rim 134 around the upper portion of the recess
where the side walls 128 meet the surface 124 of the second forming
member 190, and a bottom edge 130 around the bottom 132 of the
recesses where the side walls 128 meet the bottom 132 of the
recesses.
[0195] The recesses 114 may have any suitable plan view
configuration provided that the recesses can receive the male
elements 112 therein. The recesses 114 may have a similar plan view
configuration as the male elements 112. In other cases, some or all
of the recesses 114 may have a different plan view configuration
from the male elements 112.
[0196] The top edge or rim 134 around the upper portion of the
recess where the side walls 128 meet the surface 124 of the second
forming member 190 may have any suitable configuration. The rim 134
can be in the form of a sharp edge (as shown in FIG. 11) in which
case there is zero, or a minimal radius where the side walls 128 of
the recesses meet the surface of the second forming member 190.
That is, the rim 134 may be substantially angular, sharp,
non-radiused, or non-rounded. In other embodiments, such as shown
in FIG. 11A, the rim 134 can be radiused, or alternatively beveled.
Suitable radiuses include, but are not limited to: zero (that is,
form a sharp edge), 0.01 inch (about 0.25 mm), 0.02 inch (about 0.5
mm), 0.03 inch (about 0.76 mm), 0.04 inch (about 1 mm) (or any 0.01
inch increment above 0.01 inch) up to a fully rounded land area
between some or all of the side walls 128 around each recess 114.
The bottom edge 130 of the recesses 114 may be sharp or
rounded.
[0197] In some cases, it may be desired to roughen the surface of
all, or a portion, of the second forming member 190 and/or recesses
114 by providing the same with a plurality of discrete second
surface texture elements 142 thereon. The surface of the second
forming member 190 and/or recesses 114 can be roughened in any of
the manners described above for roughening the surface of the male
elements 112. This may provide the surface of the second forming
member 190 and/or recesses 114 with second surface texture elements
142 (and/or valleys 144, raised areas 146, and microscale texture
148 as shown in FIG. 10G) having the same or similar properties as
the first surface texture elements 140 on the male elements 112.
Thus, the second surface texture elements 142 can be distributed on
the surface of the second forming member 190 in a regular pattern
or a random pattern.
[0198] The depth of engagement (DOE) is a measure of the level of
intermeshing of the forming members. As shown in FIG. 11, the DOE
is measured from the top 184 of the male elements 112 to the
(outermost) surface 124 of the female forming member 114 (e.g., the
roll with recesses). The DOE may, for example, range from at least
about 1.5 mm, or less, to about 5 mm, or more. In certain
embodiments, the DOE may be between about 2.5 mm to about 5 mm,
alternatively between about 3 mm and about 4 mm.
[0199] As shown in FIG. 11, there is a clearance, C, between the
sides 120 of the male elements 112 and the sides (or side walls)
128 of the recesses 114. The clearances and the DOE's are related
such that larger clearances can permit higher DOE's to be used. The
clearance, C, between the male and female roll may be the same, or
it may vary around the perimeter of the male element 112. For
example, the forming members can be designed so that there is less
clearance between the sides of the male elements 112 and the
adjacent side walls 128 of the recesses 114 than there is between
the side walls at the end of the male elements 112 and the adjacent
side walls of the recesses 114. In other cases, the forming members
can be designed so that there is more clearance between the sides
120 of the male elements 112 and the adjacent side walls 128 of the
recesses 114 than there is between the side walls at the end of the
male elements 112 and the adjacent side walls of the recesses. In
still other cases, there could be more clearance between between
the side wall on one side of a male element 112 and the adjacent
side wall of the recess 114 than there is between the side wall on
the opposing side of the same male element 112 and the adjacent
side wall of the recess. For example, there can be a different
clearance at each end of a male element 112; and/or a different
clearance on each side of a male element 112. Clearances can range
from about 0.005 inches (about 0.1 mm) to about 0.1 inches (about
2.5 mm).
[0200] The precursor nonwoven web 30 is placed between the forming
members 182 and 190. The precursor nonwoven web can be placed
between the forming members with either side of the precursor web
(first surface 34 or second surface 36) facing the first forming
member, male forming member 182. For convenience of description,
the second surface 36 of the precursor nonwoven web will be
described herein as being placed in contact with the first forming
member 182. (Of course, in other embodiments, the second surface 36
of the precursor nonwoven web can be placed in contact with the
second forming member 190.)
[0201] The Nested SELF process can create wells that are larger in
diameter (ie. >1 mm). The bottom of the well can be pushed
downward with little to no fracturing of the material within the
well. The Nested SELF process could also comprise a roll with
ridges and grooves, with the ridges being broken about the
circumference by discrete regions where the ridges have been
removed. These discrete regions span two or more adjacent teeth and
form a shape, such as a circle, ellipse, square, octagon, etc.
[0202] According to an embodiment, an absorbent article can
comprise a liquid pervious topsheet. The topsheet suitable for use
herein can comprise wovens, non-wovens, apertured webs or not
aperture webs, and/or three-dimensional webs of a liquid
impermeable polymeric film comprising liquid permeable apertures.
The topsheet may be a laminate. The topsheet may have more than one
layer. The topsheet may comprise nonwoven fibers selected from the
group consisting of meltblown, nanofibers, bicomponent fibers, and
combinations thereof. The topsheet for use herein can be a single
layer or may have a multiplicity of layers. For example, the
wearer-facing and contacting surface can be provided by a film
material having apertures which are provided to facilitate liquid
transport from the wearer facing surface towards the absorbent
structure. Such liquid permeable, apertured films are well known in
the art. They provide a resilient three-dimensional fibre-like
structure. Such films have been disclosed in detail for example in
U.S. Pat. No. 3,929,135, U.S. Pat. No. 4,151,240, U.S. Pat. No.
4,319,868, U.S. Pat. No. 4,324,426, U.S. Pat. No. 4,343,314, U.S.
Pat. No. 4,591,523, U.S. Pat. No. 4,609,518, U.S. Pat. No.
4,629,643, U.S. Pat. No. 4,695,422 or WO 96/00548.
[0203] The topsheet and/or the secondary topsheet may comprise a
nonwoven material. The nonwoven materials of the present invention
can be made of any suitable nonwoven materials ("precursor
materials"). The nonwoven webs can be made from a single layer, or
multiple layers (e.g., two or more layers). If multiple layers are
used, they can be comprised of the same type of nonwoven material,
or different types of nonwoven materials. In some cases, the
precursor materials may be free of any film layers.
[0204] The fibers of the nonwoven precursor material(s) can be made
of any suitable materials including, but not limited to natural
materials, synthetic materials, and combinations thereof. Suitable
natural materials include, but are not limited to cellulose, cotton
linters, bagasse, wool fibers, silk fibers, etc. Cellulose fibers
can be provided in any suitable form, including but not limited to
individual fibers, fluff pulp, drylap, liner board, etc. Suitable
synthetic materials include, but are not limited to nylon, rayon,
and polymeric materials. Suitable polymeric materials include, but
are not limited to: polyethylene (PE), polyester, polyethylene
terephthalate (PET), polypropylene (PP), and co-polyester. Suitable
synthetic fibers may have submicron diameters, thereby being
nanofibers, such as Nufibers or be between 1 and 3 microns such as
meltblown fibers or may be of larger diameter. In some embodiments,
however, the nonwoven precursor materials can be either
substantially, or completely free, of one or more of these
materials. For example, in some embodiments, the precursor
materials may be substantially free of cellulose, and/or exclude
paper materials. In some embodiments, one or more precursor
materials can comprise up to 100% thermoplastic fibers. The fibers
in some cases may, therefore, be substantially non-absorbent. In
some embodiments, the nonwoven precursor materials can be either
substantially, or completely free, of tow fibers.
[0205] The precursor nonwoven materials can comprise any suitable
types of fibers. Suitable types of fibers include, but are not
limited to: monocomponent, bicomponent, and/or biconstituent,
non-round (e.g., shaped fibers (including but not limited to fibers
having a trilobal cross-section) and capillary channel fibers). The
fibers can be of any suitable size. The fibers may, for example,
have major cross-sectional dimensions (e.g., diameter for round
fibers) ranging from 0.1-500 microns. Fiber size can also be
expressed in denier, which is a unit of weight per length of fiber.
The constituent fibers may, for example, range from about 0.1
denier to about 100 denier. The constituent fibers of the nonwoven
precursor web(s) may also be a mixture of different fiber types,
differing in such features as chemistry (e.g., PE and PP),
components (mono- and bi-), shape (i.e. capillary channel and
round) and the like.
[0206] The nonwoven precursor webs can be formed from many
processes, such as, for example, air laying processes, wetlaid
processes, meltblowing processes, spunbonding processes, and
carding processes. The fibers in the webs can then be bonded via
spunlacing processes, hydroentangling, calendar bonding,
through-air bonding and resin bonding. The nonwoven precursor web
or nonwoven web may be aperture with a process such as overbonding
or pre-aperturing. Some of such individual nonwoven webs may have
bond sites 46 where the fibers are bonded together.
[0207] In the case of spunbond webs, the web may have a thermal
point bond 46 pattern that is not highly visible to the naked eye.
For example, dense thermal point bond patterns are equally and
uniformly spaced are typically not highly visible. After the
material is processed through the mating male and female rolls, the
thermal point bond pattern is still not highly visible.
Alternatively, the web may have a thermal point bond pattern that
is highly visible to the naked eye. For example, thermal point
bonds that are arranged into a macro-pattern, such as a diamond
pattern, are more visible to the naked eye. After the material is
processed through the mating male and female rolls, the thermal
point bond pattern is still highly visible and can provide a
secondary visible texture element to the material.
[0208] 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 30. For example, the
topsheet of a topsheet/acquisition layer laminate or composite may
have a basis weight from about 8 to about 40 gsm, or from about 8
to about 30 gsm, or from about 8 to about 20 gsm. The acquisition
layer may have a basis weight from about 10 to about 120 gsm, or
from about 10 to about 100 gsm, or from about 10 to about 80 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 30. The nonwoven precursor webs may have a
density that is between about 0.01 and about 0.4 g/cm.sup.3
measured at 0.3 psi (2 KPa).
[0209] The precursor nonwoven webs may have certain desired
characteristics. The precursor nonwoven web(s) each have a first
surface, a second surface, and a thickness. The first and second
surfaces of the precursor nonwoven web(s) may be generally planar.
It is typically desirable for the precursor nonwoven web materials
to have extensibility to enable the fibers to stretch and/or
rearrange into the form of the protrusions. If the nonwoven webs
are comprised of two or more layers, it may be desirable for all of
the layers to be as extensible as possible. Extensibility is
desirable in order to maintain at least some non-broken fibers in
the sidewalls around the perimeter of the protrusions. It may be
desirable for individual precursor webs, or at least one of the
nonwovens within a multi-layer structure, to be capable of
undergoing an apparent elongation (strain at the breaking force,
where the breaking force is equal to the peak force) of greater
than or equal to about one of the following amounts: 100% (that is
double its unstretched length), 110%, 120%, or 130% up to about
200%. It is also desirable for the precursor nonwoven webs to be
capable of undergoing plastic deformation to ensure that the
structure of the deformations is "set" in place so that the
nonwoven web will not tend to recover or return to its prior
configuration.
[0210] Materials that are not extensible enough (e.g., inextensible
PP) may form broken fibers around much of the perimeter of the
deformation, and create more of a "hanging chad" (i.e., the cap of
the protrusions may be at least partially broken from and separated
from the rest of the protrusion. The area on the sides of the
protrusion where the fibers are broken is designated with reference
number.
[0211] When the fibers of a nonwoven web are not very extensible,
it may be desirable for the nonwoven to be underbonded as opposed
to optimally bonded. A thermally bonded nonwoven web's tensile
properties can be modified by changing the bonding temperature. A
web can be optimally or ideally bonded, underbonded, or overbonded.
Optimally or ideally bonded webs are characterized by the highest
breaking force and apparent elongation with a rapid decay in
strength after reaching the breaking force. Under strain, bond
sites fail and a small amount of fibers pull out of the bond site.
Thus, in an optimally bonded nonwoven, the fibers 38 will stretch
and break around the bond sites 46 when the nonwoven web is
strained beyond a certain point. Often there is a small reduction
in fiber diameter in the area surrounding the thermal point bond
sites 46. Underbonded webs have a lower breaking force and apparent
elongation when compared to optimally bonded webs, with a slow
decay in strength after reaching the breaking force. Under strain,
some fibers will pull out from the thermal point bond sites 46.
Thus, in an underbonded nonwoven, at least some of the fibers 38
can be separated easily from the bond sites 46 to allow the fibers
38 to pull out of the bond sites and rearrange when the material is
strained. Overbonded webs also have a lowered breaking force and
elongation when compared to optimally bonded webs, with a rapid
decay in strength after reaching the breaking force. The bond sites
look like films and result in complete bond site failure under
strain.
[0212] When the nonwoven web comprises two or more layers, the
different layers can have the same properties, or any suitable
differences in properties relative to each other. In one
embodiment, the nonwoven web can comprise a two layer structure
that is used in an absorbent article. For convenience, the
precursor webs and the material into which they are formed will
generally be referred to herein by the same reference numbers. As
described above, one of the layers, a second layer, can serve as
the topsheet of the absorbent article, and the first layer can be
an underlying layer (or sub-layer) and serve as an acquisition
layer. The acquisition layer receives liquids that pass through the
topsheet and distributes them to underlying absorbent layers. In
such a case, the topsheet may be less hydrophilic than
sub-layer(s), which may lead to better dewatering of the topsheet.
In other embodiments, the topsheet can be more hydrophilic than the
sub-layer(s). In some cases, the pore size of the acquisition layer
may be reduced, for example via using fibers with smaller denier or
via increasing the density of the acquisition layer material, to
better dewater the pores of the topsheet.
[0213] The second nonwoven layer that may serve as the topsheet can
have any suitable properties. The second nonwoven layer may be
absorbent. Properties of interest for the second nonwoven layer,
when it serves as a topsheet, in addition to sufficient
extensibility and plastic deformation may include uniformity and
opacity. As used herein, "uniformity" refers to the macroscopic
variability in basis weight of a nonwoven web. As used, herein,
"opacity" of nonwoven webs is a measure of the impenetrability of
visual light, and is used as visual determination of the relative
fiber density on a macroscopic scale. As used herein, "opacity" of
the different regions of a single nonwoven deformation is
determined by taking a photomicrograph at 20.times. magnification
of the portion of the nonwoven containing the deformation against a
black background. Darker areas indicate relatively lower opacity
(as well as lower basis weight and lower density) than white
areas.
[0214] Several examples of nonwoven materials suitable for use as
the second nonwoven layer 30B include, but are not limited to:
spunbonded nonwovens; carded nonwovens; and other nonwovens with
high extensibility (apparent elongation in the ranges set forth
above) and sufficient plastic deformation to ensure the structure
is set and does not have significant recovery. One suitable
nonwoven material as a topsheet for a topsheet/acquisition layer
composite structure may be an extensible spunbonded nonwoven
comprising polypropylene and polyethylene. The fibers can comprise
a blend of polypropylene and polyethylene, or they can be
bi-component fibers, such as a sheath-core fiber with polyethylene
on the sheath and polypropylene in the core of the fiber. Another
suitable material is a bi-component fiber spunbonded nonwoven
comprising fibers with a polyethylene sheath and a
polyethylene/polypropylene blend core.
[0215] The first nonwoven layer that may, for example, serve as the
acquisition layer can have any suitable properties. Properties of
interest for the first nonwoven layer, in addition to sufficient
extensibility and plastic deformation may include uniformity and
opacity. If the first nonwoven layer serves as an acquisition
layer, its fluid handling properties must also be appropriate for
this purpose. Such properties may include: permeability, porosity,
capillary pressure, caliper, as well as mechanical properties such
as sufficient resistance to compression and resiliency to maintain
void volume. Suitable nonwoven materials for the first nonwoven
layer when it serves as an acquisition layer include, but are not
limited to: spunbonded nonwovens; through-air bonded ("TAB") carded
nonwoven materials; spunlace nonwovens; hydroentangled nonwovens;
and, resin bonded carded nonwoven materials. Of course, the
composite structure may be inverted and incorporated into an
article in which the first layer serves as the topsheet and the
second layer serves as an acquisition layer. In such cases, the
properties and exemplary methods of the first and second layers
described herein may be interchanged.
[0216] The layers of a two or more layered nonwoven web structure
can be combined together in any suitable manner In some cases, the
layers can be unbonded to each other and held together autogenously
(that is, by virtue of the formation of deformations therein). For
example, both precursor webs 30A and 30B contribute fibers to
deformations in a "nested" relationship that joins the two
precursor webs together, forming a multi-layer web without the use
or need for adhesives or thermal bonding between the layers. In
other embodiments, the layers can be joined together by other
mechanisms. If desired an adhesive between the layers, ultrasonic
bonding, chemical bonding, resin or powder bonding, thermal
bonding, or bonding at discrete sites using a combination of heat
and pressure can be selectively utilized to bond certain regions or
all of the precursor webs. In addition, the multiple layers may be
bonded during processing, for example, by carding one layer of
nonwoven onto a spunbond nonwoven and thermal point bonding the
combined layers. In some cases, certain types of bonding between
layers may be excluded. For example, the layers of the present
structure may be non-hydroentangled together.
[0217] If adhesives are used, they can be applied in any suitable
manner or pattern including, but not limited to: slots, spirals,
spray, and curtain coating. Adhesives can be applied in any
suitable amount or basis weight including, but not limited to
between about 0.5 and about 30 gsm, alternatively between about 2
and about 5 gsm. Examples of adhesives could include hot melt
adhesives, such as polyolefins and styrene block copolymers.
[0218] A certain level of adhesive may reduce the level of fuzz on
the surface of the nonwoven material even though there may be a
high percentage of broken fibers as a result of the deformation
process. Glued dual-layer laminates produced as described herein
are evaluated for fuzz. The method utilizes a Martindale Abrasion
Tester, based upon ASTM D4966-98. After abrading the samples, they
are graded on a scale of 1-10 based on the degree of fiber pilling
(1=no fiber pills; 10=large quantity and size of fiber pills). The
protrusions are oriented away from the abrader so the land area in
between the depressions is the primary surface abraded. Even though
the samples may have a significant amount of fiber breakage
(greater than 25%, sometimes greater than 50%) in the side walls of
the protrusions/depressions, the fuzz value may be low (around 2)
for several different material combinations, as long as the layers
do not delaminate during abrasion. Delamination is best prevented
by glue basis weight, for example a glue basis weight greater than
3 gsm, and glue coverage.
[0219] When the precursor nonwoven web comprises two or more
layers, it may be desirable for at least one of the layers to be
continuous, such as in the form of a web that is unwound from a
roll. In some embodiments, each of the layers can be continuous. In
alternative embodiments, one or more of the layers can be
continuous, and one or more of the layers can have a discrete
length. The layers may also have different widths. For example, in
making a combined topsheet and acquisition layer for an absorbent
article, the nonwoven layer that will serve as the topsheet may be
a continuous web, and the nonwoven layer that will serve as the
acquisition layer may be fed into the manufacturing line in the
form of discrete length (for example, rectangular, or other shaped)
pieces that are placed on top of the continuous web. Such an
acquisition layer may, for example, have a lesser width than the
topsheet layer. The layers may be combined together as described
above.
[0220] Nonwoven webs and materials are often incorporated into
products, such as absorbent articles, at high manufacturing line
speeds. Such manufacturing processes can apply compressive and
shear forces on the nonwoven webs that may damage certain types of
three-dimensional features that have been purposefully formed in
such webs. In addition, in the event that the nonwoven material is
incorporated into a product (such as a disposable diaper) that is
made or packaged under compression, it becomes difficult to
preserve the three-dimensional character of some types of prior
three-dimensional features after the material is subjected to such
compressive forces.
[0221] The nonwoven material can comprise a composite of two or
more nonwoven materials that are joined together. In such a case,
the fibers and properties of the first layer will be designated
accordingly (e.g., the first layer is comprised of a first
plurality of fibers), and the fibers and properties of the second
and subsequent layers will be designated accordingly (e.g., the
second layer is comprised of a second plurality of fibers). In a
two or more layer structure, there are a number of possible
configurations the layers may take following the formation of the
deformations therein. These will often depend on the extensibility
of the nonwoven materials used for the layers. It is desirable that
at least one of the layers have deformations which form protrusions
as described herein in which, along at least one cross-section, the
width of the cap of the protrusions is greater than the width of
the base opening of the deformations. For example, in a two layer
structure where one of the layers will serve as the topsheet of an
absorbent article and the other layer will serve as an underlying
layer (such as an acquisition layer), the layer that has
protrusions therein may comprise the topsheet layer. The layer that
most typically has a bulbous shape will be the one which is in
contact with the male forming member during the process of
deforming the web.
[0222] The heterogeneous mass may be combined with the topsheet, a
secondary topsheet, or the both using formation means. A group of
fibers, or in fact, a portion of the whole topsheet is physically
inserted into the heterogeneous mass so that within a single X-Y
plane, a fiber from the topsheet, secondary topsheet, or both, is
in direct contact with one or more fibers of the heterogeneous
mass.
[0223] It has been surprisingly found that by placing a fibrous
topsheet or a fibrous secondary topsheet, or both a fibrous
topsheet and a secondary topsheet through a formation means process
with a heterogeneous mass, one can create one or more "wells"
instead of an aperture. Wells are distinguished from apertures and
channels in that the outer surface of the wells includes one or
more fibers from the group of fibers being integrated with the core
without densifying the fibers that form the well. The "wells" may
provide improved drainage of the topsheet through the secondary
topsheet to the core comprising the heterogeneous mass. Use of
wells may lead to various benefits including high fluid bridging
between layers for reduced pooling of fluid at layer interfaces.
Additionally, the "wells" may provide a higher capillarity work
potential gradient to draw fluid away from topsheet and into the
core compared to traditional absorbent articles, such as, for
example, from 100 mJ/m.sup.2 to 8000 mJ/m.sup.2 within 0.5 mm, or
0.25 mm, or within 0.15 mm rather than current topsheets which have
a gradient of 100 mJ/m.sup.2 to 1000 mJ/m.sup.2 over about 2 mm, or
about 1.5 mm, or about 1 mm of distance. The capillarity work
potential gradient may be between 500 mJ/m.sup.2 and 7000
mJ/m.sup.2 within 0.15 mm, such as, for example, between 1000
mJ/m.sup.2 and 7000 mJ/m.sup.2, between 1500 mJ/m.sup.2 and 6500
mJ/m.sup.2, between 2000 mJ/m.sup.2 and 6000 mJ/m.sup.2, between
2500 mJ/m.sup.2 and 5000 mJ/m.sup.2, such as, for example 500,
1000, 1500, 2000, 2500, 3000, 3500, 4000, 4500, 5000, 5500, 6000,
6500, 7000, 7500 mJ/m.sup.2. Capillarity cascade relates to the
change in capillarity as fluid moves from one layer to another
layer within an absorbent structure. The thinner the materials are
in each layer or the thinner the total thickness is through all
layers, and the higher the difference in capillarity work potential
between each layer, the higher the capillarity work potential
gradient or capillarity cascade is within the absorbent structure.
Traditional absorbent structures simply cannot achieve a
capillarity work potential gradient across such a small distance in
either the z-direction or within an x-y plane containing multiple
layers of absorbent materials.
[0224] Without being bound by theory, it is believed that the
integrated layers including a topsheet and/or a secondary topsheet
with a heterogeneous mass that has a high capillary absorbent
intertwined within the layer provides multiple surprising
advantageous. Amongst these advantages may be, without limitation,
1. The ability to create bridging between the topsheet and the
absorbent core for the purpose of absorbing complex liquids, 2. The
ability to create a capillarity cascade within the topsheet to core
system that allows form the moving of complex liquids into the high
capillarity absorbent, 3. An absorbent system having an absorbent
core and a topsheet that may conform to complex body shapes and
dynamic movement, 4. An absorbent system having an absorbent core
and a topsheet that has improved tactile feel.
[0225] Without being bound by theory, it is believed that the
"wells" may provide improved drainage of the topsheet through the
secondary topsheet to the core comprising the fibrous web.
Specifically, the wells allow for improved drainage via the wells
from the topsheet to the absorbent core when fluid is placed on the
topsheet. The number of wells in an absorbent structure is set
according to the pattern chosen during the formation means.
[0226] The wells are identified and can be seen within the same XY
plane as the integrated layers. A group of fibers from the topsheet
are integrated into the heterogeneous mass layer which comprises
open cell foam. The group of fibers may be between 10 and 10,000
fibers per grouping, such as, for example, 10 fibers per grouping
of fibers, 20 fibers per grouping of fibers, 30 fibers per grouping
of fibers, 40 fibers per grouping of fibers, 50 fibers per grouping
of fibers, 60 fibers per grouping of fibers, 70 fibers per grouping
of fibers, 80 fibers per grouping of fibers, 90 fibers per grouping
of fibers, 100 fibers per grouping, 400 fibers per grouping, 500
fibers per grouping, 1,000 fibers per grouping, 2,000 fibers per
grouping, 3,000 fibers per grouping, 4,000 fibers per grouping,
5,000 fibers per grouping, 6,000 fibers per grouping, 7,000 fibers
per grouping, 8,000 fibers per grouping, or 9,000 fibers per
grouping. One or more grouping of fibers may be in direct contact.
At least one of the grouping of fibers has a portion that is the
external surface of a portion of a well.
[0227] A grouping of fibers may be inserted into the X-Y plane of
both the STS and core such that it penetrates between 10% to 100%
of the core layer, such as, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or
90%. This is unlike traditional needlepunching that only places a
few fibers down into a traditional core. Further, the group of
fibers of the topsheet, or a group of fibers of the secondary
topsheet and the fibers of the heterogeneous mass are in close
proximity to each other within this X-Y plane, on the order of 0.01
mm to 0.5 mm distance, such as, for example 0.05 mm, 0.1 mm, 0.15
mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, or 0.45 mm.
[0228] The areas of the topsheet adjacent to the wells, the
topsheet, Secondary topsheet, and core are in much closer or more
intimate contact. Without being bound by theory, it is believed
that the open cell foam may provide a resiliency or upward pressure
against the topsheet. Traditional cores would likely disintegrate
and/or would have no upward resiliency if they were placed through
a similar formation means transformation process. Further, full
foam layer cores would disintegrate and/or tear if placed through a
similar process.
[0229] As previously discussed, the "wells" may provide a higher
capillarity work potential gradient to draw fluid away from
topsheet and into the core compared to traditional absorbent
articles, such as, for example, from 100 mJ/m.sup.2 to 80,000
mJ/m.sup.2 within 0.5 mm, or 0.25 mm, or within 0.15 mm rather than
current topsheets which have a gradient of 100 mJ/m.sup.2 to 1000
mJ/m.sup.2 over about 2 mm, or about 1.5 mm, or about 1 mm of
distance. The absorbent core structure may exhibit a capillary
cascade of between, for example, 100 mJ/m.sup.2 to 80,000
mJ/m.sup.2 within 0.5 mm; 1,000 mJ/m.sup.2 to 70,000 mJ/m.sup.2
within 0.5 mm; 3,000 mJ/m.sup.2 to 70,000 mJ/m.sup.2 within 0.5 mm;
5,000 mJ/m.sup.2 to 60,000 mJ/m.sup.2 within 0.5 mm; 10,000
mJ/m.sup.2 to 50,000 mJ/m.sup.2 within 0.5 mm; 20.000 mJ/m.sup.2 to
40,000 mJ/m.sup.2 within 0.5 mm; 100 mJ/m.sup.2 to 80,000
mJ/m.sup.2 within 0.25 mm; 1,000 mJ/m.sup.2 to 70,000 mJ/m.sup.2
within 0.25 mm; 3,000 mJ/m.sup.2 to 70,000 mJ/m.sup.2 within 0.25
mm; 5,000 mJ/m.sup.2 to 60,000 mJ/m.sup.2 within 0.25 mm; 10,000
mJ/m.sup.2 to 50,000 mJ/m.sup.2 within 0.25 mm; 20.000 mJ/m.sup.2
to 40,000 mJ/m.sup.2 within 0.25 mm; 100 mJ/m.sup.2 to 80,000
mJ/m.sup.2 within 0.15 mm; 1,000 mJ/m.sup.2 to 70,000 mJ/m.sup.2
within 0.15 mm; 3,000 mJ/m.sup.2 to 70,000 mJ/m.sup.2 within 0.15
mm; 5,000 mJ/m.sup.2 to 60,000 mJ/m.sup.2 within 0.15 mm; 10,000
mJ/m.sup.2 to 50,000 mJ/m.sup.2 within 0.15 mm; or 20.000
mJ/m.sup.2 to 40,000 mJ/m.sup.2 within 0.15 mm
[0230] Additionally, the wells allow for the absorbent structure to
exhibit a capillarity cascade along not only the vertical plane but
also along the X-Y plane. Unlike other structures that may exhibit
different capillarity profiles in the vertical direction versus
within a plane, the absorbent structure having an integrated
topsheet with a heterogeneous mass layer comprising wells creates a
structure where the capillarity cascade is present within a plane.
This is due to the integration of the groups of fibers from the
topsheet through the heterogeneous mass.
[0231] The system absorbent structure having an integrated topsheet
in a heterogeneous mass stratum provides surprising improvements in
fluid acquisition. Specifically, the absorbent structure allows for
a drier topsheet as measured via an NMR mouse method. The absorbent
structure having an integrated topsheet, and/or integrated
secondary topsheet, and heterogeneous mass exhibits a residual
fluid left on a topsheet that is less than 1 ml/cm.sup.2, such as
for example, 0.75 ml/cm.sup.2, 0.5 ml/cm.sup.2, 0.4 ml/cm.sup.2,
0.3 ml/cm.sup.2, 0.2 ml/cm.sup.2, or 0.1 ml/cm.sup.2, as measured
via the NMR mouse method. The absorbent structure having an
integrated topsheet, and/or integrated secondary topsheet, and
heterogeneous mass exhibits a residual fluid left in the top 1 mm
of the absorbent article that is less than 1 ml/mm, such as for
example, 0.75 ml/mm, 0.5 ml/mm, 0.4 ml/mm, 0.3 ml/mm, 0.2 ml/ mm,
or 0.1 ml/mm, as measured via the NMR Mouse method. Further, due to
the use of wells in the integrated system, the system exhibits a
negative slope of fluid removal from the topsheet as measured via
the NMR Mouse method.
[0232] Further, fluid bridging is greatly enhanced via close
integration of all three layers by a formation means. The resulting
benefit is an ansorbent structure that is able to take in complex
fluids at a rapid rate while providing an unmatched dryness. This
is unlike previous fast topsheets, such as hydrophilically coated
topsheets that may be fast but remain wet or have high-rewet
values.
[0233] The integrated layer system may be quantified by the speed
of moisture withdrawal from topsheet after fluid insult as measured
by the NMR Mouse technique, the amount of residual moisture in the
topsheet layer as measured by the NMR Mouse technique, or the rewet
values of the pad as measured by the traditional rewet method.
[0234] The unique structure of this product can be measured by the
amount of topsheet that is below or in-plane with the core as
measured by NMR Mouse. The integrated absorbent structure may
exhibit a residual fluid amount in the top 1 mm of the integrated
topsheet core sample of less than 0.6 ml, such as, for example,
between 0.0 ml and 0.5 ml, such as, less than 0.4 ml, less than 0.3
ml, less than 0.2 ml, or between 0 and 0.1 ml according to the NMR
Mouse method.
[0235] As shown in FIGS. 27 to 29, a variety of patterns could be
used. The patterns include zones. Zones are areas exhibiting one of
either a visual pattern, a topography, an absorption rate or
property, a bending parameter, a compression modulus, a resiliency,
a stretch parameter or a combination thereof. The visual pattern
may be any known geometric shape or pattern that is visual and can
be conceived by the human mind. The topography may be any known
pattern that is measurable and can be conceived by the human mind.
Zones may be repeated or discrete. Zones may be orthogonal shapes
and continuities that provide a visual appearance. The use of zones
allows for tailoring of the fluid handling and mechanical
properties of and within the pad. The integrated absorbent
structure may have one or more visual patterns including zones
along one of either the longitudinal or lateral axis of the
integrated layers. The integrated layers may have two or more zones
comprising one or more visual patterns. The two or more zones may
be separated by a boundary. The boundary may be a topographical
boundary, a mechanical boundary, a visual boundary, a fluid
handling property boundary, or a combination thereof, provided that
the boundary is not a densification of the absorbent core
structure. The boundary property may be distinct from the two zones
adjacent to the boundary. The absorbent structure may have a
perimeter boundary that exhibits a different property than the one
or more adjacent zones to the boundary.
[0236] It has also been surprisingly found that using formation
means to integrate the topsheet, secondary topsheet, and the
heterogeneous mass results in an improved flexibility of the pad
(as measured by bunched compression. This is unlike traditional
systems that become stiffer due to welding, glues, embossing, or
when they improve capillarity through densification.
[0237] Further, by integrating a topsheet and/or a secondary
topsheet with a fibrous web having high capillarity absorbents
intertwined by either enrobement of the fibers or by using
absorbent fibers, one can create an absorbent product that has a
high degree of integration (as demonstrated by dryness of
topsheet), low rewet due to strong capillarity close to the
topsheet, and improved flexibility of the pad (as measured by the
bunched compression test). This is unlike prior approaches to
improve fluid bridging such as welding, gluing or needlepunching
the topsheet to the Secondary Topsheet which often leads to a
potential increase in the stiffness of the resulting product or a
loss in flexibility of the combined layer versus the individual
layers.
[0238] Further, the integrated topsheet and/or secondary topsheet
with the heterogeneous mass delivers unique patterns that enable
shaping dynamically without loss of structural integrity. The
unique patterns may be leveraged such that they selectively deform
some of the web enabling multiple bending modes for conforming to
complex bodily shapes without meaningful degradation of the
structural integrity of the absorbent product. Further, by
designing the bending points in the absorbent product using
formation means, one may create a product that has a better fit.
The better fit is exemplified when the product is placed in contact
with the spacing in the gluteal groove. Further, by enabling the
product to have three dimensional topography, the absorbent product
may bend and stretch to complex shapes and various surface
topographies to be closer to the body of the user. Bending may be
different for different sections.
[0239] The bunched compression method is a multi-axis bending test
that is executed on product or core samples. When formation means
is executed on a traditional layered core or a foam layer, in-use
properties rapidly degrade or create product/core integrity issues.
The ratio of the peak force to wet recovery energy communicates the
balance between flexibility and shape stability of the product. The
lower the peak force the more flexibility the product/material has
when bending and conforming to her complex shape.
[0240] The absorbent structure may be deformed in the z direction
with low compressive force while nevertheless preserving
simultaneous the ability to conform and flow with complex bodily
movements.
[0241] As discussed above, the topsheet and/or secondary topsheet
integrated with a heterogeneous mass having a high capillarity
absorbent has been found to impart curved, stretchable contours
that can flow with the body without significant force to deform
while not displacing her tissues aggressively. Further, the
absorbent structure lacks strong densification, sharp tears, or
shredding as seen with traditional cellulose based materials.
Strong densification, sharp tears, and shredding may provide sharp
contour which lead to a reduction in comfort and tactile softness.
This property is exhibited using the Z-compressibility and the
BC/Kawabata test methods.
[0242] Increased product flexibility may directly lead to improved
comfort by the user. Increased flexibility allows for the product
to follow the topography of the user's body and thereby may create
better contact between the article and the body. Further, improved
flexibility leads to a better usage experience because the product
behaves more like a garment and may follow the contours of the body
through dynamic motions. Another vector that improves overall
comfort for the user is the level of cushion that the absorbent
article may provide. Due to the direct contact with the body,
increasing the cushion of the product and removing any rough
surfaces leads to an improved tactile feel and comfort for the
user.
[0243] A dynamic flexibility range and sustained product shape is
given to the product by the specified ratio of peak to wet recovery
of less than 150 gf/N*mm and greater than 30 gf/N*mm Conformance is
also communicated to the user thru initial interaction with the pad
the "cushiness" in caliper, stiffness and resiliency properties of
the absorbent product in the thru thickness direction. In market
products have demonstrated a consumer desirable stiffness gradient
that signals a premium quality softness and product conformance in
the product thru thickness direction. The quilted and/or pillowy
nature of particular formation means patterns with the desireable
stiffness gradient provide simultaneously a ZD direction cushiness
that is desirable as well as active body cleaning locations that
enhance the comfort experience in a way that the topography of
traditional in market core systems cannot.
TABLE-US-00001 TABLE 1 Description of materials, material layers,
integrated layers, suppliers, basis weight, caliper, capillarity
work potential, and capillarity gradients. Distance Basis Topsheet
to CWP MATERIAL Weight Caliper CWP Absorbent Gradient DESCRIPTIONS
(gsm) (mm) (mJ/m{circumflex over ( )}2) Layer, mm (mJ/,{circumflex
over ( )}2)/mm Prior Art 1 Always Ultra Market N/A N/A N/A N/A N/A
Product Composition: Topsheet 25 0.75 130 Secondary Topsheet 77
0.77 330 0.75 267 Absorbent Core 180 1.15 860 0.77 688 Prior Art 2
Infinity Market Product N/A N/A N/A N/A N/A Composition: Topsheet
28 0.38 115 Foam Layer 1 188 1.5 1300 0.38 3118 Foam Layer 2 188
0.6 7000 1.5 3800 Inventions 3a, 3b, 3c, 4a, 4b, 4c Nonwoven
Topsheet 50 1.1 125 Heterogenous Mass 224 1.8 7870 0.5 15490
Stratum 0.25 30980 0.15 51633 Inventions 3d, 4d Nonwoven Topsheet
28 0.38 115 BiCO Heterogenous Mass 224 1.8 7870 0.5 15510 Stratum
0.25 31020 0.15 51700
[0244] As shown in Table 1, Prior Art 1 is an Always Ultra Market
product, Prior Art 2 is an Always Infinity product, Inventions 3a,
3b, 3c, 4a, 4b, and 4c are a nonwoven topsheet with a heterogeneous
mass stratum, and Inventions 3d and 4d are a nonwoven BiCo topsheet
with a heterogeneous mass stratum. As shown by the data in Table 1,
the combination of different material layers and the integration of
those layers can be used to create a high capillarity work
potential gradient across an absorbent structure, or said another
way, an optimized capillarity cascade. For instance, a capillarity
gradient between two layers within an Always Ultra pad can be
determined by comparing the capillarity of the first layer, e.g.
topsheet (130 mJ/m.sup.2) and the capillarity of the second layer,
e.g. STS (330 mJ/m.sup.2), and then dividing the capillarity work
potential by the distance the fluid must travel. In this case, the
capillarity difference, 200 mJ/m.sup.2 is divided by the distance
between the two top surfaces (e.g. 0.75 mm distance), giving a
capillarity gradient of about 267 mJ/m.sup.2/mm. The distance
between the top surface of the STS and the top surface of the core
is 0.77 mm and the difference in capillarity work potential between
the two materials is 530 mJ/m.sup.2. Thus, the capillarity gradient
between these two layers is about 688 mJ/m.sup.2/mm. For a measure
of the overall performance of an absorbent article, the difference
between the capillarity work potential of the topsheet to the
storage layer, or core, should be evaluated. For an Always Ultra
pad, the capillarity of the storage layer or core is 860
mJ/m.sup.2, so the capillarity difference between the topsheet and
core is 730 mJ/m.sup.2. The overall system has a total fluid travel
distance of 1.52 mm and a capillarity work potential difference of
730 mJ/m.sup.2, so the capillarity gradient of this absorbent
system is about 480 mJ/m.sup.2/mm.
[0245] With an absorbent product made with similar nonwoven
topsheet (125 mJ/m.sup.2 capillarity work potential, 1.1 mm
caliper), no STS, and a heterogeneous mass core (7870 mJ/m.sup.2)
wherein both layers have been integrated through formation means or
solid state formation, the capillarity gradient is significantly
stronger because the distance between the two layers has also been
significantly reduced via solid state formation. The actual
distance the fluid has to travel from the top surface of the
topsheet to the top of the heterogeneous mass core has been reduced
to between 0.15 mm and 0.5 mm. If the distance the fluid has to
travel is reduced to 0.5 mm, the capillarity gradient is now 15490
mJ/m.sup.2/mm. In the situation where surface wells as previously
described have been formed by solid state formation, the distance
between the topsheet and core may be as less than or equal to 0.25
mm, and the fluid can travel in either the Z direction or within
multiple X-Y planes due to the topsheet and heterogeneous mass
layer being closely integrated within the wells. In this case, the
capillarity gradient may be as high as 30,980 mJ/m.sup.2/mm.
[0246] Therefore, one embodiment of the present invention is an
absorbent product having a capillarity gradient between the
topsheet and storage layer that may be greater than 8,000
mJ/m.sup.2/mm, such as for example, between 8,000 mJ/m.sup.2/mm and
60,000 mJ/m.sup.2/mm, such as for example, 14,000 mJ/m.sup.2/mm, or
20,000 mJ/m.sup.2/mm, or 28,000 mJ/m.sup.2/mm, or 36,000
mJ/m.sup.2/mm, or 50,000 mJ/m.sup.2/mm, or 60,000
mJ/m.sup.2/mm.
[0247] Table 2A and 2B. Examples from combining different
materials, cores, topsheet integration, types of integration and
resulting mechanical characteristics.
TABLE-US-00002 TABLE 2A Bunched Compression 1st Cycle Wet Recovery
Ratio Dry Peak Topsheet Dry Peak Energy 5th Over Wet Examples
Integration? Force, gf Cycle, N mm Energy Prior Art 1 None 200 1.2
167 Prior Art 2 None 121 2.6 47 Invention 3a None 350 3.5 100
Invention 3b RIPS-DB1 257 1.9 135 Invention 3c Jellyfish 171 1.94
88 Invention 3d Diamond 319 1.8 177 Invention 4a None 98 2.2 45
Invention 4b RIPS-DB1 74 1.5 49 Invention 4c Jellyfish 75 1.4 54
Invention 4d Diamond 78 1.0 78
TABLE-US-00003 TABLE 2B Z-Compression Slope (Newton/mm)@ Percent
Compression of Initial Caliper Kawabata Testing Compressive
Kawabata Dry, MD Energy Examples (gf*cm{circumflex over ( )}2/cm)
13% 25% 38% 50% Resiliency (N mm) Prior Art 1 1.74 2.04 5.04 14.63
71.26 77% 21.0 Prior Art 2 10.65 5.49 9.30 9.78 17.82 40% 16.8
Invention 3a 11.65 4.30 7.57 13.82 20.18 40% 25.2 Invention 3b 3.82
5.29 10.03 13.25 17.32 40% 13.0 Invention 3c 1.49 5.28 14.07 25.96
45.09 43% 22.2 Invention 3d 2.77 6.29 10.44 13.11 18.42 40% 20.5
Invention 4a 6.55 4.30 7.57 13.82 20.18 40% 25.2 Invention 4b 2.92
5.29 10.03 13.25 17.32 40% 13.0 Invention 4c 1.88 5.28 14.07 25.96
45.09 43% 22.2 Invention 4d 2.43 6.29 10.44 13.11 18.42 40%
20.5
[0248] Tables 2A and 2B combined show separates mechanical
characteristics into three distinct groups. The invention samples
are integrated. The Bunch Compression data is important to the
consumer because a product that is too stiff when dry will be
uncomfortable to wear as it will tend to chafe the inner thigh
during movement. Further, a product that tends to disintegrate
after becoming wet or soiled will also be uncomfortable to wear as
it will tend to remain bunched and not provide good coverage of the
panty. Therefore, an optimized product should have a 1.sup.st cycle
Dry Peak Force compression of between about 30 and 100 gf and a Wet
Recovery energy of between about 1 and 2 N*mm.
[0249] Kawabata drape testing is a common industrial standard
method for measuring the ability of a material to bend. Given the
complex geometry of the intimate area, it has been found that a
desirable dry bending measurement according to this method is
between 2 and 10.5 (gf*cm.sup.2)/cm as measured in either the MD or
CD direction. A desirable wet bending measurement is between 1.25
and 10 (gf*cm.sup.2)/cm as measured in either the MD or CD
direction when 0.5 mls of 0.9% saline solution is slowly added to
the sample over a 5 minute period and the product tested on the
Kawabata instrument after a further 2 minute waiting period.
Referring to the previous discussion about the desire for the
product to not disintegrate when wet, it is desirable that the wet
bending measurement according to the Kawabata drape testing when
ran for a wet sample should drop less than about 50% of the
measurement for the same sample when dry, such as, for example,
less than about 40%, less than 30%, less than 20%, or less than
about 10%.
[0250] Without being bound by theory, it is understood that
compression recovery is also important to consumers. Consumers want
the product to remain in contact with their intimate area without
exerting a noticeable or unpleasant pressure against the skin. It
has been found that there is an optimum compressive energy of
between about 10 and 20 N*mm. It is also desirable to have a
resiliency of between 20 and 50%. Further, it is desirable to have
a compression profile that has a force of (N*mm) at different
percentages of compression that falls within the following
ranges:
TABLE-US-00004 % Compression of product thickness N/mm optimal
range 1-13 2.5 to 6 13-25 7 to 14 25-38 10 to 26 38-50 17 to 45
[0251] It has been surprisingly found that by having a percent
compression of product thickness exhibiting the N/mm optimal ranges
from above, one can create a product that has a smooth compression
profile during dynamic bodily movements.
[0252] The surprising value of these measurements is in identifying
unique new structures and products which have an optimized bunch
compression in both the dry and wet states over multiple cycles of
movement, an ability to conform to tight bending radii without
creasing or breaking, and to provide a moderate level of resiliency
so as to be invisible to the consumer while she is wearing the
product.
[0253] In one embodiment, an absorbent article has a dry bending
measurement according to the Kawabata method of between 2 and 10.5
(gf*cm.sup.2)/cm as measured in either the MD or CD direction or a
wet bending measurement between 1.25 and 10 (gf*cm.sup.2)/cm as
measured in either the MD or CD direction, and in addition,
optionally, one or more of any of the following; a 1.sup.st cycle
Dry Peak Force compression of between about 30 and 150 gf, a Wet
Recovery energy of between about 1 and 2 N/mm, a compressive energy
of between about 10 and 20 N/mm, a resiliency of between 20 and
50%, or a speed of recovery as measured by the Z-Compressive slope
(N/mm) at 1-13% of between 2 and 6 N/mm, at 13-25% of between 7 and
14 N/mm, at 25-38% of between 10 and 26 N/mm, or at 38-50% of
between 17 and 45 N/mm.
[0254] In one embodiment, an absorbent article has a speed of
recovery as measured by the Z-Compressive slope (N/mm) at 1-13% of
between 2 and 6 N/mm, at 13-25% of between 7 and 14 N/mm, at 25-38%
of between 10 and 26 N/mm, or at 38-50% of between 17 and 45 N/mm,
and in addition, optionally, one or more of any of the following; a
1.sup.st cycle Dry Peak Force compression of between about 30 and
150 gf, a Wet Recovery energy of between about 1 and 2 N/mm, a
compressive energy of between about 10 and 20 N/mm, a resiliency of
between 20 and 50%, or a dry bending measurement according to the
Kawabata method of between 2 and 10.5 (gf*cm.sup.2)/cm as measured
in either the MD or CD direction or a wet bending measurement
between 1.25 and 10 (gf*cm.sup.2)/cm as measured in either the MD
or CD direction.
TABLE-US-00005 TABLE 3 Examples from combining different materials,
cores, topsheet integration, types of integration and resulting
fluid handling characteristics. FLUID Handling Testing NMR-K-
NMR-K- NMR-K- Blot, Total NMR- Proflle Profile Proflle Absorbent
Topsheet Residual, Residual (% decay (% decay (% decay LiTS
Material/System Integration? mg ml/mm @60 sec) @100 sec) @300 sec)
(g) Prior Art 1 None 80 1.25 0 8 12 0.32 Prior Art 2 None 22 0.3 30
69 90 0.05 Invention 3a None 52 0.57 2 13 60 0.22 Invention 3b
RIPS-DB1 21 0.33 85 87 89 0.05 Invention 3c Jellyfish 18 0.29 87 90
93 0.04 Invention 3d Diamond 16 0.25 90 94 95 0.04 Invention 4a
None 52 0.57 2 13 60 0.22 Invention 4b RIPS-DB1 21 0.33 85 87 89
0.05 Invention 4c Jellyfish 18 0.29 87 90 93 0.04 Invention 4d
Diamond 16 0.25 90 94 95 0.04
[0255] Table 3 indicates the ability of the new absorbent structure
to quickly dry the topsheet relative to current commercial products
as measured by the Mouse NMR K-Profile at 60 seconds, 100 seconds,
or 300 seconds. The Mouse NMR method for residual fluid measures
the ability of the new absorbent structure to efficiently wick
fluid away from the topsheet within the top millimeter of the
topsheet. The LiTS method measures residual fluid within the
topsheet. The Blot test assesses the competition for fluid between
a skin analog and the absorbent product.
[0256] In one embodiment, as measured by the Mouse NMR K-Profile
method, the new absorbent article is able to remove more than 90%
of the fluid within 300 seconds after insult, more than 70% of the
fluid within 100 seconds after insult, and more than 30% of the
fluid within 60 seconds after insult, and in addition, optionally,
one or more of any of the following; the ability to reduce the
level of fluid remaining on the skin analog to a level below 20 mg
as measured by the Blot test, the ability to reduce the residual
fluid in the top 1 mm of the absorbent article to below 0.30 ml/mm
as measured by the Mouse NMR method for residual fluid, or the
ability to reduce the residual fluid in a topsheet to a value of
0.04 g or less using the LiTS method for measuring residual
fluid.
[0257] In one embodiment, the new absorbent structure is able to
reduce the level of fluid remaining on the skin analog to a level
below 20 mg as measured by the Blot test, and in addition,
optionally, one or more of any of the following; the ability to
remove more than 90% of the fluid within 300 seconds after insult,
more than 70% of the fluid within 100 seconds after insult, and
more than 30% of the fluid within 60 seconds after insult as
measured by the Mouse NMR K-Profile method or the ability to reduce
the residual fluid in the top 1 mm of the absorbent article to
below 0.30 ml/mm as measured by the Mouse NMR method for residual
fluid.
[0258] In one embodiment, the new absorbent structure is able to
reduce the residual fluid in the top 1 mm of the absorbent article
to below 0.30 ml/mm as measured by the Mouse NMR method for
residual fluid, and in addition, optionally, one or more of any of
the following; the ability to remove more than 90% of the fluid
within 300 seconds after insult, more than 70% of the fluid within
100 seconds after insult, and more than 30% of the fluid within 60
seconds after insult as measured by the Mouse NMR K-Profile method
or the ability to reduce the level of fluid remaining on the skin
analog to a level below 20 mg as measured by the Blot test.
[0259] In one embodiment, the new absorbent structure is able to
reduce the residual fluid in a topsheet to a value of 0.04 g or
less using the LiTS method for measuring residual fluid.
[0260] Improving mechanical properties of the absorbent product,
such as its ability to conform to complex geometries via improved
bending properties, optimized bunch compression and resiliency
properties, and Z-compression has the potential to negatively
affect fluid handling properties. For instance, as the absorbent
article conforms to the body better, the body exudates no longer
contact the absorbent article over a broad area. Rather, the body
exudates are more likely to contact the topsheet of the absorbent
article on a smaller portion of the topsheet. This results in a
need for the absorbent article to also have an improved ability to
transport larger amounts of fluid down and away from the point of
fluid contact with the absorbent article. Not addressing this need
will leave the consumer feeling wet longer and dissatisfied with
the product performance even though the product fits better and is
more comfortable to wear. Therefore, there is a need to provide an
absorbent article with improved fluid handling properties in
combination with improvement of mechanical properties. The improved
absorbent article disclosed herein addresses both of those needs
via the following combinations.
[0261] In one embodiment, the new absorbent article has a dry
bending measurement between 2 and 10.5 gf*cm.sup.2/cm or a wet
bending measurement between 1.25 and 10 gf*cm2/cm according to the
Kawabata method measured in either the MD or CD direction, and is
able to remove more than 90% of the fluid within 300 seconds after
insult, more than 60% of the fluid within 100 seconds after insult,
or more than 30% of the fluid within 60 seconds after insult
according to the NMR K-Profile test method.
[0262] In one embodiment, the new absorbent article has a dry
bending measurement between 2 and 10.5 gf*cm.sup.2/cm or a wet
bending measurement between 1.25 and 10 gf*cm2/cm according to the
Kawabata method measured in either the MC or CD direction, and is
able to reduce the fluid remaining on the skin analog to below 20
mg, below 40 mg, or below 60 mg as measured by the Blot test.
[0263] In one embodiment, the new absorbent article is able to
remove more than 90% of the fluid within 300 seconds after insult,
more than 60% of the fluid within 100 seconds after insult, or more
than 30% of the fluid within 60 seconds after insult and has a
bunch compression ratio of 1.sup.st cycle dry peak force (gf) over
5.sup.th cycle wet recovery energy (N*mm) of between 45 and 135
gf/N*mm.
[0264] In one embodiment, the new absorbent article has a bunch
compression ratio of 1.sup.st cycle dry peak force (gf) over
5.sup.th cycle wet recovery energy (N*mm) of between 45 and 135
gf/N*mm and is able to reduce the fluid remaining on the skin
analog to below 20 mg, below 40 mg, or below 60 mg as measured by
the Blot test.
[0265] Further, by utilizing repeating patterns of bending models
on a meso-scale versus historical macro scale that are bendable and
shapeable based on each user's unique anatomical shape and how the
user deforms the absorbent system while wearing, it has been found
that one can create an absorbent structure that is able to have
improved contact between the absorbent product and the user.
[0266] As used herein, meso-scale relates to a mechanical
transformation that displaces larger more infrequent modifications
to the absorbent article. For instance, traditional absorbent
articles may have two to seven zones involving structures or
mechanical transformations. In this context, meso-scale refers to a
mechanical transformation that involves 10-70 mechanical
transformations within the absorbent article. For instance,
traditional hot pin aperturing or needle punching involves 1 to 10
fibers whereas a meso-scale mechanical transformation may involve
greater than 10 and up to 100 fibers or more. In another example,
an absorbent article may have one to five bending moments across
the width or length of the absorbent article. In contrast, a
meso-scale mechanical transformation may involve 5 to 50
transformations.
[0267] Without being bound by theory, applicants have found that it
is desireable to create a repeating pattern of bending modes
delivered by formation means that is significantly more that has
ever been offered before and to do this without compromising
resiliency or imparting discomfort. This improved bending is
exemplified using the BC, Kawabata test method plus the
z-compression method. The Increased dynamic body conformance
promotes a panty-like fit experience. Further, without being bound
by theory, it is believed that the proposed method and combination
of selective materials may lead to the creation of pillow-like 3D
topography creates structures that have a low initial stiffness
gradient in the first 50% of compression as this compression
increases the stiffness gradient becomes stiffer becoming
equivalent or slightly greater than the base structure due to the
pre-compression built in to the structure by topsheet integration.
The low initial stiffness gradient promotes the feeling of an airy
soft feeling signaling comfort to her.
[0268] Textured surface and increased stiffness gradient (when
compressed) aides in active cleaning of her body with an additional
frictional component known as "plowing friction". Locally skin/fat
deforms down into the undulations of the pad surface as her body
and pad form an interface and pressure is created. Pad and body
move relative to one another fluid is wiped away by the pad and
quickly wicked away from her body by the highly absorbent TS/core
assembly. Active or dynamic cleaning of her body gives her a clean,
dry and fresh feeling.
[0269] The absorbent core structure may be attached to the
topsheet, the backsheet, or both the topsheet and backsheet using
bonds, a bonding layer, adhesives, or combinations thereof.
Adhesives may be placed in any suitable pattern, such as, for
example, lines, spirals, points, circles, squares, or any other
suitable pattern. Bonds may be placed in any suitable pattern, such
as, for example, lines, spirals, points, circles, squares, or any
other suitable pattern.
[0270] The absorbent layers may be combined using an intermediate
layer between the two layers. The intermediate layer may comprise a
tissue, a nonwoven, a film, or combinations thereof. The
intermediate layer may have a permeability greater than the 200
Darcy.
[0271] FIG. 12 a perspective view of one embodiment of a sanitary
napkin. The illustrated sanitary napkin 10 has a body-facing upper
side 11 that contacts the user's body during use. The opposite,
garment-facing lower side 13 contacts the user's clothing during
use.
[0272] A sanitary napkin 10 can have any shape known in the art for
feminine hygiene articles, including the generally symmetric
"hourglass" shape as shown in FIG. 12, as well as pear shapes,
bicycle-seat shapes, trapezoidal shapes, wedge shapes or other
shapes that have one end wider than the other. Sanitary napkins and
pantyliners can also be provided with lateral extensions known in
the art as "flaps" or "wings". Such extensions can serve a number
of purposes, including, but not limited to, protecting the wearer's
panties from soiling and keeping the sanitary napkin secured in
place.
[0273] The upper side of a sanitary napkin generally has a liquid
pervious topsheet 14. The lower side generally has a liquid
impervious backsheet 16 that is joined with the topsheet 14 at the
edges of the product. An absorbent core 18 is positioned between
the topsheet 14 and the backsheet 16. A secondary topsheet may be
provided at the top of the absorbent core 18, beneath the
topsheet.
[0274] The topsheet 12, the backsheet 16, and the absorbent core 18
can be assembled in a variety of well-known configurations,
including so called "tube" products or side flap products, such as,
for example, configurations are described generally in U.S. Pat.
No. 4,950,264, "Thin, Flexible Sanitary Napkin" issued to Osborn on
Aug. 21, 1990, U.S. Pat. No. 4,425,130, "Compound Sanitary Napkin"
issued to DesMarais on Jan. 10, 1984; U.S. Pat. No. 4,321,924,
"Bordered Disposable Absorbent Article" issued to Ahr on Mar. 30,
1982; U.S. Pat. No. 4,589,876, and "Shaped Sanitary Napkin With
Flaps" issued to Van Tilburg on Aug. 18, 1987. Each of these
patents is incorporated herein by reference.
[0275] The backsheet 16 and the topsheet 14 can be secured together
in a variety of ways. Adhesives manufactured by H. B. Fuller
Company of St. Paul, Minn. under the designation HL-1258 or H-2031
have been found to be satisfactory. Alternatively, the topsheet 14
and the backsheet 16 can be joined to each other by heat bonding,
pressure bonding, ultrasonic bonding, dynamic mechanical bonding,
or a crimp seal. A fluid impermeable crimp seal 24 can resist
lateral migration ("wicking") of fluid through the edges of the
product, inhibiting side soiling of the wearer's undergarments.
[0276] As is typical for sanitary napkins and the like, the
sanitary napkin 10 of the present invention can have
panty-fastening adhesive disposed on the garment-facing side of
backsheet 16. The panty-fastening adhesive can be any of known
adhesives used in the art for this purpose, and can be covered
prior to use by a release paper, as is well known in the art. If
flaps or wings are present, panty fastening adhesive can be applied
to the garment facing side so as to contact and adhere to the
underside of the wearer's panties.
[0277] The backsheet may be used to prevent the fluids absorbed and
contained in the absorbent structure from wetting materials that
contact the absorbent article such as underpants, pants, pyjamas,
undergarments, and shirts or jackets, thereby acting as a barrier
to fluid transport. The backsheet according to an embodiment of the
present invention can also allow the transfer of at least water
vapour, or both water vapour and air through it.
[0278] Especially when the absorbent article finds utility as a
sanitary napkin or panty liner, the absorbent article can be also
provided with a panty fastening means, which provides means to
attach the article to an undergarment, for example a panty
fastening adhesive on the garment facing surface of the backsheet.
Wings or side flaps meant to fold around the crotch edge of an
undergarment can be also provided on the side edges of the
napkin.
[0279] FIG. 13 is a cross-sectional view of the sanitary napkin 10
of FIG. 12, taken through line 2-2. As shown in the figure, the
absorbent core 18 structure comprises of a heterogeneous mass 22
comprising open-cell foam pieces 25. The topsheet is integrated
into the heterogeneous mass 22 forming wells 32.
[0280] FIG. 14 is a zoomed in version of a portion of FIG. 13. As
shown in FIG. 14, The topsheet 12 is incorporated into the
absorbent core 18 comprising a heterogeneous mass 22 stratum. The
heterogeneous mass 22 has open cell foam pieces 25. A well is 32 is
shown between the open cell foam pieces 25. A group of fibers 74 is
in the same X-Y plane as the heterogeneous mass 22 layer. from the
topsheet 12
[0281] FIG. 15 is an SEM micrograph of a heterogeneous mass 22
prior to any formation means or forming of canals. As shown in FIG.
15, the absorbent stratum 40 is a heterogeneous mass 22 comprising
a first planar nonwoven 44 having a first surface 46 and a second
surface 48 and a second planar nonwoven 50 having a first surface
52 and a second surface 54. An open cell foam piece 25 enrobes a
portion of the first planar nonwoven 44 and a portion of the second
planar nonwoven 50. Specifically, the open cell foam piece 25
enrobes enrobeable elements 58 in both the second surface 48 of the
first planar nonwoven 44 and the first surface 52 of the second
planar nonwoven 50.
[0282] FIG. 16 is an SEM micrograph of a heterogeneous mass 22
after formation means. As shown in FIG. 16, the absorbent stratum
40 is a heterogeneous mass 22 comprising a first planar nonwoven 44
having a first surface 46 and a second surface 48 and a second
planar nonwoven 50 having a first surface 52 and a second surface
54. An open cell foam piece 25 enrobes a portion of the first
planar nonwoven 44 and a portion of the second planar nonwoven 50.
The planar nowovens are shown as wavy due to the impact of the
formation means.
[0283] FIGS. 17 and 18 are top views of a topsheet 12 that has been
integrated with a heterogeneous mass 22 stratum. A top view of one
or more wells 32 or points of topsheet discontinuity 76 are
indicated. FIG. 17 has been created using polarized light.
[0284] FIG. 19 is a cross section view of a portion of FIG. 18.
FIG. 19 is an SEM micrograph of a heterogeneous mass 22 after
formation means. As shown in FIG. 19, the absorbent stratum 40 is a
heterogeneous mass 22 comprising a first planar nonwoven 44 having
a first surface 46 and a second surface 48 and a second planar
nonwoven 50. An open cell foam piece 25 enrobes a portion of the
first planar nonwoven 44 and a portion of the second planar
nonwoven 50. The planar nowovens are shown as wavy due to the
impact of the formation means. Wells 32 or points of topsheet
discontinuity 76 are shown between the open cell foam pieces 25. A
group of fibers 74 is in the same X-Y plane as the heterogeneous
mass 22 layer. The distal end of a well is shown as 78. As shown in
FIG. 19, by integrating the topsheet with the absorbent structure,
one reduces the distance in an X-Y plane (X-Y distance) 82 that
fluid must travel to be absorbed into the absorbent core structure.
As fluid goes deeper into the well 32, the X-Y distance 82 becomes
small within each X-Y plane creating a higher capillary cascade.
This is shown by the two X-Y distance arrows identified as 82. This
is unlike the traditional fluid path wherein fluid travels a
vertical distance or Z-distance 87 through a non-integrated portion
of the topsheet before reaching the core.
[0285] FIGS. 20 and 21 are top views of a topsheet 12 that has been
integrated with a heterogeneous mass 22. A top view of one or more
wells 32 or points of topsheet discontinuity 76 are indicated. FIG.
20 has been created using polarized light.
[0286] FIG. 22 is a cross section view of a portion of FIG. 21.
FIG. 22 is an SEM micrograph of a heterogeneous mass 22 after
formation means. As shown in FIG. 22, the absorbent stratum 40 is a
heterogeneous mass 22 comprising a first planar nonwoven 44 and a
second planar nonwoven 50. An open cell foam piece 25 enrobes a
portion of the first planar nonwoven 44 and a portion of the second
planar nonwoven 50. The planar nowovens are shown as wavy due to
the impact of the formation means. One or more wells 32 or points
of topsheet discontinuity 76 are shown between the open cell foam
pieces 25. A group of fibers 74 is in the same X-Y plane as the
heterogeneous mass 22 layer. The distal end of a well is shown as
78.
[0287] FIG. 23 is a zoomed in portion of FIG. 22. FIG. 23 is an SEM
micrograph of a heterogeneous mass 22 after formation means. As
shown in FIG. 23, the absorbent stratum 40 is a heterogeneous mass
22 comprising a first planar nonwoven 44 and a second planar
nonwoven 50. An open cell foam piece 25 enrobes a portion of the
first planar nonwoven 44 and a portion of the second planar
nonwoven 50. The planar nowovens are shown as wavy due to the
impact of the formation means. A well 32 or point of topsheet
discontinuity 76 is shown between the open cell foam pieces 25. A
group of fibers 74 is in the same X-Y plane as the heterogeneous
mass 22 layer. The distal end of a well is shown as 78.
[0288] FIG. 24 is a top views of a topsheet 12 that has been
integrated with a heterogeneous mass 22 stratum. One or more wells
are indicated as 32.
[0289] FIG. 25 is a cross section view of a portion of FIG. 24.
FIG. 25 is an SEM micrograph of a heterogeneous mass 22 after
formation means. As shown in FIG. 22, the absorbent stratum 40 is a
heterogeneous mass 22 comprising a first planar nonwoven 44 and a
second planar nonwoven 50. An open cell foam piece 25 enrobes a
portion of the first planar nonwoven 44 and a portion of the second
planar nonwoven 50. The planar nowovens are shown as wavy due to
the impact of the formation means. A well 32 or point of topsheet
discontinuity 76 is shown between the open cell foam pieces 25. A
group of fibers 74 is in the same X-Y plane as the heterogeneous
mass 22 layer. The distal end of a well is shown as 78.
[0290] FIG. 26 is a zoomed in view of a portion of FIG. 25. FIG. 26
is an SEM micrograph of a heterogeneous mass 22 after formation
means. As shown in FIG. 26, the absorbent stratum 40 is a
heterogeneous mass 22 comprising a first planar nonwoven 44 having
a first surface 46 and a second surface 48 and a second planar
nonwoven 50. An open cell foam piece 25 enrobes a portion of the
first planar nonwoven 44 and a portion of the second planar
nonwoven 50. The planar nowovens are shown as wavy due to the
impact of the formation means. A well 32 or point of topsheet
discontinuity 76 is shown between the open cell foam pieces 25. A
group of fibers 74 is in the same X-Y plane as the heterogeneous
mass 22 layer. The distal end of a well is shown as 78.
[0291] FIGS. 27-29 are images of different topsheets 12 that have
been integrated with a heterogeneous mass 22 stratum. FIGS. 27-29
show elongated wells 32 and non-deformed areas 33 that have not
been treated with a deformation means. FIG. 29 show a first zone 80
and a second zone 81 and a first boundary 84 and a second boundary
85. FIG. 29 is a conceptual core showing a plurality of zones
within the same product. The different zones are created using
forming means. In this case, the core may be modified to provide
optimum fluid acquisition in the middle, optimum fluid
transportation in the front and back, and enhanced barrier (height,
absorbency, etc.) around the perimeter of the pad. The core of FIG.
29 is not to be considered a limiting embodiment. One of ordinary
skill in the art would, upon seeing the core of FIG. 29, understand
that the core may comprise additional zones such as, for example,
between 2 and 10 zones, such as, for example, 3 zones, 4 zones, 5
zones, 6 zones, 7 zones, 8 zones, or 9 zones.
[0292] Additionally, each one exhibits a distinct topographical
surface and visual geometry. As shown in FIG. 29, more than one
geometry may be located within a single absorbent article.
ZD Compression
[0293] The ZD compression of a specimen is measured on a constant
rate of extension tensile tester (a suitable instrument is the MTS
Alliance using Testworks 4.0 Software, as available from MTS
Systems Corp., Eden Prairie, Minn.) using a load cell for which the
forces measured are within 10% to 90% of the limit of the cell. The
bottom stationary fixture is a circular, stainless steel platen 100
mm in diameter, and the upper movable fixture is a circular,
stainless steel platen 40.00 mm in diameter. Both platens have
adapters compatible with the mounts of the tensile tester, capable
of securing the platens parallel to each other and orthogonal to
the pull direction of the tensile tester. All testing is performed
in a room controlled at 23.degree. C..+-.3 C.degree. and 50%.+-.2%
relative humidity.
[0294] Samples are conditioned at 23.degree. C..+-.3 C.degree. and
50%.+-.2% relative humidity two hours prior to testing. Identify
the longitudinal and lateral center of the product. Remove the
layer of interest from the article using cryo-spray as needed. From
the longitudinal and lateral midpoint, die cut a square
50.0.+-.0.05 mm. Specimens are prepared from five replicate
samples.
[0295] Before the compression test can be performed, the caliper of
a specimen is measured using a calibrated digital linear caliper
(e.g., Ono Sokki GS-503 or equivalent) fitted with a 24.2 mm
diameter foot with an anvil that is large enough that the specimen
can lie flat. The foot applies a confining pressure of 0.69 kPa to
the specimen. Zero the caliper foot against the anvil. Lift the
foot and insert the specimen flat against the anvil with its
longitudinal and lateral midpoint centered under the foot. Lower
the foot at about 5 mm/sec onto the specimen. Read the caliper (mm)
5.0 sec after resting the foot on the specimen and record to the
nearest 0.01 mm.
[0296] Set the nominal gage length between the platens to
approximately 3 mm greater than the specimens to be tested. Place
the specimen, body facing side upward, onto the bottom platen with
the longitudinal and lateral midpoint of the specimen centered
under the upper platen. Zero the crosshead and load cell. Lower the
crosshead at 1.00 mm/s until the distance between the bottom
surface of the upper platen and the upper surface of the bottom
platen is equal to the measured caliper of the specimen. This is
the adjusted gage length. Start data collection at a rate of 100
Hz. Lower the crosshead at 1.00 mm/s to 50% of the adjusted gage
length. Hold for 0.00 sec and then return the crosshead to the
adjusted gage length Immediately repeat this cycle for four
additional cycles. Return the crosshead to the nominal gage length
and remove the specimen. From the resulting Force (N) versus
Displacement (mm) curves, calculate and record the Peak Force (N)
for Cycle 1 and Cycle 5 to the nearest 0.01N.
[0297] In like fashion, repeat the measure for a total of 5
replicate samples. Calculate and report the arithmetic mean for the
five Peak Force (N) for Cycle 1 and Peak Force (N) for Cycle 5
values separately to the nearest 0.01N.
Bunch Compression Test
[0298] Bunched Compression of a sample is measured on a constant
rate of extension tensile tester (a suitable instrument is the MTS
Alliance using Testworks 4.0 software, as available from MTS
Systems Corp., Eden Prairie, Minn., or equivalent) using a load
cell for which the forces measured are within 10% to 90% of the
limit of the cell. All testing is performed in a room controlled at
23.degree. C..+-.3 C.degree. and 50%.+-.2% relative humidity. The
test can be performed wet or dry.
[0299] As shown in FIG. 30, The bottom stationary fixture 3000
consists of two matching sample clamps 3001 each 100 mm wide each
mounted on its own movable platform 3002a, 3002b. The clamp has a
"knife edge" 3009 that is 110 mm long, which clamps against a 1 mm
thick hard rubber face 3008. When closed, the clamps are flush with
the interior side of its respective platform. The clamps are
aligned such that they hold an un-bunched specimen horizontal and
orthogonal to the pull axis of the tensile tester. The platforms
are mounted on a rail 3003 which allows them to be moved
horizontally left to right and locked into position. The rail has
an adapter 3004 compatible with the mount of the tensile tester
capable of securing the platform horizontally and orthogonal to the
pull axis of the tensile tester. The upper fixture 2000 is a
cylindrical plunger 2001 having an overall length of 70 mm with a
diameter of 25.0 mm. The contact surface 2002 is flat with no
curvature. The plunger 2001 has an adapter 2003 compatible with the
mount on the load cell capable of securing the plunger orthogonal
to the pull axis of the tensile tester.
[0300] Samples are conditioned at 23.degree. C..+-.3 C.degree. and
50%.+-.2% relative humidity for at least 2 hours before testing.
When testing a whole article, remove the release paper from any
panty fastening adhesive on the garment facing side of the article.
Lightly apply talc powder to the adhesive to mitigate any
tackiness. If there are cuffs, excise them with scissors, taking
care not to disturb the top sheet of the product. Place the
article, body facing surface up, on a bench. On the article
identify the intersection of the longitudinal midline and the
lateral midline. Using a rectangular cutting die, cut a specimen
100 mm in the longitudinal direction by 80 mm in the lateral
direction, centered at the intersection of the midlines. When
testing just the absorbent body of an article, place the absorbent
body on a bench and orient as it will be integrated into an
article, i.e., identify the body facing surface and the lateral and
longitudinal axis. Using a rectangular cutting die, cut a specimen
100 mm in the longitudinal direction by 80 mm in the lateral
direction, centered at the intersection of the midlines.
[0301] The specimen can be analyzed both wet and dry. The dry
specimen requires no further preparation. The wet specimens are
dosed with 7.00 mL.+-.0.01 mL 10% w/v saline solution (100.0 g of
NaCl diluted to 1 L deionized water). The dose is added using a
calibrated Eppendorf-type pipettor, spreading the fluid over the
complete body facing surface of the specimen within a period of
approximately 3 sec. The wet specimen is tested 15.0 min.+-.0.1 min
after the dose is applied.
[0302] Program the tensile tester to zero the load cell, then lower
the upper fixture at 2.00 mm/sec until the contact surface of the
plunger touches the specimen and 0.02 N is read at the load cell.
Zero the crosshead. Program the system to lower the crosshead 15.00
mm at 2.00 mm/sec then immediately raise the crosshead 15.00 mm at
2.00 mm/sec. This cycle is repeated for a total of five cycles,
with no delay between cycles. Data is collected at 100 Hz during
all compression/decompression cycles.
[0303] Position the left platform 3002a 2.5 mm from the side of the
upper plunger (distance 3005). Lock the left platform into place.
This platform 3002a will remain stationary throughout the
experiment. Align the right platform 3002b 50.0 mm from the
stationary clamp (distance 3006). Raise the upper probe 2001 such
that it will not interfere with loading the specimen. Open both
clamps. Referring to FIG. 31a, place the specimen with its
longitudinal edges (i.e., the 100 mm long edges) within the clamps.
With the specimen laterally centered, securely fasten both edges.
Referring to FIG. 31b, move the right platform 3002b toward the
stationary platform 3002a a distance 20.0 mm. Allow the specimen to
bow upward as the movable platform is positioned. Manually lower
the probe 2001 until the bottom surface is approximately 1 cm above
the top of the bowed specimen.
[0304] Start the test and collect displacement (mm) verses force
(N) data for all five cycles. Construct a graph of Force (N) versus
displacement (mm) separately for all cycles. A representative curve
is shown in FIG. 32a. From the curve record the Maximum Compression
Force for each Cycle to the nearest 0.01N. Calculate the % Recovery
between the First and Second cycle as (TD-E)/(TD-E1)*100 where TD
is the total displacement and E2 is the extension on the second
compression curve that exceeds 0.02 N. Record to the nearest 0.01%.
In like fashion calculate the % Recovery between the First Cycle
and other cycles as (TD-E.sub.i)/(TD-E1)*100 and report to the
nearest 0.01%. Referring to FIG. 32b, calculate the Energy of
Compression for Cycle 1 as the area under the compression curve
(i.e., area A+B) and record to the nearest 0.1 mJ. Calculate the
Energy Loss from Cycle 1 as the area between the compression and
decompression curves (i.e., Area A) and report to the nearest 0.1
mJ. Calculate the Energy of Recovery for Cycle 1 as the area under
the decompression curve (i.e. Area B) and report to the nearest 0.1
mJ. In like fashion calculate the Energy of Compression (mJ),
Energy Loss (mJ) and Energy of Recovery (mJ) for each of the other
cycles and record to the nearest 0.1 mJ
[0305] For each sample, analyze a total of five (5) replicates and
report the arithmetic mean for each parameter. All results are
reported specifically as dry or wet including test fluid (0.9% or
10%).
Kawabata Bending Rigidity
[0306] Bending rigidity is measured using a Kawabata Evaluation
System KES-FB2-A, Pure Bend Tester Sensor (available from Kato Tech
Co., Japan) and is reported in gfcm.sup.2/cm for both machine
direction (MD) and cross direction (CD). The instrument is
calibrated as per the manufacturer's instructions. All testing is
performed at about 23.degree. C..+-.2 C..degree. and about
50%.+-.2% relative humidity.
[0307] The Bending Rigidity is measured as the slope between 0.0
cm.sup.-1 and 0.25 cm.sup.-1 and -0.0 cm.sup.-1 and -0.25
cm.sup.-1. Instrument conditions are set as Maximum curvature:
Kmax=.+-.2.5 cm.sup.-1, Cycles=1, Bending rate=2.5 cm.sup.-1/sec.
The sensitivity is set appropriately for the sample's rigidity but
a nominal value of 50 is representative.
[0308] Articles or materials are preconditioned at about 23.degree.
C..+-.2 C..degree. and about 50%.+-.2% relative humidity for 2
hours prior to testing. If the sample is an article, remove the
layer of interest from the article using cryo-spray as needed. The
"Standard Condition" specimen size is 20.0 cm.times.20.0 cm, and
should be used when available. If the standard size is not
available cut the width of the specimen to the nearest cm (e.g., if
the width is 17.4 cm, cut to 17.0 cm) then use the "Optional
Condition" setting on the instrument to specify the width to the
nearest cm. If necessary based on the rigidity of the specimen, the
width can be reduced to allow measurement of the specimen within
the instruments capability. A total of ten (10) specimens are
prepared, five for testing in each MD and CD direction.
[0309] Insert the specimen into the instrument with the body facing
surface directed upward, such that the bending deformation is
applied to the width direction. Start the test and record Bending
Rigidity to the nearest 0.01 gfcm.sup.2/cm. Repeat testing for all
specimens. Calculate Bending Rigidity as the geometric mean of the
five CD specimens and of the five MD specimens and report
separately to the nearest 0.01 gfcm.sup.2/cm.
Capillary Work Potential
[0310] Pore Volume Distribution measures the estimated porosity of
the effective pores within an absorbent body. The approach (i)
applies pre-selected, incremental, hydrostatic air pressure to a
material that may absorb/desorb fluid through a fluid saturated
membrane and (ii) determines the incremental and cumulative
quantity of fluid that is absorbed/desorbed by the material at each
pressure. A weight is positioned on the material to ensure good
contact between the material and membrane and to apply an
appropriate mechanical confining pressure. Pore Volume Distribution
for a sample may be measured between about 5 .mu.m and 1000 .mu.m.
From the distribution curves the Capillary Work Potential (CWP) can
be calculated.
[0311] A representative instrument is a one based on the
TRI/Autoporosimeter (TRI/Princeton Inc. of Princeton, N.J.), in
which the operation and data treatments is described in The Journal
of Colloid and Interface Science 162(1994), pp. 163-170,
incorporated here by reference.
[0312] A representation of the equipment is shown in FIG. 33 and
consists of a balance 800 with fluid reservoir 801 which is in
direct fluid communication with the sample 811 which resides in a
sealed, air-pressurized sample chamber 810.
[0313] Determining the Pore Volume Uptake or Pore-Size Distribution
involves recording the increment of liquid that enters or leaves a
porous material as the surrounding air pressure is altered. A
sample in the test chamber is exposed to precisely controlled
changes in air pressure. As the air pressure increases or
decreases, the void spaces or pores of the porous media de-water or
uptake fluid, respectively. Total fluid uptake is determined as the
total volume of fluid absorbed by the porous media.
[0314] Pore-Size Distribution can further be determined as the
distribution of the volume of uptake of each pore-size group, as
measured by the instrument at the corresponding pressure. The pore
size is taken as the effective radius of a pore and is related to
the pressure differential by the following relationship:
Pressure differential=[2.gamma. cos .PHI.)]/effective radius
where .gamma.=liquid surface tension, and .PHI.=contact angle
[0315] For this experiment: .gamma.=27 dyne/cm.sup.2 divided by the
acceleration of gravity; cos .PHI.=1.degree. The automated
equipment operates by precisely changing the test chamber air
pressure in user-specified increments, either by decreasing
pressure (increasing pore size) to cause fluid uptake by the porous
media, or by increasing pressure (decreasing pore size) to drain
the porous media. The liquid volume absorbed (drained) at each
pressure increment yields the pore size distribution. The fluid
uptake is the cumulative volume for all pores taken up by the
porous media, as it progresses to saturation (e.g. all pores
filled).
Experimental Conditions
[0316] Take a 9 cm diameter, 0.22 .mu.m membrane filter (mixed
cellulose esters, Millipore GSWP, EMD Millipore Corp., Billerica
Mass.) by adhering the filter to a 9 cm diameter by 0.6 cm thick
Monel porous frit 807 (available from Mott Corp, Conn.) using
KRYLON.RTM. spray paint (FilmTools Gloss White Spray Paint #1501).
Allow the frit/membrane to dry before use.
[0317] Fill the inner base 812 of the sample chamber with
hexadecane (available from Sigma-Aldrich CAS #544-76-3). Place the
frit 807 membrane side up onto the base of the sample chamber 810,
and secure it into place with a locking collar 809. Fill the
connecting tube 816, reservoir 802, and the frit 807 with
hexadecane assuring that no bubbles are trapped within the
connecting tube or the pores within the frit and membrane. Using
the legs of the base 811, level the sample camber and align the
membrane with the top surface of the fluid within the
reservoir.
[0318] Dye cut a specimen 5.5 cm square. Measure the mass of the
specimen to the nearest 0.1 mg. A 5.5 cm square, Plexiglas cover
plate 804 and confining weight 803 are selected to provide a
confining pressure of 0.25 psi.
[0319] Place the top of the sample chamber 808 in place and seal
the chamber. Apply the appropriate air pressure to the cell
(connection 814) to achieve a 5 .mu.m effective pore radius. Close
the liquid valve 815. Open the sample chamber, place the specimen
805, cover plate 804 and confining weight 803 into the chamber onto
the membrane 806 and seal the camber. Open the liquid valve 815 to
allow free movement of liquid to the balance.
[0320] Progress the system through a sequence of pore sizes
(pressures) as follows (effective pore radius in .mu.m): 5, 10, 20,
30, 40, 50, 60, 70, 80, 90,100, 120, 140, 160,180, 200, 250, 300,
350, 400, 450, 500, 500, 550, 600, 700, 800, 1000, 800, 700, 600,
550, 500, 450, 400, 350, 300, 250, 200, 180, 160, 140, 120, 100,
90, 80, 70, 60, 50, 40, 30, 20, 10, 5, 10, 20, 30, 40, 50, 60, 70,
80, 90, 100, 120,140, 160,180, 200, 250, 300, 350, 400, 450, 500,
500, 550, 600, 700, 800, 1000. The sequence is progressed to the
next radius when an equilibrium rate of less than 25 mg/min is
measured at the balance.
[0321] In like fashion, measure the
acquisition/drainage/acquisition cycle blank without a sample.
Based on the incremental volume values, calculate the
blank-corrected values for cumulative volume.
Cumulative Volume (mm.sup.3/mg)=[Specimen Fluid Uptake (mg)-Blank
Fluid Uptake (mg)]/Density of Hexadecane (g/cm.sup.3)/Sample Mass
(mg)
The Capillary Work Potential (CWP) is the work done by the sample
normalized by the area of the specimen. The trapezoidal rule is
used to integrate the ith pressure as a function of cumulative
volume over n data points:
CWP [ mJ m 2 ] = W A w = i = 1 n 1 2 m w ( CV i + 1 - CV i ) ( P i
+ P i + 1 ) A w ( 10 3 [ mJ J ] ) ##EQU00001##
where
[0322] m.sub.w=mass of web (mg)
[0323] CV=Cumulative Volume (m.sup.3/mg)
[0324] P=Air Pressure (Pa)
[0325] A.sub.w=Area (m.sup.2)
[0326] Record the CWP to the nearest 0.1 mJ/m.sup.2. In like
fashion, repeat the measure on a total of three (3) replicate
specimens. Calculate the arithmetic mean of the replicates and
report to the nearest 0.1 mJ/m.sup.2.
Kinetics and 1D Liquid Distribution by NMR-MOUSE
[0327] The NMR-MOUSE (Mobile Universal Surface Explorer) is a
portable open NMR sensor equipped with a permanent magnet geometry
that generates a highly uniform gradient perpendicular to the
scanner surface. A frame 1007 with horizontal plane 1006 supports
the specimen and remains stationary during the test. A flat
sensitive volume of the specimen is excited and detected by a
surface rf coil 1012 placed on top of the magnet 1010 at a position
that defines the maximum penetration depth into the specimen. By
repositioning the sensitive slice across the specimen by means of a
high precision lift 1008, the scanner can produce one-dimensional
profiles of the specimen's structure with high spatial
resolution.
[0328] An exemplary instrument is the Profile NMR-MOUSE model PM25
with High-Precision Lift available from Magritek Inc., San Diego,
Calif. Requirements for the NMR-MOUSE are a 100 .mu.m resolution in
the z-direction, a measuring frequency of 13.5 MHz, a maximum
measuring depth of 25 mm, a static gradient of 8 T/m, and a
sensitive volume (x-y dimension) of 40 by 40 mm.sup.2. Before the
instrument can be used, perform phasing adjustment, check resonance
frequency and check external noise level as per the manufacturer's
instruction. A syringe pump capable of delivering test fluid in the
range of 1 mL/min to 5 mL/min.+-.0.01 mL/min is used to dose the
specimen. All measurements are conducted in a room controlled at
23.degree. C..+-.0.5.degree. C. and 50%.+-.2% relative
humidity.
[0329] The test solution is Paper Industry Fluid (PIF) prepared as
15 g carboxymethylcellulose, 10 g NaCl, 4 g NaHCO.sub.3, 80 g
glycerol (all available from SigmaAldrich) in 1000 g distilled
water. 2 mM/L of Diethylenetriaminepentaacetic acid gadolinium
(III) dihydrogen salt (available from SigmaAldrich) is added to
each. After addition the solutions are stirred using an shaker at
160 rpm for one hour. Afterwards the solutions are checked to
assure no visible undissolved crystals remain. The solution is
prepared 10 hours prior to use.
[0330] Products for testing are conditioned at 23.degree.
C..+-.0.5.degree. C. and 50%.+-.2% relative humidity for two hours
prior to testing. Identify the intersection of the lateral and
longitudinal center line of the product. Cut a 40.0 mm by 40.0 mm
specimen from the product, centered at that intersection, with the
cut edges parallel and perpendicular to the longitudinal axis of
the product. The garment facing side of the specimen 1003 is
mounted on a 50 mm.times.50 mm.times.0.30 mm glass slide 1001 using
a 40.0 mm by 40.0 mm piece of double-sided tape 1002 (tape must be
suitable to provide NMR Amplitude signal). A top cap 1004 is
prepared by adhering two 50 mm.times.50 mm.times.0.30 mm glass
slides 1001 together using a 40 mm by 40 mm piece of two-sided tape
1002. The cap is then placed on top of the specimen. The two tape
layers are used as functional markers to define the dimension of
the specimen by the instrument.
[0331] First a 1-D Dry Distribution Profile of the specimen is
collected. Place the prepared specimen onto the instrument aligned
over top the coils. Program the NMR-MOUSE for a
Carr-Purcell-Meiboom-Gill (CPMG) pulse sequence consisting of a
90.degree. x-pulse follow by a refocusing pulse of 180.degree.
y-pulse using the following conditions:
[0332] Repetition Time=500 ms
[0333] Number of Scans=8
[0334] Number of Echoes=8
[0335] Resolution=100 .mu.m
[0336] Step Size=-100 .mu.m
[0337] Collect NMR Amplitude data (in arbitrary units, a.u.) versus
depth (.mu.m) as the high precision lift steps through the
specimen's depth. A representative graph is shown in FIG. 36a.
[0338] The second measure is the Kinetic Experiment of the test
fluid moving though the sensitive NMR volume as test fluid is
slowly added to the top of the specimen. The "trickle" dose is
followed by a "gush" dose added using a calibrated dispenser pipet.
Program the NMR-MOUSE for a CPMG pulse sequence using the following
conditions:
[0339] Measurement Depth=5 mm
[0340] Repetition Time=200 ms
[0341] 90.degree. Amplitude=-7 dB
[0342] 180.degree. Amplitude=0 dB
[0343] Pulse Length=5 .mu.s Echo Time=90 .mu.s
[0344] Number of Echoes=128
[0345] Echo Shift=1 .mu.s
[0346] Experiments before trigger=50
[0347] Experiments after trigger=2000
[0348] Rx Gain=31 dB
[0349] Acquisition Time=8 .mu.s
[0350] Number of Scans=1
[0351] Rx Phase is determined during the phase adjustment as
described by the vendor. A value of 230.degree. was typical for our
experiments. Pulse length depends on measurement depth which here
is 5 mm. If necessary the depth can be adjusted using the spacer
1011.
[0352] Using the precision lift adjust the height of the specimen
so that the desired target region is aligned with the instruments
sensitive volume. Target regions can be chosen based on SEM cross
sections. Program the syringe pump to deliver 1.00 mL/min.+-.0.01
mL for 1.00 min for PIF test fluid or 5.00 mL/min.+-.0.01 mL for
1.00 min for 0.9% Saline test fluid. Start the measurement and
collect NMR Amplitude (a.u.) for 50 experiments before initiating
fluid flow to provide a signal baseline. Position the outlet tube
from the syringe pump over the center of the specimen and move
during applying liquid over the total sample surface, but do not
touch the borders of the sample. Trigger the system to continue
collection of NMR amplitude data while simultaneously initiating
fluid flow for 1 mL over 60 sec. At 300 sec after the trigger, add
0.50 mL of test fluid at approximately 0.5 mL/sec to the center of
the specimen via a calibrated Eppendorf pipet. A representative
example of the NMR Amplitude versus time graph is shown in FIG.
37.
[0353] The third measurement is a 1-D Wet Distribution Profile
Immediately after the Kinetic measurement is complete, replace the
cap on the specimen. The Wet Distribution is run under the same
experimental conditions as the previous Dry Distribution, described
above. A representative graph is shown in FIG. 36b.
[0354] Calibration of the NMR Amplitude for the Kinetic signal can
be performed by filling glass vials (8 mm outer diameter and a
defined inner diameter by at least 50 mm tall) with the appropriate
fluid. Set the instrument conditions as described for the kinetics
experiment. A calibration curve is constructed by placing an
increasing number of vials onto the instrument (vials should be
distributed equally over the 40 mm.times.40 mm measurement region)
and perform the kinetic measurements. The volumes are calculated as
the summed cross sectional area of the vials present multiplied by
the z-resolution where Resolution (mm) is calculated as
1/Acquisition Time (s) divided by the instruments Gradient Strength
(Hz/mm). The Calibration of the NMR Amplitude for the Distribution
Profile is performed as an internal calibration based on the dry
and wet profiles. In this procedure the area beneath wet and dry
profile were calculated and after subtracting them the total area
(excluding markers) was obtained. This total area is correlated to
the amount of applied liquid (here 1.5 mL). The liquid amount
(.mu.L) per 100 .mu.m step can then be calculated.
[0355] 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."
[0356] Values disclosed herein as ends of ranges are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each numerical range
is intended to mean both the recited values and any integers within
the range. For example, a range disclosed as "1 to 10" is intended
to mean "1, 2, 3, 4, 5, 6, 7, 8, 9, and 10."
[0357] All documents cited in the Detailed Description of the
Invention are, in relevant part, incorporated herein by reference;
the citation of any document is not to be construed as an admission
that it is prior art with respect to the present invention. 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.
[0358] 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.
* * * * *