CN102844009A

CN102844009A - Absorbent composite with resilient coform layer

Info

Publication number: CN102844009A
Application number: CN2011800193668A
Authority: CN
Inventors: K·C·施勒德; G·R·沃尔特曼; D·M·杰克逊; D·A·菲尔; K·L·威斯; T·J·内特科文
Original assignee: Kimberly Clark Worldwide Inc
Current assignee: Kimberly Clark Worldwide Inc; Kimberly Clark Corp
Priority date: 2010-04-16
Filing date: 2011-03-15
Publication date: 2012-12-26
Also published as: KR20130072193A; WO2011128790A2; EP2558050A2; AU2011241903A1; WO2011128790A3; RU2012148555A; AR081756A1; EP2558050A4; RU2564613C2; AU2011241903B2; BR112012025375A2; MX2012011717A

Abstract

An absorbent composite disposed in an absorbent article between a topsheet and a backsheet is presented, the absorbent composite including a first intake layer disposed between the topsheet and the backsheet, and a retention layer disposed between the topsheet and the backsheet, wherein one of the first intake layer and the retention layer includes a resilient coform material. When the first intake layer includes a resilient coform material, the retention layer includes one of a high-density, hydrogen-bonded, fluff/superabsorbent polymer material, a spunlace material, a superabsorbent polymer/adhesive composite material, and a foam material. The absorbent composite can further include a distribution layer disposed between the topsheet and the backsheet, the distribution layer including one of a meltblown microfiber material, a spunlace material, and a foam material.

Description

Have resilience be shaped altogether the layer absorbent composite

Background

This application requirement is filed in the priority of the application number 61/324,982 on April 16th, 2010.The full content of application number 61/324,982 is incorporated herein with way of reference.

Be used to absorb urine, blood and be challenging based on the fluidic high-absorbable goods of blood such as the exploitation of incontinence pad and clothes, menopad (for example, sanitary towel), tapon, wound dressing, binder and surgical drapes.For example in the situation of incontinence pad and menopad, consumer is desirably in comfortable and applying, fluidic reservation and MIN contamination aspect have high-caliber performance.In a word, think that it is unacceptable that fluid leaks into underwear from pad.Though the structure and material that is used for such structure has been carried out many improvement, the performance that improves such pad remains the cause of an arduousness.Eliminate seepage, particularly, do not reduce simultaneously and fit and comfort, also can not satisfy the demand that consumer thirsts for along the seepage of femoribus internus.

The absorbing structure of pad generally includes one or more fibrous layers from permeable topsheet, to collect the fluid of discharge and it is distributed in the storage area of lower floor at present.The absorbing structure that is used for the thin relatively version of existing product generally includes fluid collection or the blot coat adjacent with permeable topsheet.This blot coat is made by air-flow method fibre web or synthetic property nonwoven web usually.Below this blot coat is main absorbent cores, and this absorbent cores is made by air-flow method or wet method fibre web usually.

The existing absorbing structure of being processed by fibrous layer has many problems.Problem is to have difficulties aspect the top flat sufficiently dry guaranteeing.The chance that such structure causes medicated clothing and health to pollute is also bigger.This is because absorbing structure lacks resilience, causes the pack of filling up.This elastic shortage and consequential pack also can cause these existing pads to provide user with relatively poor fit sense and comfort.The 5th, 849, No. 805 United States Patent (USP)s of Dyer have been confirmed the subject under discussion of traditional absorbing structure and traditional unresolved this problem of absorption fibrous web.

A kind of solution of trial property replaces fiber blot coat and absorbed layer with foam, as available from employed INFINICEL foam in the ALWAYS INFINITY plain edition pad of the P&G of Cincinnati, Ohio.This foam is often expensive more than fibrous web.

The nonwoven web that is shaped altogether is the composite of meltblown fibers matrix and absorbent material (for example, fluff pulp fibers), in multiple application, is used as absorbed layer, comprises absorbing products, the dried towel of absorbability, wet tissue and mop.Most of tradition fibre web that is shaped altogether adopts the meltblown fibers that is formed by polypropylene homopolymer.Yet the problem that so common moulding material meets on occasion is when moulding material receives bending force altogether, may not have enough resiliences.For example, when the cleaning piece that is shaped was altogether wrinkled, moulding material can't return to its primary smooth, non-wrinkled state altogether.Another instance is the tendency that the common moulding material that in personal care absorbent product, is used as absorbent cores has pack.

Therefore, need a kind of improved nonwoven web that is shaped altogether to be used for various application at present, the said improved nonwoven web that is shaped altogether shows the tendency of recovering flat condition to the raising of bending force resistance and in the demonstration of folding back.The improved nonwoven web that is shaped altogether like this can combine with other multiple material to can be used for the absorbent composite of future generation in the personal care absorbent property goods with generation.

General introduction

The inventor is carrying out intensive development efforts aspect the absorbing products improving, and has developed and be used to have enough moist and dryness elastic force and enough absorbent composites of absorbefacient absorbent cores, and does not mainly use the foam of costliness.The inventor also find they can through with resilience altogether moulding material and other material merge and adjust these performances, to give its high resilience and absorbent properties.

The invention provides a kind of absorbent composite that in absorbing products, places between top flat and the egative film; Said absorbent composite comprises first blot coat that places between top flat and the egative film; And placing the retaining layer between top flat and the egative film, one in wherein said first blot coat and the said retaining layer comprises resilience moulding material altogether.When said first blot coat comprises resilience altogether during moulding material, said retaining layer comprises a kind of in high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite and the foamed materials.Absorbent composite can also comprise the distribution layer that places between top flat and the egative film, and said distribution layer comprises a kind of in melt-blown micro-fiber material, spunlaced material and the foamed materials.

The present invention also provides a kind of absorbent composite that in absorbing products, places between top flat and the egative film; Said absorbent composite comprise first blot coat and place top flat and egative film between retaining layer; Said first blot coat comprises common moulding material, resilience a kind of in moulding material, air-flow method material, bonded carded web (BCW) material and the foamed materials altogether; Said retaining layer comprises common moulding material, resilience a kind of in moulding material, air-flow method material, high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite and the foamed materials altogether, and one in wherein said first blot coat and the said retaining layer comprises resilience moulding material altogether.

The present invention also provides a kind of absorbent composite that in absorbing products, places between top flat and the egative film; Said absorbent composite comprise first blot coat and place said top flat and said egative film between retaining layer; Said first blot coat comprises altogether moulding material of resilience, and said retaining layer comprises common moulding material, resilience a kind of in moulding material, air-flow method material, high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite and the foamed materials altogether.

The present invention also provides a kind of absorbent personal care article with top flat and egative film; Said goods comprise the absorbent composite that places between top flat and the egative film; Said absorbent composite comprise first blot coat and place said top flat and said egative film between retaining layer; Said first blot coat comprises altogether moulding material of resilience, and said retaining layer comprises common moulding material, resilience a kind of in moulding material, air-flow method material, high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite and the foamed materials altogether.

The method that the present invention also provides a kind of preparation to have the absorbent personal care article of absorbent composite, said method comprise absorbent material stream and meltblown fibers stream and close to form composite material stream; On profiled surface, collect said composite material stream to form the resilience nonwoven web that is shaped altogether; Combine with top flat and egative film with nonwoven web that said resilience is shaped altogether.

The present invention also provides a kind of absorbent composite that is applicable to the absorbing products with top flat and egative film; Said absorbent composite comprises: comprise the blot coat that places the foamed materials between said top flat and the said egative film, said blot coat has a plurality of holes of passing this blot coat; And place the retaining layer between said top flat and the said egative film, wherein said retaining layer to comprise resilience moulding material altogether.

This paper has carried out more detailed discussion to further feature of the present invention and aspect.

Brief description of drawings

With reference to following description, accompanying claims and accompanying drawing, of the present inventionly above-mentionedly will become more obvious, and the present invention self will be easier to understanding with further feature and aspect and the mode of this characteristic and aspect that realizes.

Fig. 1 is the schematic illustration of an aspect of the method for the formation fibre web that is shaped altogether of the present invention;

Fig. 2 is the explanation of some characteristic of device shown in Figure 1;

Fig. 3 is the cutaway view of an aspect of the veined nonwoven web that is shaped altogether formed according to the present invention;

Fig. 4 is the photo of an aspect of the veined nonwoven web that is shaped altogether;

Fig. 5 for wrinkled from the veined nonwoven web that is shaped altogether of Fig. 4 and loosen after photo;

Fig. 6 is the photo of another aspect of the veined nonwoven web that is shaped altogether;

Fig. 7 for wrinkled from the veined nonwoven web that is shaped altogether of Fig. 6 and loosen after photo;

Fig. 8 is a schematic biopsy cavity marker devices plane graph of having included the feminine hygiene products of absorbent composite of the present invention in;

Fig. 9 is a partial schematic side view of having included the feminine hygiene products of absorbent composite of the present invention in;

Figure 10 is the schematic plan view that is used to test the embodiment of the pass pattern on the absorbent composite profile of absorbent composite of the present invention; With

Figure 11 is the schematic plan view of embodiment that is used to test the absorbent composite profile of absorbent composite of the present invention.

The repeated use of reference character is intended to represent identical or similar characteristic of the present invention or element in this description and accompanying drawing.

Detail

What it will be understood by those skilled in the art that is, this discussion is only described illustrative aspects, rather than in order to limit wideer scope of the present invention.

In detail with reference to each side of the present invention, hereinafter one or more embodiment is described now.With the mode explained rather than limit mode of the present invention each embodiment is provided.In fact, under the prerequisite that does not depart from scope of the present invention or essence, can make various modifications and variation it will be apparent to those skilled in the art that to the present invention.For example, explain or the characteristic that is described as the part of an aspect can be used for another part to produce another aspect.Therefore, the present invention is intended to contain this modification and variation.

As used herein, term " nonwoven web " typically refers to the fibre web of the structure with single fiber or line, and said single fiber or line are mutual, but is not to carry out alternately like the discernible mode in knitted fabric.The instance of fine fabric of nonwoven or fibre web includes but not limited to, meltblown web, spunbond net, bonded carded web, air-flow method fibre web, be shaped fibre web, Hydroentangled net etc. altogether.

As used herein, term " spunbond fibre web " typically refers to the fibre web that contains the basic continuous fiber of minor diameter.Through molten thermoplastic material is extruded, reduce the diameter of the fiber of extruding through for example drawing drawing and/or other well-known spun-bond process mechanism rapidly then from a plurality of fine and closely woven, capillary tubies of being generally circular spinneret.The description of the production of spunbond fibre web and explanation are shown in people such as Appel for example people such as the 4th, 340, No. 563 United States Patent (USP)s, Dorschner the 3rd, 692; The 3rd, 338 of the 3rd, 802, No. 817 United States Patent (USP)s of people such as No. 618 United States Patent (USP)s, Matsuki, Kinney; The 3rd, 502 of the 3rd, 341, No. 394 United States Patent (USP)s of No. 992 United States Patent (USP)s, Kinney, Hartman; The 3rd, 542 of people such as the 3rd, 502, No. 538 United States Patent (USP)s of No. 763 United States Patent (USP)s, Levy, Dobo; The 5th, 382, No. 400 United States Patent (USP)s of people such as No. 615 United States Patent (USP)s and Pike are for all purposes are introduced this paper as a reference with its full content.Collect surperficial last time when being deposited on, spun-bonded fibre is not clamminess usually.The diameter of spun-bonded fibre sometimes can be less than about 40 microns, and are generally about 5 to about 20 microns.

Generally speaking, the present invention relates to have resilience be shaped altogether layer and optional at least one or the absorbent composite of a plurality of other layers.Form by the resilience that contains meltblown fibers matrix and the absorbent material nonwoven web that is shaped altogether like the following resilience in greater detail layer that is shaped altogether.Absorbent composite can be used in personal nursing or other the suitable goods.

As an instance, absorbent composite can be used as the absorption component in the feminine hygiene products.As shown in Figure 8, feminine hygiene products 70 comprises peel strip 72, and said peel strip 72 combines binding agent 74 to be bonded on the side of garment side egative film 76 by medicated clothing.With construction adhesive the opposite side of egative film 76 is bonded to absorbed layer 78.Absorbed layer 78 is bonded to side liner or top flat 80.Absorbent composite 84 of the present invention can suitably replace absorbed layer 78.Hope ground, use absorbent composite 84 can when wearable product, suppress the pack of product, thereby improve whole efficiency and reduce seepage.Those skilled in the art know other suitable constructions that is used to form the personal care product with absorbent core material.Aspect a hope, absorbent composite 84 has veined surface.Veined surface is positioned at towards the position of top flat 80 with hoping, to promote that fluid sucks and make absorbent cores to have higher absorbability sooner.

Except that resilience altogether the moulding material, place top flat 80 and can not the egative film 76 of transflective liquid between absorbent composite of the present invention 84 comprise one to three layer.As shown in Figure 9, absorbent composite 84 can comprise the optional first liquid blot coat 86, the optional second liquid blot coat 88 or optional first distribution layer 90, retaining layer 94 and the second optional distribution layer 96.At the inner layer of absorbent composite 84 usually with aspectant towards placement.

In many aspects of the present invention, the comparable retaining layer of first blot coat 86 94 is wideer and/or longer, and can be made into shape beyond the rectangle with the health of when wearing, fitting better.In another aspect of the present invention, comprise resilience altogether the layer of moulding material can be the wideest and/or the longest layer.In another aspect of the present invention, the layer that comprises air-flow method material can be the wideest and/or the longest layer.

At least one comprises that the resilience of serving as fluid suction material or fluid reserved materials respectively is total to moulding material in first blot coat and the retaining layer 86,94.Comprise the altogether aspect of moulding material of resilience for first blot coat 86, absorbent composite 84 comprises other one deck, and this other one deck can be the second liquid blot coat 88, first distribution layer 90, retaining layer 94 or second distribution layer 96.Comprise the altogether aspect of moulding material of resilience for retaining layer 94, absorbent composite 84 comprises other one deck, and this other one deck can be the first liquid blot coat 86, the second liquid blot coat 88, first distribution layer 90 or second distribution layer 96.

Be described in more detail below every layer of material that comprises.First blot coat 86 can comprise common moulding material, resilience moulding material, air-flow method material, bonded carded web (BCW) material or foamed materials altogether, and also can comprise Time of Fluff Slurry.The second liquid blot coat 88 can comprise the BCW material, air-flow method material or foamed materials.First distribution layer 90 can comprise spunlaced material, melt-blown micro-fiber material, or foamed materials.Retaining layer 94 can comprise common moulding material, resilience moulding material or air-flow method material altogether, and wherein every kind also can comprise super-absorbent material (SAM).Alternatively, retaining layer 94 can comprise high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite or foamed materials.In these retaining layer materials any one also can comprise Time of Fluff Slurry.At last, second distribution layer 96 can comprise melt-blown micro-fiber material, spunlaced material or foamed materials, and also can comprise Time of Fluff Slurry.

Absorbent composite 84 of the present invention can be used in the various products.For example, absorbent composite 84 can be incorporated into and can absorb in water or other the fluidic absorbing products.The instance of such absorbing products includes but not limited to, personal care absorbent property goods are like diaper, training pants, absorbent pants, incontinence articles, feminine hygiene (for example, sanitary towel), swimming suit, baby's wet tissue, glove towel etc.; Medical absorbing products is like clothing, the material of windowing, nursing pad, mattress, binder, absorption curtain and medical wet tissue; The food and beverage sevice cleaning piece; Apparel product; Bag etc.Those skilled in the art know material and the technology that is fit to form such goods.The 5th, 649, No. 916 United States Patent (USP)s of people such as DiPalma; The 6th, 110, No. 158 United States Patent (USP)s of Kielpikowski; The 6th, 663, No. 611 United States Patent (USP)s of people such as Blaney have been described some instances of this absorbing products, for all purposes are incorporated its full content into this paper with way of reference.People's such as Fell U.S. Patent Application Publication 2004/0060112A1, and the 4th, 886, No. 512 United States Patent (USP)s of people such as Damico; The 5th, 558, No. 659 United States Patent (USP)s of people such as Sherrod; The 6th, 888, No. 044 United States Patent (USP) of people such as Fell; With the 6th, 511, No. 465 United States Patent (USP)s of people such as Freiburger other suitable goods have been described also, for all purposes are introduced this paper as a reference with its full content.When in absorbing products, adopting, absorbent composite 84 of the present invention can form the assembly of absorbent cores or any other absorbability assembly of absorbing products well-known in the art.

Term " be shaped altogether " typically refers to the blend of meltblown fibers and absorbency fiber such as cellulose fibre, can form meltblown polymeric material and will be suspended in fiber in the air-flow simultaneously through air-flow to spray into meltblown fibers and form in flowing.Moulding material also can comprise other material altogether, like super-absorbent material.Collecting meltblown fibers and absorbing fiber (with other optional material) on like the surface that guipure provided on the profiled surface.Profiled surface can comprise the material of the Tou Guoed gas that places on the profiled surface.The 5th, 508, No. 102 and the 5th, 350 of people such as Georger have further described common moulding material in the 4th, 100, No. 324 United States Patent (USP)s of No. 624 United States Patent (USP)s and Anderson, and its full content is introduced this paper as a reference, do not contradict each other with it and exceed.

As used herein; Term " resilience is shaped altogether " typically refers to the resilience that comprises meltblown fibers matrix and the absorbent material fine layer of nonwoven that is shaped altogether; Wherein meltblown fibers constitutes the fibre web of 30wt% to about 99wt%; And absorbent material constitutes the fibre web of 1wt% to about 70wt%; In addition, wherein meltblown fibers is formed by the thermoplastic compounds that contains at least a propylene/alpha-olefins copolymer, and the propylene content of said propylene/alpha-olefins copolymer is that about 60 moles of % are to about 99.5 moles of %; And alpha-olefin content is that about 0.5 mole of % is to about 40 moles of %; Wherein the density of copolymer is about 0.86 to about 0.90 gram/cubic centimetre, though and actual consideration can reduce high-end melt flow rate (MFR) scope, the melt flow rate (MFR) that under 230 ° of C, records compositions according to ASTM method of testing D1238-E is about 120 to about 6000 grams/10 minutes.

The meltblown fibers of nonwoven web of being shaped altogether accounts for the 30wt% of fibre web to about 99wt%, and about 1wt% that absorbent material accounts for fibre web about 70wt% extremely.More preferably, the meltblown fibers of the nonwoven web that is shaped altogether accounts for the 45wt% of fibre web to about 99wt%, and absorbent material accounts for about 1wt% of fibre web to about 55wt%.Meltblown fibers is formed by the thermoplastic compounds of at least a propylene/alpha-olefins copolymer of containing of following description, and said propylene/alpha-olefins copolymer has certain monomers content, density, melt flow rate (MFR) etc.The resultant composition that is chosen as to the propylene/alpha-olefins copolymer of particular type provides improved hot property to form common shaping fibre web.For example, thermoplastic compounds crystallization under speed relatively slowly, thus make fiber in forming process, keep faint viscosity.This viscosity can provide multiple benefit, sticks to the ability on the absorbent material as improving meltblown fibers in the process that forms at fibre web.About 30wt% that meltblown fibers can account for common shaping fibre web is to about 99wt%, in particular aspects for about 45wt% to about 99wt%, be about 50wt% about 90wt% extremely in aspect more specific, be extremely about 80wt% of about 50wt% in aspect more specific.Equally, about 1wt% that absorbent material can account for common shaping fibre web is to about 70wt%, in particular aspects be 1wt% to about 55wt%, be extremely about 50wt% of 10wt% in aspect more specific, be extremely about 50wt% of about 20wt% in aspect more specific.

Except improving the cementitiousness of meltblown fibers, thermoplastic compounds of the present invention also can be given resulting other benefit of shaped structure altogether.For example in some aspects in, can use the three-dimensional surface to give common shaping fibre web texture.In aspect such, the crystalline rate relatively slowly of meltblown fibers can improve the ability of its identical three-dimensional surface profile.Yet in case the fiber crystallization, meltblown fibers just can reach the resilience to a certain degree that is higher than conventional polypropylene, thereby allows its reservation and recover the highly textured surface on the 3D shape and the fibre web that is shaped altogether.

Another benefit that fiber viscosity prolongs in forming process is that the layer adhesive strength that multilamellar is shaped between the layer of nonwoven web altogether increases the necessary extra shearing ability of generation layering.The increase of this layer adhesive strength can reduce or eliminate can negative effect sheet material characteristic such as the needs of the embossing of thickness and density.The layer adhesive strength that in the assigning process of the cleaning piece that the nonwoven web that is shaped altogether by multilamellar makes, needs increase especially.The texture that uses three-dimensional as herein described surface to be given can be through increasing the long-pending layer adhesive strength that further improve of contact surface between the layer.

Now each side of the present invention will be described in further detail.

Thermoplastic compounds of the present invention contains the copolymer of at least a propylene and alpha-olefin, said alpha-olefin such as C ₂-C ₂₀Alpha-olefin, C ₂-C ₁₂Alpha-olefin or C ₂-C ₈Alpha-olefin.Suitable alpha-olefin can be straight or branched (for example, one or more C ₁-C ₃Alkyl branches, or aromatic yl group).Particular instance comprises ethylene, butylene; 3-methyl-1-butene; 3,3-dimethyl-1-butylene; Amylene; Has the substituent amylene of one or more methyl, ethyl or propyl group; Has the substituent hexene of one or more methyl, ethyl or propyl group; Has the substituent heptene of one or more methyl, ethyl or propyl group; Has the substituent octene of one or more methyl, ethyl or propyl group; Has the substituent nonene of one or more methyl, ethyl or propyl group; The substituted decene of ethyl, methyl or dimethyl; Laurylene; Styrene etc.The alpha-olefin comonomer that needs especially is ethylene, butylene (for example 1-butylene), heptene and octene (for example, 1-octene or 2-octene).The propylene content of such copolymer is about 60 moles of % to about 99.5 moles of %, in further be about 80 moles of % to about 99 moles of %, be extremely about 98 moles of % of about 85 moles of % in a still further aspect.Likewise, alpha-olefin content can be about 0.5 mole of % to about 40 moles of %, in further be about 1 mole of % to about 20 moles of %, be extremely about 15 moles of % of about 2 moles of % in a still further aspect.In forming the different molecular weight fraction of propylene copolymer, the distribution of alpha-olefin comonomer normally at random and uniformly.

The density of propylene/alpha-olefins copolymer can be the length of alpha-olefin and the function of content.That is to say that the length of alpha-olefin is long more, the content of existing alpha-olefin is high more, and the density of copolymer is low more.In general, the higher copolymer of density can form three dimensional structure better, and lower those of density have better elasticity and rebound performance.Therefore, in order between texture and resilience, to reach optimum balance, selecting density usually is about 0.860 gram/cubic centimetre (g/cm ³) to about 0.900g/cm ³The propylene/alpha-olefins copolymer, be about 0.861 to about 0.890g/cm in further ³, be about 0.862g/cm in a still further aspect ³To about 0.880g/cm ³In addition, selecting density usually is to restrain (g/cm for every cubic centimetre 0.860 approximately ³) to about 0.940g/cm ³Thermoplastic compounds, be about 0.861 to about 0.920g/cm in further ³, be about 0.862g/cm in a still further aspect ³To about 0.900g/cm ³

Usually can adopt in the multiple known technology any one to form employed propylene/alpha-olefins copolymer in the meltblown fibers.For example, can use free radical or complex catalyst (for example, Ziegler-Natta) to form olefin polymer.Preferably, copolymer is formed by the unit point complex catalyst, like metalloscene catalyst.Such antigravity system produces propylene copolymer, and wherein comonomer is randomly dispersed in the strand and is evenly distributed in the different molecular weight fractions.The 7th, 105, No. 609 United States Patent (USP)s people such as for example Datta; The 6th, 500, No. 563 United States Patent (USP)s of people such as Datta; The 5th, 539, No. 056 United States Patent (USP) of people such as Yang; With the propylene copolymer of having described metallocene catalyst in the 5th, 596, No. 052 United States Patent (USP) of people such as Resconi, for all purposes are introduced this paper as a reference with its full content.The instance of metalloscene catalyst comprises two (n-butyl cyclopentadienyl) titanium chloride; Two (n-butyl cyclopentadienyl) zirconium dichloride; Two (cyclopentadienyl group) Scium chloride (Sc4Cl12); Two (indenyl) zirconium dichloride; Two (methyl cyclopentadienyl) titanium chloride; Two (methyl cyclopentadienyl) zirconium dichloride; Cobaltocene; The cyclopentadienyl group titanous chloride.; Ferrocene; The dichloro hafnocene; Isopropyl (cyclopentadienyl group-1-fluorenyl) zirconium dichloride; Dichloro two luxuriant molybdenums; Dicyclopentadienyl nickel; Dichloro two luxuriant niobiums; Ruthenocene; Cyclopentadienyl titanium dichloride; Hydrogen chlorine zirconocene; Bis cyclopentadienyl zirconium dichloride etc.Use the polymer of metalloscene catalyst preparation to have narrower molecular weight ranges usually.For example, the polymer of metallocene catalyst can have the polydispersity (M below 4 _w/ M _n), short-chain branched distribution and the steric regularity of control of control.

In aspect specific, the propylene/alpha-olefins copolymer comprised is used to form about 50wt% of thermoplastic compounds of meltblown fibers or more, is about 60wt% or more in further, is about 75wt% or more in a still further aspect.In others; The propylene/alpha-olefins copolymer comprised be used to form meltblown fibers thermoplastic compounds at least about 1wt% and be lower than about 49wt%; Be at least about 1% and be lower than about 45wt% in aspect specific; Be at least about 5% and be lower than about 45wt% further, be at least about 5wt% in a still further aspect and be lower than about 35wt%.Certainly, only otherwise the desired properties of composite is had a negative impact, other thermoplastic polymer also can be used for forming meltblown fibers.For example, meltblown fibers can contain other polyolefin (for example, polypropylene, polyethylene etc.), polyester, polyurethane, polyamide, block copolymer etc.In one aspect, meltblown fibers can comprise other acrylic polymers, like polypropylene homopolymer or propylene copolymer.Other acrylic polymers for example can be formed by isotactic basically polypropylene homopolymer or copolymer, and its other monomer that contains is equal to or less than 10% percentage by weight, promptly by weight at least about 90% propylene.Such polypropylene can exist with grafting, form random or block copolymer; Can be mainly crystallization; Because it has the above sharp melting point of about 110 ° of C, be about 115 ° more than the C in further, be about 130 ° more than the C in a still further aspect.These other polyacrylic instance has been described in the 6th, 992, No. 159 United States Patent (USP)s of people such as Datta, for all purposes with its full content to introduce this paper as a reference.

In particular aspects, about 0.1wt% that other polymer can account for thermoplastic compounds is to about 90wt%, further in for about 0.5wt% to about 50wt%, be extremely about 30wt% of about 1wt% in a still further aspect.Equally, about 15wt% that aforesaid propylene/alpha olefin copolymer can account for thermoplastic compounds is to about 99.9wt%, further in for about 50wt% to about 99.5wt%, be extremely about 99wt% of about 70wt% in a still further aspect.

The thermoplastic compounds that is used to form meltblown fibers also can contain just like other additive known in the art, like surfactant, melt stabilizing agent, processing stabilizers, heat stabilizer, light stabilizer, antioxidant, heat ageing stabilizing agent, brightening agent etc.Phosphites stabilizers (for example, IRGAFOS, available from the Ciba Specialty Chemicals of Tarrytown, New York, and DOVERPHOS are available from the Dover Chemical Corp. of Dover, Ohio) be exemplary melt stabilizing agent.In addition, hindered amines stabilizing agent (for example, CHIMASSORB is available from Ciba Specialty Chemicals) is typical light and heat stabilizing agent.In addition, hindered phenol is usually as antioxidant.Some suitable hindered phenols comprise available from those of the commodity of Ciba Specialty Chemicals (Ciba) IRGANOX by name, like IRGANOX phenol 1076,1010 or E 201.When adopting; Such additive (for example; Antioxidant, stabilizing agent, surfactant etc.) exist to the amount of about 15wt% with about 0.001wt% of can be the thermoplastic compounds that is used to form meltblown fibers; Being extremely about 10wt% of about 0.005wt% further, is that about 0.01wt% is to about 5wt% in a still further aspect.Can one or more surfactants be added in polymer compositions so that polymer fiber more is prone to fluid intake performance moistening and the common moulding material of raising.That suitable surfactant comprises is cationic, anionic, amphoteric and nonionic surfactant.Particularly suitable inner surface activating agent is available from Techmer PM, Clinto, and Tennessee is hydrophilic melt additive PPM15560 surfactant.When adopting; The amount of each surfactant can be used to form the extremely amount existence of about 10wt% of about 0.5wt% of the thermoplastic compounds of meltblown fibers; Being extremely about 7.5wt% of about 1.0wt% further, is that about 1.5wt% is to about 5wt% in a still further aspect.Also can surfactant be applied to the meltblown fibers outside as Local treatment.

Through selecting some polymer and content thereof, the hot property of resulting thermoplastic compounds can be more superior than the common polypropylene homopolymer that adopts in the meltblown web.For example, thermoplastic compounds common polypropylene homopolymer that adopts in nature usually than meltblown web is more amorphous.For this reason, through measure its " hypocrystalline time "-be that half of materials becomes the required time of crystal, find that the crystalline rate of thermoplastic compounds is slower.For example, the hypocrystalline time that under 125 ° of C temperature, records thermoplastic compounds is usually greater than about 5 minutes, is about 5.25 minutes to about 20 minutes in further, is about 5.5 minutes to about 12 minutes in a still further aspect.On the contrary, the hypocrystalline time of conventional polypropylene homopolymer is generally 5 minutes or shorter.In addition, the melt temperature (" T of thermoplastic compounds _m") can be about 100 ° of C to about 250 ° of C, in further be about 110 ° of C to about 200 ° of C, be extremely about 180 ° of C of about 140 ° of C in a still further aspect.The crystallization temperature (" T of thermoplastic compounds _c") (under the cooling rate of 10 ° of C/min measure) can be about 50 ° of C to about 150 ° of C, in further be about 80 ° of C to about 140 ° of C, be extremely about 120 ° of C of about 100 ° of C in a still further aspect.Can use differential scanning calorimetry well known to those skilled in the art (" DSC ") to measure hypocrystalline time, melt temperature and crystallization temperature.

The melt flow rate (MFR) that also can in particular range, select thermoplastic compounds is to optimize the performance of resulting meltblown fibers.Melt flow rate (MFR) is forced through the weight (in gram) of the polymer in extrusion rheometer hole (diameter is 2.09mm (0.0825 inch)) for when when in 10 minutes, applying the power of 2160 grams under 230 ° of C.In general, melt flow rate (MFR) is enough high with the raising melt processable, but can highly not produce adverse influence to the binding ability to fiber and absorbent material.Therefore; Of the present invention most of aspect in; The melt flow rate (MFR) of the thermoplastic compounds of measuring according to ASTM method of testing D1238-E be per 10 minutes about 120 to about 6000 grams; Further be per 10 minutes about 150 to about 3000 grams, be to restrain to about 1500 in per 10 minutes about 170 in a still further aspect.

Term " meltblown fibers " be meant with molten thermoplastic material from a plurality of fine and closely woven, be generally the circular die capillaries and extrude; The gas that gets into high speed, common heating as line or silk (for example; Air) formed fiber in the stream, said air-flow can be cut down the silk of molten thermoplastic material to reduce its diameter.In the particular case that is total to forming technology, meltblown fibers stream is crossing with one or more materials streams of introducing from different directions.Afterwards, carry meltblown fibers and other material and be deposited on through high velocity air and collect on the surface.Distribution and the direction of meltblown fibers in formed fibre web depends on how much and process conditions.Under some technology and appointed condition, the fiber that is produced is " continuously " basically, is defined as when under 10x or 20x enlargement ratio, having several separation, debris or tapering point during through a plurality of visual field of microscopy.When producing " continuously " meltblown fibers, the side of the single fiber in single fibre length is parallel usually and have the fibre diameter difference of minimum.On the contrary, under other condition, fiber can be overdrawd, and the fracture of line thigh also forms a series of irregular, discrete fibre length and many broken ends.The retraction of the broken fiber that has attenuated can produce bigger polymer group usually.Such technology is disclosed in the 3rd, 849, No. 241 United States Patent (USP)s of people such as Butin for example, with the mode consistent with it its content is introduced this paper as a reference.

Meltblown fibers can be one pack system or multicomponent.The polymer that homofil is extruded by single extruder usually or the blend of polymer form.Two or more polymer that multicomponent fibre is extruded by different extruders usually (for example, bicomponent fibre) form.Can polymer be arranged on the cross section of fiber in the substantially invariable zones of different in location.Can arrange component by any required configuration, like skin-core formula, parallel type, cake formula, island formula, three island type, buphthalmos formula or various other arrangement known in the art.The 5th, 336 of people such as the 4th, 789, No. 592 United States Patent (USP)s of people such as Taniguchi, Strack; The 4th of people such as the 5th, 108, No. 820 United States Patent (USP)s of people such as No. 552 United States Patent (USP)s, Kaneko, Kruege; The 5th, 382 of people such as 795, No. 668 United States Patent (USP)s, Pike; The 6th of people such as people's such as No. 400 United States Patent (USP)s, Strack the 5th, 336, No. 552 United States Patent (USP)s and Marmon; 200, No. 669 United States Patent (USP) has been described the whole bag of tricks that is used to form multi-constituent fibre, for all purposes are introduced this paper as a reference with its full content.Also can form and have various erose multicomponent fibres, like the 5th of the 5th, 277, No. 976 United States Patent (USP)s of people such as Hogle, Hills; The 5th, 466 of 162, No. 074 United States Patent (USP)s, Hills; The 5th of people such as people's such as No. 410 United States Patent (USP)s, Largman the 5th, 069, No. 970 United States Patent (USP)s and Largman; 057, No. 368 United States Patent (USP) is described, for all purposes are introduced this paper as a reference with its full content.Should note using usually wetting agent to handle melt-blown material to be used for application as described herein.Can use any wettability to handle.

Usually any absorbent material can in the nonwoven web that is shaped altogether, be adopted, like absorbency fiber, granule etc.In one aspect, absorbent material comprises the fiber that is formed by various pulping process, like kraft pulp, sulfite pulp, thermomechanical pulp etc.Pulp fibres can comprise cork fibrous, and greater than 1mm, particularly about 1.5 to 5mm based on the length weighted mean for its average fiber length.Such cork fibrous can include but not limited to, northern softwood, southern softwood, Chinese larch, Western Red Cedar, Chinese hemlock spruce, pinaster (for example, southern pinaster), PiceameyeriRehd. Et Wils. (for example, Picea mariana), its combination etc.Be applicable to that exemplary commercially available pulp fibres of the present invention comprises available from Washington, the pulp fibres of the Weyerhaeuser Co. of Federal Way, name is called " CF-405 ".Also can use hardwood fiber, like Eucalyptus, maple, birch, Cortex Populi dividianae etc.In some cases, need eucalyptus fibers to improve the flexibility of fibre web especially.Eucalyptus fibers also can improve brightness, increases opacity, and the pore structure of change fibre web is to improve its wicking capacity.In addition, if desired, can use the secondary stock that from salvage material, obtains, Tathagata is from originating the for example fiber pulp of newsprint, Reclaimed board and wastepaper.In addition, other natural fiber also can be used for the present invention, like bamboo, abaca, India's grass, milkweed floss, pineapple leaves etc.In addition, in some cases, synthetic fibers also capable of using.

Except that pulp fibres or with pulp fibres, combine, absorbent material also can comprise the super-absorbent material that exists with forms such as fiber, granule, gels.In general, super-absorbent material can absorb the water-swellable material at least about 10 times of its weight in the sodium-chloride water solution that contains 0.9 percetage by weight, in some cases, and at least about 20 times of its weight or at least about 30 times.Super-absorbent material can be formed by natural polymer and material natural, synthetic and modification.As disclosed in the 6th, 623, No. 576 United States Patent (USP)s of people such as Mitchell, the instance of synthetic super absorbent polymer comprises the material that contains lightly crosslinked do not neutralize acid water-absorbing resins and lightly crosslinked unneutralized alkaline water-absorbing resins.In addition, instance comprise gather (acrylic acid) and gather (methacrylic acid), gather (acrylamide), gather (vinyl ethers), maleic anhydride and vinyl ethers and alpha-olefin copolymer, gather (vinyl pyrrolidone), gather (vinyl morpholone), gather (vinyl alcohol), and composition thereof with the alkali metal salt and the ammonium salt of copolymer.In addition; Super-absorbent material comprises natural and natural polymer modification; Like acryionitrile grafted starch, acrylic acid grafted starch, methylcellulose, chitosan, carboxymethyl cellulose, the hydroxypropyl cellulose of starch, hydrolysis, and natural gum, like alginate, xanthan gum, locust bean gum etc.Mixture natural and synthetic super absorbent polymer wholly or in part also can be used for the present invention.Specially suitable super absorbent polymer is that HYSORB 8760 super-absorberts are (available from the BASF of Charlotte; The North Carolina state) and FAVOR SXM 9500 super-absorbent materials (available from the EVONIK Stockhausen of Greensboro, the North Carolina state).

The fibre web that is shaped altogether of the present invention is formed by prepared usually, and wherein at least one meltblown beam (for example, two) is arranged near the chute, adds absorbent material through said chute, forms fibre web simultaneously.The 4th of people such as Anderson; The 5th, 350 of people such as 100, No. 324 United States Patent (USP)s, Georger; The 5th of people such as No. 624 United States Patent (USP)s and Georger; People's such as people's such as 508, No. 102 United States Patent (USP)s and Keck U.S. Patent Application Publication 2003/0200991 and Dunbar 2007/0049153 disclose this some instance of forming technique altogether, for all purposes are introduced this paper as a reference with its all the elements.

With reference to Fig. 1, for example, shown an aspect of the equipment that is used to form the fibre web that is shaped altogether of the present invention.In aspect this, equipment comprises the particle hopper 12 or 12 ' of extruder 14 or 14 ' respectively, can the propylene/alpha-olefins thermoplastic compounds be introduced wherein.Extruder 14 and 14 ' has the extruding screw (not shown) separately, and the CD-ROM drive motor (not shown) through routine drives.When polymer advances through extruder 14 or 14 ', because the rotation of the extrusion screw rod of drive motor and it is heated to molten condition gradually.Can in a plurality of separation steps, realize heating, when it raises through isolating heating region temperature when meltblown die 16 and 18 advances of extruder 14 and 14 ' respectively gradually.Meltblown die 16 and 18 can be another kind of heating region, and wherein the temperature of thermoplastic resin remains on high level so that extrude.

As stated, when using two or more meltblown beam, should understand that the fiber that is produced by single die head can be dissimilar fibers.That is to say that one or more sizes, shape or polymeric compositions can be different, and fiber can be one pack system or multicomponent fibre.For example, first meltblown beam can produce bigger fiber, is about 10 microns or bigger fiber like average diameter; Be about 15 microns or bigger further; Be about 20 to about 50 microns in a still further aspect, and second die head can produce less fiber, is about 10 microns or littler fiber like average diameter; Being about 7 microns or littler further, is about 2 to about 6 microns in a still further aspect.In addition, hope that each die head can extrude the polymer of approximately identical amount, so that the relative percentage of the basic weight of the common shaping nonwoven web material that is obtained by each meltblown beam is basic identical.Alternatively, it also is desirable that relative basic weight generation departs from, the fibre web so that a die head or another responsible major part in basic weight are shaped altogether.As a concrete instance; For basic weight is the meltblown fibers nonwoven web material of 1.0 ounces every square yard or " osy " (every square metre 34 gram or " gsm "); Hope that first meltblown beam produces basic weight about 30% of meltblown fibers nonwoven web material, and one or more subsequently meltblown beam produce remaining meltblown fibers nonwoven web material basic weight 70%.In general, total basic weight of the nonwoven web that is shaped altogether is extremely about 350gsm of about 10gsm, more particularly is extremely about 200gsm of about 17gsm, still more particularly is extremely about 150gsm of about 25gsm.

Each meltblown die 16 and 18 is set forms single air-flow, when molten thread 20 leaves hole or the hole 24 of each meltblown die, can carry secretly and drawing-off molten thread 20 so that two attenuating blasts of each mould converge.Molten thread 20 forms diameters usually less than the fiber of the diameter in hole 24, or forms microfibre according to the degree of drawing-off.Therefore, each meltblown die 16 and 18 has the single air-flow 26 and 28 that contains the thermoplastic polymer fibers of carrying secretly accordingly.The air-flow 26 and 28 that adjustment contains polymer fiber is to merge in collision area 30.Usually arrange meltblown beam 16 and 18 with certain angle, described in the 5th, 508, No. 102 United States Patent (USP)s of people such as Georger and the 5th, 350, No. 624 United States Patent (USP)s with respect to profiled surface.With reference to Fig. 2, for example, meltblown die 16 and 18 can angle [alpha] be orientated, and said angle [alpha] is recorded by tangent line to two mould 16 and 18 of plane " A ".As shown in the figure, plane " A " usually with profiled surface 58 parallel (Fig. 1).Usually, each mould 16 and 18 angle are set to about 30 to about 75 degree, are about 35 ° to about 60 ° in further, are about 45 ° to about 55 ° in a still further aspect.Mould 16 and 18 can be orientated identical or different angle.In fact, in fact can strengthen the texture of common shaping fibre web towards the angle different through making a mould with another mould.

Once more with reference to Fig. 1, at collision area 30 absorbency fiber 32 (for example, fluff pulp fibers) is added respectively in two strands of air-flows 26 and 28 of thermoplastic polymer fibers 20 and 21.The purpose of absorbency fiber 32 being introduced respectively in two strands of air-flows 26 and 28 of thermoplastic polymer fibers 20 and 21 is to produce the absorbency fiber 32 of distribution gradually in the inside of the thermoplastic polymer fibers stream 26 and 28 that merges.This can incorporate between two strands of air-flows 26 and 28 of thermoplastic polymer fibers 20 and 21 through second air-flow 34 that will contain absorbency fiber 32 and realizes, so that all three strands of air-flows converge with controllable mode.Because it still is clamminess relatively after formation and is the semi-molten state, so meltblown fibers 20 and 21 can adhere to simultaneously and be wrapped in absorbency fiber 32 time on the absorbency fiber 32 to form coherent non-woven constructions.

For realizing the merging of fiber, can adopt any conventional equipment, as have the sorting roller bearing 36 of a plurality of teeth 38, said tooth 38 is suitable for the pad of absorbency fiber or bat are separated into single absorbency fiber 32.When adopting, through roller assembly 42 with the sheet material of fiber 32 or fill up 40 and add in the sorting roller bearing 36.After the tooth 38 of sorting roller bearing 36 is separated into independent absorbency fiber 32 with the pad 40 of fiber 32, single fiber 32 is delivered in the thermoplastic poly condensating fiber stream through nozzle 44.Shell 46 surrounds sorting roller bearings 36 and between the surface of the tooth 38 of shell 46 and sorting roller bearing 36, passage or gap 48 is provided.By air flue 50 with gas for example air be supplied in the surface of sorting roller bearing 36 and the passage or gap 48 between the shell 46.Air flue 50 52 places, cross point in nozzle 44 and gap 48 can admission passage or gap 48 in.The capacity supply gas is to serve as the medium of carrying absorbency fiber 32 through nozzle 44.Also can serve as the supplementary means that absorbency fiber 32 is removed from the gas of air flue 50 supplies from the tooth 38 of sorting roller bearing 36.Can pass through any conventional device provisioning gas, for example aerator (not shown).Be contemplated that additive and/or other material can add or be entrained in the air-flow to handle absorbency fiber 32.Usually about speed of leaving the tooth 38 of sorting roller bearing 36 with absorbency fiber 32 is transmitted single absorbency fiber 32 through nozzle 44.In other words, when absorbency fiber 32 leaves the tooth 38 of sorting roller bearing 36 and gets into nozzle 44, usually begin to keep its speed at size and Orientation from its that of tooth 38 of leaving sorting roller bearing 36.The 4th, 100, No. 324 United States Patent (USP)s of people such as Anderson have been discussed such device in further detail.

If hope, the speed that can adjust secondary gas flow 34 is to realize the different common shaped structure of performance.For example, when the speed of adjustment secondary gas flow 34 made the speed of its each strand air-flow 26 that is higher than

thermoplastic polymer fibers

20 and 21 and 28 when in collision area 30 contacts, absorbency fiber 32 was incorporated in the common shaping nonwoven web 54 with the gradual change type structure.That is to say that absorbency fiber 32 is higher than the concentration at outer surface in the concentration that is shaped altogether between the nonwoven web 54.On the other hand, when in collision area 30 contact the speed of secondary gas flow 34 during with 28 speed, absorbency fiber 32 is incorporated in the common shaping nonwoven web 54 with basically uniform mode less than each strand air-flow 26 of thermoplastic polymer fibers 20 and 21.That is to say that the concentration of absorbency fiber 32 in the nonwoven web 54 that is shaped altogether is basic identical.This is because the low-speed flow of absorbency fiber 32 is inhaled into and can strengthens eddy current in the high velocity stream of thermoplastic polymer fibers 20,21 and mix, and causes the continuous distribution of absorbency fiber 32.

For the composite material stream 56 with thermoplastic polymer fibers 20,21 and absorbency fiber 32 is converted into the fine structure 54 of common shaping nonwoven, gathering-device is positioned in the path of composite material stream 56.Gathering-device can be rotated shown in arrow among Fig. 1 62 for the profiled surface 58 (for example, bag, drum, line, cloth etc.) that is driven by roller bearing 60.The merging stream of thermoplastic polymer fibers 20,21 and absorbency fiber 32 is collected as the fibrous matrix that links up on the surface of profiled surface 58, to form common shaping nonwoven web 54.If hope, can adopt the vacuum tank (not shown) to assist and to draw to shape surface 58 near fused meltblown fibers.Resulting veined altogether shaped structure 54 links up, and can remove and as the self-supporting non-woven material from profiled surface 58.

Should understand that the present invention never is limited to above-mentioned aspect.For example, aspect selective in, can adopt first and second meltblown beam of basically extending along profiled surface, its direction is basically across the direction of motion of profiled surface.Die head can be arranged in vertical basically position equally, promptly perpendicular to profiled surface, so that consequent meltblown fibers is sprayed directly on on the profiled surface.Such configuration well known in the art is described in detail in people's such as for example Dunbar No. 2007/0049153 U.S. Patent application.In addition, though above-mentioned aspect adopts a plurality of meltblown beam to produce the fiber of different size, also can adopt single die head.The instance of such technology has been described, for all purposes are introduced this paper as a reference with its full content in people's such as for example Lassig No. 2005/0136781 U.S. Patent application.

As implied above, need form common shaping fibre web in some cases with texture.With reference to Fig. 1, for example one aspect of the present invention has adopted profiled surface 58 with holes in essence once more, so that fiber can be pulled through the opening on surface and form from the three-dimensional cloth specimen clump of the material surface projection of profiled surface 58 split sheds of correspondence.Surface with holes can provide through any material that makes enough openings that some fibre penetrates, like highly transparent shaping silk thread.The geometry of silk thread braiding and processing conditions can be used for changing the texture or the clump of material.Described peak size, shape, the degree of depth, surface clump " density " (that is the quantity of the peak of per unit area or clump) etc. are depended in specific selection.For example in one aspect in, the aperture area of silk thread is about 35% to about 65%, is about 40% to about 60% in further, is about 45% to about 55% in a still further aspect.An exemplary high open area profiled surface is Albany International Co.of Albany, the FORMTECH 6 shaping silk threads that New York produces." the silk thread order number " of such silk thread for per square inch about six strands take advantage of six strands (taking advantage of 2.4 strands for every square centimeter about 2.4); Promptly; Produce about 36 holes or " hole " (5.6 every square centimeter approximately) per square inch, therefore can form about 36 clumps or peak (every square centimeter of about 5.6 peaks) in the material per square inch.The warp diameter of FORMTECH 6 shaping silk threads is about 1 millimeter polyester, and diameter of the weft yarn is about 1.07 millimeters polyester, and nominal permeability is about 41.8m ³/ min (1475ft ³/ min), nominal thickness is about 0.2 centimetre (0.08 inch), and the open area is about 51%.Another is FORMTECH 10 shaping silk threads available from the exemplary profiled surface of Albany International Co.; Its silk thread order number for per square inch about 10 strands take advantage of 10 strands (taking advantage of 4 strands for every square centimeter about 4); Promptly produce about 100 holes or " hole " (every square centimeter about 15.5) per square inch, therefore can form about 100 clumps or peak (every square centimeter of about 15.5 peaks) in the material per square inch.Another suitable shaping silk thread is FORMTECH 8 shaping silk threads, and its aperture area is 47%, also available from Albany International.Certainly, also can adopt other shaping silk thread and surface (for example, drum, plate, pad etc.).For example, can use the surface to be carved with the pad of depression and fill depression, produce and the corresponding clump of caving in so that be total to shaped fibers.Depression (clump) can present different shape, includes but not limited to circle, square, rectangle, vortex shape, rib shape, linear, cloud form etc.In addition, changes in surface can include but not limited to alternative Weaving pattern, alternative chain size, release coat (for example, silicone, fluorine-containing chemicals etc.), electrostatic dissipation processing etc.People's such as Dunbar No. 2007/0049153 U.S. Patent application described adoptable other suitable surface with holes.

No matter adopt which kind of specific veining method, the formed Cong Jun of meltblown fibers of the present invention can keep required form and surface profile better.That is,, it can be covered and the coating surface profile because meltblown fibers with relatively slow speed crystallization, is softish when being deposited on profiled surface therefore.After the fiber crystallization, they can keep shape and form clump.The type that the size of resultant clump and shape depend on employed profiled surface, sedimentary fiber type, be used for below the silk thread the fiber suction on profiled surface and the volume of the air vacuum of profiled surface and other correlative factor.For example, clump can from material surface outstanding about 0.25 millimeter at least about 9 millimeters, further in, be about 0.5 millimeter to about 3 millimeters.In general, clump has been full of fiber so when being used for wiping and cleaning, has had ideal elasticity.

Fig. 3 has shown the diagram of the cross section of the veined fibre web 100 that is shaped altogether, and the said fibre web 100 that is shaped altogether has first outer surface 122 and second outer surface 128.At least one has the three-dimensional surface texture in the outer surface 122,128.For example in Fig. 3, first outer surface 122 has the three-dimensional surface texture, and it comprises upwardly extending clump or peak 124 from the plane that is total to moulding material.Be shaped altogether a kind of peak-paddy ratio that is expressed as of three-dimensional property size of fibre web 100, computational methods are that integral thickness " T " is divided by the paddy degree of depth " D ".When carrying out veining according to the present invention, the peak-to-valley ratio of the fibre web 100 that is shaped altogether is generally about 5 or littler, is about 0.1 to about 4 in further, is about 0.5 to about 3 in a still further aspect.Clump 24 quantity is different with arranging according to required final use.In the more thick particular aspects of texture, the veined fibre web 100 every square centimeter of meetings that are shaped altogether have about 2 to about 70 clumps 24, and in others, every square centimeter has about 5 to 50 clumps 24.In aspect more sparse some of texture, be shaped altogether fibre web 100 every square metre can have about 100 to about 20,000 clumps, further in every square metre have about 200 to about 10,000 clumps.The veined fibre web 100 that is shaped altogether also can show three-D grain on the second surface of net 120.This situation especially can appear in the lower material of basic weight, as since " mirror image " and basic weight less than the material of every square metre 70 gram approximately, wherein the second surface of material shows that the peak squints or between the peak of first outer surface 122 of material, shows.In this case, measure the paddy depth D of outer surface 122,128 as stated, confirm total material paddy degree of depth then mutually.

Can understand common moulding material 100 of the present invention better with reference to following be shaped altogether method of testing and embodiment.

Method of testing altogether is shaped

Melt flow rate (MFR):

Melt flow rate (MFR) (" MFR ") is forced through the weight (in gram) of the polymer in extrusion rheometer hole (diameter is 2.09mm (0.0825 inch)) for when when in 10 minutes, applying the load of 2160 grams under 230 ° of C.Except as otherwise noted, measure melt flow rate (MFR) according to ASTM method of testing D1238-E usually.

Hot property:

According to ASTM D-3417, measure melt temperature and crystallization temperature through differential scanning calorimetry (DSC).Differential scanning calorimetry (DSC) is the DSC Q100 differential scanning calorimetry (DSC) of equipment cooled with liquid nitrogen accessory and UNIVERSAL ANALYSIS 2000 (4.6.6 version) analysis software program, all available from T.A.Instruments Inc.ofNew Castle, and Delaware.For avoiding directly contacting sample, use tweezers or other instrument.Sample is placed the aluminum dish, and accurate weighing is 0.01 milligram on analytical balance.With lid material sample is pressed on the dish.Usually resin particle directly being put into weighing plate and cutting fibre is placed on the weighing plate and covers lid to adapt to.

Described in the workbook of differential scanning calorimetry (DSC), use indium metal reference material calibration differential scanning calorimetry (DSC) and carry out baseline correction.The test cabinet of material sample being put into differential scanning calorimetry (DSC) uses blank panel as contrast to test.All tests are all carried out after the nitrogen (technical grade) that uses per minute 55-cubic centimetre purifies test cabinet.For the resin particle sample, the heating and cooling program is the 2-loop test, begins during from the test cabinet balance to-25 ° of C; It then was first heating cycle; Being heated to temperature with the rate of heat addition of 10 ° of C of per minute is 200 ° of C, and then balance sample 3 minutes under 200 ° of C then was first cooling cycle; Be cooled to temperature with the cooldown rate of 10 ° of C of per minute and be-25 ° of C; Then balance sample 3 minutes under-25 ° of C was second heating cycle then, and being heated to temperature with the rate of heat addition of 10 ° of C of per minute is 200 ° of C.All tests are all carried out after the nitrogen (technical grade) that uses per minute 55-cubic centimetre purifies test cabinet.Use UNIVERSAL ANALYSIS 2000 analysis software program appraisal results then, confirm and fusion and crystallization temperature are quantized.

The embodiment that is shaped altogether

As stated and as shown in Figure 1, the various samples of the fibre web that is shaped are altogether flowed with single Fibrotic pulp fibres by the meltblown fibers stream of two bursts of heating and form.In various samples, meltblown fibers is formed by following polymer composition:

1. the polymer composition of embodiment 1 is a Noblen, and its density is 0.91g/cm ³, melt flow rate (MFR) be 1200g/10 minute (230 ° of C, 2.16kg); Crystallization temperature is 113 ℃, and melt temperature is 156 ℃, available from LyondellBasell Industries in Rotterdam; The Netherlands, commodity are called METOCENE MF650X polymer.

2. the polymer composition of embodiment 2 is that (VISTAMAXX 2370 polymer, density are 0.868g/cm for 75wt% Noblen (ACHIEVE 6936G1 polymer) and 25wt% propylene/ethylene copolymer ³, melt flow rate (MFR) is the blend of 200g/10 minute (230 ° of C, 2.16kg)), density is 0.89g/cm ³, melt flow rate (MFR) be 540g/10 minute (230 ° of C, 2.16kg), available from ExxonMobil Chemical Corp.of Houston, Texas.

3. the polymer composition of embodiment 3 is that (VISTAMAXX 2330 polymer, density are 0.868g/cm for elastomer based on alkene ³, melt flow rate (MFR) is 290g/10 minute (230 ° of C, 2.16kg), ethylene contents is 13.0wt%), available from ExxonMobil Chemical Corp.ofHouston, Texas.

Each polymer composition also contains the surfactant (IRGASURF HL 560 surfactants are available from Ciba/BASF of Charlotte, North Carolina) of 3.0wt%.Pulp fibres is the southern softwood slurry of handling fully, available from Weyerhaeuser Co.ofFederal Way, and Washington, " CF-405 " by name.

For each embodiment, be that the hole of .020 inch is supplied to meltblown die separately with the polymer of every kind of meltblown fibers stream with the speed of 2.0 pounds of polymer of per inch die tip per hour, to obtain the meltblown fibers content of 50wt% through diameter.The distance of collision area and shaping silk thread (that is, forming height) is about 12 inches, and the distance between the meltblown die tip is about 6 inches.The meltblown die that is positioned at the pulp fibres stream upper reaches is towards the angle with respect to 48 ° of slurry streams, and another meltblown die (be positioned at slurry and flow down trip) is towards the angle with respect to 48 ° of slurry streams.The shaping silk thread is FORMTECH 8 shaping silk threads (Albany International Corp.of Albany, New York).In order to obtain dissimilar clumps, rubber blanket is placed the upper surface of shaping silk thread.The thickness of a this pad is about 0.95 centimetre, and contains the hole of arranging with hexagonal array.The diameter in hole is about 0.64 centimetre, at interval about 0.95 centimetre (center to center).Also can use the pad (for example, cloud form) of other type.Vacuum tank is positioned at shaping silk thread below to assist the deposition of net, and it is set to 30 inchess of water(in H.

In order to prove the resilient nature of common shaping fibre web, the sample of each embodiment is carried out " rubbing wrinkle " test.Every kind of sample is three inches and takes advantage of seven inches.Dry and moistening sample are tested.Moistening sample has the water that adds its weight of 3x in this sample.Push every kind of sample through in tester's hands, making bulk gently, and kept 10 seconds.Discharge sample then, tremble out gently and spread onboard, make sample open and flat afterwards never in any form.Fig. 4 shows the sample photo of rubbing the preceding embodiment 1 of wrinkle.Fig. 5 shows and accomplishes the sample photo rub the embodiment 1 after the wrinkle test.Fig. 6 shows the sample photo of rubbing the preceding embodiment 3 of wrinkle.Fig. 7 shows and accomplishes the sample photo rub the embodiment 3 after the wrinkle test.The resilience of sample that can find out embodiment 3 from Fig. 4-7 is stronger, promptly in that to rub the unfolded sample than embodiment 1 in wrinkle test back more smooth.The same sample of embodiment 2 of finding has similar performance with the sample of embodiment 3.

In another aspect of the present invention, wherein one deck of absorbent composite 84 can comprise air-flow method material.Air-flow method material if in retaining layer 94, so also can comprise the super-absorbent material of the mentioned kind that is used for the common layer that is shaped, and it comprises superabsorbent polymer particles or super absorbent polymer fiber.The fluff pulp fibers that also can comprise the mentioned kind that is used for the common layer that is shaped at the air-flow method material of random layer.Commercially available air-flow method material comprises the Gatineau available from Concert Gatineau of, Quebec, the air-flow method material of Canada.Air-flow method material is the combination of Time of Fluff Slurry and binder fibre, it is heated binder fibre is fused into Time of Fluff Slurry to produce rock-steady structure.

Air-flow method material can be made up of the blend of first group of fiber, the binding agent that preferably exists with the form of second group of fiber, and also can comprise super-absorbent material.Combination is cured to form stable air-flow method absorbing structure.Air-flow method material in aspect this can have the basic weight of predetermined about 50gsm to about 600gsm.Preferably, the basic weight of air-flow method material is that about 100gsm is to about 400gsm.Most preferably, the basic weight of air-flow method material is about 200gsm.First group of fiber can be cellulose fibre such as fluff pulp fibers, and its length is shorter, has higher denier values, and is hydrophilic.First group of fiber can be made up of 100% cork fibrous.Preferably, first group of fiber is the southern pine kraft pulp fiber, and its length is about 2.5mm, and denier values is greater than 2.0.Can test the denier values of measuring cellulose fibre to obtain roughness value through on the Kajanni analyser, carrying out roughness, unit be milligram per 100 meters (mg/100m).Then with roughness value divided by constant value 11.1 to obtain the common fabric denier values, unit is gram per 9000 meters (g/9000m).The suitable material that is used for first group of fiber comprises the Way available from Weyerhaeuser Company of Federal; Weyerhaeuser NB 416 pulp fibres of Washington and the fluff pulp fibers of CF 405 section processes; With available from Georgia Pacific of Atlanta; The Golden Isles 4881 of Georgia and 4825 fluff pulp fibers, but can use any suitable fluff pulp fibers.

The binding agent of retaining layer partly can be immersion coating.Preferably, the binding agent of retaining layer part can comprise second group of fiber.Second group of fiber can be synthetic property binder fibre.Synthetic property binder fibre can comprise Fibervisions Incorporated of Athens available from several suppliers, Georgia and Fibervisions a/sof Varde, Denmark.The supplier of other binder fibre is Huvis Corporation of SouthKorea and Far Eastern Textile Company Ltd.of Taiwan.Preferably, second group of fiber is bicomponent fibre, and it has the polyester core of being surrounded by the polyethylene sheath.Alternatively, second group of fiber can be bicomponent fibre, and it has the polypropylene cores of being surrounded by the polyethylene sheath.In aspect selective, can use the air-flow method material of processing by these dissimilar synthetic property binder fibres.

The fiber normal length that constitutes second group of fiber is longer, and denier values is littler than the fiber that constitutes first group of fiber.The fibre length of second group of fiber can be about 3mm to about 6mm.The fibre length better performances of 3mm.The denier values of the fiber of second group of fiber is less than or equal to 2.0.Second group of fiber reply moisture is insensitive, and can be and curl or non-crimping.Preferred crimped fibre is because it is easier to processing.

Air-flow method material also can contain super-absorbent material.Super-absorbent material is the material that every gram super-absorbent material can absorb at least 10 gram water.Super-absorbent material is preferably short grained shape, but also can use fiber, the super-absorbent material of thin slice or other form.Suitable super-absorbent material is available from EVONIK Stockhausen, Inc.of Greensboro, FAVOR SXM 9500 super-absorbent materials of North Carolina.Also can use the super-absorbent material of other similar type, some of them are available from BASF of Charlotte, and North Carolina is like HYSORB 8760 super-absorbent materials.Preferably, super-absorbent material is that about 5% to about 60% amount exists with percentage by weight.

The amount of existing single component can be inequality in the air-flow method material.In addition, component can be evenly or is distributed in unevenly in the air-flow method material.Yet found that following percentage ratio can perform well in forming thin absorbing products.First group of fiber can account for about 30% to about 85% of air-flow method material by weight.Second group of fiber can account for about 5% to 20% of air-flow method material by weight.Super-absorbent material can account for about 5% to about 60% of air-flow method material by weight.Found first group of fiber with about 77%, about 8% second group of fiber and about 15% super-absorbent material form air-flow method material can perform well in absorbing and keeping urine and menstruation.

First group of fiber can be present in the percentage ratio that is higher than second group of fiber by weight in the air-flow method material.Can reduce the totle drilling cost of air-flow method material through the first group of fiber that uses higher percent.First group of fiber can guarantee that also absorbing products has enough fluid absorbency.Cellulose fibre such as fluff pulp fibers are more cheap than synthetic adhesive fiber usually.In order to obtain good performance, second group of fiber can be formed by weight the air-flow method material at least about 5%, has enough hot strengths to guarantee air-flow method material.As stated, air-flow method material should be the mixture of component.

In one aspect of the invention, be heating and curing about 8 seconds under about 165 degrees centigrade temperature to about 10 seconds time, under the condition of substantially dry, air-flow method material being squeezed to density is every cubic centimetre of about 0.05 gram g/cm ³To about 0.3g/cm ³Preferably, under the condition of substantially dry, air-flow method material is squeezed to density and is about 0.07g/cm ³To about 0.22g/cm ³Most preferably, under the condition of substantially dry, air-flow method material being squeezed to density is about 0.12 (g/cm ³).This being extruded with of air-flow method material helped form thin absorbing products.

When being used for blot coat, air-flow method material does not comprise super-absorbent material usually, and density is 0.05g/cm ³To 0.15g/cm ³The air-flow method material that is used for retaining layer generally includes super-absorbent material, and density is 0.1g/cm ³To about 0.3g/cm ³

It should be noted that the stabilizing material of forming air-flow method material should have enough hot strengths so that it is wrapped on the spool on the machine direction, can and on conversion equipment, handle its expansion afterwards.Through changing the content of binder fibre, the adjustment condition of cure changes the proportion that fiber pushes, and alternate manner well known by persons skilled in the art, can obtain enough hot strengths.Find that the hot strength of air-flow method material should be the every 50mm of 12 newton (N/50mm) at least.Preferably, the hot strength of air-flow method material should be 18N/50mm at least.More preferably, the required hot strength of air-flow method material should be 25N/50mm at least.But the hot strength of use test appearance test material is as available from MTS Systems Corporation of Research Triangle Park, the Model MTS/Sintech1/S tester of North Carolina.From the object of the invention, be fixed on two hot strengths of movably measuring between the claw at peak load of tester for elongation through 50mm band with stabilizing material.Initial two claws separate the distance of about 10cm.With 25cm/ minute speed two claws are ruptured up to material bands to away from each other outer side shifting then.Hot strength is recorded as peak load.

In another aspect of the present invention, retaining layer 94 can comprise high-density hydrogen bonding fine hair/super absorbent polymer material, as available from EAM Corporation of Jesup, the NOVATHIN absorbent cores of Georgia.These materials comprise the mixture of Time of Fluff Slurry and super-absorbent material, and this mixture is forming also densification between the napkin cover, to form high density composite between two-layer napkin or other nonwoven fiber material.Specially suitable super absorbent polymer is HYSORB 8760 super-absorbent materials (BASF of Charlotte; North Carolina) and FAVOR SXM 950 super-absorbent materials (available from EVONIK Stockhausen ofGreensboro, North Carolina).Compositions does not comprise chemical adhesive usually.Combination also can comprise synthetic property binder fibre.

Basis weight can be 80 to 800gsm.Density can be 0.1 to 0.45g/cc.Particle content can be 0-70%.As the part of densification process, can on compositions, impress different pattern, comprise the bond pattern of level and smooth, circular or customization.

The hydrogen bonding process has been eliminated the combination that is used for the stable synthetic fibers of netting and/or latex and baking box and has been used.Alternatively, it depends on the combination that is used to cause the temperature and pressure of hydrogen bonding in calendering in the step, thereby makes net stable.The main advantage of this technology has been simplified production process for having avoided expensive unit operations.Other advantage comprises owing to not containing absorbefacient material of influence such as synthetic fibers and binding agent makes the capacity of particulate matter such as super-absorbent material bigger, and absorption efficiency is higher.

In another aspect of the present invention, one or more layers can comprise spunlaced material.Spunlaced material comprises the part (for example, laminate) of meltblown fibers as structure.Material is applied Hydroentangled to promote the entanglement of various fibers and/or filament.This causes the entanglement of higher degree and allows in laminate, to use various other fibrous materials.In addition, use meltblown fibers can reduce the amount of the required energy of Hydroentangled laminate.In spunlaced or Hydroentangled adhering technique; Usually with the loose end of having of sufficient amount (for example, the short fiber and the wood fiber), include in the fleece with parcel and become entangled in around the cross points such as fiber filaments, foam, net than minor diameter and the mobile fiber of higher fiber.If there is not such fiber, the cohesive of net can be relatively poor.Think that no loose end and mobile less successive major diameter filament are the relatively poor fibers that is used to tangle.Yet, find that meltblown fibers can effectively wrap up and tangle or twine.This is because fiber has less diameter and higher surface area, and when spraying machine transmits sufficiently high energy and flows, fibrous fracture, motion and this fact of other fiber of tangling.No matter whether meltblown fibers is above-mentioned stratiform form or mixed form, all this phenomenon can take place.

The use of meltblown fibers (for example, microfibre) provides the product of improvement because the meltblown fibers in laminate and other material for example the entanglement of fibrous material improve.Therefore, because meltblown fibers has big relatively length and relatively little thickness, meltblown fibers is improved around the entanglement of other material in laminate.In addition, meltblown fibers has high relatively surface area, less diameter, and enough distances of being separated by to each other move freely and be wrapped on the meltblown fibers and inside to allow other fibrous material in laminate.In addition, because meltblown fibers One's name is legion and have high relatively surface area, little diameter and almost continuous, this fiber can be bonding with loose fiber (for example, the wood fiber and short fiber) and self admirably.This fiber is fixed or is laminated to the entanglement energy that needs low relatively energy on the meltblown fibers.

Use Hydroentangled technology to comprise that other mechanical interlocking is technological rather than only use other adhering technique to come fibrous material (is for example carried out mechanical interlocking; Mechanical adhesion); The compound non-woven fibre Web materials that can provide intensity, integrity and feel and drapability to improve; And allow to control better the attribute of other products, like absorbability, wet strength etc.

An instance of spunlaced cloth is an OPTIMAL GSM 30-250100%Rayon cloth, available from Baiksan Lintex Co., Ltd.of Siheung-City, South Korea.

Spunlaced cloth typically refers to the material that receives Hydroentangled processing.Though spunlaced cloth is relatively inexpensive, ventilative and can be out of shape, it has been generally acknowledged that distortion is nonvolatil and can be described as expendable stretching.Know that already the fiber that diameter is very little or the nonwoven web of microfibre can see through air and steam, keep liquid and/or particulate relative impenetrability simultaneously.Fiber forming process capable of using is melt-blown process for example, through extruding the useful fibre web that the inelastic body thermoplastic polymer prepares small diameter fibers.Though the nonwoven web of the meltblown fibers that is formed by non-elastomer polymer is cheap relatively and ventilative, the fibre web that highly tangles is often relatively poor to the tensile force response.It has been generally acknowledged that in this material, take place extend to nonvolatil, expendable extension (that is expendable stretching).For example, it has been generally acknowledged that the nonwoven web by traditional thermoplastic polypropylene preparation has expendable stretching.

Of the present invention aspect another in, one or more layers comprised foamed materials of absorbent composite 84 is as available from The Dow Chemical Company of Midland, the material of Michigan.The 6th of people such as Mork; 627; The 7th of people such as the 6th, 071, No. 580 United States Patent (USP)s of people such as 670B2 United States Patent (USP), Bland, Strandburg; 439; People's such as people's such as 276B2 United States Patent (USP) and Vansumeren WO2008/036942A2 PCT is open, Kim WO2007/011728A2 PCT is open, the WO2008/052122A1 PCT of Menning is open and people's such as Stockton WO2008/100842A1 PCT has openly described representational absorbent foam, and its full content to introduce this paper as a reference, is not contradicted each other with it and to exceed.

Such absorbable polymer foamed materials has hydrophilic, the softish polymer foam structure of interconnection open cells.What can be used for defining preferred foam of polymers is characterized as abscess (cell) structure.The shape that contains the abscess that monomeric oil phase polymerization forms of abscess, especially the water drop through surrounding relative monomer-free is essentially spherical usually.These spherical abscesses are connected with each other through opening, below said opening are called the hole between the abscess.The size of this sphere abscess or the diameter of the opening (hole) between " diameter " and abscess are generally used for characterizing foam.Because abscess and the hole between abscess in given foam of polymers sample may not be roughly the same size, therefore be often referred to and allocate equal abscess and aperture (that is, average abscess and bore dia).

Abscess and aperture comprise these foamy fluid wicking properties for influencing the parameter of foamy a lot of important machinery and performance characteristic, and at the inner capillary pressure that forms of foaming structure.Many technology can be used for confirming foamy average abscess and aperture.Useful technology relates to the simple measurement based on the scanning electron micrograph of foam sample.Foam can be used as the absorbent of aqueous fluids, and the average bubble aperture is preferably about 20 to about 200 μ m, and more preferably about 30 to about 190 μ m, most preferably is about 80 to about 180 μ m; The number average aperture is about 5 to about 45 μ m, is preferably about 8 to about 40 μ m, most preferably is about 20 to about 35 μ m.

For example, people's such as Bland the 6th, 071, No. 580 United States Patent (USP)s described absorbefacient, extrude, the open cells thermoplastic foam.Foamy open cells content is about 50% or higher, and the average bubble aperture is up to about 1.5 millimeters.When absorbing liquid, foam can absorb 50% or more liquid of its theoretical capacity.Foamy average effective aperture is preferably about 5 microns or bigger.Foam preferably has cell wall and abscess corbeling basically.The method that adopts the foam that produces through the extrudate that extends extrusion die to absorb liquid has also been described; With improve the absorbefacient method of open cells foam through surfactant being applied to foamy exposed surface; Make surfactant be retained in the surface, can not infiltrate suitable distance and get in the foam.

The suitable foam material also can comprise various types of foams, includes but not limited to thermoplastic foam, High Internal Phase Emulsion (HIPE) foam and reverse High Internal Phase Emulsion (I-HIPE) foam and other suitable polymers foam; Include but not limited to people such as Ko people such as the 7th, 053, No. 131 United States Patent (USP)s, Krueger the 7th; 358; People's such as people's such as No. 282 United States Patent (USP)s and DesMarais the 5th, 692, No. 939 United States Patent (USP)s and Radwanski US2006/0148917 U.S. Patent application discloses disclosed foam of polymers; Its full content is introduced this paper as a reference, do not contradict each other with it and exceed.A kind of instance of suitable foamed materials is the polyurethane foam with negative poisson ' s ratio.Usually the material that in conventional sanitary towels, is used as egative film also is suitable.Osborn, the 5th, 611, No. 790 United States Patent (USP)s of people such as III have been described the instance of extensible stock footage, and its full content is introduced this paper as a reference, do not contradict each other with it and exceed.Described other instance of suitable absorbent foam during people's such as Zhang US2006/0246272 U.S. Patent application is open, its full content has been introduced this paper as a reference, do not contradicted each other with it and exceed.

In another aspect of the present invention, retaining layer 94 can comprise super absorbent polymer/viscosity composite, comprises extensile super absorbent polymer/viscosity composite.The 5th of people such as the 5th, 411, No. 497 United States Patent (USP)s of people such as Tanzer, Tanzer; The 7th of people such as 433, No. 715 United States Patent (USP)s and Schewe; 247; People's such as No. 215 United States Patent (USP)s and Nhan 2005/0096623A1 U.S. Patent application has openly been described such composite, and its full content is introduced this paper as a reference, does not contradict each other with it and exceeds.

In another aspect of the present invention, one or more layers comprised bonded carded web of absorbent composite 84 (BCW) is like the 5th, 364 of people such as Latimer; No. 382 United States Patent (USP)s, the 5th, 429 of people such as Latimer; The 5th, 486 of people such as No. 629 United States Patent (USP)s and Bishop; No. 166 United States Patent (USP)s are introduced this paper as a reference with its full content, do not contradict each other with it and exceed.The general basis weight of BCW material comprises the basis weight of 30-300gsm.These patents have been described the method for preparing of BCW surge technology and BCW surge material.

In another aspect of the present invention, one or more layers comprised melt-blown micro-fiber material of absorbent composite 84.An instance of such melt-blown micro-fiber material is that 50gsm melts and sprays the hydrophilic meltblown fibers material of bar white, available from Yuhan-Kimberly Kimcheon Nonwoven Mill of KimCheon City, KyungSangBuk-Do, Korea.The polypropylene fibre diameter of this material is the 1-5 micron; Composite density is 0.124-0.218g/cc; The aperture is 15-18 micron (a maximum 21-30 micron); Can comprise that also wettable surfactant is as available from Cytec Industries Inc.of West Paterson, the AEROSOL GPG surfactant of New Jersey.

Be used for absorbing blood and be challenging based on the fluidic high-absorbable goods of blood such as the exploitation of menopad (for example, sanitary towel), tapon, wound dressing, binder and surgical drapes.Compare with urine with water, blood and be the mixture of relative complex based on the fluid such as the menstruation of blood has dissolving and solvent components (for example, erythrocyte or erythrocyte) not.Especially, fluid such as the menstruation based on blood is bigger than water and urine viscosity.This higher viscosity hinder traditional absorbent material effectively and apace with these based on the fluid transport of blood to away from the initial ability that flows out the zone of point.Undissolved element also possibly stop up the capillary tube of these absorbent materials in these fluids based on blood.This makes and to be used to absorb based on the design of the absorption system of the fluid of blood such as menstruation particularly difficulty.

In the situation of menopad, the women is desirably in comfortable and applying, fluidic reservation and MIN contamination aspect have high-caliber performance.In a word, think that it is unacceptable that fluid leaks into underwear from pad.Though menopad structure and the material that is used for this structure have been carried out many improvement, and the performance that improves this menopad remains the cause of an arduousness.Yet the elimination seepage particularly along the seepage of femoribus internus, does not reduce and fits and comfort simultaneously, can not satisfy the demand that consumer thirsts for yet.

The absorbing structure of menopad (for example sanitary towel) generally includes one or more fibrous layers from permeable topsheet, to collect the fluid of discharge and it is distributed in the storage area of lower floor at present.The absorbing structure that is used for the relative thin version of existing menstruation product generally includes fluid collection or the blot coat adjacent with permeable topsheet.This blot coat is processed by air-flow method fabric web or synthetic property non-woven fleece usually.Below this blot coat is main absorbent cores, and this absorbent cores is made by air-flow method or wet method fabric usually.

The existing absorption of menses absorbing structure of being processed by fibrous layer has many problems.One of them difficulty is to guarantee the top flat sufficiently dry.The chance that such structure causes underwear and health to pollute is also bigger.This is because absorbing structure lacks resilience, causes the pack of filling up.This elastic shortage and consequential pack also can cause these existing menopads to provide user relatively poor fit and comfort.Confirmed the subject under discussion of traditional menses absorption structure and traditional unresolved this problem of absorption fibrous web in the 5th, 849, No. 805 United States Patent (USP)s of Dyer.

A kind of solution of trial property replaces fiber blot coat and retaining layer with foam, as available from The Procter and Gamble Company of Cincinnati, employed INFINICEL foam in the ALWAYS INFINITY plain edition pad of Ohio.Such foam is often expensive more than fibrous web.

The nonwoven web that is shaped altogether is the composite of meltblown fibers matrix and absorbent material (for example, fluff pulp fibers), in multiple application, is used as absorbed layer, comprises absorbing products, absorbability dry towel, wet towel and mop.Most of tradition fibre web that is shaped altogether adopts the meltblown fibers that is formed by polypropylene homopolymer.Yet the problem that so common moulding material meets on occasion is when moulding material receives bending force altogether, not have enough resiliences.For example, shown in Figure 4 and 5, when the cleaning piece that is shaped was altogether wrinkled, moulding material can't return to its primary smooth, non-wrinkled state altogether.Another instance is the tendency that the common moulding material that in personal care absorbent product, is used as absorbent cores has pack.

Therefore, the improved nonwoven web that is shaped altogether disclosed herein can be used for various application, and demonstration shows the tendency of recovering flat condition to the raising of the resistance of bending force and in folding back.Shown in Fig. 6 and 7, so improved nonwoven web that is shaped altogether can combine to be used for generation the absorbent composite of future generation of personal care absorbent property goods with other multiple material.

The inventor has carried out intensive development efforts aspect the absorbing products improving; And developed the absorbent composite that is used for absorbent cores; Said absorbent cores has enough moist and dryness resilience force and enough absorbabilitys, does not need the main expensive foam that uses.The inventor also find they can through with resilience altogether moulding material and other material merge and adjust these characteristics, give its high resilience and absorbent properties.

When consumer tested the commodity that replace fibrous web with foam, the product of having included material described herein in had produced unexpected and surprising result.Menopad and the commercially available ALWAYS INFINITY plain edition pad of having included the INFINICEL hipe foam in are compared; Said menopad comprises that the resilience of 215gsm 50%VISTAMAXX polymer is total to moulding material/50% Time of Fluff Slurry blend blot coat 86 and combines with the retaining layer 94 that comprises EAM 150gsm NOVATHIN high-density hydrogen bonding fine hair/super absorbent polymer material, and said super absorbent polymer material comprises 25% superabsorbents.Although two kinds of technological means are different with cost, total two kinds of products have all obtained equal purchase intention and identical to comfortable and absorbefacient impression.Because the benefit that the more expensive INFINICEL foam of conjecture brings exceeds the resilience cheaply of being tested and is shaped altogether/the NOVATHIN combination of materials, so this result is beyond thought.Test other in the same manner and do not comprise resilience be shaped altogether layer or the foamy commercially available prod of INFINICEL, but do not provide and the described two kinds of comfort levels that product is identical of this section.

As stated, because absorbing structure lacks resilience, cause the pack of filling up, therefore the menses absorption structure of existing employing fibrous web causes underwear also bigger with the chance of health pollution.This elastic shortage and consequential pack also can cause these existing menopads to provide user with relatively poor fit and comfort.On the contrary, as described in Table 1, absorbing structure disclosed herein has solved this problem.

Table 1: consumer tests result

The unit rating method of above-mentioned digitized representation five point scale, 5 representatives are better.Result in pro-two row does not have the remarkable meaning of statistics.Show with preceding two row to have statistically-significant difference in tertial result, show relatively poor result.

Can understand absorbent composite 84 of the present invention better with reference to following absorbent composite method of testing and embodiment.

Absorbent composite method of testing: side extruding test

Side extruding test is through carrying out lateral compression to the pad sample, and the pliability and the resilience that reduce pressure then and measure the feminine pads sample.Use CRE (constant speed elongation rate) tension tester (like MTS SINTECH 500/S model, sequence number 500S/062696/203 or equivalent) to carry out this test.Data acquisition software be MTS TESTWORKS for Windows Ver.4.11C (MTS Systems Corporation, Eden Prairie, MN).According to the peak power value of institute's specimen, the side extrusion element is selected from 50 newton or maximum 100 newton, so that most of peak load value falls between the 10-90% of side extrusion element gamut value.In this test, two edges (being the liner and the outer covering layer of laminate) of pad are clipped in top and the bottom clamping part of tension tester, the center of the centrally aligned clamping part of sample, sample is positioned at clamping part and hits exactly.The clamping face width is 3 inches (76.2mm), and the approximate altitude of clamping part is 1.0 inches (25.4mm).Test speed is 5 ± 0.04 inches/min (127 ± 1mm/min) under extruding and pressure reducing mode.Initial measurement length is set to 55mm.When the test beginning, clamping part moves with the extruding sample toward each other, is 20 ± 1mm up to the clamping part distance.Clamping part returns its initial position when EOT then.Can test drying sample.In addition, the drying sample tested of available 5mL fluid wets and test again under wetting conditions.

The image of drawing pressure and distance is to produce extrusion graph.When squeezed state discharges sample down, also drawing the image of pressure and distance, produce decreasing pressure curve.

Three important test parameters of this tester are following.Peak extruding force (gf) is the detected maximum, force that reaches the extruding distance in extrusion graph.Higher value show need be bigger power product is squeezed to specific thickness.In practical application, consumer's wearable product also is squeezed in them between her both legs.Higher peak force show need be bigger the effort extruded product.Extruding can (gfcm) be the area under the extrusion graph.Higher value shows that product is difficult to extruding more.In practical application, this means needs more energy that product is squeezed between the both legs.This parameter has been considered all points and has not been peak force.At last, extruding resilience (%) is the ratio of decompression with squish area.Higher value shows bigger response rate.In practical application, consumer's wearable product also is squeezed in them between her both legs.Product recovers original state when decontroling.This helps reducing pack and distortion problem.Ideally, aspect comfort level, people need be easy to the product of extruding (peak force is lower, and energy is lower) and resilience.

Identical method of testing is used for the wet extruding and the resilience data of generation table 2, except using syringe liquid distribution is added the 5ml menses simulant in the dry pad in the whole zone of side liner.Employed menses simulant is processed by Sanguis sus domestica that is diluted to by volume 30% hematocrit levels and the thickness Ovum Gallus domesticus album that is added to the shearing that has the mucin composition of simulating menstruation.These analogies are available from Cocalico Biologicals, Inc.of Reamstown, Pennsylvania; And also at the 5th, 883, No. 231 United States Patent (USP)s of people such as Achter; Be described in the 7th, 632, No. 258 United States Patent (USP)s of people such as Misek; Its full content is introduced this paper as a reference, do not contradict each other with it and exceed.

The embodiment of absorbent composite

Embodiment A: commercially available ALWAYS INFINITY plain edition menopad.

Embodiment B: U by KOTEX CLEANWEAR plain edition pad.

For following examples, VISTAMAXX 2330 polymer are available from ExxonMobil Chemical Corp., CF 405 pulp fibres available from Weyerhaeuser Co. and FAVOR SXM9500 superabsorbent particles available from Evonik Stockhausen, Inc.

Embodiment 1: production and test have the pad of shape as described in Figure 11; Said pad comprises first blot coat (86) and retaining layer (94); Said first blot coat (86) comprises that the resilience with 108gsmVISTAMAXX 2330 polymer and 108gsm CF405 pulp fibres is total to moulding material, and said retaining layer (94) comprises EAM NOVATHINJ1501825DTNB material (high-density hydrogen bonding fine hair/super absorbent polymer material).

Embodiment 2: produce and test has as described in Figure 10 shape but the pad of atresia (95); Said pad comprises first blot coat (86) and retaining layer (94); Said first blot coat (86) comprises that the resilience with 108gsm VISTAMAXX 2330 polymer and 108gsm CF405 pulp fibres is total to moulding material, and said retaining layer (94) comprises EAM NOVATHIN J1501825DTNB material (high-density hydrogen bonding fine hair/super absorbent polymer material).

Embodiment 3: produce and test has as described in Figure 10 shape but the pad of atresia (95); Said pad comprises first blot coat (86), retaining layer (94) and distribution layer (96); Said first blot coat (86) comprises that the resilience with 108gsm VISTAMAXX 2330 polymer and 108gsm CF 405 pulp fibres is total to moulding material; Said retaining layer (94) comprises EAM NOVATHINJ1501825DTNB material (high-density hydrogen bonding fine hair/super absorbent polymer material), and said distribution layer (96) comprises 2 layers of 50gsm meltblown fibers.

Embodiment 4: produce and test has as described in Figure 10 shape but the pad of atresia (95); Said pad comprises the ground floor and the second layer, and said ground floor comprises that the resilience with 108gsm VISTAMAXX 2330 polymer and 108gsmCF405 pulp fibres is total to moulding material, and the said second layer comprises Glatfelter Airlaid DT200.102.

Embodiment 5: production and test have the pad of shape as described in Figure 10; Said pad comprises first blot coat (86) and retaining layer (94); Said first blot coat (86) comprises that density is 150gsm expanded polyolefin and the spunbond base material of 0.5osy of 0.07g/cc, and said retaining layer (94) comprises that the 215gsm that is processed by 108gsmVISTAMAXX 2330 polymer, 75gsmCF405 pulp fibres and 32gsm FAVOR SXM9500 superabsorbent particles is total to moulding material.Formation runs through the sectional hole patterns in two-layer 41 holes (95), and each bore dia is 3mm, is arranged as pattern as described in Figure 10.The profile of the described pad of Figure 10 is used for the general contact in context display aperture (95).

Embodiment 6: produce and test has as described in Figure 10 shape but the pad of atresia (95); Said pad comprises first blot coat (86) and retaining layer (94); Said first blot coat (86) comprises that the resilience with 108gsm VISTAMAXX 2330 polymer and 108gsm CF 405 pulp fibres is total to moulding material, and said retaining layer (94) comprises that the 215gsm that is processed by 108gsm VISTAMAXX 2330 polymer, 75gsmCF 405 pulp fibres and 32gsm FAVOR SXM9500 superabsorbent particles is total to moulding material.

Embodiment 7: produce and test has as described in Figure 10 shape but the pad of atresia (95); Said pad comprises first blot coat (86) and retaining layer (94); Said first blot coat (86) comprises that the resilience with 108gsm VISTAMAXX 2330 polymer and 108gsm CF 405 pulp fibres is total to moulding material, and said retaining layer (94) comprises the spunlaced material of 100gsm.

Table 2: test result: side extruding test

-VM2330 is meant VISTAMAXX 2330 polymer available from ExxonMobil Chemical Corp.

-CF 405 is meant CF 405 pulp fibres available from Weyerhaeuser Co..

-SXM9500 is meant the Stockhausen available from Evonik, the FAVOR SXM9500 superabsorbent particles of Inc..

-because the shape of pad also can influence the extrudability and the resilience of measurement, pulvilliform shape shown in Figure 11 being used for embodiment 1, pulvilliform shape shown in figure 10 is used for embodiment 2-7.

Above-mentioned common each embodiment of moulding material of resilience that comprises has the peak force that is equivalent to or is lower than ALWAYSINFINITY plain edition pad.

Though from concrete aspect the present invention is described in detail, should understand that those skilled in the art can easily expect change, variation and the equivalent way aspect these after understanding aforementioned content.Therefore, scope of the present invention should be confirmed as the scope of accompanying claims and its any equivalent way.In addition, should point out that any given range described herein is intended to comprise any and all less scope that comprises.For example, the scope of 45-90 also comprises 50-90,45-80,46-89 etc.

Claims

1. one kind places the absorbent composite between top flat and the egative film in absorbing products, and said absorbent composite comprises:

Place first blot coat between top flat and the egative film; With

Place the retaining layer between top flat and the egative film,

One in wherein said first blot coat and the said retaining layer comprises resilience moulding material altogether.

2. absorbent composite according to claim 1; Wherein said first blot coat comprises altogether moulding material of resilience, and wherein said retaining layer comprises common moulding material, resilience a kind of in moulding material, bonded carded web (BCW) material and the air-flow method material altogether.

3. absorbent composite according to claim 2, wherein, said retaining layer also comprises super-absorbent material.

4. absorbent composite according to claim 2, wherein, said retaining layer also comprises Time of Fluff Slurry.

5. absorbent composite according to claim 1; Wherein said first blot coat comprises altogether moulding material of resilience, and wherein said retaining layer comprises a kind of in high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite and the foamed materials.

6. absorbent composite according to claim 5, wherein, said retaining layer also comprises Time of Fluff Slurry.

7. absorbent composite according to claim 1; Wherein, Said retaining layer comprises altogether moulding material of resilience, and wherein said first blot coat comprises common moulding material, resilience a kind of in moulding material, air-flow method material, bonded carded web (BCW) material and the foamed materials altogether.

8. absorbent composite according to claim 7, wherein, said first blot coat also comprises Time of Fluff Slurry.

9. absorbent composite according to claim 7, wherein, the said resilience in said retaining layer moulding material altogether comprises super-absorbent material.

10. absorbent composite according to claim 1 also comprises the distribution layer that places between top flat and the egative film, and said distribution layer comprises a kind of in melt-blown micro-fiber material, spunlaced material and the foamed materials.

11. absorbent composite according to claim 1, wherein said first blot coat comprise resilience moulding material altogether, and wherein said retaining layer comprises high-density hydrogen bonding fine hair/super absorbent polymer material.

12. absorbent composite according to claim 1, wherein, said first blot coat comprises resilience moulding material altogether, and wherein said retaining layer comprises air-flow method material.

13. absorbent composite according to claim 1, wherein, said first blot coat and said retaining layer include resilience moulding material altogether.

14. absorbent composite according to claim 13, wherein, said retaining layer also comprises super-absorbent material.

15. absorbent composite according to claim 1; Also comprise usually second blot coat with the parallel placement of said first blot coat, said second blot coat comprises a kind of in air-flow method material, bonded carded web (BCW) material, the common moulding material of resilience and the foamed materials.

16. absorbent composite according to claim 1, wherein, said blot coat is between said top flat and said retaining layer, and wherein said retaining layer is between said egative film and said blot coat.

17. one kind places the absorbent composite between top flat and the egative film in absorbing products, said absorbent composite comprises:

First blot coat, said first blot coat comprise common moulding material, resilience a kind of in moulding material, air-flow method material, bonded carded web (BCW) material and the foamed materials altogether; With

Place the retaining layer between top flat and the egative film; Said retaining layer comprises common moulding material, resilience a kind of in moulding material, air-flow method material, high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite and the foamed materials altogether, and one in wherein said first blot coat and the said retaining layer comprises resilience moulding material altogether.

18. one kind is adapted at placing in the absorbing products absorbent composite between top flat and the egative film, said absorbent composite comprises:

First blot coat, said first blot coat comprise resilience moulding material altogether; With

Place the retaining layer between top flat and the egative film, said retaining layer comprises common moulding material, resilience a kind of in moulding material, air-flow method material, high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite and the foamed materials altogether.

19. the absorbent personal care article with top flat and egative film, said goods comprise:

Place the absorbent composite between top flat and the egative film; Said absorbent composite comprise first blot coat and place said top flat and said egative film between retaining layer; Said first blot coat comprises altogether moulding material of resilience, and said retaining layer comprises common moulding material, resilience a kind of in moulding material air-flow method material, high-density hydrogen bonding fine hair/super absorbent polymer material, spunlaced material, super absorbent polymer/viscosity composite and the foamed materials altogether.

20. a method for preparing the absorbent personal care article with absorbent composite, said method comprises:

Absorbent material stream and meltblown fibers stream are merged to form composite material stream;

On profiled surface, collect said composite material stream to form the resilience nonwoven web that is shaped altogether; With

The said resilience nonwoven web that is shaped is altogether combined with top flat and egative film.

21. an absorbent composite that is applicable to the absorbing products with top flat and egative film, said absorbent composite comprises:

Comprise the blot coat that places the foamed materials between said top flat and the said egative film, said blot coat has a plurality of holes of passing this blot coat; With

Place the retaining layer between said top flat and the said egative film, wherein said retaining layer comprises resilience moulding material altogether.

22. absorbent composite according to claim 21, wherein, said retaining layer has a plurality of holes of passing this retaining layer.