JP2003508156A - Embossed liner for absorbent articles - Google Patents

Abstract

(57) A liner for a personal care product having at least two layers facing each other and having at least one embossed concave configuration and preferably a row of such configurations. Provided. These concave features can have different shapes, such as square, diamond, circular, or aesthetically pleasing designs. However, for maximum benefit, this concave configuration reduces the necessary depth and distance between each other to create a physical barrier that allows for fluid absorption while reducing its spread to the fluid. Must have. The liner may be manufactured from a combination of a topsheet material, a surge layer, and an absorbent core that have been embossed together.

Description

Detailed Description of the Invention

TECHNICAL FIELD The present invention relates to absorbent personal care products. More specifically, the present invention provides
Women's sanitary napkins, diapers and training pants, and disposables such as trauma dressings and adult incontinence products with liners with modified surface properties to improve performance. An absorbent system for an article.

BACKGROUND OF THE INVENTION Disposable products are generally top sheet materials (also called cover sheets),
It has a structure including an absorbent core and a fluid water repellent backsheet. Some disposable products may also have a surge layer or other specialized layer between the topsheet and the absorbent core. The structure referred to herein as a "liner" is a combination of at least a first layer (top sheet) and a second layer (surge layer) in a face-to-face relationship.

The function of the topsheet material is to provide the flexibility needed for user comfort while wearing the product, as it is the layer that contacts the user's body, but more importantly It is necessary that the topsheet material have structural properties that allow for rapid absorption of fluids from the user's body. Fast absorbency is important to reduce the possibility of fluid spreading outside the absorbent material perimeter and into the wearer's garment, causing unwanted leaks and dirt. The absorbent material has the function of removing fluid from the topsheet and preferably distributes and retains fluid throughout the length, width, and thickness of the absorbent material. The material of the topsheet is often manufactured from non-woven fabric or a film having apertures. Films with apertures are patterned rolls such as those described in US Pat. No. 5,536,555 to Zerazoski et al. And US Pat. No. 5,704,101 to Majors et al. And anvil rolls can be used to mechanically perforate the film top sheet. Another material used in this type of application can be found in U.S. Pat. No. 4,342,314, which is assigned to Procter & Gamble Company and which describes vacuum-perforated films.

The surge layer is most commonly inserted between the top sheet and another layer, such as a distribution layer or a retention layer, and has intimate, fluid communication contact with those layers. The surge layer is usually adjacent to the inner surface of the topsheet (the side away from the wearer). To further facilitate liquid transfer, the top and bottom surfaces of the surge layer need to be attached to the top sheet and the next layer, respectively. Absorbent cores used in hygiene personal care products are generally made from pulp fibers or pulp fibers mixed with superabsorbent particles. These structures may also include binder fibers to maintain integrity.

Difficulties in the design of products that absorb the typical fluids released in hygiene products such as feminine care products and infant care products are well known in the art. For infant care products, the concern is to absorb urine and fecal (BM) exudates, while feminine care products are primarily concerned with the absorbed menstrual fluid. Due to differences in viscosities, densities, and compositions of each fluid, each type of personal care product presents a separate and complex problem for product designers to optimize the absorption properties of each material used in the final product.

One thing that is common to all product designs is that each of those designs does not allow fluid to spread outside the absorbent perimeter, but at the same time the wet topsheet can create wetting. In order to reduce the sensation and the potential for skin irritation,
It is necessary to have the ability to rapidly absorb fluid while holding it far away from the topsheet and the user's body. For these reasons, the structure of any product must be developed in such a way that each component works well with other components to optimize their use. This means that the absorbent core needs to have the ability to desorb the topsheet material at high speed while still having the ability to dispense and retain its fluid.

Many patents attempt to address the balance issues needed between flexibility and fluid absorption. For example, US Pat. No. 4,32,32 to Aziz.
No. 3,068 describes a topsheet material with raised protrusions to separate the surface from the user's body and improve dryness. U.S. Pat. No. 4,041,951 to Sanford discloses a topsheet material containing a large number of recessed areas for separating the user's skin from the moisture of the absorbent. However, as taught in US Pat. No. 4,323,068, this 4,041,951
The '961 patent has the disadvantage of not having the structural integrity necessary to maintain the protrusions of material after pressure is applied. U.S. Pat. No. 3,934,588 issued to Mesek describes a nonwoven topsheet made of long and short fibers that provides a narrow area to serve as a preferential passageway for fluid absorption. is doing. U.S. Pat. No. 5,695,595 to Van Hout et al. Teaches a method of forming a material having a plurality of narrow regions that allow the passage of steam and water vapor shaped in the form of protrusions. . U.S. Pat. No. 4,741,941 to Englebert et al. Describes a nonwoven web with hollow protrusions that can be designed to provide the appropriate structural properties to allow rapid suction times. is doing. All of the above references allow modification of the topsheet structure to provide separation of the user's body from the disposable article while providing the necessary absorptive action for rapid fluid transfer to the absorbent core. Indicates what is needed. However, for a liner of personal care products that will absorb fluid into a designated area and can retain its integrity while under pressure loading, while at the same time retaining its absorbent properties. The need remains. It is an object of the present invention to provide a new structure that enhances the fluid absorption properties of high viscoelastic fluids such as menses and feces (BM) and also retains their integrity under pressure.

DISCLOSURE OF THE INVENTION The object of the present invention is achieved by a liner whose surface will be modified to enhance the absorbent properties of the porous material. An ideal personal care product would be one that could quickly absorb fluid as soon as it was released into the product without spreading the fluid outside the absorbent perimeter. However, due to the differences in fluid properties observed between fluid discharges, the selection and design of materials used in personal care products is
It's pretty complicated. Accordingly, the invention described herein retains fluid to reduce the likelihood of leaks, while fluid absorption characteristics of an absorbent system that can also be improved with surface modification to improve its absorption characteristics. Tackle the problem of.

For example, modifying the surface to absorb viscous fluids such as menses, urine, and BM has at least one concave morphology embossed on the composite structure,
However, it is preferable that the column has such a form. A composite structure, referred to herein as a liner, includes at least a first layer (top sheet) and a second layer in a face-to-face relationship.
It is a composite material with a layer (surge layer). A third layer, an absorbent layer, may optionally be present. Any of these members can have more than one layer. Embossing the concave morphology onto a structure made with only the topsheet and surge layer gives the best results and is therefore preferred.

Definitions "Disposable" includes disposal after a single use and is not intended to be cleaned or reused. As used in this specification and claims, the term "comprising" is inclusive or non-limiting and excludes additional, unlisted members, components, or method steps. is not. As used herein, the term "nonwoven or non-woven web" means a web having a structure of individual fibers or threads interleaved in a non-identifiable manner such as a knitted fabric. To do. Nonwovens or webs have been formed by many processes, such as meltblowing, spunbonding, and bonded carded web processes. The basis weight of non-woven fabrics is typically the ounce (o) per square yard of material.
sy), or grams per square meter (gsm), useful fiber diameters are usually expressed in microns. (To convert osy to gsm, use 3 for osy.
Note that it is multiplied by 3.91. )

“Spunbond fiber” means a small diameter fiber formed by extruding a molten thermoplastic material as filaments from a plurality of fine capillaries of a spinneret. Such a method is described, for example, in U.S. Pat.
, 563, U.S. Pat. No. 3,692,618 to Dauschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. No. 3,338,992 to Kinney. And 3,341,394, U.S. Pat. No. 3,502,763 to Hartman, and U.S. Pat. No. 3,542,615 to Dobo et al. This fiber also describes fibers having non-traditional shapes, US Pat. No. 5,277,976 to Hogle et al., US Pat. No. 5,466,410 to Hills.
And U.S. Pat. Nos. 5,069,970 and 5 to Largman et al.
, 057,368.

A “composite fiber” is formed from at least two polymers arranged in discrete regions located in a substantially constant relationship across the cross section of the fiber, which is then continuous along the length of the fiber. It means a fiber that stretches to. Composite fibers are described in U.S. Pat. No. 5,108,820 to Kaneko et al. And U.S. Pat.
, 552, and US Pat. No. 5,382,400 to Pike et al.

“Bonded carded web” means a web made from staple length fibers sent through a combing or carding device that separates or breaks staple length fibers to machine direction. To form a fibrous nonwoven web that is oriented in the machine direction and is oriented in a generally machine direction. Such fibers are usually purchased in bundles,
The bale is placed in an unpacker / mixer or a sorter that separates the fibers before the carding device. With the web formed, the web is then bonded by one or more of several known bonding methods. One such bonding method is powder bonding, in which the powdered adhesive is dispensed through the web and activated, typically by heating the web and adhesive with hot air.

Another suitable bonding method is pattern bonding, in which a heated calender roll or ultrasonic bonding device is used to bond the fibers to each other, usually in a localized bonding pattern, but if desired. , The web can also be bonded over its entire area. An example of a pattern is US Pat. No. 3, issued to Hansen and Pennings,
Hansen Pennings or "HP" pattern having a bond area of about 30% at about 200 bonds / in2, as taught in US Pat. This HP
The pattern has square points or pin binding areas, the side dimension of each pin being 0.
038 inches (0.965 mm), the spacing between pins is 0.070 inches (1.778 mm), and the bond depth is 0.023 inches (0.584 mm). The resulting pattern has a bond area of about 29.5%.
Another common point bond pattern is the extended Hansen Pennings or "EHP" bond pattern, which produces a bond area of 15%. There are many other binding patterns. Another suitable and well-known bonding method, especially when using composite staple filaments, is through air bonding, in which hot air passes through the web and at least partially melts the components of the web. Creates a bond.

“Air deposition” is a well known process that can form a fibrous nonwoven layer. In air deposition processes, bundles of fibrils having a typical length in the range of about 3 to about 19 millimeters (mm) are separated and entrained in the feed air, after which
It is usually deposited on the forming screen with the help of an applied vacuum. The randomly deposited fibers are then bonded together using, for example, hot air or spray adhesive.

By “co-perforated” is meant a composite in which (at least two) materials are co-perforated to create a hole extending through a layer. Interfaces are created between the materials that are represented by light contacts and / or entanglements and / or interpenetrations and / or bonds. The degree or extent depends on the particular material composition and processing conditions. Openings extending through the layers are represented by a fibrous / film-like structure created through melting and some flow of fibers.

“Personal care products” means diapers, training pants, absorbent pants,
It refers to adult incontinence products, feminine hygiene products, wound care products such as bandages, and other articles. "Feminine hygiene products" means sanitary napkins or pads, tampons and panty liners. "Target area" means an area or location on a personal care product where fluid emissions are normally expelled by the wearer.

Test Method Rate Block Suction Test : This test is used to measure the suction time of a known amount of fluid into a material and / or material system. The test device consists of a transparent, preferably acrylic rate block 10 as shown in FIG. 12 and a timer or stopwatch. 4 inch x 4 inch of liner material 13 to be tested (
(102 mm × 102 mm) part is punched out. (The particular liner tested is described in the particular example.) The absorbent material 14 used in these experiments is described below under "Test Materials".

The rate block 10 has a width of 3 inches (76.2 millimeters) and a depth (to the page) of 2.87 inches (72.9 millimeters) and an overall height of 1.125 inches (28. 6 mm), which has a height of 0.125 inches (3.2 mm) and a width of 0.886 inches (22.5 mm) that projects away from the body of the rate block 10. , A central area 19 on the bottom of the rate block 10 is included. The rate block 10 has a capillary tube 12 having an inner diameter of 0.186 inches (4.7 millimeters) extending obliquely downward at an angle of 21.8 degrees from the horizontal from one side surface 15 to a center line 16. Capillary tube 12
Can be made by drilling an appropriately sized hole starting at an appropriate angle from side surface 15 of rate block 10 at a point 0.726 inches (18.4 millimeters) above the bottom of rate block 10. However, with the proviso that the starting point of the perforated hole on side surface 15 must then be closed to prevent the test fluid from flowing therefrom. The top hole 17 has a diameter of 0.312 inches (7.9 mm) and a depth of 0.625 inches (15.9) so that it intersects the capillary 12.
Mm). Top hole 17 is perpendicular to the top surface of rate block 10 and is centered 0.28 inches (7.1 millimeters) from side surface 15. The top hole 17 is an opening in which the funnel 11 is placed. Center hole 18
Is for observing the progress of the test fluid, and is actually an ellipse toward the plane of FIG. The central hole 18 is centrally located in the width direction of the rate block 10 and has a bottom hole width of 0.315 inches (8 millimeters) and a length of 1.50 inches (38.1 millimeters). , The center-to-center length of a 0.315 inch (8 millimeter) diameter semicircle that forms the end of this oval. For ease of observation, the size of the oval is 0.44 inches (1
1.2 mm) above and a width of 0.395 inches (10 mm) and a length of 1.930 inches (49 mm). The top hole 17 and the central hole 18 can also be made by drilling.

The sample to be tested is placed over the absorbent material 14, and the rate block 10 is placed over the two materials. 2 ml of artificial menstrual fluid, prepared as described below, is fed into the funnel 11 of the test device and the timer is started. This fluid travels from the funnel 11 into the capillary tube 12 where it is delivered to the material 13 or material system in the center of the central bore 18. The fluid typically spreads toward the ends of the oval of the central hole 18. When observing through the central hole 18 and the capillary tube 12 in the rate block 10, the timer is stopped when all of the fluid has been absorbed into the material or material system. The suction time for a known amount of test fluid is recorded for a given material or material system. This value is a measure of the absorbency of a material or material system. Lower suction times represent a more absorbent system. The test is repeated 5 times for each type of sample and the results are averaged to get one value.

Rewet Test : This test is used to measure the amount of fluid that will return to the surface of the topsheet when a load is applied. The amount of fluid that returns through this surface is called the rewet value. The more fluid that returns to the surface, the higher the rewet value, while the less fluid that returns to the surface, the lower the rewet value. Lower rewet values are associated with the desiccant material and thus the desiccant product. After the above suction test is performed, the material system (top sheet and absorber, or
The topsheet, surge layer and absorber) are placed on top of a closed bag partially filled with saline to better distribute the force on the system. This fluid bladder is placed over the lab jack. Two blotters are pre-weighed and placed on the material system. The bag, material system, and paper are lifted in a lab jack until a total of 1 lb / in 2 is added to a fixed acrylic plate. The pressure is held constant for 3 minutes, after which the pressure is removed and the blotter paper is weighed again. The weight difference between the weight of the first blotter paper and its weight after the test is recorded as the rewet value. The test is repeated 5 times for each type of sample and the results are averaged to get one value.

Outflow test : 4 inches x 4 inches (102 mm x 102 mm)
Parts of the material system are placed on an acrylic table with a 20 ° tilt angle. 1
A milliliter of artificial menstruation is ejected from a distance of 5 millimeters with a pipette in the center of the material system. Any fluid flowing out of the material sample is collected in a pre-weighed plastic container and the residue left on the acrylic platform is removed using a pre-weighed absorbent gauze. The effluent value is obtained by summing the fluid absorbed in the gauze and the fluid retained in the plastic container. Lower effluent values mean better fluid absorption. The test is repeated 5 times for each type of sample and the results are averaged to get one value.

Material Caliper (Thickness) : The material caliper or thickness in inches is 2
"Fragger" Spring-Type Compresometer # 326 Bulk Tester with Inch (50.8 mm) Legs (Fragger Precision, 925 Swine Drive, Hagerstown, MD 21740, USA)
Instrument Corporation), 0.05, 0.20, and
It is measured at three different pressures of 0.50 pounds per square inch. The test is repeated 5 times for each type of sample and the results are averaged to get one value.

Preparation of Artificial Menstruation : The artificial menstrual fluid used in the test is described in US Pat. No. 5,883,
No. 231, the blood is separated into plasma and erythrocytes, and egg white is referred to as a thickened portion, meaning that the "thickness" has a viscosity after homogenization greater than about 20 centipoise at 150 / sec. It was made from blood and egg white by separating into a thin portion and combining the concentrated egg white with plasma and mixing thoroughly, and finally adding red blood cells and mixing again thoroughly. The more detailed procedure is as follows.

In the present example, the blood, which is the blood of pigs excluding fibrin, was 3000 for 30 minutes.
Separated by centrifugation at revolutions / minute, although other methods, speeds and times can be used if effective. Plasma is separated and stored separately, buffy coat removed and discarded, and compressed red blood cells are similarly stored separately. Note that blood needs to be handled in some way so that it can be processed without coagulation. Various methods are known to those skilled in the art, such as methods for removing fibrin from blood to remove clotting fibrous materials, addition of anticoagulant drugs, and others. Blood must not clot in order to be useful, and any method that achieves this without damaging plasma and red blood cells is acceptable.

Oversized chicken eggs are sorted and the yolk and egg band are discarded to retain the egg white. The egg white is separated into a thick portion and a thin portion by straining for about 3 minutes through a 1000-micron nylon mesh, and the thinner portion is discarded. The thick portion of egg white retained on the net was collected and aspirated into a 60 cc syringe, which was then placed on a programmable syringe pump to release and refill the contents five times. Homogenize the egg whites. The amount of homogenization is controlled by a syringe pump speed of about 100 milliliters / minute and a tube inner diameter of about 0.12 inch. After homogenization, the concentrated egg white has a viscosity of about 20 centipoise at 150 / sec and then placed in a centrifuge and spun at about 3000 rpm for about 10 minutes to remove debris and bubbles. It

After centrifugation, homogenized concentrated egg white containing ovamucin is added using a syringe to a 300 cc “FENWAL® Transfer” pack container. Next, add 6 to the “FENWAL® Transfer” pack container.
0 cc of porcine plasma is added. This "FENWAL (R) Transfer" pack container is clamped, all air bubbles are removed, and the "Stomacker" is allowed to mix the pack container at normal (or moderate) speed for about 2 minutes.
Place in laboratory mixer. The "FENWAL® Transfer" pack container is then removed from the mixer and 60 cc of porcine red blood cells are added and mixed by hand kneading the contents for about 2 minutes or until the contents appear uniform. To be done. The hematocrit of the final mixture should exhibit an erythrocyte content of about 30 weight percent, and generally should be in the range of at least 28-32 weight percent for an artificial menstruation made according to this example. The amount of egg white is about 40 weight percent.

The materials and equipment used for the preparation of artificial menstruation are readily available. The list of manufacturers of items used is as follows, but of course other manufacturers may be used as long as they are roughly equivalent. Blood (pig): Cocalico Biologicals, Inc., Stevens Road, 449, 17567, PA, USA (Telephone) (717) 336-1990. "Fenwal® Transfer" Pack Container, 300 ml, Coupler, Code 4R2014: Baxter Healthcare Corporation, Deerfield, Illinois, USA 60015, Fenwall (F
department). Harvard Appalatas Programmable Syringe Pump Model No. 55-4143
: Harvard, South Natick, 01760, Massachusetts, USA
Appalatas. Streamer 400 experimental mixer, model number BA7021, serial number 3196
8: Seward Medical, London, England. 1000 micron mesh, item number CMN-1000-B: 330, Florida, USA
14-0650, Small Parts Incorporated, Miami Lakes, PO Box 4650, (telephone) 1-800-220-4242. Hemata Stat-II Instrument for Hemocrit Measurements, Serial Number 1194Z03127: Separation Technology Inc., Rainer Drive, Altamont Springs, 32714, Florida, USA.

BEST MODE FOR CARRYING OUT THE INVENTION In personal care products, the topsheet material is the layer in contact with the skin of the wearer and is therefore in contact with liquids or other excretions from the wearer. It is the first layer.
The topsheet should also help to isolate the wearer's skin from liquids retained in the absorbent structure, be compliant, soft feel and non-irritating to the skin. A variety of materials can be used to form the bodyside topsheet of the present invention, including perforated plastic films, woven fabrics, nonwoven webs, foams and the like. Nonwoven materials have been found to be particularly suitable for use in forming topsheets, which include spunbonds of polyolefin, polyester, and polyamide (or other similar fiber-forming polymer) filaments. Meltblown webs or bonded carded webs of natural polymer (eg rayon or cotton fibers) and / or synthetic polymer (eg polypropylene or polyester) fibers are included. For example, the topsheet can be a nonwoven spunbond web of synthetic polypropylene filaments. The nonwoven web has a thickness of from about 10.0 grams per square meter (gsm) to about 68.0 gsm, more specifically about 14.0 gs.
a basis weight in the range of m to about 42.0 gsm and a bulk or thickness in the range of about 0.13 millimeters (mm) to about 1.0 millimeter, more specifically about 0.18 mm to about 0.55 mm. , About 0.025 grams / cubic centimeter (g / cc)
To about 0.12 g / cc, more specifically 0.068 g / cc to about 0.08
And a density of 3 g / cc. Further, the transmission of such nonwoven webs can be from about 150 Darcy to about 5000 Darcy. The nonwoven web may be surface treated with a selected amount of surfactant, such as about 0.28% "TRITON® X-102" surfactant, or otherwise treated. Thus, a target level of wettability and hydrophilicity can be provided. If a surfactant is used, it can be applied to the web by any conventional means such as spraying, baking, and brushing. The non-woven top sheet is
It is usually produced from staple length fibers, for example by the carding method, or from long fibers, for example by the melt spinning method. These nonwoven webs are often made from polyolefins or polyesters, and may be composite fibers of polypropylene and polyester or polyethylene, which are composed of different rows, for example sheath-core or side-by-side. . Mixtures of different fibers can also be used. These materials are
It can be joined by different techniques to provide the required mechanical integrity. Such means may include thermal bonding or through air bonding, adhesive bonding or ultrasonic bonding using latex or other adhesive, or entanglement with water or puncture. The topsheet is typically joined to the next layer and backing sheet using hot melt or latex adhesives or ultrasonic or mechanical bonding.

The surge layer is most commonly inserted between the topsheet and another layer, such as a distribution or retention layer, and has intimate liquid communication contact with those layers. This surge layer typically underlies the inner surface (not exposed) of the topsheet. It may be necessary to attach the upper and / or lower surface of the surge layer to the top sheet and the next layer, respectively, to further facilitate liquid transfer. Adhesive bonding (using water-based adhesives, solvent-based adhesives and thermally activated adhesives), thermal bonding, ultrasonic bonding, puncturing, pin drilling, and combinations thereof, including but not limited to: Any suitable conventional mounting technique can be utilized, including other suitable mounting methods. For example, if the surge layer is adhesively bonded to the topsheet, the amount of adhesive added will be above the target level of bonding without unduly limiting the flow of liquid from the topsheet into the surge layer. Must be sufficient to give.

Various foams and woven and non-woven webs can be used to make the surge layer. For example, the surge layer may be a non-woven layer consisting of a meltblown or spunbond web of polyolefin filaments. Such nonwoven layers can include staple lengths or other lengths of bicomponent fibers, bicomponent fibers, and homopolymer fibers, as well as mixtures of such fibers with other types of fibers. The surge layer can also be a bonded carded web or an air-laid web composed of natural and / or synthetic fibers. The bonded carded web may be, for example, a powder bonded carded web, an infrared bonded carded web, or a through air bonded carded web. The bonded carded web can optionally include a mixture or blend of different fibers, the length of the fibers within the selected web being about 3 mm.
To about 60 mm. An exemplary surge layer is at least about 0.
50 ounces per square yard basis weight, at a pressure of 68.9 Pascals at least about 0.010 grams per cubic centimeter, 68.
． It may have a bulk of at least about 1.0 mm at a pressure of 9 Pascals, a bulk recovery of at least about 75 percent, a permeability of about 500 to about 5,000 Darcy, and a surface area / void volume of at least about 20 square centimeters / cubic centimeter. it can. The surge layer may be composed of a substantially hydrophobic material, which hydrophobic material is optionally treated with a surfactant or otherwise treated to a targeted level. It is possible to impart wettability and hydrophilicity. The surge layer can have a substantially uniform thickness and cross-sectional area. Exemplary surge materials are US Pat. Nos. 5,879,343 and 5,820 to Dodge et al.
, 973.

In the practice of the present invention, it is preferred that there be rows of concave morphology. These concave forms can have different shapes, such as square, diamond, circular, or aesthetically pleasing designs. However, for maximum benefit, the preferred row of concave features creates a physical barrier that allows fluid absorption while at the same time containing fluid and reducing its spread, between the depth and recess needed for that. Must have a distance of. These concave structures are designed to provide a temporary reservoir of fluid, allowing the topsheet to receive fluid at its own velocity without spreading the fluid. Currently available products do not have this morphology and typically allow fluid to spread in an irregular path when using materials with slow suction times.

Although a description of how to produce these results is disclosed herein, one of ordinary skill in the art can suggest alternative ways of achieving similar results. One way to achieve this type of construction is to use a calender unit with embossing rolls and corresponding female rolls. The modified material is fed simultaneously through the nip of the calender system. Heat and pressure (or ultrasonic waves) permanently emboss the concave morphology into the material. This type of processing may be included in an off-line operation or it may be integrated into the manufacturing line.

In another aspect of the invention, material savings can be achieved by using a narrow surge layer specially placed in the target area of the product. This means that the surge (second) layer needs to be at least one-third narrower than the topsheet (first) layer. It is preferred that the materials used to create the structures of the present invention be melt compatible. By "melt compatible" is meant that the materials can be joined together by heat alone or by heat and pressure. Materials that are not melt compatible can be joined together by other means, such as by entanglement or by the use of adhesives. When using materials with melt compatibility, the composites obtain the high mechanical strength necessary to maintain the integrity of the material after use after embossing. In suboptimal embodiments where the materials are not melt compatible, hot melt or latex adhesives could be used as an alternative means of achieving the bond between the layers.

In addition to surfactants, other chemical treating agents may be added to the materials of the present invention. One area of increasing consumer interest is in the area of "skin health" treatments, such as aloe, which are believed by many to actively promote skin health. Other skin health agents are known in the art. Preferred embodiments of the present invention have a suction value of less than 40 seconds, a rewet value of less than 0.35 grams, an outflow value of less than 0.50 grams, and a caliper loss under pressure of less than 50%.

Test Materials and Preparations The materials used to describe the invention were as follows. The non-woven top sheet layer is 8 weight percent titanium dioxide (Product Code 41
438, White Plains Road 660, Tarrytown, NY, USA
0.3% by weight of "AHCOVEL (R) -based N-62" soluble surfactant (available from ICI Surfactants, Wilmington, Del., USA) containing Ampacet Corporation ) Treated with 3.5 dpf (denier) and 0.6 osy (20.3 gsm) polypropylene fibers by spunbonding. This cloth is
Although having an HP-type binding pattern, the binding pattern chosen is not critical to the functioning of the invention.

The surge layer was 6 dpf and 0.7 osy (23.7 gsm), to which was added an HR6 finish obtained from Chisso Corporation (Fiber Division) of Osaka, Japan.
Of 100% by weight polypropylene / polyethylene (PP / PE) sheath-core bicomponent fiber through-air bonded carded web. The absorbent is 250 gsm and 90 weight percent "Coosa 0".
054 "pulp and T-255 fiber bond made from 10 weight percent Kosa (formerly Trevira Inc., formerly Hoechst Celanese) having a density of 0.14 grams / cubic centimeter (unless otherwise stated). It was manufactured according to the air deposition method using the agent. The concave morphology was applied to the material using a hot press model OK380 obtained from Practix MFG Company, Cantorell 3416, Practix Road AC, Worth, Georgia 30101, USA. The temperature used on the heating plate was 177 ° C. (350 ° F.) with a residence time of 15 seconds and a pressure of 50 pounds per square inch.

Two sets of plates with equal depth but different hole size male and female configurations were manufactured for this test. -Plate 1 has a row of protrusions and holes, each protrusion being 4.5 millimeters in diameter, separated by 1 millimeter from each hole. Each hole has a volume of 0.05 cc, and
It was 3 millimeters deep. Plate 1 produced a material having a morphology, hereinafter referred to as "morphology 1." -Plate 2 has a row of protrusions and holes, each protrusion being 8.5 millimeters in diameter and separated by 1 millimeter from each hole. Each hole has a volume of 0.18 cc, and
It was 3 millimeters deep. Plate 2 produced a material having a morphology, hereinafter referred to as "morphology 2."

The matrix test The following examples are suction test described in the previous section, rewet tests, and,
A runoff test was used to evaluate the fluid absorption properties of each material. 1: Top sheet of spunbond cloth only, no embossing. 2: Top sheet of spunbond cloth only, embossing of Form 1. 3: Top sheet of spunbond fabric only, embossing of Form 2. 4: Top sheet of spunbond cloth covering the surge layer, without embossing. 5: Top sheet of spunbond fabric covering the surge layer, this combination as Form 1
Embossed with. 6: Top sheet of spunbond fabric covering the surge layer, this combination as Form 2
Embossed with. 7: Top sheet of spunbond fabric covering the absorbent core, embossing this combination using Form 1. 8: Topsheet of spunbond fabric covering absorbent core, embossing this combination using Form 2. 9: Top sheet of spunbond fabric covering surge layer and absorbent core, embossing this combination using Form 1. 10: Topsheet of spunbond fabric covering surge layer and absorbent core, this combination embossed using Form 2. 11: Topsheet of spunbond fabric covering the surge layer and absorbent core, this combination embossed with Form 2, absorbent core density 0.06 grams / cubic centimeter.

Structures with modified surfaces were created by joining them together (if applicable) through an embossed concave morphology. All materials are
Tested with the absorbent core described above. The results obtained by testing the material are shown in Table 1.

(Table 1)

As seen in Table 1, fluid absorption was enhanced by modification of the composite surface. Adding a surge layer below the topsheet material affects fluid absorption by significantly reducing rewetting of the topsheet material, which is a result of the additional volume brought by the surge material. And results in separation of the absorbent core and the topsheet material. Materials that meet the requirements of the present invention have a rewet value of less than 0.40 grams, and preferably less than 0.35 grams.

When a concave morphology is added to the composite liner structure (top sheet / surge layer), the fluid absorption properties are enhanced as evidenced by the significant reduction in suction time obtained in the test. Materials satisfying the requirements of the present invention have a suction time of less than 50 seconds, preferably less than 40 seconds. As can be seen from this result, the void volume of the recess has a direct relationship with the material performance. Form 1 shows an improvement over the composite without single layer spunbond and embossing, but does not provide the performance benefits of the improvement of Form 2.

Another improvement that has been made with the present invention is the reduction of fluid outflow. The addition of the surge layer in addition to the concave morphology can significantly reduce fluid movement in the absorbent material and retain more fluid volume within the perimeter of the absorbent structure.
The non-embossed combination of topsheet and surge material alone cannot achieve this effect due to the lack of physical barriers. Materials that meet the requirements of the present invention have an output of less than 0.60 grams, and preferably less than 0.50 grams.

In the following example, a concave morphology is added to an absorbent system of topsheet and absorbent material compared to a system of topsheet, surge layer and absorbent material co-embossed together. The effect is described.

(Table 2)

As seen in Table 2, the results show that high density (0.14 grams / cubic centimeter) air-laid absorbent cores have slower suction times than single layer systems. This is believed to be a result of the increased densification of the absorbent layer, which may slow the absorption of fluid into the absorbent layer. This effect is also believed to be apparent from the fact that the suction time of spunbond / surge layer / absorber Examples 9 and 10 was increased relative to similar Examples 5 and 6 with no absorbent. . Nevertheless, the samples with concave morphology exhibited lower outflow values in all examples compared to the flat system. One way to improve the observed slow suction time is to see it before embossing, as can be seen from the examples with 0.06 grams / cubic centimeter absorbent that gave faster suction times and lowest outflow values. To use a lower density absorbent core.

As can be seen from this data, the choice of topsheet, surge layer, and absorbent material plays an important role in the functionality of the modified topsheet structure. The addition of the concave morphology to the above three layers results in a more stable structure, but can compromise the absorbent functionality of the system, depending on the material selected. The absorbent system is
Adjustments to the degree of compaction and the type and concentration of surfactant can be optimized for a particular application.

A common requirement for this type of material structure is the ability of the material structure to retain its integrity after use or after manufacture and packaging of the product. Typically, in order to optimize the space occupied by the product on the shelves, the manufacturer chooses to fold the product either in half or in three, applying a high pressure load to the product. For this reason, the thickness lost at different pressures was evaluated for different samples. The results of the evaluation are shown in Table 3.

(Table 3)

Table 3 shows that the addition of concave morphology to a single spunbond topsheet results in a decrease in material thickness when loaded. This effect is a result of having a hollow embossed form that easily loses its integrity when loaded.
Reduces the ability to achieve fluid absorption. By contrast, having a topsheet and surge system reduces the amount of thickness lost when a load is applied. As can be seen in Table 3, the structure constructed with the topsheet, surge layer, and absorbent core together exhibits the lowest thickness loss of all samples. This is a result of structural modifications achieved using a process that modifies both the air-laid fiber binder, the topsheet, and the surge layer to create a stable structure. Materials meeting the requirements of the present invention have a caliper loss of less than 60 percent between 0.05 and 0.5 pounds per square inch, preferably less than 50 percent.

Referring now to the figures, the product may have many possible arrangements of recesses,
Moreover, it can be appreciated that it is within the spirit and spirit of the invention. 1 and 2 show an overview of a material with recesses 1 of different dimensions, in this case a bilayer material. FIG. 3 is a cross-sectional view of a material composed of two layers and having a recess 1. 4-10 illustrate various forms of feminine hygiene products included in the present invention. In FIG. 4, the recesses 1 are lined up near the periphery of the inner part 2 of the product.
FIG. 5 shows the recesses 1 which are aligned only in the target area 3 of the product. FIG. 6 shows a recess 1 having an aesthetically sharp or “capricious” design in a slightly enlarged target area 3. FIG. 7 shows the recesses 1 arranged in an ordinary row-by-row configuration. FIG. 8 shows a female pad having recesses 1 arranged in an irregular pattern.
FIG. 9 shows a pattern of large and small recesses 1 arranged in one product. FIG. 10 shows an array of recesses, each of which is considerably smaller. FIG. 11 shows a three layer material embossed with a recess 1 according to the present invention.

The concave features of the present invention may vary with respect to size, depth, shape, and separation between recesses. The form diameter can be up to 10 centimeters, preferably in the range of 3 to 20 millimeters in diameter, more preferably about 8 millimeters. The depth can be up to 20 millimeters, and preferably
It is between 1 and 10 millimeters, more preferably about 3 millimeters. The separation between the recesses will depend on the targeted effect. Closer packed recesses will provide a more effective fluid barrier by reducing movement of liquid across the liner. The features may also contact, whereby the features are in fluid communication with each other to facilitate movement of fluid within the liner. However, the recesses, depending on their shape, preferably line the separation between the feature edges between about 0.5 and 10 millimeters.

Embodiments of the present invention can be prepared with recesses of different shapes and / or sizes. This may be done purely for aesthetic purposes or to create different absorption properties in different areas of the personal care product.
For example, in the case of diapers exposed to urine and BM, the pattern of smaller depressions can be incorporated into the most urine-exposed areas of the product, and the pattern of larger depressions sometimes becomes liquid. It can be incorporated into the area within the product most likely to be exposed to the BM obtained. Alternatively, the recess can be applied only to the target area or central region of the product, resulting in reduced spread. As yet another alternative arrangement, the recess can be arranged only on the peripheral edge of the product,
As a result, it will probably prevent the fluid from migrating outside the product. Designs that combine such forms may be envisioned to improve overall product performance and protection. The exact dimensions, location, etc. will depend on the fluid being processed and the target benefit. Yet another alternative embodiment can include a liner, for example, a topsheet and a layer such as a surge layer perforated together. Such piercing together can be done in a pattern such that an aperture is created at the bottom of each recess.
The placement of various treatments such as surfactants and skin health agents can also be varied, eg, they are placed only on the bottom of each recess or on the inner surface of the liner. Yet another way to facilitate the flow of fluid into the recesses is to place fibers in each recess perpendicular to the plane of material. The fibers allow fluids to be directed into the recess, thus reducing the possibility of liquid spillage from the product. As will be appreciated by those skilled in the art, modifications and variations to the present invention are believed to be within the ability of those skilled in the art. The inventor intends such modifications and variations to fall within the scope of the invention.

[Brief description of drawings]

[Figure 1]   FIG. 6 shows an example of a concave form row of liners according to the present invention.

[Fig. 2]   FIG. 8 shows another example of a concave form row of liners according to the present invention.

[Figure 3]   FIG. 5 is a cross-sectional view of a two-layer composite material having a concave shape.

FIG. 4 illustrates an example of a feminine hygiene product having a concave morphology placed in various rows on the product.

FIG. 5 illustrates an example of a feminine hygiene product having a concave form placed in various rows on the product.

FIG. 6 illustrates an example of a feminine hygiene product having a concave morphology placed in various rows on the product.

FIG. 7 illustrates an example of a feminine hygiene product having a concave morphology placed in various rows on the product.

FIG. 8 illustrates an example of a feminine hygiene product having a concave morphology placed in various rows on the product.

FIG. 9 illustrates an example of a feminine hygiene product having a concave morphology placed in various rows on the product.

FIG. 10 illustrates an example of a feminine hygiene product having a concave morphology placed in various rows on the product.

FIG. 11   FIG. 6 illustrates a three layer embodiment having a concave morphology.

FIG. 12 is a schematic diagram of a rate block device suitable for use in measuring the fluid suction time of a material or material system.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) A61F 13/53 A41B 13/02 C 13/534 E // A61F 13/02 310 (81) Designated country EP ( AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE), OA (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG), AP (GH, GM, KE, LS, MW, MZ, SD, SL, SZ, TZ, UG, ZW), EA (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), AE, AG, AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, BZ, A, CH, CN, CR, CU, CZ, DE, DK, DM, DZ, EE, ES, FI, GB, GD, GE, GH, GM, HR, HU, ID, IL, IN, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR, LS, LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, MZ, NO, NZ, PL, PT, RO , RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT, TZ, UA, UG, UZ, VN, YU, ZA, ZW (72) Inventor Alican Mei Ines United States Georgia 30066 Marietta Windsor Oaks Drive 4474 (72) Inventor Crowser David George, Georgia, USA 30004 Alpharetta Arbor Hill Lane 1060 (72) Inventor Daily Michael Are United States Georgia 30005 Alpharetta Hatterley Drive 5865 (72) Inventor Dermay Emmanuel Cecil United States Georgia 30350 Dunwoody Roswell Road 8390 Be (72) Inventor Jones Eric Mitchell United States Georgia 30076 Roswell North Talbot Court 215 (72) Inventor Lyndon Jack Nelson U.S.A. Georgia 30201 Alpharetta East Bullfloor 14810 (72) Inventor Paul Susan Carroll U.S.A. Georgia 30022 Alpharetta Tanners Crossing 310 (72) Inventor Potts David Charles U.S.A. Georgia 30338 Dunwoody Winterhall Court 5268 ( 72) Inventor Seis Philip Anthony USA State of Georgia 30135 Douglasville Grace Lake Drive 9455 (72) Inventor Valona Eugeneio Go United States of America Georgia 30062 Marietta Woodrun Trail 3309 F Term (Reference) 3B029 BD19 4C003 AA06 4C098 AA09 CC03 CC05 CC08 DD02 DD06 DD08 DD10 DD12 DD12 DD14 DD12 DD12 DD14 DD12 DD12 DD14 DD12 DD14 DD12 DD14 DD12 DD14 DD12 DD12 DD12 DD25 DD26 DD28

Claims (29)

[Claims] 1. A personal care product, comprising a first layer and a second layer, facing each other and having at least one embossed concave form. Liner. 2. A column having a sectioned concave form.
Liner described in. 3. The liner of claim 2, wherein the array of segmented concave features has fibers in at least one recess in a direction perpendicular to the layer. 4. The first and second layers are bonded to each other by a method selected from the group consisting of adhesive, mechanical, entanglement, thermal, and ultrasonic means. The liner according to claim 2. 5. The liner of claim 2, wherein the first and second layers are melt compatible. 6. The liner of claim 2, wherein the first layer has been treated with a soluble surfactant. 7. The method of claim 6, wherein each of the recesses has a bottom, and the first layer is treated with a soluble surfactant at the bottom of each of the recesses.
Liner described in. 8. The liner of claim 2, wherein the first layer is treated with a skin health chemical. 9. The liner of claim 2, wherein the first layer comprises a nonwoven web made of polyolefin fibers. 10. The liner of claim 8, wherein the polyolefin is polypropylene. 11. The first layer further comprises an opening portion.
Liner described in. 12. The liner of claim 2, wherein the first and second layers are perforated together. 13. The liner of claim 2, wherein the first layer is made from a film perforated by a method selected from the group consisting of vacuum perforation and mechanical perforation. 14. The second layer comprises a bonded carded web of polyolefin fibers bonded by a method selected from the group consisting of through air bonding, thermal bonding, and adhesive bonding. The liner according to claim 2. 15. The liner of claim 13 further comprising bicomponent fibers. 16. The liner of claim 2, wherein the second layer is more wettable than the first layer. 17. The liner of claim 2, wherein the second layer comprises a foam material. 18. The liner of claim 2, wherein the concave feature is located in a target area. 19. A suction value of less than 50 seconds.
Liner described in. 20. The liner of claim 2 having a rewet value of less than 0.40 grams. 21. The liner of claim 2 having an outflow value of less than 0.60 grams. 22. The liner of claim 2 having a caliper loss under pressure of less than 60 percent. 23. The liner of claim 2, wherein the concave form has a diameter of less than 10 centimeters. 24. The liner of claim 2, wherein the concave form has a depth of less than 20 millimeters. 25. A feminine hygiene pad comprising the cloth according to claim 2. 26. A diaper comprising the cloth according to claim 2. 27. An adult incontinence product comprising the fabric of claim 2. 28. A first layer and a second layer in opposed relation to each other and having rows of segmented embossed concave features, a suction value of less than 40 seconds, less than 0.35 grams. A liner for personal care products, which has a rewet value of less than 0.50 grams, an outflow value of less than 0.50 grams, and a caliper loss under pressure of less than 50 percent. 29. The personal care product of claim 27, wherein the second layer is at least one third narrower than the first layer.