CN116847817A

CN116847817A - Feminine hygiene product comprising a composite with improved in-plane permeability

Info

Publication number: CN116847817A
Application number: CN202280005113.3A
Authority: CN
Inventors: 张军; 瑞恩·乔·恩格; 琼·马里切尔·迭戈-德古兹曼; 查尔斯·E·米勒
Original assignee: International Paper Co
Current assignee: International Paper Co
Priority date: 2021-03-09
Filing date: 2022-03-09
Publication date: 2023-10-03

Abstract

The present disclosure features a feminine hygiene product comprising: a nonwoven layer comprising polymeric fibers and/or filaments; a crosslinked cellulosic layer comprising crosslinked cellulosic fibers; wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer (e.g., there is no intermediate layer other than the crosslinked cellulosic layer and the nonwoven layer; in some embodiments, the crosslinked cellulosic layer is immediately adjacent the nonwoven layer); and an interface region between the nonwoven layer and the crosslinked cellulosic layer, the interface region comprising physically entangled polymer fibers and/or filaments from the nonwoven layer and crosslinked cellulosic fibers from the crosslinked cellulosic layer. The nonwoven layer and the crosslinked cellulosic layer of the composite fabric are mechanically inseparable in the dry state.

Description

Feminine hygiene product comprising a composite with improved in-plane permeability

Cross Reference to Related Applications

The present application claims the benefit of U.S. patent application Ser. No. 63/158,471, filed on day 2021, 3, and day 23, and U.S. patent application Ser. No. 17/678,588, filed on day 2022, 2, the disclosures of each of which are incorporated herein by reference in their entirety.

Background

Personal care absorbent products, such as infant diapers, adult incontinence pads and undergarments, and feminine care products, typically comprise a fluid absorbent core. Many absorbent articles include a fluid-absorbent core disposed between a topsheet and a backsheet. The topsheet is typically formed of a fluid permeable material adapted to facilitate transfer of fluid into the absorbent core, such as upon liquid insult, the topsheet typically having minimal fluid retention. Southern pine fluff pulp is commonly used in absorbent cores, often in the form of a fibrous matrix, sometimes in combination with superabsorbent polymers (SAP) dispersed in the fibrous matrix. Fluff pulp is considered worldwide to be a preferred fiber for absorbent products based on factors such as its high fiber length, fiber coarseness, and its relative ease of processing into an air-laid web from wet-laid and dry pulp sheets. The raw material for this type of cellulosic fluff pulp is southern pine (e.g., pinus koraiensis, pinus taeda). The feedstock is renewable and the slurry is prone to biodegradation. These fibers are inexpensive on a per unit mass basis as compared to SAP, but tend to be more expensive on a per unit liquid retention basis. These fluff pulp fibers are mainly absorbed in the interstices between the fibers.

SAPs are water-swellable, generally water-insoluble absorbent materials that have a high absorbent capacity for fluids. SAP swells and becomes a gel upon absorbing fluid, retaining such fluid in excess of its weight. The commonly used SAPs are mainly derived from acrylic acid. Acrylic-based polymers also account for a significant portion of the cost structures of diapers, incontinence pads and undergarments. SAPs are designed to have high gel strength (as evidenced by high absorbency under load or AUL). The high gel strength (upon swelling) of the SAP particles currently in use helps them maintain significant void space between the particles, which aids in rapid fluid absorption. However, this high "void volume" simultaneously results in significant interstitial (inter-particle) liquid in the product at saturation.

While fluff pulp fibers and SAPs can store very large amounts of liquid, they generally cannot distribute liquid from the point of insult to a more remote area of the absorbent article and cannot quickly acquire liquid at the rate at which the article receives liquid. For this reason, acquisition members are used which provide a temporary acquisition of a large amount of liquid and which also generally allow the dispensing of liquid. Whereby the acquisition member plays an important role in using the entire absorbent capacity provided by the storage member.

Materials suitable for meeting the above-mentioned requirements of the liquid acquisition layer must meet these requirements not only under standard or ideal conditions, but also under various conditions, i.e. at different temperatures and pressures occurring during use and during storage and handling.

Some absorbent articles, such as diapers or adult incontinence pads, include an Acquisition and Distribution Layer (ADL) for collecting fluid and distributing the fluid evenly and timely from the fluid insult to the absorbent core. The ADL is typically placed between the topsheet and the absorbent core and may, for example, take the form of a composite web, wherein the top third of the web has higher denier fibers with relatively large voids and higher void volume for efficient acquisition of the presented fluid, even at relatively high discharge rates. The middle third of the ADL composite fabric may be made of low denier fibers with smaller voids, while the lower third of the fabric may be made of lower and smaller denier fibers, but with finer voids. The higher density portion of the composite has more and finer capillaries, thus creating a greater capillary pressure, thus moving a greater volume of fluid to the outer region of the structure, thus enabling proper directing and dispensing of the fluid in a uniform manner, thereby allowing the absorbent core to absorb all liquid insults in a time-limited manner to allow the SAP within the absorbent core to neither retain nor gel insults too slowly nor too quickly. ADLs provide for faster liquid acquisition (minimizing overflow in the target zone) and ensure faster fluid transport and thorough distribution into the absorbent core.

There is a need for a fluid distribution layer or core wrap material having improved liquid handling characteristics compared to the articles disclosed above. There is a need for absorbent articles that are more comfortable to wear and in particular provide excellent dryness. The present disclosure is directed to satisfying these needs and providing further related advantages.

Disclosure of Invention

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

In one aspect, the disclosure features a composite fabric comprising: a nonwoven layer comprising polymeric fibers and/or filaments; a crosslinked cellulosic layer comprising crosslinked cellulosic fibers; wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer (e.g., there is no intermediate layer other than the crosslinked cellulosic layer and the nonwoven layer; in some embodiments, the crosslinked cellulosic layer is immediately adjacent the nonwoven layer); and an interface region between the nonwoven layer and the crosslinked cellulosic layer, the interface region comprising physically entangled polymer fibers and/or filaments from the nonwoven layer and crosslinked cellulosic fibers from the crosslinked cellulosic layer, wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in a dry state, and wherein the composite fabric has 0.06g/cm ³ To 0.15g/cm ³ (e.g., 0.06 g/cm) ³ 、0.12g/cm ³ 、0.08g/cm ³ Or 0.06-0.08g/cm ³ ) Is a density of (3).

In another aspect, the disclosure features an absorbent article that includes a composite fabric as described herein.

In yet another aspect, the disclosure features an absorbent article that includes: a liquid impermeable backsheet defining an inner surface and an outer surface; an absorbent core disposed on an inner surface of the backsheet; and a topsheet covering an upper surface of the absorbent core and contacting an inner surface of the backsheet. The absorbent core comprises: an absorbent material defining an upper surface and a lower surface of the absorbent core; and a composite fabric surrounding at least a portion of the upper surface and the lower surface, the composite fabric comprising: a nonwoven layer comprising polymeric fibers and/or filaments; a crosslinked cellulosic layer comprising crosslinked cellulosic fibers, wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer; and an interface region between the nonwoven layer and the crosslinked cellulosic layer, the interface region comprising physically entangled polymer fibers and/or filaments from the nonwoven layer and crosslinked cellulosic fibers from the crosslinked cellulosic layer, wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in a dry state.

In yet another aspect, the disclosure features a feminine hygiene product that includes: a composite fabric, the composite fabric comprising: a nonwoven layer comprising polymeric fibers and/or filaments; a crosslinked cellulosic layer comprising crosslinked cellulosic fibers, wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer; and an interface region between the nonwoven layer and the crosslinked cellulosic layer, the interface region comprising physically entangled polymer fibers and/or filaments from the nonwoven layer and crosslinked cellulosic fibers from the crosslinked cellulosic layer, wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in a dry state.

In yet another aspect, the disclosure features a method of making a composite fabric of the disclosure, comprising: supplying polymer fibers and/or filaments; supplying crosslinked cellulosic fibers; air-laying or wet-laying the crosslinked cellulosic fibers to provide a crosslinked cellulosic layer on a nonwoven layer of polymeric fibers and/or filaments, wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer; and physically entangling the polymeric fibers and/or filaments from the nonwoven layer and the crosslinked cellulosic fibers from the crosslinked cellulosic layer to provide the composite fabric, wherein the composite fabric comprises an interfacial region between the nonwoven layer and the crosslinked cellulosic layer, wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in a dry state.

Drawings

The foregoing aspects and many of the attendant advantages of this disclosure will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

fig. 1 is a schematic illustration of a hydroentanglement process of the present disclosure.

Fig. 2A is a schematic diagram of an embodiment of a fluid Acquisition and Distribution Layer (ADL) of the present disclosure.

Fig. 2B is a schematic cross-sectional view of an embodiment of a core wrap of the present disclosure.

Fig. 3 is a schematic cross-sectional view of an embodiment of a core wrap of the present disclosure.

Fig. 4 is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 5A is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 5B is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 5C is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 5D is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 5E is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 6A is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 6B is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 6C is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 6D is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 7A is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 7B is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 8A is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 8B is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 8C is a schematic cross-sectional view of an embodiment of an absorbent article of the present disclosure.

Fig. 9 is a bar graph showing a comparison of the wicking distance from the insult point for an embodiment of the ADL diaper construction of the present disclosure in a no load saddle wicking test with a commercial diaper.

Fig. 10 is a bar graph showing a comparison of the intake time of an embodiment of the ADL diaper construction of the present disclosure in a flat-panel acquisition test under load with a commercial diaper.

Fig. 11 is a bar graph showing a comparison of rewet values for an embodiment of the ADL diaper construction of the present disclosure and a commercial diaper in a flat-panel acquisition test under load.

Fig. 12 is a bar graph showing a comparison of the wicking distance of an embodiment of the ADL diaper construction of the present disclosure in a flat-panel acquisition test under load with a commercial diaper.

Figure 13 is a bar graph showing a comparison of the intake time of an embodiment of the core wrap diaper construction of the present disclosure in a no load saddle wicking test with a commercial diaper.

FIG. 14 is a bar graph showing a comparison of the wicking distance from the insult point for an embodiment of the core wrap diaper construction of the present disclosure in a no load saddle wicking test with a commercial diaper.

Figure 15 is a bar graph showing a comparison of the intake time of an embodiment of the core wrap diaper construction of the present disclosure in a flat acquisition test under load with a commercial diaper.

Figure 16 is a bar graph showing a comparison of rewet values for an embodiment of the core wrap diaper construction of the present disclosure and a commercial diaper in a flat-acquisition test under load.

Figure 17 is a bar graph showing a comparison of the wicking distance of an embodiment of the core wrap diaper construction of the present disclosure in a flat-panel acquisition test under load with a commercial diaper.

Figure 18 is a bar graph showing the intake time of an example of a core wrap diaper construction of the present disclosure versus the average value of a commercial fuzz free diaper in a no load saddle wicking test.

Figure 19 is a bar graph showing a comparison of the wicking distance from the point of insult for an embodiment of the core wrap diaper construction of the present disclosure in a no load saddle wicking test to the average value of a commercial fuzz free diaper.

Figure 20 is a bar graph showing the intake time of an example of a core wrap diaper construction of the present disclosure versus the average value of a commercial fluff-free diaper in a flat-panel acquisition test under load.

Figure 21 is a bar graph showing a comparison of rewet values for an embodiment of the core wrap diaper construction of the present disclosure in a flat-acquisition test under load with the average value of a commercial fluff-free diaper.

Figure 22 is a bar graph showing a comparison of the wicking distance of an embodiment of the core wrap diaper construction of the present disclosure in a flat-acquisition test under load to the average value of a commercial fluff-free diaper.

Fig. 23 is a bar graph showing a comparison of wicking distance from the point of insult for an embodiment of the ADL diaper construction of the present disclosure in a no load saddle wicking test versus the average value of a commercial fluff core diaper.

Figure 24 is a bar graph showing a comparison of the wicking distance from the point of insult for an embodiment of the ADL diaper construction of the present disclosure in a flat acquisition test under load versus the average value of a commercial fluff core diaper.

Figure 25 is a photograph of an embodiment of a feminine hygiene absorbent core of the present disclosure after rewet and distribution testing.

Fig. 26A is a schematic diagram illustrating an exemplary feminine hygiene product 2600A including an absorbent composite 2610A according to an embodiment of the present disclosure.

Fig. 26B is a schematic diagram illustrating a multi-layer construction in which the absorbent composite includes one or more stacked layers of the physically entangled composite fabric described with reference to fig. 1, according to an embodiment of the present disclosure.

Fig. 27A shows a comparative feminine hygiene product 2700 available in the north american market.

Fig. 27B shows a comparative feminine hygiene product 2750 available in the east asia market.

Fig. 28A is a schematic view of a cross-section of the exemplary feminine hygiene product of fig. 26A, showing a material layer of absorbent composite, in accordance with an embodiment of the present disclosure.

Fig. 28B is a schematic diagram illustrating a cross-section of the exemplary feminine hygiene product of fig. 26B including an absorbent composite formed from a plurality of stacked layers of a composite formed by physical entanglement of a crosslinked cellulosic layer with a nonwoven layer with an interface region formed therebetween, according to an embodiment of the present disclosure.

Fig. 29 is a graph of inhalation time data showing improvement in the common properties among negative control products without cellulosic material, comparative example 1, comparative example 2, and examples 1 and 2, according to an embodiment of the present disclosure.

Fig. 30 is a graph of performance measurement data for intake times of comparative example 1 and example 1, highlighting improved intake time performance of an exemplary feminine hygiene product relative to a comparative product from the north american market, according to an embodiment of the present disclosure.

Fig. 31 is a graph of data from rewet quality measurements for five products from the same group. As previously described, according to embodiments of the present disclosure, rewet quality measures the amount of liquid exuding from an absorbent article after a set pressure is applied.

Fig. 32 is a graph of data from wicking distance determinations for five products from the same group. As previously described, according to embodiments of the present disclosure, the wicking distance measures the performance of a feminine hygiene product to accept and dispense liquid insults during a prescribed period of time.

Detailed Description

Definition of the definition

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment.

Conversely, various features of the disclosure that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.

Moreover, the inclusion of particular elements in at least some of these embodiments may be optional, wherein additional embodiments may include one or more embodiments specifically excluding one or more of these particular elements. Moreover, while advantages associated with certain embodiments of the disclosure have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments must exhibit such advantages to fall within the scope of the disclosure.

The terms "a" and "an" as used herein and unless otherwise indicated, mean "one", "at least one" or "one or more". As used herein, singular terms shall include the plural and plural terms shall include the singular unless the context requires otherwise.

Throughout the specification and claims, the words "comprise", "comprising", and the like are to be interpreted in an inclusive rather than an exclusive or exhaustive sense, unless the context clearly requires otherwise; that is, the meaning of "including but not limited to". Words using the singular or plural number also include the plural and singular number accordingly. In addition, as used in this disclosure, the words "herein," "above" and "below," and words of similar import, shall refer to this disclosure as a whole and not to any particular portions of this disclosure.

As used herein, "absorbent article" refers to products that absorb and contain liquid, and more specifically, refers to products that are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body. Absorbent articles include, but are not limited to, diapers, adult incontinence briefs, training pants, diaper holders and liners, sanitary napkins, and the like. These articles may include a topsheet, a backsheet, an absorbent core, and optionally a receiving layer and/or a distribution layer, as well as other components, wherein the absorbent core is typically disposed between the backsheet and the receiving system or topsheet. The absorbent article also includes wipes, such as household cleaning wipes, baby wipes, and the like.

As used herein, the term "absorbent core" refers to a single component that is disposed or disposed in an absorbent article and includes absorbent material enclosed in a core wrap. The core wrap may be a sheet of encapsulated absorbent material and may, for example, comprise a composite fabric of the present disclosure. The term "absorbent core" does not extend to a receiving or distribution layer or any other component of the absorbent article that is not an integral part of the core wrap or is not disposed within the core wrap. The absorbent core may have the highest absorbency in the absorbent article and may comprise superabsorbent polymers (SAP) and/or fluff pulp.

As used herein, the term "disposable" refers to articles that are not generally intended to be laundered or otherwise restored or reused, i.e., they are intended to be discarded after a single use and, possibly, to be recycled, composted or otherwise disposed of in an environmentally compatible manner.

As used herein, the term "disposed" refers to an element(s) formed (joined and positioned) at a particular site or location as a unitary structure with other elements or as a separate element joined to another element.

As used herein, the term "diaper" refers to an absorbent article that is typically worn by infants and incontinent persons about the lower torso.

The terms "thickness" and "caliper" are used interchangeably herein.

As used herein, the terms "nonwoven", "nonwoven fabric" and "nonwoven web" are interchangeable and refer to a sheet, web or mat product made of oriented or randomly arranged fibers and/or filaments that are bonded together by friction and/or by cohesion and/or adhesion. The fibers may be of natural (e.g., cotton) or regenerated (e.g., regenerated cellulose) or synthetic origin, and may be staple or continuous fibers or formed in situ. The fibers may have diameters in the range of less than about 0.001mm to greater than 0.2mm and may be available in several different forms, for example, staple fibers (so-called staple or chopped fibers), continuous monofilaments (filaments or monofilaments), untwisted bundles of continuous filaments (cables) and twisted bundles of continuous fibers (yarns). Nonwoven webs may be formed by a variety of processes such as, for example, melt blowing, spunbonding, solvent spinning, electrospinning, carding, and air-laying or air-laying, or any combination thereof. The basis weight of nonwoven webs is typically measured in grams per square meter (g/m ² G or gsm). Synthetic fibers and/or filaments include, but are not limited to, polyolefins such as polypropylene, polyethylene, and polyesters (e.g., polyethylene terephthalate), and any combination thereof (e.g., bicomponent fibers).

As used herein, helix ^TM Crosslinked cellulosic fibers based on untreated fluff pulp (e.g. from International Paper Company))。Helix ^TM Such as described in U.S. patent nos. 5,399,240, 5,437,418 and 6,436,231, each of which is incorporated herein by reference in its entirety.

As used herein, helix ^TM + is a cross-linked fiber based on treated or debonded fluff grade (e.gAnd/or +.>+)。Helix ^TM Such as described in U.S. patent nos. 5,399,240, 5,437,418 and 6,436,231, each of which is incorporated herein by reference in its entirety. Debonding slurries are described, for example, in U.S. patent No. 6,306,251, which is incorporated herein in its entirety.

In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

Furthermore, the particular arrangements shown in the drawings should not be construed as limiting, and it should be understood that other embodiments may include more or less of each of the elements shown in a given drawing. Furthermore, some of the illustrated elements may be combined or omitted. Furthermore, exemplary embodiments may include elements not shown in the drawings.

As used herein, "about" means +/-5% with respect to measurement. As used herein, the ranges include endpoints such that 0.5 mol% to 99.5 mol% includes both 0.5 mol% and 99.5 mol%.

Principles and conceptual aspects of various embodiments of the present disclosure. In this regard, no attempt is made to show structural details of the present disclosure in more detail than is necessary for a fundamental understanding of the present disclosure, the description taken with the drawings and/or examples making apparent to those skilled in the art how the several forms of the present disclosure may be embodied in practice.

Composite fabric

Absorbent products are becoming thinner and softer. Thus, loss of void volume in the absorbent core has occurred, which in turn requires a more powerful absorbent system for fluid management to provide acceptable leakage protection to the consumer.

The present disclosure describes a composite fabric comprising crosslinked cellulosic fibers and a nonwoven that can be used in absorbent articles, such as in acquisition and distribution layers ("ADLs") and/or core wraps of absorbent articles. Crosslinked cellulosic fibers have unique properties that are advantageous in absorbent articles, such as excellent wet bulk and elasticity. However, the commercially available crosslinked cellulose fibers are in the form of pressed bales, which limits their use in most manufacturing facilities due to the lack of bale openers in many commercial operations. The rolled form of the crosslinked cellulose fibers can increase convenience and simplify the manufacturing process. As will be described in more detail below, webs composed of crosslinked cellulosic fibers may be formed by air-laid or wet-laid processes and subsequently entangled into nonwoven fabrics, such as Bonded Carded Webs (BCW), to form composite fabrics. Penetration of the cellulose fibers into the nonwoven fabric may be controlled (e.g., by controlling the water jet pressure in the hydroentanglement process), and the composite fabric may have a bi-layer structure from less penetration of the crosslinked cellulose fibers in the nonwoven fabric to a fully interpenetrating network of crosslinked cellulose fibers in the nonwoven fabric.

Accordingly, the present disclosure features a composite fabric comprising: a nonwoven layer comprising polymeric fibers and/or filaments; a crosslinked cellulosic layer comprising crosslinked cellulosic fibers; wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer; and an interface region between the nonwoven layer and the crosslinked cellulosic layer, the interface region comprising physically entangled polymer fibers and/or filaments from the nonwoven layer and crosslinked cellulosic fibers from the crosslinked cellulosic layer. The nonwoven layer and the crosslinked cellulosic layer of the composite fabric are mechanically inseparable in the dry state. The composite fabric had a weight of 0.06g/cm ³ To 0.15g/cm ³ (e.g., 0.06 g/cm) ³ 、0.12g/cm ³ 、0.08g/cm ³ Or 0.06-0.08g/cm ³ ) Is a density of (3). The density was measured according to the "thickness, bulk and density measurement" method described below. The average density is the average of at least 5 density values measured in the sample. The crosslinked cellulosic layer is disposed opposite the nonwoven layer without an intermediate layer that is different from the crosslinked cellulosic layer and the nonwoven layer. In some embodiments, the crosslinked cellulosic layer is immediately adjacent to and entangled in the nonwoven layer. In some embodiments, the composite fabric consists essentially of the nonwoven layer and the crosslinked cellulosic layer and the interfacial region between the nonwoven layer and the crosslinked cellulosic layer. In some embodiments, the composite fabric is comprised of a nonwoven layer and a crosslinked cellulosic layer and an interfacial region between the nonwoven layer and the crosslinked cellulosic layer.

In some embodiments, the polymeric fibers and/or filaments of the nonwoven layer include synthetic polymeric fibers and/or filaments, such as polyolefin and/or polyester fibers and/or filaments. The nonwoven layer may comprise a web that may be produced by a melt-spinning process. In some embodiments, the nonwoven layer is a bonded carded web. In some embodiments, the nonwoven layer comprises bonded carded web fabrics, carded webs, spunbond fabrics, meltblown fabrics, unbonded synthetic fibers, or any combination thereof.

In some embodiments, the nonwoven layer and the crosslinked cellulosic layer overlap (i.e., overlap each other) and interpenetrate at the interface region. In some embodiments, the crosslinked cellulosic layer and the nonwoven layer are fully interpenetrating.

The composite fabric may have an "x" dimension and a "y" dimension corresponding to the width and length of the composite fabric. The composite fabric may also have a "z" dimension corresponding to the thickness of the composite fabric. In some embodiments, the nonwoven layer has a first thickness, the crosslinked cellulosic layer has a second thickness, and the interfacial region has a thickness less than or equal to the first thickness or the second thickness. In some embodiments, when the crosslinked cellulosic layer is fully entangled in the nonwoven layer, the interfacial region can have a thickness that spans the entire thickness of the nonwoven layer. In some embodiments, when the crosslinked cellulosic layer is partially entangled in the nonwoven layer, the interfacial region can have a thickness that is less than the thickness of the nonwoven layer and/or the crosslinked cellulosic layer.

In some embodiments, the composite fabric has regions where the crosslinked cellulosic layer is entangled more into the nonwoven layer than other regions, such that the interfacial region can vary in thickness. Without wishing to be bound by theory, it is believed that when the composite fabric has more entangled interfacial regions, paths or channels may be formed in the composite fabric to direct the flow of liquid through the composite fabric.

In some embodiments, the nonwoven layer may comprise a bonded carded web fabric (e.g., a resin bonded carded web fabric), a carded web, a spunbond fabric, a melt-oriented or blow-molded fabric, unbonded synthetic fibers, staple fibers (e.g., synthetic fibers that are laid into a mat and are not bonded by any mechanism), or any combination thereof. Nonwoven fabrics may include manufactured sheets, webs or mats of randomly oriented fibers and/or filaments bonded by friction and/or cohesion and/or adhesion, excluding woven, knitted, tufted, stitch bonded with bonded yarns or filaments, or papers and products felted by wet milling (whether or not otherwise needled). The fibers and/or filaments in the nonwoven layer may be of synthetic or natural origin, such as a polyolefin (e.g., polypropylene, polyethylene), polyester, or any combination thereof (e.g., bicomponent fibers).

Commercially available fibers may have diameters of from less than about 0.001mm to greater than about 0.2mm and take the form of staple fibers (short or chopped), continuous filaments (filaments or monofilaments), untwisted bundles of continuous filaments (tows), and twisted bundles of continuous filaments (yarns). Fibers are classified according to their origin, chemical structure, or both.

The nonwoven web may be formed by a direct extrusion process during which the fibers and web are formed at about the same point in time, or by preformed fibers which may be formed into a web at a significantly later point in time. Exemplary direct extrusion processes include, but are not limited to: spunbond, meltblown, solvent-spun, electrospun, and combinations thereof are typically formed into layers.

All of the above fibers and manufacturing techniques may be useful in providing a composite fabric according to the present disclosure.

The crosslinked cellulosic fibers may include polyacrylic acid crosslinked cellulosic fibers. Crosslinked cellulosic fibers are described, for example, in U.S. patent nos. 7,513,973, 8,722,797, 6,716,306, 6,736,933, 6,748,671, 7,018,508, 6,782,637, 6,865,822; 7,290,353, 6,769,199, 7,147,446, 7,399,377, 6,306,251, 5,183,707, and 5,998,511, each of which is incorporated herein in its entirety. Exemplary crosslinking systems include esterification, etherification, ionic and free radical reactions. As an example, the crosslinked cellulosic fibers include bleached polyacrylic acid crosslinked cellulosic fibers, wherein the polyacrylic acid crosslinked cellulosic fibers are treated with one or more bleaching agents to provide crosslinked cellulosic fibers having high bulk and improved whiteness. In another example, the crosslinked cellulosic fibers may include a polyacrylic acid crosslinking agent, including polyacrylic acid, that incorporates phosphorus into the polymer chain (as a phosphinate salt) by introducing sodium hypophosphite during the polymerization process.

For example, individualized, chemically crosslinked cellulosic fibers may be intra-fiber crosslinked with a polymeric polycarboxylic acid crosslinking agent. As used herein, the term "polymeric polycarboxylic acid" refers to a polymer having a plurality of carboxylic acid groups that are available for forming ester bonds (i.e., cross-links) with cellulose. Suitable cross-linking agents that can be used to form the cross-linked fibers of the present disclosure include polyacrylic acid polymers, polymaleic acid polymers, acrylic acid copolymers, maleic acid copolymers, and mixtures thereof. Polyacrylic acid polymers include polymers formed by polymerizing acrylic acid, acrylic esters, and mixtures thereof. Other suitable polymeric polycarboxylic acids include commercially available polycarboxylic acids such as polyaspartic acid, polyglutamic acid, poly (3-hydroxy) butyric acid, and polyitaconic acid. Polyacrylic acid polymers include polymers formed by polymerizing acrylic acid, acrylic esters, and mixtures thereof. Polymaleic acid polymers include polymers formed by polymerizing maleic acid, maleates, maleic anhydride, and mixtures thereof. Examples of suitable polyacrylic acid copolymers include poly (acrylamide-co-acrylic acid), poly (acrylic acid-co-maleic acid), poly (ethylene-co-acrylic acid) and poly (1-vinylpyrrolidone-co-acrylic acid) as well as other polyacrylic acid derivatives such as poly (ethylene-co-methacrylic acid) and poly (methyl methacrylate-co-methacrylic acid). Suitable polymaleic acid copolymers include poly (methyl vinyl ether-co-maleic acid), poly (styrene-co-maleic acid), and poly (vinyl chloride-co-vinyl acetate-co-maleic acid). Suitable comonomers for forming polyacrylic acid and polymaleic acid copolymers include any comonomer that when copolymerized with acrylic acid or maleic acid (or esters thereof) provides a polycarboxylic acid copolymer crosslinker that produces crosslinked cellulosic fibers having the following advantageous properties: bulk, absorbent capacity, liquid acquisition rate, and stable intra-fiber crosslinking. Representative comonomers include, for example, ethyl acrylate, vinyl acetate, acrylamide, ethylene, vinyl pyrrolidone, methacrylic acid, methyl vinyl ether, styrene, vinyl chloride, itaconic acid, and tartaric monosuccinic acid. Preferred comonomers include vinyl acetate, methacrylic acid, methyl vinyl ether and itaconic acid. Polyacrylic acid and polymaleic acid copolymers prepared from the representative comonomers described above are available from commercial sources in a variety of molecular weights and molecular weight ranges. In a preferred embodiment, the polycarboxylic acid copolymer is a copolymer of acrylic acid and maleic acid.

Polycarboxylic acid polymers useful for forming crosslinked cellulosic fibers include autocatalytic polycarboxylic acid polymers. For example, the autocatalytic polycarboxylic acid crosslinking agent may comprise a copolymer of acrylic acid or maleic acid with low molecular weight mono-alkyl substituted phosphinates and phosphonates. These copolymers may be prepared using hypophosphorous acid and its salts (e.g., sodium hypophosphite) and/or phosphoric acid as chain transfer agents. The polycarboxylic acid polymers and copolymers may be used alone, in combination, or in combination with other crosslinking agents known in the art.

In some embodiments, a polymeric polycarboxylic acid crosslinking agent may be used with a crosslinking catalyst to accelerate the bonding reaction between the crosslinking agent and the cellulose fibers, thereby providing crosslinked cellulose fibers. Suitable crosslinking catalysts include any catalyst that increases the rate of ester bond formation between the polycarboxylic acid crosslinking agent and the cellulosic fibers. For example, crosslinking catalysts include alkali metal salts of phosphorus-containing acids, such as alkali metal hypophosphites, alkali metal phosphites, alkali metal polyphosphonates, alkali metal phosphates, and alkali metal sulfonates.

In some embodiments, suitable cross-linking agents for preparing cross-linked cellulose fibers are difunctional, capable of bonding with hydroxyl groups and creating covalent bonding bridges between hydroxyl groups on cellulose molecules within the fiber. The cross-linking agent comprises a polycarboxylic acid or is selected from urea derivatives such as methylolated urea, methylolated cyclic urea, methylolated lower alkyl substituted cyclic urea, methylolated dihydroxycyclic urea. Preferred urea derivative cross-linking agents are dimethylol dihydroxyethylene urea (DMDHEU), dimethylol dihydroxyethylene urea. Mixtures of urea derivatives may also be used. Preferred polycarboxylic acid cross-linking agents are citric acid, tartaric acid, malic acid, succinic acid, glutaric acid or citraconic acid. These polycarboxylic acid cross-linking agents are particularly useful when the proposed paperboard use is food packaging. Other polycarboxylic acid cross-linking agents that may be used are poly (acrylic acid), poly (methacrylic acid), poly (maleic acid), poly (methyl vinyl ether-co-maleate) copolymers, poly (methyl vinyl ether-co-itaconate) copolymers, maleic acid, itaconic acid, and tartaric acid monosuccinic acid. Mixtures of polycarboxylic acids may also be used. The cross-linking agent may include a catalyst to accelerate the bonding reaction between the cross-linking agent and the cellulose molecule, but most cross-linking agents do not require a catalyst. Suitable catalysts include acidic salts that are useful when urea-based crosslinking materials are used. Such salts include ammonium chloride, ammonium sulfate, aluminum chloride, magnesium chloride, or mixtures of these or other similar compounds. Alkali metal salts of phosphorous acid may also be used.

Other crosslinking agents are described in U.S. patent No. 3,440,135 to Chung; U.S. patent No. 4,935,022 to Lash et al; U.S. patent No. 4,889,595 to Herron et al; U.S. patent No. 3,819,470 to Shaw et al; U.S. patent No. 3,658,613 to Steijer et al; U.S. patent No. 4,822,453 to Dean et al; and Graef et al, U.S. Pat. No. 4,853,086, all of which are incorporated herein by reference in their entirety.

In some embodiments, the polyacrylic acid crosslinked cellulosic fibers may be prepared by applying polyacrylic acid to the cellulosic fibers in an amount sufficient to effect intra-fiber crosslinking. The amount applied to the cellulosic fibers may be from about 1 wt% to about 10 wt% based on the total weight of the fibers. In one embodiment, the amount of crosslinking agent is about 4 wt% to about 6 wt% based on the total weight of the dry fiber. In some embodiments, polyacrylic acid crosslinked cellulosic fibers may be prepared using a crosslinking catalyst. Suitable catalysts may include acidic salts such as ammonium chloride, ammonium sulfate, aluminum chloride, magnesium nitrate, more preferably alkali metal salts of phosphorous acid such as phosphoric acid, polyphosphoric acid, phosphorous acid and hypophosphorous acid. In one embodiment, the crosslinking catalyst is sodium hypophosphite. The amount of catalyst used may be from about 0.1 to about 5 weight percent of the total weight of the dry fiber.

In certain embodiments, the crosslinked cellulosic fibers may include crosslinked rayon or lyocell fiber derivatives.

Cellulose fibers suitable for crosslinking cellulose fibers may be derived primarily from wood pulp. Suitable wood pulp fibers can be obtained by well known chemical methods such as the sulfate and sulfite processes, with or without bleaching. Pulp fibers may also be processed by thermomechanical methods, chemithermomechanical methods, or combinations thereof. Preferred pulp fibers are produced by chemical means. Milled wood fibers, recycled or secondary wood pulp fibers, and bleached and unbleached wood pulp fibers may be used. Preferred starting materials are prepared from long fiber conifer species such as southern pine, douglas fir, spruce and hemlock. Details of producing wood pulp fibers are well known to those skilled in the art. Suitable fibers are commercially available from a number of companies, including International Paper Company. For example, suitable cellulosic fibers produced from southern pine that can be used in preparing the present disclosure can be named from International Paper Company And->+ obtained.

In some embodiments, the nonwoven layer has 15g/m in the composite fabric ² (e.g. 20g/m ² 、25g/m ² 、30g/m ² 、35g/m ² 、40g/m ² Or 45g/m ² ) To 50g/m ² (e.g. 45g/m ² 、40g/m ² 、35g/m ² 、30g/m ² 、25g/m ² Or 20g/m ² ) Is used as a dry basis of the (c) polymer. The composite fabric may be used, for example, as an acquisition distribution layer in an absorbent article.

In some embodiments, the crosslinked cellulosic layer comprises 20g/m in the composite fabric ² (e.g., 40 g/m) ² 、60g/m ² 、80g/m ² 、100g/m ² 、120g/m ² 、140g/m ² Or 160g/m ² ) To 185g/m ² (e.g., 160 g/m) ² 、140g/m ² 、120g/m ² 、100g/m ² 、80g/m ² 、60g/m ² Or 40g/m ² ) Is used as a dry basis of the (c) polymer. The composite fabric may be used, for example, to encapsulate an absorbent material in an absorbent core of an absorbent article (e.g., as a core wrap). In some embodiments, the composite web may be used to sandwich the absorbent material such that a first layer of the composite web overlies the absorbent material and a second layer of the composite web underlies the absorbent material.

In some embodiments, the composite fabric in the absorbent article has a dry basis weight of 20g/m ² Or above (e.g., 30 g/m) ² Or above, 40g/m ² Or above) and/or 50g/m ² Or below (e.g., 40 g/m) ² Or below or 30g/m ² Or below), for example, a dry basis weight of 20g/m ² To 50g/m ² (e.g., 30 g/m) ² To 40g/m ² ) Is a nonwoven layer having a dry basis weight of 70g/m ² Or above (e.g., 80 g/m) ² Or above, 90g/m ² Or above, 100g/m ² Or above or 110g/m ² Or above) and/or 120g/m ² Or below (e.g., 110 g/m) ² Or below, 100g/m ² Or below, 90g/m ² Or below or 80g/m ² Or below), for example, 70g/m dry basis ² To 120g/m ² (e.g., 80 g/m) ² To 110g/m ² ) Is used for the cross-linked cellulose layer. The absorbent article may include a fluid acquisition distribution layer comprising a composite fabric. For example, the composite web may be disposed on an absorbent core or superabsorbent polymer. The crosslinked cellulosic layer of the composite fabric may face the surface of the absorbent core. When the absorbent article includes a fluid acquisition distribution layer comprising a composite fabric, the absorbent article may have a wicking distance percentage of at least 60% after the third fluid exposure in an unloaded saddle wicking test. In some embodiments, the absorbent article is a diaper or incontinence product.

In certain embodiments, the composite fabric comprises a dry basis weight of 20g/m ² Or above (e.g., 30 g/m) ² Or above or 40g/m ² Or above) to 50g/m ² Or below (e.g., 40 g/m) ² Or below or 30g/m ² Or below) a nonwoven layer having a dry basis weight of 40g/m ² Or above (e.g., 50 g/m) ² Or above, 60g/m ² Or above) and/or 70g/m ² Or below (e.g., 60 g/m) ² Or below or 50g/m ² Or below) a crosslinked cellulosic layer. In some embodiments, the composite fabric comprises a dry basis weight of 20g/m ² To 50g/m ² (e.g., 30 g/m) ² To 40g/m ² ) Is 40g/m ² To less than 70g/m ² (e.g., 40 g/m) ² To 60g/m ² Or 50g/m ² ) Is used for the cross-linked cellulose layer. The absorbent article may comprise a composite fabric that may encapsulate the absorbent material in an absorbent core (e.g., as a core wrap). For example, the composite web may encapsulate an absorbent material (e.g., superabsorbent polymer) in the absorbent core. In some embodiments, the composite web completely encapsulates the absorbent material (e.g., bulk absorbent material, such as bulk superabsorbent polymer) in the absorbent core. In some embodiments, the composite web may be used to sandwich the absorbent material such that a first layer of the composite web overlies the absorbent material and a second layer of the composite web underlies the absorbent material. The crosslinked cellulosic layer of the composite fabric may contact the surface of the absorbent material. When (when)When the absorbent article comprises a composite fabric encapsulating an absorbent material, the absorbent article may have a wicking distance percentage of at least 60% after the third fluid exposure in the no-load saddle wicking test. In some embodiments, the absorbent article is a diaper or incontinence product.

The absorbent core is described, for example, in U.S. patent No. 8,674,169 and PCT publication No. WO20/046627, each of which is incorporated herein in its entirety. In some embodiments, the absorbent core may include a conventional fluff core, a channeled fluff core, a composite core (e.g., a multi-layer core), and/or an SAP. In some embodiments, the SAP is in the form of particles, which may be contained inside the absorbent article by means of a binder.

The composite fabric of the present disclosure may be embossed, folded, and/or perforated with one or more patterns. When used in absorbent articles, the embossments, folds, and/or perforations may physically distribute, direct, or otherwise affect the flow of liquid insult. For example, the composite fabric may be embossed with a pattern, such as a repeating pattern. For example, the composite fabric may be pleated, folded, or otherwise textured with a textured surface such that the cross-section of the composite fabric has hills and valleys formed by the pleats or folds. Absorbent material, such as SAP, may be present in the valleys of the composite fabric. When the composite fabric is pleated, folded or otherwise provided with a textured surface, the nonwoven layer or crosslinked cellulosic layer may face the absorbent material of the absorbent core of the absorbent article. In some embodiments, the composite fabric may be perforated with through openings, such as slits, channels, and/or holes.

In some embodiments, the composite fabric neutralizes odors when subjected to (e.g., wetted with) a biological fluid.

In any of the above embodiments, the composite fabric may include latex, latex binder fibers, water saturated layers, pre-treated nonwoven layers, lyocell fibers, and/or rayon.

The composite fabrics of the present disclosure may be incorporated into absorbent articles, such as personal care absorbent products, as described below. Personal care absorbent products may include diapers, incontinence products, feminine hygiene products, wipes, towels, and tissues.

Method for manufacturing composite fabric

In some embodiments, a crosslinked cellulosic layer is air-laid or dry-laid onto a nonwoven layer to provide a composite fabric of the present disclosure. In some embodiments, the crosslinked cellulosic layer is wet-laid onto the nonwoven layer. Crosslinked cellulosic fibers from the crosslinked cellulosic layer may be hydraulically entangled in the interfacial regions into polymeric fibers and/or filaments from the nonwoven layer. For example, in a hydroentanglement process, hydroentangled water jets first contact the cellulosic fibers and drive the cellulosic fibers into the nonwoven polymer fibers. Hydroentanglement processes are described, for example, in U.S. publication No. 2018/0326999 and CA patent No. 841,938, each of which is incorporated herein by reference in its entirety.

The hydroentangling step entangles the different types of fibers by the action of a plurality of fine high pressure water jets impinging on the fibers. The fine, movable spun-laid filaments twist and entangle with themselves and with other fibers, which gives the material very high strength, with all types of fibers intimately mixed and integrated. The entangled water is drained through the forming fabric and can be recycled after purification if desired. The energy supply required for hydroentanglement is relatively low, i.e. the material is easily entangled.

A hydroentanglement process for forming a fabric occurs by mechanically wrapping and knotting the fibers in the web to each other using high-velocity water jets. The process uses fine high-speed water jets to impinge on the web and crimp and entangle the fibers with each other. The water jets penetrate the web and entangle the fibers, creating a fabric that reflects the pattern of the forming belt that carries the web under the water jets. This results in a fabric having the appearance of a woven fabric and good drape. Binders may be added to some hydroentangled fabrics to increase their strength and dimensional stability to render them liquid repellent. The process may be used on both dry-laid webs and wet-laid webs. A lower energy hydroentanglement process using lower velocity water jets can provide a product with less entanglement, which can optionally include an adhesive. The hydroentanglement process is described, for example, in The Nonwovens Fabric Handbook published by Association of the Nonwovens Fabric Industry (INDA), cary NC 1999, which is incorporated herein by reference in its entirety.

Examples of "web-forming" processes include wet-forming and air-forming (the latter sometimes also being referred to as dry-forming). Examples of dry-laid processes include, but are not limited to, air-laying, carding, and combinations thereof, which typically form a layer. Examples of combinations include, but are not limited to, spunbond-meltblown-spunbond (SMS), spunbond-carded (SC), spunbond-air-laid (SA), meltblown-air-laid (MA), and combinations thereof, typically layered. Combinations involving direct extrusion may be combined at about the same point in time as the direct extrusion process (e.g., spinners and coforms of SA and MA), or at a later point in time. In the above examples, each process may produce one or more separate layers. For example, SMS may represent a three-layer 'SMS' web, a five-layer "ssmms" web, or any reasonable variation thereof, where lower case letters represent individual layers and upper case letters represent a collection of similar adjacent layers.

Fig. 1 illustrates a hydroentangling process for entangling crosslinked cellulosic fibers into a nonwoven material, which may be in the form of a fabric or fiber. Referring to fig. 1, crosslinked cellulosic fibers 114 are provided onto a nonwoven material 112 and a water jet 102 is directed at the crosslinked cellulosic fibers to push the cellulosic fibers into the nonwoven material, thereby providing a composite fabric 110. The water jet pressure may be varied such that at higher water pressures, the degree of penetration of the crosslinked cellulosic fibers into the nonwoven material increases, and the interface region 116 may increase in thickness.

In some embodiments, the disclosure features a method of making a composite fabric, comprising: supplying polymer fibers and/or filaments; supplying crosslinked cellulosic fibers; air-laid or wet-laid cross-linked cellulose fibers to provide a cross-linked cellulose layer on a nonwoven layer of polymer fibers and/or filaments, wherein the cross-linked cellulose layer is positioned relative to the nonwoven layer (e.g., without an intermediate layer other than the cross-linked cellulose layer and the nonwoven layer; in some embodiments, the cross-linked cellulose layer is immediately adjacent to the nonwoven layer); and physically entangling the polymeric fibers and/or filaments from the nonwoven layer and the crosslinked cellulosic fibers from the crosslinked cellulosic layer to provide an interfacial region between the nonwoven layer and the crosslinked cellulosic layer, wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in a dry state.

In some embodiments, physically entangling the polymeric fibers and/or filaments from the nonwoven layer and the crosslinked cellulosic fibers from the crosslinked cellulosic layer includes hydroentangling the crosslinked cellulosic fibers into the polymeric fibers and/or filaments. The polymer fibers and/or filaments may be in the form of bonded carded web fabrics, carded webs, spunbond fabrics, meltblown fabrics, or any combination thereof. In some embodiments, the polymer fibers are synthetic.

In some embodiments, the nonwoven layer is the top layer and the crosslinked cellulosic layer is the bottom layer. In certain embodiments, the nonwoven layer is the bottom layer and the crosslinked cellulosic layer is the top layer. The crosslinked cellulosic layer may be preformed prior to entanglement with the nonwoven layer. In some embodiments, the crosslinked cellulosic layer is not preformed prior to entanglement with the nonwoven layer, and/or the nonwoven layer is not preformed prior to entanglement with the crosslinked cellulosic layer. In certain embodiments, the nonwoven layer may be preformed or formed in situ during the entangling process.

The present disclosure combines the integrity of nonwoven and the absorbency of crosslinked cellulosic fibers to provide excellent fluid management and physical properties such as elasticity/non-gathering.

Absorbent article

The composite fabric of the present disclosure may be used in absorbent articles. Referring to fig. 2A, the composite web 110 may be used as a fluid Acquisition and Distribution Layer (ADL) on an absorbent material 210, which may include fluff or SAP, for example, in an absorbent article. The composite web 110 may be disposed on an absorbent core comprising fluff or superabsorbent polymers, and the crosslinked cellulosic layer 114 faces and/or contacts the surface of the absorbent material. In some embodiments, referring to fig. 2B and 3, the composite fabric 110 of the present disclosure may be used to encapsulate an absorbent material 220 (e.g., as a core wrap around the absorbent material 220), with the crosslinked cellulosic layer 114 facing and/or contacting the surface of the absorbent material 220. In some embodiments, the composite web may be used to sandwich the absorbent material such that a first layer of the composite web overlies the absorbent material and a second layer of the composite web underlies the absorbent material. The absorbent material 220 may include fluff pulp (i.e., fluff), high-loft, breathable bonded carded webs (TABCW), and/or SAP 330. In some embodiments, the absorbent material 220 may include highly densified fluff pulp and SAP. As shown in fig. 3, the encapsulated absorbent material may be sandwiched between a liquid permeable topsheet 310 and a backsheet 320 to provide an absorbent article 300. The backsheet 320 may be liquid impermeable.

In some embodiments, the absorbent material comprises 30% or more (e.g., 40% or more, 50% or more, 60% or more, 70% or more, 80% or more) and/or 90% or less (e.g., 80% or less, 70% or less, 60% or less, 50% or less, or 40% or less) of the absorbent synthetic polymer by weight, and 10% or more (e.g., 20% or more, 30% or more, 40% or more, 50% or more, 60% or more) and/or 70% or less (e.g., 60% or less, 50% or less, 40% or less, 30% or less, or 20% or less) of the fluff pulp by weight. In some embodiments, the absorbent material may comprise a highly densified mixture of fluff pulp and SAP.

When the composite fabric is used as an ADL, as an envelope around an absorbent material, or otherwise encases an absorbent material, improved fluid management can be observed in absorbent articles as compared to absorbent articles comprising conventional ADLs or core wrap materials, or as compared to absorbent articles having one of a nonwoven layer or a crosslinked cellulosic layer or a combination of a non-entangled nonwoven layer and a crosslinked cellulosic layer.

In some embodiments, when the absorbent material comprises SAP, the SAP may be in the form of particles held inside the absorbent article by means of, for example, an adhesive through a fabric.

When the composite fabric is wrapped around an absorbent material (e.g., fluff and/or SAP) to provide an absorbent core (e.g., fig. 2B and 3), the absorbent material may be fully or partially wrapped by the composite wrap. Functionally, the composite fabric may also be used as a fluid acquisition distribution layer in this simplified design.

The absorbent article may comprise a personal care absorbent product, which may include, for example, diapers, incontinence products, feminine hygiene products (e.g., sanitary napkins, panty liners), wipes, towels, and/or tissues. In certain embodiments, the absorbent article is a diaper, incontinence product, or feminine hygiene product.

In some embodiments, when the absorbent article comprises a fluid acquisition distribution layer comprising a composite fabric, the absorbent article of the present disclosure reduces the intake time from a first fluid exposure to a second subsequent fluid exposure in a flat acquisition under load test by at least 23%.

In some embodiments, when the absorbent article comprises a composite fabric encapsulating the absorbent material, the intake time of the absorbent article from a first fluid exposure to a second subsequent fluid exposure in a flat acquisition test under load is reduced by at least 25%.

In some embodiments, when the absorbent article includes a fluid acquisition distribution layer comprising a composite fabric, the intake time of the absorbent article from a second fluid exposure to a third subsequent fluid exposure in a flat acquisition test under load is reduced by at least 8%.

In some embodiments, when the absorbent article comprises a composite fabric encapsulating the absorbent material, the intake time of the absorbent article from a second fluid exposure to a third subsequent fluid exposure in a flat acquisition test under load is reduced by at least 12%.

In some embodiments, when the absorbent article includes a fluid acquisition distribution layer comprising a composite fabric, the absorbent article has a wicking distance percentage of at least 60% after a third fluid exposure in an unloaded saddle wicking test.

In some embodiments, when the absorbent article comprises a composite fabric encapsulating the absorbent material, the absorbent article has a wicking distance percentage of at least 60% after the third fluid exposure in the no-load saddle wicking test.

In some embodiments, when the absorbent article includes a fluid acquisition distribution layer comprising a composite fabric or a composite fabric encapsulating an absorbent material, the absorbent article has a rewet amount from a first fluid exposure of less than 0.5g in a flat acquisition test under load.

In some embodiments, when the absorbent article includes a fluid acquisition distribution layer comprising a composite fabric, the amount of rewet of the absorbent article from a second fluid exposure in a flat acquisition test under load is less than 0.5g.

In some embodiments, when the absorbent article comprises a composite fabric encapsulating the absorbent material, the absorbent article has an amount of rewet less than or equal to 0.8g from a second fluid exposure in a flat acquisition test under load.

In some embodiments, when the absorbent article includes a fluid acquisition distribution layer comprising a composite fabric, the amount of rewet of the absorbent article from a second fluid exposure to a third subsequent fluid exposure increases by less than 11.9g in a flat acquisition test under load.

In some embodiments, when the absorbent article includes a fluid acquisition distribution layer comprising a composite fabric, the amount of rewet of the absorbent article from a first fluid exposure to a second subsequent fluid exposure increases by less than 0.35g in a flat acquisition test under load.

In some embodiments, when the absorbent article comprises a composite fabric encapsulating the absorbent material, the rewet amount of the absorbent article from the second fluid exposure to the third subsequent fluid exposure increases by less than 4.42g in a flat acquisition test under load.

In some embodiments, when the absorbent article comprises a composite fabric encapsulating the absorbent material, the rewet amount of the absorbent article increases by less than 0.73g from a first fluid exposure to a second subsequent fluid exposure in a flat acquisition test under load.

An exemplary rewet range for each fluid exposure of some embodiments of diapers comprising ADLs or composite webs of encapsulated absorbent materials is shown in table 1.

Table 1. Rewet amount per fluid exposure for diapers comprising ADL or core wrapped composite fabrics.

Feminine hygiene product

The composite fabrics of the present disclosure may be used in absorbent articles, such as feminine hygiene products (e.g., sanitary napkins, panty liners). The feminine hygiene product can include a composite fabric comprising: a nonwoven layer comprising polymeric fibers and/or filaments; a crosslinked cellulosic layer comprising crosslinked cellulosic fibers, wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer; and an interface region between the nonwoven layer and the crosslinked cellulosic layer, the interface region comprising physically entangled polymer fibers and/or filaments from the nonwoven layer and crosslinked cellulosic fibers from the crosslinked cellulosic layer, wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in a dry state.

The feminine hygiene product can include an absorbent core comprising an absorbent material. In some embodiments, the composite fabric is disposed on the absorbent core. In some embodiments, the composite fabric encapsulates at least a portion of the absorbent material. In some embodiments, the composite web may be used to sandwich the absorbent material such that a first layer of the composite web overlies the absorbent material and a second layer of the composite web underlies the absorbent material.

When stained with fluid, the composite fabric distributes fluid to the front, middle and rear portions of the feminine hygiene product. In some embodiments, the front, middle, and back portions of the composite fabric of the feminine hygiene product each comprise an amount of fluid within 20wt% to 45wt% of each portion when subjected to fluid insult. As used herein, the intermediate portion is 7.5cm in length and is located between the front and rear portions, with the remaining length being equally divided between the front and rear portions.

Absorbent article construction-absorbent core

The composite webs of the present disclosure may be included in absorbent articles and may be used as an acquisition-distribution layer (ADL), or for wrapping at least partially around an absorbent material, which may be or include one or more of a number of absorbent materials, among other purposes. Various exemplary configurations of the "core wrapped" absorbent article are described in the following paragraphs with reference to fig. 4-8C.

Fig. 4 is a schematic diagram illustrating an exemplary absorbent article 400 according to an embodiment of the present disclosure. In some embodiments, the exemplary absorbent article 400 includes: a backsheet 405, an absorbent core 410, and a topsheet 415. The exemplary absorbent article 400 is configured to receive liquid insult via the topsheet 415, distribute liquid through the absorbent core 410, and absorb liquid while preventing liquid from bypassing the backsheet 405, thereby reducing or eliminating wetness, discomfort, and/or irritation experienced by the wearer of the absorbent article 400. The exemplary absorbent article 400 is an example of the absorbent article 300 described with reference to fig. 3.

In some embodiments, the backsheet 405 includes one or more layers of liquid impermeable constituent materials, such as polymers, elastomers, and/or metallic materials that create a liquid impermeable barrier. Conversely, the topsheet 415 may comprise a liquid permeable material such that liquid insults incident on the topsheet 415 may be wicked, directed, or otherwise passed through the topsheet 415 to the absorbent core 410 with negligible physical resistance. When assembled, the topsheet 415 may overlie the absorbent core 410 and may contact the interior surface of the backsheet 405. In this manner, contacting the interior surface of the backsheet 405 may include contacting the backsheet 405 at one or more points, surrounding the periphery of the absorbent core 410 and/or being coextensive with the backsheet 405. Various configurations may allow the absorbent article to bend or twist without significant bunching or crushing of the absorbent core 410.

The backsheet 405 may define an inner surface 420 and an outer surface 425. The inner surface 420 may be or include a physical clasp, latch, tab, adhesive, or another configuration whereby the backsheet 405 may be mechanically coupled with the absorbent core 410 and/or the topsheet 415, and whereby the backsheet 405 may be removably coupled with the garment of the wearer. In some embodiments, the absorbent article may be in the form of a pant without any fasteners. For example, the absorbent core 410 may be disposed on the inner surface 420 of the backsheet 405 and may be held, retained, secured, or otherwise mechanically coupled to the backsheet 405. In some embodiments, the backsheet 405 and the topsheet 415 together define a pouch in which the absorbent core 410 is removably disposed. In this manner, the absorbent article 400 may be reusable or may be disassembled to facilitate disposal of the compostable materials and recycling of the plastic parts.

In some embodiments, the backsheet 405, topsheet 415, absorbent core 410, and composite fabrics of the present disclosure may be embossed folded, pleated, and/or perforated to physically distribute, direct, or otherwise affect the flow of liquid insults incident on the topsheet 415, wherein the folded or pleated composite fabrics optionally include absorbent materials within the folds or pleats. When the composite fabric is pleated, folded or otherwise provided with a textured surface, the nonwoven layer or crosslinked cellulosic layer may face the absorbent material of the absorbent core of the absorbent article.

In some embodiments, the topsheet 415 is textured to improve the feel of the wearer when wearing the absorbent article. In an illustrative example, the texture and/or pattern may include one or more apertures to improve circulation of air through the absorbent article 400, thereby reducing wetness near the wearer's skin surface and sequestering and/or denaturing odorous gases. Similarly, the topsheet 415 may include a micro-textured surface to impart a soft feel to the surface without altering the liquid permeability or porosity of the topsheet 415.

Referring to fig. 5A-5E, various configurations of core-wrapped absorbent articles are described. Fig. 5A shows one example of contemplated constituent materials and constructions. Figures 5B-8C illustrate additional and/or alternative constructions and/or materials that may be included in embodiments of absorbent articles.

Fig. 5A is a schematic diagram illustrating the internal structure of the exemplary absorbent article 400 of fig. 4 according to an embodiment of the present disclosure. The exemplary absorbent article 400 includes a distribution layer 505 as part of the absorbent core 410, which may comprise or be formed of the composite fabric of the present disclosure, disposed about at least a portion of the absorbent material 510. The distribution layer 505 and absorbent material 510 may together serve to distribute and absorb liquid insults incident on the topsheet 415 and reduce rewet after subsequent initial absorption.

In some embodiments, the absorbent material 510 defines an upper surface 515 and a lower surface 520 of the absorbent core 410. The distribution layer 505 in turn surrounds at least a portion of the upper surface 515 and the lower surface 520. The distribution layer 505 may completely surround the upper surface 515 and the lower surface 520 of the absorbent core 410. For example, the distribution layer 505 may be or include a rectangular planar material having four edges wrapped around the absorbent material 510 such that the two edges contact each other along the lower surface 520 or along the upper surface 515 of the absorbent core 410.

The distribution layer 505 may be or include a composite fabric 110 that includes two or more component layers. The component layers may include a nonwoven layer 112 and a crosslinked cellulose layer 114. The nonwoven layer 112 may be or include polymeric fibers and/or filaments as described in more detail with reference to the previous figures. Instead, the crosslinked cellulosic layer 114 may be or include crosslinked cellulosic fibers.

The crosslinked cellulosic layer 114 may be positioned opposite the nonwoven layer 112 and may define an interface region 116 between the nonwoven layer 112 and the crosslinked cellulosic layer 114, as described in more detail with reference to fig. 1-3. The interface region 116 may include physically entangled polymer fibers and/or filaments from the nonwoven layer 112 and crosslinked cellulose fibers from the crosslinked cellulose layer 114. In this manner, the nonwoven layer 112 and the crosslinked cellulose layer 114 may be mechanically inseparable in the dry state.

Referring to fig. 5B and 5C, alternatively, the distribution layer 505 may define a gap 525 on the upper surface 515 or the lower surface 520 of the absorbent core 410. Where the gap 525 can hold liquid or can otherwise impair the distribution of liquid through the distribution layer 505, the absorbent core 410 can further include a cover distribution layer 530 disposed over the gap 525. The cover distribution layer 530 may overlie at least a portion of the distribution layer 505 such that the distribution layer 505 is disposed between at least a portion of the cover distribution layer 530 and the absorbent material 510. In terms of assembly, the distribution layer 505 may be wrapped around a portion of the absorbent material 510, defining a gap 525 on the upper surface 515 or the lower surface 520, and may be coupled by pressure, adhesive, physical closure, or other means, over which the cover distribution layer 530 may be physically coupled with the distribution layer 505 by similar techniques. In some embodiments, the cover distribution layer 530 is or includes a composite web 110 such that where the cover distribution layer 530 contacts the absorbent material 510, it is used to distribute liquid in a manner similar to the distribution layer 505.

Referring to fig. 5D and 5E, an overlay distribution layer 530 may underlie at least a portion of the distribution layer 505 such that the overlay distribution layer 530 is disposed between at least a portion of the distribution layer 505 and the absorbent material 510. In terms of assembly, the cover distribution layer 530 may be physically coupled to the absorbent material 510 by pressure, adhesive, physical closure, or other means, over which the distribution layer 505 may wrap around the portion of the absorbent material 510, defining a gap 525 on the upper surface 515 or the lower surface 520, and thereby may be coupled to the cover distribution layer 530 and the absorbent material 510.

Referring to fig. 6A-6D, the cover distribution layer 530 can be or include a spunbond-meltblown-spunbond (SMS) material, a Spunbond (SB) material, a spunbond-carded (SC), a spunbond-air-laid (SA), a meltblown-air-laid (MA) or a combination thereof as previously described. As described with reference to fig. 5B-5E, SMS and SB materials may be disposed overlying at least a portion of the distribution layer 505 or underlying the distribution layer 505 and may be disposed on the upper surface 515 or the lower surface 520 corresponding to the location of the gap 525 on the absorbent core 410.

Referring to fig. 7A and 7B, in some embodiments, the distribution layer 505 overlaps at least a portion 535 of the width of the distribution layer 505 on the upper surface 515 or lower surface 520 of the absorbent core 410. In the example of rectangular planar material, the two edges may overlap on the upper surface 515 or on the lower surface 520. Advantageously, the configuration including the overlapping portions may be manufactured with less process than including steps involving the preparation and placement of the cover distribution layer 530.

Referring to fig. 8A, 8B, and 8C, the absorbent material 220 is described with reference to the absorbent article 300, which may also be included as part of the exemplary article 400 of fig. 4. The absorbent material 220 in the absorbent core may be or include one or more constituent materials selected to provide improved absorption, wicking, and/or retention properties of the absorbent article 300. For example, the absorbent material 220 may be or include a synthetic absorbent polymer 330 and a high loft air permeable bonded carded web (TABCW) 810. In another example, the absorbent material 220 may be or include an absorbent synthetic polymer 330 and fluff pulp 815. The absorbent material 220 may comprise a combination of the above materials. In some embodiments, the absorbent material 220 includes 30% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 70% by weight of the fluff 815. The composition of the absorbent material may be determined, at least in part, by the balance of absorbency, weight, density, and other wetting properties, as described with reference to the absorbent article testing procedure below. For example, while the absorbent synthetic polymer 330 may exhibit increased retention, the fluff 815 may improve acquisition and wicking. In this way, the overall performance of the absorbent article may depend on the particular application, for example when wicking may be more desirable, such as when relatively high volumes of liquid are to be absorbed rapidly, as opposed to applications where volumes are relatively low but absorption is to be stable over a period of time.

In this manner, the absorbent material 220 may include 5% to 99% by weight of the absorbent synthetic polymer 330 and 1% to 95% by weight of the fluff 815, 10% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 90% by weight of the fluff 815, 15% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 85% by weight of the fluff 815, 20% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 80% by weight of the fluff 815, 25% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 75% by weight of the fluff 815, 30% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 70% by weight of the fluff 815, 35% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 65% by weight of the fluff 815, 40% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 60% by weight of the fluff 815, 45% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 55% by weight of the fluff 815, 50% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 50% by weight of the fluff 815, 55% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 45% by weight of the fluff 815, 60% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 40% by weight of the fluff 815, 65% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 40% by weight of the fluff 815, 70% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 30% by weight of the fluff 815, 75% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 25% by weight of the fluff 815, 80% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 20% by weight of the fluff 815, 85% to 90% by weight of the absorbent synthetic polymer 330 and 10% to 15% by weight of the fluff 815, including fractions or interpolations thereof.

Absorbent article testing procedure

No-load saddle wicking for absorbent articles

This test determines how quickly an absorbent sanitary product can absorb a certain amount of fluid when constrained in a "U" shaped saddle that simulates the position of the absorbent article when in use by a person. In addition, the test determines the distance that is wicked by the fluid after all doses of the fluid. This test evaluates the fluid intake and fluid distribution capabilities of absorbent articles in a configuration similar to real life use.

Equipment and materials required

The equipment and materials required for this test are as follows: ruler, simulated urine (0.9% saline solution), saddle device, peristaltic pump with dispensing tube (with accessories to prevent dispensing tube from touching diaper), timer, stopwatch, magnetic plate, and 4 magnets.

Sample preparation

1. The size of the sample is determined.

2. If the infant product is tested, the product length and width are measured.

3. The center of the sample length is marked.

4. 9cm was measured toward the front of the sample and marked with an "X" ensuring that the "X" was centered relative to the absorbent core width. "X" will be the fouling point.

5. Alternatively, the elastic leg gathers of the diaper may be cut to facilitate testing, so long as the cut does not interfere with the absorbent capacity of the diaper.

Calibration of

1. An appropriate amount of 0.9% saline solution was prepared for testing in a container that could be fitted with the inlet of the test pump.

2. The pump is set to the desired flow rate and dose volume.

The infant product should have a rate of (900 ml/min) and a dosage of 85 ml.

3. 1 dose was dispensed into a graduated cylinder. If the dose is incorrect, the tube is calibrated.

Test program

1. The distribution tube is placed perpendicular to the point of insult and as close as possible to the surface of the absorbent article without bringing the surface into contact with the distribution point.

2. The peristaltic pump, stopwatch and timer (set to 20 minutes) were started simultaneously.

3. Stop the stopwatch when the liquid is absorbed.

4. When the 20 minute timer is over, the steps 1-3 are repeated twice more.

5. After the third wheel 20 minute timer expires, the absorbent article is removed and flattened on the magnetic plate and secured in place.

6. The distance of fluid wicking from the insult point to the front and back ends of the absorbent article is measured. To determine the wicking distance, the tester should determine the furthest wicking distance for most of the fluid to wick and exclude the remote wicking distance.

Flat acquisition under load of absorbent sanitary products

The test determines how quickly an absorbent sanitary product can absorb a quantity of fluid under high pressure and how well the product retains the fluid. Thus, the test evaluates the fluid management capabilities of the absorbent article under load.

Equipment and materials required

The equipment and materials required for this test are as follows: magnetic plates and magnets, balance with 1,000 gram capacity sensitive to 0.01g, ruler, simulated urine (0.9% saline solution), offset plates, rewetted plates, peristaltic pump with dispensing tube, blotter paper, weight producing 0.38psi, 2 timers, stopwatch.

Sample preparation

1. Two magnets are used to attach the sample to the magnetic plate from either the front or rear two tabs.

2. The diaper is pulled taut and two other magnets are used to maintain tension by holding the diaper down at two available tabs.

3. The insult point was marked 150mm from the front of the absorbent core and in the center width direction of the absorbent core.

Calibration of

2. The pump is set to the desired volume and rate.

3. The infant product should have a rate of 900mL/min and a dosage of 85 mL.

4. 1 dose was dispensed into a graduated cylinder. If the dose is incorrect, the pump is calibrated.

Test program

First inhalation/rewet

a) The insult panel is placed onto the product and the front edge of the insult panel is aligned with the front edge of the absorbent core. Ensuring that the fouling point is in the centre of the cartridge.

b) The plate was loaded to 0.38psi.

c) 85ml of saline solution was dispensed into the cartridge.

d) Immediately after dispensing, a stopwatch was started simultaneously and the timer was set to 15 minutes.

e) When all the saline is absorbed into the product, stop the stopwatch and record the acquisition time.

f) Weigh 1 dry blotter paper and record the weight.

g) A pre-weighed amount of rewet blotter paper was placed with its short edge aligned with the front edge of the absorbent core and the rewet plate centered on top of the blotter paper.

h) The rewet plate was loaded at 0.38psi.

i) The timer set to 2 minutes is started again.

j) After waiting 2 minutes for rewetting, the rewetted plate and rewetted blotting paper are removed.

k) The blotter paper was weighed.

l) measuring the fluid wicking distance from the insult point to the front and back ends of the absorbent article and recording as "front wicking distance" and "back wicking distance", respectively, independently. To determine the wicking distance, the tester should determine the furthest wicking distance that is wicked by most of the fluid and reject the remote wicking fluid.

Second inhalation/rewet

a) The procedure for inhalation 1 was followed except that 2 dry blotters were used for rewet.

Third inhalation/rewet

The procedure for inhalation 1 was followed except that 3 dry blotters were used for rewet.

Calculation of

Rewet value (g) =weight of blotter after rewet (g) -weight of blotter before rewet (g).

In-plane radial Permeability (IPRP) test

Permeability generally refers to the amount of porous material that allows a liquid or gas to pass through, and is therefore generally determined by the mass flow rate of a given fluid passing through it. The permeability of an absorbent structure is related to the ability of the material to rapidly acquire and transport liquid within the structure, both of which are key features of the absorbent article. Thus, measuring permeability is an indicator that evaluates whether a material is suitable for use in an absorbent article. The in-plane radial permeability (IPRP) of the porous material was measured according to the method described in U.S. patent No. 10,287,383, which is incorporated herein by reference. The amount of saline solution (0.9% nacl) flowing radially through the annular sample of material at constant pressure was measured as a function of time and the test was performed at 23 ℃ ± 2 ℃ and 50% ± 5% relative humidity. All samples were conditioned in this environment for twenty four (24) hours prior to testing.

Thickness, bulk and Density

The method is used to determine the monolithic thickness of a material using a specified load applied for a specified time by using a motor-driven micrometer. The method is based on TAPPI T411.

The method is suitable for measuring apparent thickness using IPC soft platen technology. This technique uses a micrometer with a pressure face covered with soft neoprene. This has the effect of reducing the thickness reading due to the ability of the latex to conform to surface irregularities. This is useful when measuring materials with rough or irregular surfaces, such as linerboards and corrugated medium.

The required equipment:the motor drives the micrometer to an accuracy of 0.001mm.

Wire or other suitable alignment gauge having a thickness within 0.0005mm is known. The gauge should extend over a range of thicknesses (e.g., 0.2-1.0 mm).

The procedure is as follows:

step 1.1: the surface of the platen was cleaned with a lint-free paper (Bausch and Lomb Sightsaver silicon wipe) and the micrometer reading was adjusted to zero.

Step 1.2: with the pressure face closed, the reading is set to zero. Zero is not reset during the following steps.

Step 1.3: the gap between the pressure faces is opened and closed again.

Step 1.4: insert one of the calibrated gauges and read the thickness to the nearest 0.001-mm. Four replicates were recorded for each thickness reading and average.

Step 1.5: another gauge thickness is selected and step 4 is repeated. The remaining thickness gauge (four different thicknesses in total) is continued.

Step 1.6: the mean and coefficient of variation for each gauge reading was calculated. Recording. The consistency of the reading to the calibration gauge reading should be within 0.5%. The coefficient of variation should be 0.5% or less.

Step 2.1: for the gauge closest to the range used, steps 1.1 to 1.4 are followed.

Step 2.2: according to step 1.6.

Step 2.3: the parallelism of the upper and lower platens was checked by inserting a single gauge on one side of the underside (1-2 mm from the edge of the face) and closing the surface. Recording was accurate to 0.001-mm. Repeating at an edge directly opposite the edge.

Step 2.4: step 2.3 is repeated to take readings at positions rotated 90 ° from the first two (i.e., at the front and rear edges of the lower platen if the first readings are taken on the left and right edges). Error (P) of calculating parallelism:

P＝0.5[(d ₁ ) ² +(d ₂ ) ² ] ^1/2

wherein: d, d ₁ Difference between readings, step 8.2.3.

d ₂ Difference between readings, step 8.2.4.

P is recorded in the log to the nearest 0.001-mm.

If P >0.005mm, the instrument should be inspected by the instrument device before proceeding.

Step 3: the sample should be sufficient to obtain 50 readings (as specified in 8.6).

Step 4: the surface of the platen was cleaned with lint-free paper and the micrometer reading was adjusted to zero.

Step 5: a single sample was inserted into the caliper opening, closing the pressure face and stabilizing the reading. Any manual stress applied to the sample is avoided when making the readings. Readings are recorded using a sample manager through a manual or serial port entry.

Step 6: 10 caliper readings (e.g., 5 readings from the outer ring 15-25mm and 5 readings from the center ring 15-25 mm) are done in a random format.

Step 7: each plate was read 5 times: twice in the top region, once in the middle and twice in the lower region.

After each sample, the inspection instrument "zero" still reads zero.

Calculation of

The calculation is done by a computer.

Step 1: air-dry bulk, cubic centimeter per gram was calculated:

bulk, cm ³ /g＝1000A/B

Wherein: a = thickness, mm

B = air dry basis weight, g/m ²

Step 2: air-dry ("apparent") density in kilograms per cubic meter was calculated:

density of kg/m ³ ＝B/A

Wherein: a = thickness, mm

B = air dry basis weight, g/m ²

Odor control evaluation

Method for measuring free TMA reduction

A method of measuring the reduction of free Trimethylamine (TMA) sequestered by an absorbent material, such as a composite fabric of the present disclosure or an absorbent article made therefrom. In an embodiment, the absorbent material is disposed in a closed container and contacted with an amount of TMA. After the absorbent material has a chance to sequester at least a portion of the amount of TMA, e.g., the amount of TMA has reached equilibrium between the gas headspace of the closed container and the absorbent material, a portion of the gas headspace is withdrawn from the closed container. In an embodiment, a quantity of TMA is contacted with the absorbent material for a sufficient time to reach equilibrium prior to withdrawing a portion of the gaseous headspace from the closed vessel, thereby also providing sufficient time for at least a portion of the initial quantity of TMA to sequester within the absorbent material. One of ordinary skill in the art will readily know how to generate a balance curve or other suitable tool to monitor and identify balance.

In an embodiment, the closed container is a flexible container configured to at least partially collapse in response to a portion of the gaseous headspace being withdrawn. In this regard, it is easier for a user to withdraw a portion of the gaseous headspace from the closed container.

Measuring gas headspace extractionAnd in part to determine the gas concentration of free TMA present in the headspace. In an embodiment, measuring the amount of free TMA in the withdrawn portion comprises passing the withdrawn portion of the gas headspace through a stationary phase loaded with a colorimetric label that changes color upon contact with TMA; and measuring the amount of color change in the stationary phase in response to passing the withdrawn portion of the gas headspace through the stationary phase. In an embodiment, determining the withdrawn portion of the gas headspace to measure the gas concentration of free TMA includes using a colorimetric gas detector tube, e.g.A gas detector tube system. Although a colorimetric detection method is described, it should be understood that other methods of TMA detection consistent with the methods of the present disclosure may be used, such as, but not limited to, gas chromatography.

The decrease in free TMA was measured relative to the control. In an embodiment, the control is a zero control, wherein the zero control comprises a control that does not include contacting TMA molecules with an absorbent material. In an embodiment, the control is an absorbent material control, wherein the absorbent material control is an absorbent material that is substantially free or free of added carboxylic acid coupled to the fibrous matrix (in which case "substantially free of added carboxylic acid" or "substantially free of added carboxylic acid" is understood to mean that no carboxylic acid is added or that the amount of added carboxylic acid is between 0wt% and 1wt%, as limited by known detection methods). As used herein, "added carboxylic acid" is understood to mean that the amount of carboxylic acid added or otherwise coupled to the absorbent material during processing or manufacture is higher and exceeds any carboxylic acid present in the untreated absorbent material. In an embodiment, the control absorbent material comprises fluff pulp that has not been treated with or otherwise coupled to carboxylic acid, such as southern bleached softwood kraft pulp. In this regard, the user can determine the TMA reduction of carboxylic acid coupled to the fibrous matrix of the absorbent material described herein relative to the selected control.

In an embodiment, the non-absorbed material is sequestered and the amount of TMA (TMA _g ) And allow for headspace of control gasThe amount of unchelated TMA (TMA in the control experiments of inter-internal equilibrium _c ) A comparison is made. The decrease in gas concentration of free TMA measured in the headspace above the absorbent material relative to the control can be expressed as a percent decrease in free TMA (% TMA) _red ). The percentage reduction can be calculated by the following equation.

％TMA _red ＝(TMA _c -TMA _g /TMA _c )×100％

It should be noted that TMA-containing fluids located on the sides or other portions of the closed container, such as fluids used to stain absorbent materials or absorbent articles, may affect TMA reduction results. Such TMA-containing fluids that do not contact the absorbent material or absorbent article may result in an increase in the volatilization of TMA from the TMA-containing solution into the gaseous headspace of the closed container. Such increased TMA volatilization may result in a higher relative concentration of gaseous TMA than when the TMA-containing solution directly contaminates the absorbent material or absorbent article, incorrectly indicating the ability (or lack of ability) of the absorbent material or absorbent article to sequester TMA.

Feminine hygiene product evaluation protocol

The feminine hygiene test protocol generates data using a standardized method that can be used to compare the performance of one product to another. The tests included product weight, rewet performance and liquid distribution.

Measuring physical properties such as product weight, basis weight, and density provides baseline information for comparing one product to another.

The basis weight and density of the absorbent product affects the liquid absorption, liquid wicking, and pad integrity of the entire pad. The basis weight and density uniformity of the entire mat or intentional profiling within the mat portion affects product performance.

The rewet test provides evidence of dryness of the skin after the absorbent structure is stained with fluid. The rewet value is affected by the rate at which liquid is absorbed into the structure, the extent to which liquid is wicked from the insult point, and the extent to which liquid is retained within the product. The liquid distribution test quantifies the amount of fluid wicking from the point of insult to the end of the absorbent product. These are important properties in analyzing the performance of absorbent feminine hygiene products.

Inhalation and rewet assay for feminine care products(Hygiene)Fluid management capability of the product when placed on a flat panel. The fluid used in this test was a menstrual fluid simulator. The results of the standardized assays allow for comparison of the ability of the product to aspirate fluid, mitigate rewet or backflow of fluid, and/or wick distance by fluid.

Equipment and materials required

The equipment and materials required for the feminine hygiene test are as follows: a rewet and liquid distribution template for marking the pad; a basis weight-density template; filter paper, cut into 7.5cm by 6.2cm rectangle; peristaltic pump-calibrated to 0.33mLs/min, with 3 cams for 3 tubes; weights, rectangular, 0.46psi or equivalent; synthetic menstrual fluid, laboratory timer, balance sensitive to 0.01 g; a pair of scissors; ruler; weighing disc; 4-250ml plastic beaker; a stainless steel pipe seat; samco series 70 presses or equivalent; positioning a template and a die cutter; cutting the plate; standard silicone tubes.

For the inhalation and rewet assays, the required materials are as follows: an absorbent pad, a insult block; 3 or 5ml syringe; a timer; a stopwatch; synthetic Menstrual Fluid (SMF) -processed porcine blood (PSB) -see detailed procedure for preparing SMF below; filter paper, whatman #3 size 11em; a weight-normalized pressure setting of 0.55psi was generated; a balance sensitive to at least 0.001 g; ruler; 250ml plastic bottle; 50-ml test tube.

Test procedure:

product weight variation

Step 1: all feminine hygiene products were weighed using a standard test spreadsheet and balance to determine the average weight, standard deviation, and coefficient of variation.

Step 2: when you weigh the pads, the weight of each pad is written down somewhere on the wrap or directly on the pad.

Step 3: the pads are stacked in ascending/descending order by weight.

Step 4: if the wrap is not easily removed and the test is to be performed with the wrap, at least five wraps are carefully removed and weighed.

Step 5: individual values are entered in a standard test spreadsheet to calculate an adjusted average product weight.

Step 6: after weighing the samples to determine the adjusted average product weight, 6-12 pads with a product weight closest to the adjusted average product weight (depending on how many repetitions you are doing the test) were selected and set aside for rewet and liquid distribution testing.

Pad preparation for rewet and liquid distribution

Step 1: pads were set aside for rewet and fluid distribution testing and they were divided into two groups:

first group: 3-6 pads to be tested

Second group: 3-6 pads for tare

Step 2: the wrap deployment samples were loosened and opened so that they could lie flat, spanned.

Step 3: the samples were allowed to lay flat for a period of time (4-8 hours) to allow them to aerate and flatten. Applying some light weight helps to accelerate the process.

Step 4: the center of the sample was located by finding the center of the wing and the product for dosing was marked.

Preparation of test using rewet and distribution templates

Step 1: the rewet and distribution template is a thin plexiglass and has two slits that are used to mark the sample and divide the sample into three sections. The aperture in the center of the template indicates the center of the template and where it should be located on the feminine hygiene pad. Once it is in place at the dosing point, a line can be drawn on the pad with a marker using the slit as a guide.

The die plate is positioned over the length and width of the pad with the center hole of the die plate aligned with the center mark or dosing point of the pad.

Step 2: the pad (and wrap, if applicable) is marked with a permanent marker by tracking within the seam of the template. This divides the pad into three sections. If desired, a ruler is used to extend the wire on the pad to the plastic wrap.

Step 3: each section of the sample is marked with a replica number and a position identification:

for test replica #1, each segment is labeled as follows: #1f (front), #1m (middle), and #1b (rear). If the front of the pad is not distinguishable from the rear of the pad, the indicia are as follows: end # 1-A, #1 middle, and #1 end-B. For the tare copy #1, each section should be preceded by the letter "T" (for tare) -T #1F, T #1M, T #1.

Step 4: after marking all pads, the pad for tare weight is selected and cut along a line made using a template.

Step 5: the weight of each section was weighed and recorded.

The average tare weight of each section is calculated and applied to the distribution-pad section of the work table to determine the liquid distribution. After the test is completed, the liquid distribution is completed when the wetted portions are cut, weighed and recorded in a spreadsheet. (wet weight, g. -dry weight, g = rewetted, g).

The average value of each section (front = 3.04g, middle = 3.01g, rear = 8.59 g) was added as "starting weight, g" to the distribution-pad section.

Preparation of Filter paper

The filter paper was conditioned at ambient room temperature/humidity for at least two hours before the actual test began.

Three sets of ten 7.5cm by 6.2cm filters were counted and weighed for each test sample.

When the filter paper was weighed, the weight (g.) was written down on the filter paper and recorded.

After the synthetic menstrual fluid has been dosed, the filter paper is marked according to the location on the pad where it will be applied.

Actuation and calibration of peristaltic pump

Step 1: the pump was calibrated to deliver 20mL of synthetic menstrual fluid in 60 minutes. If the sample is very small, a smaller dose of 10mL may also be used within 30 minutes. A second pump was also provided to deliver a smaller dose of 5mL in 30 minutes.

The operation and calibration of the peristaltic pump was verified by filling a 250mL beaker with approximately 50mL of synthetic menstrual fluid.

Step 2: three separate 250ml beakers were pre-weighed and labeled A, B and C.

Step 3: the weight of each beaker was recorded as tare.

Step 4: three inlet (also labeled A, B and C) ends of the tube were placed into menstrual fluid.

Step 5: the outlet end was placed in an empty 250ml beaker.

Step 6: to activate the pump, it is turned on and allowed to run long enough to flush out DI water or air trapped in the line from previous testing or long standing.

Step 7: once the pump was activated and the tube filled with synthetic menstrual fluid, it was confirmed that at least 40mL of fluid remained in the 250mL main beaker for calibration and testing.

Step 8: carefully remove each tube and place each outlet tube end into three correspondingly marked pre-weighed beakers. (tube A placed in beaker A, tube B placed in beaker B, etc.)

Step 9: the timer was set to three minutes and the pump was started-a small amount of fluid was seen to enter each beaker.

Step 10: when the timer was stopped, the tube was carefully removed from the beaker and each beaker was weighed and the weight was recorded as gross weight, g.

Step 11: the tare weight was subtracted from the gross weight to calculate the net weight for each individual line and the net weight was recorded to confirm calibration.

All three tubes need to be validated before testing. If the net difference of any tube is greater than 10%, calibration is again performed following the same procedure described above.

Step 12: if all three tubes are precisely calibrated, they are passed through the corresponding stainless steel tube seats in preparation for testing.

Rewet and liquid distribution test

Step 1: the weight of each pad was weighed and recorded.

Step 2: the pads to be tested were placed on a counter in a feminine hygiene testing room and positioned with the metering tube 1cm above the marked stain point of the pads. If the edges of the pads are curled, the pads are glued to the counter top using laboratory tape, leaving them flat.

Step 3: the laboratory timer was set to 1 hour and the pump was started.

Step 4: the feminine hygiene test chamber is closed.

Step 5: at the end of the one hour dosing, the sample was allowed to stand for 20 minutes.

Step 6: at the end of the 20 minute rest period, the filter paper stacks were placed on top of the respective sections of the sample by starting from the middle and then placing the other two stacks at the front and rear of the pad so that they contact the middle stack.

Step 7: a separate timer was set to five minutes.

Step 8: a rectangular weight was placed on top of the filter paper and pad and a 5 minute timer was started.

Step 9: at the end of 5 minutes, the weight was removed.

Step 10: the filter stacks were weighed and the wet weight of each was recorded.

Step 11: weigh the entire wet pad and record the weight.

Step 12: each sample was cut one at a time along the line on the pad (drawing) as precisely as possible.

Step 13: each wet pad section (# 1f, #1m, and # 1b) was weighed and the weight was recorded. The process is repeated with all other replicas until the test is complete.

And (3) calculating:

rewet valueThe amount of liquid absorbed by the filter paper after dosing. Rewetted, g = wet filter paper, g minus dry filter paper, g.

Liquid distribution-each (cut) section of pad: total amount of liquid absorbed by the front, middle and rear portions.Liquid distribution, g = weight per section + rewet value per section minus average dry product weight per (tare weight) section.

Step 14: if flowing from the pad onto the table, a malfunction occurs, if flowing into the wing and/or side channel is acceptable.

Step 15: after the test is completed, all peristaltic pump lines are rinsed with DI water.

Step 16: the remaining synthetic menstrual fluid is stored in a refrigerator.

Inhalation and rewet of feminine hygiene products

Preparation of SMF from processed pig blood (PSB)

Step 1: the processed pig blood is contained in a bag.

Step 2: the bag was gently kneaded to mix the contents.

Step 3: the edges of the bag were cut off and the contents were poured into 250ml plastic bottles.

Step 4: the label was removed from the bag and placed on a 250ml plastic bottle.

Step 5: from a 250ml plastic bottle, a 50ml test tube was filled with approximately 40ml. The excess PSB is returned to the refrigerator. Since the viscosity of blood varies with time, it is important to withdraw a small amount of PSB at a time.

Step 6: the PSB was allowed to reach room temperature for about 1 hour.

Step 7: the viscosity reading of the PSB was taken. The viscosity may vary from bag to bag and within each bag over time. The viscosity of the blood can change the inhalation time.

Step 8: at the time of testing, a second 50ml tube may be filled with PSB to allow temperature to be reached.

Sample preparation for feminine hygiene products

Step 1: the prototype should include a backsheet and a pad. The length and width of the absorbent core of the product were measured.

Step 2: the center of the length and width of the absorbent core is marked with an "X". "X" will be the fouling point.

Step 3: for commercial products with wings, the center should be the middle of the wing.

Inhalation and rewet test procedure for feminine hygiene products:

step 1: the protruding side of the offset is placed on the product with the hole in the center of the offset.

Step 2: the "pre-rewet" weights of three filter papers were weighed and their initial weights were recorded.

Step 3: the syringe was actuated with a menstrual fluid simulator.

Step 4: 2mL of PSB was drawn into the syringe, ensuring that there was no air bubble.

Step 5: the tip of the syringe is placed on the product at the point of insult, and the syringe is placed on the insult block without exerting any pressure on the block.

Step 6: the menstrual fluid simulant was initially dispensed with a target dosage rate of 5ml/3 seconds. Simultaneously start the stopwatch and the 10 minute timer.

Step 7: stop the stopwatch when the fluid is absorbed.

Step 8: when the 10 minute timer is over, the steps 3-6 are repeated twice more.

Step 9: after the end of the third cycle of the 10 minute timer, the fouling block is removed.

Step 10: three rewetted filter papers were placed on top of the product, covering most of the fluid.

Step 11: the weight was placed on the filter paper. A timer was started for 2 minutes.

Step 12: when the 2 minute timer expires, the weight and filter paper are removed from the product.

Step 13: the "rewetted" weight of the filter paper was weighed and the weight recorded.

Step 14: if a wicking distance is desired, the length and width of the PSB on the sample are measured.

Step 15: the length and width of the wicking fluid distance are recorded.

Step 16: the product is folded and placed in a biohazard waste bin.

Step 17: the acrylic suction rewet sheet is cleaned with a disinfectant solution.

Example

Example 1 manufacture of composite fabrics

The crosslinked fiber layers of this example were made using laboratory scale air-laying equipment. The crosslinked fibers in the form of dry loose fluff are fed into a chamber with blunt mixing blades to further disperse the fibers. Air is supplied to the chamber to push the crosslinked fibers through the wire onto the tissue laid on a 14 inch by 14 inch forming wire. The air-laid cross-linked fibrous mat was then sandwiched between blotters and pressed at 12000 psi. The pressed mat was cut to a size of 12 inches by 12 inches and then stored for later use. Resin bonded carded webs and spunbond materials were prepared by cutting the nonwoven to the same dimensions (12 inches by 12 inches) as the crosslinked fibrous mats. Fluff dimensions were prepared by placing loose, dry fluff Mao Wei in 2L of water and dispersing the mixture in a British mill at 1500 rpm. A 12 inch x 12 inch laboratory scale wet laid apparatus was prepared by placing a forming wire over the discharge area and sealing the apparatus so that water did not leak out. The fluff Mao Wei-water slurry was mixed under low velocity air impingement for 2 minutes. After 2 minutes the air impingement was stopped and water was drained and fluff Mao Wei was deposited onto the forming wire. The wet laid fluff pad was sandwiched between blotters and dried at 105 ℃ for 15 minutes.

To prepare the two layers of crosslinked cellulose fibers and nonwoven/fluff Mao Wei for hydroentanglement, an air-laid crosslinked cellulose fiber mat is removed from the blotter paper and placed on a resin bonded carded web, spunbond or wet-laid fluff Mao Wei mat such that the crosslinked cellulose fiber mat is immediately positioned on the nonwoven/fluff dimensional layer.

Hydroentanglement of the samples is performed with a laboratory scale hydroentanglement apparatus comprising a conveyor belt, a forming wire on top of the conveyor belt, a jet strip positioned above the conveyor belt to extrude the water jet, and a pump for controlling the pressure of the water jet exiting the jet strip. The forming wire is positioned above the conveyor belt such that it is not below the spray bar. The combined mat of crosslinked fibers and nonwoven/fluff web is placed on a forming wire so that it is not directly beneath the spray bar and the crosslinked layer directly faces the spray bar while the nonwoven/fluff web layer is in direct contact with the forming wire. The water pump is turned on to provide a low pressure water jet of less than 100 psi. A pass is defined as the movement of the material to be hydroentangled through the water jet in one direction from one end to the opposite end without stopping or changing the direction of the conveyor belt. The conveyor belt is manipulated to subject the crosslinked fibers and nonwoven/fluff web pads to four passes under low pressure conditions to pre-wet the fibers. The pressure of the water jet was then manipulated to reach the pressure listed in table 2 and the crosslinked fibers and nonwoven/fluff pad were subjected to one pass at that pressure. For example, sample 10, hydroentangled with a crosslinked fibrous mat on top of a resin bonded carded web, consisted of 4 pre-wet passes followed by one pass at 200 psi. Once the samples were hydroentangled, they were trapped between two Teflon pads and dried at 105 ℃ for 15-20 minutes.

Table 2 shows different combinations of hydroentangled crosslinked fibers and nonwoven materials at various pressures. As the hydroentangling pressure increases, the degree of penetration of the crosslinked cellulosic fibers into the nonwoven increases. In table 2, the nonwoven material is a resin bonded carded web: a web comprising synthetic fibers that have been resin bonded; a spunbond web formed from filaments from a fusion process; or fluff dimensions, which are synthetic fibers laid as mats and not bonded by any mechanism.

Table 2. Composition of the composite fabric and hydroentanglement pressure.

Example 2 diaper construction and Properties

Referring to table 3, various BCWs can be combined with crosslinked cellulose fibers to produce a range of densities of the resulting composite structure. All composite fabrics comprising BCW and crosslinked cellulose fibers show improved rewet and intake values despite the different densities.

Table 3. Composition of the composite fabric.

For this example, two diaper constructions, referred to as ADL and core wrap constructions, are formed. The basic diaper used for construction was a commercial diaper 1, i.e., a diaper having a nonwoven acquisition layer, crosslinked cellulosic fibers underlying the nonwoven, and a fluff core with channels. Commercial diaper 2 had a multi-layer core design and was used as a comparison of core wrap diaper constructions using the composite fabrics of the present disclosure.

For ADL constructions, the nonwoven and crosslinked cellulosic fibers are removed and the substitute material is cut to the size of the nonwoven layer.

For core wrap constructions, nonwoven and Heix were removed ^TM And (3) fibers. The core is removed and wrapped with a composite fabric material.

Example 2 shows that the nonwoven materials used in the composite structure can be breathable bonded or resin bonded. Example 2 also shows that the magnitude of the improvement in absorbent properties is unique to the use of crosslinked fibers as the cellulosic fiber layer. The nonwoven may have a flow rate range of 7700-18500IPRP and retain properties when used in a composite containing crosslinked fibers. Composites having a basis weight of 150gsm + -10% may have a basis weight of 0.052-0.099g/cm ³ And the diaper construction performance is unchanged.

Example 3 diaper construction and Properties

Referring to table 4, a series of TABCW and crosslinked cellulose fiber composite fabrics were produced.

Material Properties-basis weight, thickness measurement, density

Heix as a fiber component under substantially the same basis weight and hydroentanglement conditions ^TM The thickness measurement of the compound is increased by-14%. The use of Groz-B sparging strips increased the gauge of the composite by-14%.

Table 4. Material properties.

TABCW is a breathable bonded carded web that is used as the nonwoven portion of the composite.

This experiment resulted in two diaper constructions, called ADL and core wrap constructions. The basic diaper used in this construction was a commercial diaper 1, i.e., having a nonwoven acquisition layer and Helix under the nonwoven ^TM A fluff-free core diaper of fibrous distribution layers. Commercial diaper 2 had a multi-layer core design and was used as a comparison of core wrap diaper constructions using the composite fabrics of the present disclosure.

For ADL constructions, nonwoven and Helix were removed ^TM A fibrous distribution layer and cutting the substitute material to the size of the nonwoven layer.

For core wrap constructions, the nonwoven and Heilix are also removed ^TM A fiber distribution layer. The core is removed and wrapped with the composite material of the present disclosure.

Constructed diapers:

TABCW/Helix ^TM 110gsm core wrap

TABCW/Helix ^TM 110gsm ADL

TABCW/Helix ^TM +110gsm ADL

TABCW/Helix ^TM +110gsm core wrap, groz-B64 jet strip

NW/Helix ^TM +50gsm core wrap

The no-load saddle wick test and the flat acquisition under load test are as described in the test methods section.

FIG. 9 is a bar graph showing the present invention in an ADL diaper configuration in a no load saddle wicking testComparison of wicking distance from the insult point for the disclosed composite fabrics. Statistically, the distance that the deconstructed control diaper wicked toward the back is small. Heix (Helix) ^TM (not shown) and Heix ^TM Both + composite fabrics were greater in distance than the control wicking. Heix (Helix) ^TM The composite fabric can be compared with Helix ^TM />The + composite fabric wicks farther toward the front. The increased wicking distance indicates better utilization of the core.

Fig. 10 is a bar graph showing a comparison of the composite fabric of the present disclosure in an ADL diaper construction with respect to intake time for a flat acquisition test under load. The deconstructed and reconstituted control diapers had no significant effect on the intake time. Composites comprising crosslinked fibers had significantly shorter times for inhalations 2 and 3. When using Helix ^TM (not shown) and Heix ^TM + there was no significant difference in intake time when used as the fibrous component of the composite structure in the diaper construction.

Fig. 11 is a bar graph showing a comparison of rewet values of the composite fabrics of the present disclosure in an ADL diaper construction with respect to a flat acquisition test under load. Reduced rewet values are shown for intake 1, 2 and 3, with intake 3 having a rewet value significantly less than that in commercial diaper 1.

Fig. 12 is a bar graph showing a comparison of average wicking distances for diapers of the composite fabric of the present disclosure in an ADL diaper construction as compared to commercial diaper 1. The composite fabric in the ADL diaper construction wicked significantly farther than the control diaper. Heix as a crosslinked fiber component of the present disclosure ^TM (not shown) in inhalation 1 than Helix ^TM The + version wicks farther. However, the process is not limited to the above-described process,there was no statistical difference in wicking distance from doses 2 and 3 between the two crosslinked fiber constructions.

Fig. 13 is a bar graph showing a comparison of average intake times for diapers comprising the composite fabric of the present disclosure in a core wrap diaper construction in a no load saddle wicking test. All diapers including the composite fabric of the present disclosure had significantly improved intake times compared to the control commercial diaper 2. Including the one containing Helix ^TM (not shown) or Helix ^TM There was no significant difference between the intake times of diapers of the + composite. When hydroentangled with different spray bars, helix as a fibrous component in the composite ^TM />+ showed no significant difference.

Fig. 14 is a bar graph showing a comparison of the wicking distance from the point of insult for a composite fabric of the present disclosure in a core wrap diaper configuration in a no load saddle wicking test. All diaper constructions comprising the composite fabric of the present disclosure showed significantly improved wicking distance relative to the control. Heix as a fiber component in a composite ^TM (not shown) with respect to Helix as a fiber component ^TM + shows improved wicking distance.

Figure 15 is a bar graph showing a comparison of the composite fabric of the present disclosure in a core wrap diaper construction with respect to intake time from a flat acquisition test under load. All diaper constructions including the composite fabric of the present disclosure showed significant improvements in intake time relative to the control.

Figure 16 is a bar graph showing a comparison of rewet values for a composite fabric of the present disclosure in a core wrap diaper construction with respect to a flat acquisition test under load. All diaper constructions comprising the composite fabric of the present disclosure showed significant improvements over the control diaper.

Figure 17 is a bar graph showing a comparison of average wicking distances for the composite fabrics of the present disclosure used in core wrap diaper designs. The construction of the diaper comprising the core wrap is a more simplified design compared to the multi-layer core design of the commercial diaper 2. All diaper constructions employing the composite fabric of the present disclosure showed improved wicking distance toward the front for doses 1 and 2. When Helix ^TM When used as a crosslinked cellulosic fiber component in a composite fabric, the test fluid immediately wicks the entire distance of the diaper core. All diaper constructions containing crosslinked fiber composites showed significantly improved wicking distances compared to the control diapers.

Example 3 shows that when Helix is entangled with spray bars of different patterns ^TM At + there was no significant difference in performance of the diaper construction. In all diaper constructions, have a Heix ^TM Shows a complex with Heix ^TM />+improved wicking compared to the previous. Improved wicking occurs in all insults or in the first two insults.

Table 5 adl application-flat acquisition under load

TABLE 6 core wrap application-Flat acquisition under load

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EXAMPLE 4 laboratory carded staple fiber Compound

TABLE 7 suction time of laboratory carded staple fiber composites in flat acquisition under load test

Table 8. Rewet values for laboratory carded staple fiber composites under load in a flat acquisition test.

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TABLE 9 wicking distance of laboratory carded staple fiber composites in flat acquisition under load test

The three tables above show that when the nonwoven layer consists of unbonded staple fibers formed by the carding process, then subsequently with Heix ^TM When the + fibers are hydroentangled, the resulting composite still behaves comparable to a composite formed with a pre-bonded nonwoven web. In this example, both petroleum-based staple fibers and cellulose-derived staple fibers are used as the nonwoven layer. Composites made with carded staple fibers core wrap prototypes were made following the same procedure described in example 2. The carded web composites exhibit a similar intake time trend under load in a flat acquisition test when compared to composites made with pre-bonded nonwoven webs. In addition, the rewet value and wicking distance of the carded web composite are both within the values previously measured with the pre-bonded nonwoven composite. Staple fibers that can be used in the nonwoven portion of the composite The diversity allows flexibility in the source of raw materials used to make the composite.

EXAMPLE 5 comparison of fluff core-less diapers

This example demonstrates the benefits provided by the hydroentangled crosslinked fibers and nonwoven composite fabrics of the present disclosure for core wrapping applications (see, e.g., fig. 4). Further benefits may be observed if the basis weight of the crosslinked fibers is increased.

As ADL, the crosslinked fiber composite achieved an equivalent in saddle wicking results. The crosslinked fiber composites are notable for flat acquisition under load, improved intake time, rewet values, and early wicking distance. Various grades of materials can be manufactured by varying the basis weight.

Figure 18 is a bar graph showing the average intake time of a fluff-free diaper in a no-load saddle wick test for a diaper using a composite fabric in a core wrap configuration as compared to the average value of a commercial fluff-free core diaper. The composite fabric can significantly improve fluid intake time in core wrap applications for the no load saddle wicking test.

Figure 19 is a bar graph showing a comparison of wicking distance from the point of insult for a diaper using a composite fabric in a core wrap configuration as compared to the average value of a commercial fluff core-free diaper. The composite fabric is capable of increasing the wicking distance compared to the average wicking distance of a commercial fluff core free diaper.

Figure 20 is a bar graph showing a comparison of the intake time of a napeless diaper under load in a flat-acquisition test compared to the average value of a commercial napeless core diaper using a composite fabric in a core wrap configuration. The composite fabric can significantly improve the intake time for all three fluid insults in core wrap applications.

Figure 21 is a bar graph showing a comparison of the rewet values of a napless diaper in a flat-acquisition test under load as compared to the average value of a commercial napless core diaper using a composite fabric in a core wrap configuration. The composite fabric is capable of significantly improving the second and third rewet values in core wrap applications.

Figure 22 is a bar graph showing a comparison of average wicking distances of a napped diaper under load in a flat acquisition test as compared to the average of a commercial napped core diaper using a composite fabric in a core wrap configuration. The composite fabric is capable of increasing the wicking distance of all three fluid insults in a flat acquisition under load test in a core wrap application.

Figure 23 is a bar graph showing a comparison of a diaper using a composite fabric in an ADL construction with a commercial fluff core diaper in comparison to the average value of the fluff core diaper at the point of insult to the diaper construction in a no load saddle wicking test. In the no-load saddle wicking test, the composite fabric was able to increase the wicking distance relative to the average wicking distance of a commercial fluff core diaper.

Figure 24 is a bar graph showing a comparison of the wicking distance of a diaper using a composite fabric in an ADL construction to the average value of a commercial fluff core diaper. For all three fluid insults, the composite fabric was able to significantly increase the wicking distance relative to the average wicking distance of a commercial fluff core diaper in a flat-acquisition under load test.

Example 6 diaper and adult incontinence product (Wet-laid composite) -construction and Properties

The following describes a preliminary approximation of the commercially available hybrid carding pulp technology. Production of Heix in nonwoven Compound on Wet-laid pilot production line ^TM Starting from the preparation of the fiber raw material. Will dry Heix ^TM +fibers are added to the water tank and diluted to a concentration of 2% or less. The tank was continuously stirred with a stirrer that did not compromise the fiber quality. Slurry is pumped from the storage tank to the headbox of the wet-laid system. In this process, the slurry is further diluted with water to improve the formation of the fibers as they are deposited onto the forming wire. The diluted stock then enters a headbox and is distributed onto a forming wire to form Heix ^TM />A web of + fibers. The water is then removed from the fibers by gravity or vacuum slot under the forming wireThe net is discharged. When the web is sufficiently dry, it is transferred from the forming wire to the pre-bonded nonwoven web. And Heix ^TM />The nonwoven web has an equal or greater width than the + web. The two-layer nonwoven and web were pre-hydroentangled with low pressure water jets to help hold the two layers together. The water jet first contacts the fiber side of the web to push the fibers into the nonwoven. After pre-hydroentanglement, the water is removed by vacuum slot. The web was then passed through a heated tank dryer system in which minimal heat was applied to assist in dewatering the web to about 50% solids. The partially dried web is then wound into a roll and wrapped in plastic to prevent further moisture loss. The plastic wrapped rolls are then stored for further hydroentanglement.

The roll is loaded onto an unwind stand and unwound such that the nonwoven side of the web contacts the carrier web and the fiber side of the web faces the hydroentangling jets. Carrying the web to cause unbonded Heix in the nonwoven material ^TM By at least two hydroentangling jets to further couple Helix ^TM The + fibers push into the nonwoven, bonding the two layers together. The composite structure was dewatered by vacuum slot and passed through a through-air drying system to dry the composite completely to a solids content of greater than 90%. The dry composite is wound into a roll for further use.

Although a two-step process for making a composite fabric is described in this example, one skilled in the art will appreciate that a one-step process may be readily performed.

Referring to Table 10, the composite material used in this example was composed of 100% Helix ^TM The fibrous layer of + composition is formed and the nonwoven layer is a breathable bonded carded web. Test sample codes 1-4Performance as ADL; samples 5 and 6 were tested for performance as core wraps.

Table 10. Test composite composition.

Commercial infant diapers and commercial adult incontinence products were chosen as commercial comparisons of prototypes. ADL from each product was removed and replaced with a composite fabric of exactly the same dimensions: codes 1-4 were tested in each commercial product.

The intake time in a flat acquisition test under load was obtained for a commercial comparative diaper. Commercial comparative diapers 1 and 4 had the fastest intake times. In the ADL diaper construction, the ADL of commercial comparative diaper 1, 2, 3 or 4 was replaced with a composite fabric sample code 1, 2, 3 or 4, which composite fabric sample code 1 exhibited significantly reduced intake time compared to comparative diaper 2 or 3, respectively, in a flat-acquisition test under load. For all ADL diaper constructions using the code 1, 2, 3 and 4 composite fabric samples, a reduction in intake time was observed compared to comparative diaper 1. For ADL diaper constructions using code 1, 3 and 4 composite fabric samples, and for intake 1 and 3 with the ADL diaper construction using code 2 composite fabric sample, a reduction in intake time was observed compared to comparative diaper 4.

For the intake time of the examples of core wrap diaper constructions in which either the code 5 or 6 composite fabric samples wrapped around the absorbent core of the commercial comparative diaper 1, both code 5 and 6 composite fabric samples provided a significant reduction in intake time compared to the commercial comparative diapers 1 and 5 in a flat acquisition test under load.

In the flat acquisition under load test, commercial comparison diapers 1 and 4 of the commercial comparison diapers had the lowest rewet values at rewet 3. In the commercial comparative diapers 1-4, the code 1 composite fabric provided an improvement in rewet value, and this was particularly evident in rewet 3. In the flat acquisition under load test, an improvement in rewet values at rewet 2 and 3 was also observed compared to commercial comparative diaper 5, particularly in a core wrap diaper configuration in which the code 5 or 6 composite fabric sample wrapped around the absorbent core of commercial comparative diaper 1.

For the average total wicking distance in the examples of ADL diaper constructions, the wicking distance was improved compared to that of commercial comparative diaper 1 in a flat-acquisition under load test using code 1, 2, 3, or 4 composite fabric samples instead of the ADL of commercial comparative diaper 1.

For the average total wicking distance in the examples of core wrap diaper constructions, the absorbent cores of commercial comparative diapers 1 were wrapped with code 5 or 6 composite fabric samples, with improved wicking distances compared to the wicking distances of commercial comparative diapers 1 and 5 in a flat acquisition under load test.

In the no-load saddle wick test, the intake time of the ADL construction using codes 1, 2, 3, and 4 was improved as compared to the intake time of comparative diaper 4.

In the no-load saddle wicking test, the core wrap diaper construction made with the code 5 and code 6 composite fabric samples showed improvements in intake times 2 and 3 compared to the commercial comparative diaper 5.

In the ADL diaper construction, the wicking distance of the composite fabric samples using codes 1, 2, 3, or 4 was improved (i.e., increased) as compared to the wicking distance of commercial comparative diaper 3 and commercial comparative diaper 1.

In the core wrap diaper construction, the wicking distance of wrapping the absorbent core with the code 5 or 6 composite fabric sample was improved (i.e., increased) as compared to the wicking distance of commercial comparison diapers 1 and 5.

To compare the average intake time of ADL adult-incontinence product constructions in the no-load saddle-type wicking test, the ADL adult-incontinence product constructions made with code 1, 2, 3, and 4 composite fabric samples showed improvements (i.e., lower intake times) in intake times 2 and 3 as compared to commercial comparative adult-incontinence products using code 1, 2, 3, or 4 composite fabric samples instead of the ADL of commercial comparative adult-incontinence products.

To compare the wicking distance from the point of insult (front and back) to the total wicking distance for ADL adult-incontinence product constructions in the no-load saddle-type wicking test, code 1, 2, 3, or 4 composite fabric samples were used in place of the ADL for commercial comparative adult-incontinence products, and ADL adult-incontinence product constructions made with code 1, 2, 3, and 4 composite fabric samples exhibited improvements in wicking distance (i.e., greater wicking distance) when compared to commercial comparative adult-incontinence products.

In this example, code 1 shows improvement in intake time and wicking distance for a flat acquisition test under load for most commercial infant diaper comparative examples. For a commercial comparative diaper 1, the composite fabric may help an absorbent core with a very high SAP content to utilize more absorbent core than conventional ADLs. ADL diaper constructions comprising code 1, 2, 3 or 4 composite fabrics showed a significant increase in wicking distance in both flat acquisition under load and no load saddle wicking tests.

Example 7: chelation of TMA with HELIX in nonwoven

Heix in nonwoven sheets ^TM Cut into 1g pieces and compared to the fibrillated fluff to form a mat, placed in a sealed container, and stained with trimethylamine solution. The fibrillated fluff is treated with chemicals to sequester trimethylamine.

The comparative fluff pulp sheets were cut into strips and then fibrillated in a Kamas mill. The fluff pulp was then formed into 2 inch diameter mats having an average weight of 0.94.+ -. 0.02 g. These mats were compressed in a Carver press to a pressure of 2000 psi.

The test vessel consisted of a Kirkland 500mL water bottle selected for its compressibility. The 16 gauge needle was driven through the plastic cap of the water bottle, glued in place, and sealed with a silicone caulking. A rubber tube is placed around the shank of the needle to allow an airtight seal between the shank and the measuring device.

The compressed fluff discs were placed into a test vessel, stained with 15g of solution, sealed, and then after 2 hours the headspace above was tested for TMA. Referring to Table 11, TMA solutions at a concentration of 0.053 wt.% were tested. According to literature values, normal vaginal fluid not associated with bacterial vaginosis has a trimethylamine level of 0.0005 wt.%.

Tma solution.

Two hours after the insult, the concentration of trimethylamine in the headspace of the container was tested over both slurries. Using model 105SEA tube. These tubes are labeled for use with ammonia, but can also be used with trimethylamine. By combiningThe reading is multiplied by a conversion factor of 0.5 to give the actual trimethylamine concentration. / >

Three samples of each material were tested. For Heix and fluff pulp in the nonwoven composite, the concentration of trimethylamine in the headspace above the mat was compared. Referring to Table 12, it was found that Helix in the nonwoven composite was more able to reduce the headspace concentration of TMA than fluff pulp.

Table 12 tma headspace test.

Example 8 feminine hygiene product evaluation

Basis weight 150g/m ² NW/Helix of (a) ^TM + composite fabrics were evaluated in a flat sheet construction and used as absorbent cores for use in sanitary pads. The nonwoven side faces the incoming liquid. Referring to fig. 25, the composite fabric had the most uniform fluid distribution compared to 7 commercial comparative sanitary pads. Complexes or Heix ^TM />The basis weight of the + portion appears to have no effect on the distribution.

Table 13. Feminine hygiene product dimensions.

Fig. 26A is a schematic diagram illustrating an exemplary feminine hygiene product 2600A including an absorbent composite 2610A according to an embodiment of the present disclosure. The absorbent composite 2610A may be or include a composite fabric formed by physically entangling a crosslinked cellulosic fiber layer and a nonwoven polymer layer, as described in greater detail with reference to fig. 1, as an example of the composite fabric 110 of fig. 1. The exemplary feminine hygiene product 2600A further includes a liquid impermeable backsheet 2605 and a topsheet 2615, as described in more detail with reference to fig. 4. In comparison to the conventional feminine hygiene product described with reference to the comparative examples of fig. 27A and 27B, the exemplary feminine hygiene product 2600A may omit a dedicated acquisition-distribution layer (ADL), at least in part because the composite fabric 2610A may perform the same or similar functions and have improved results, as described below.

The example feminine hygiene product 2600A defines an inner surface 2620 and an outer surface 2625 relative to the wearing orientation and the intended liquid insult incidence direction. To this end, the topsheet 2615 may be or include a nonwoven material or another liquid permeable material, such as a Spunbond (SB) material or a breathable bonded carded web (TABCW), or a perforated film. In some embodiments, the topsheet 2615 may receive an embossed pattern or perforation pattern to facilitate or otherwise improve capillary action and/or wicking/distribution of liquid from the inner surface toward the absorbent composite 2610A. Thus, embossments and/or perforations can propagate into and/or through the absorbent composite 2610A.

As shown in fig. 26A, the composite fabric 2610A may employ a core wrap configuration described in more detail with reference to fig. 28A. In contrast, fig. 26B illustrates a multi-layered construction in accordance with an embodiment of the present disclosure, wherein the absorbent composite 2610B comprises one or more stacked layers of the physically entangled composite fabric described with reference to fig. 1. To this end, the stacked layers may be disposed relative to the inner surface 2620, wherein the crosslinked cellulosic material physically contacts the backsheet 2605.

Referring to fig. 29-32, which present data generated from comparative testing of exemplary feminine hygiene products 2600A and/or 2600B according to embodiments of the present disclosure, fig. 27A-27B are schematic diagrams illustrating cross-sections of comparative examples 1 and 2, respectively. Comparative example 1 and comparative example 2 represent existing commercial feminine hygiene products that are considered to be market leaders in north american and asian markets, respectively.

Fig. 27A illustrates an exemplary commercial feminine hygiene product 2700 available in the north american market. The exemplary commercial feminine hygiene product 2700 includes a backsheet 2705, a cellulosic layer 2710 including superabsorbent polymer 2715 dispersed in cellulosic layer 2710, an acquisition distribution layer 2720 formed of a hydroentangled material, and a liquid permeable topsheet 2725 formed of a perforated film material. Fig. 27B illustrates an exemplary commercial feminine hygiene product 2750 available in the east asia market. An exemplary commercial feminine hygiene product 2750 includes a backsheet 2705, a cellulosic layer 2710 including superabsorbent polymer 2715 dispersed in cellulosic layer 2710, an acquisition distribution layer 2730 formed of a breathable bonded carded web (TABCW) material, and a liquid permeable topsheet 2725 formed of a TABCW material. In addition, the exemplary commercial feminine hygiene product 2750 includes two hydroentangled layers between the cellulosic layer 2710 and the ADL2730 and between the cellulosic layer 2710 and the backsheet 2705. In contrast to the exemplary embodiments of the present disclosure, the average physical characteristics of the exemplary commercial feminine hygiene products 2700 and 2750 are described in table 14. The data in table 14 is tabulated from six examples of each product construction.

Table 14: average material data of comparative examples and exemplary examples

Advantageously, the inclusion of smaller mass petrochemical materials improves the overall sustainability of feminine hygiene products by reducing the use of petroleum, which represents a reduction in non-renewable resource usage on the order of thousands or millions of tons each year worldwide. In addition, replacing petrochemical materials with cellulosic materials represents replacing non-sustainable materials with renewable resources. In some embodiments, the example feminine hygiene products 2600A and 2600B include from about 0.5g to about 5g of cellulosic material, from about 1.0g to about 5g of cellulosic material, from about 1.5g to about 5g of cellulosic material, from about 2.0g to about 5g of cellulosic material, from about 2.5g to about 5g of cellulosic material, from about 3.0g to about 5g of cellulosic material, from about 3.5g to about 5g of cellulosic material, from about 4.0g to about 5g of cellulosic material, or from about 4.5g to about 5g of cellulosic material, including fractions and interpolations thereof. It should be appreciated that while additional absorbent materials will increase the overall volume capacity of the example feminine hygiene product 2600A or 2600B, typically the wearer's experience is compromised as the product weight increases. Thus, lower mass may be desired in balance with reduced liquid receiving and retaining performance due to reduced amounts of absorbent material.

In some embodiments, the example feminine hygiene products 2600A and 2600B include about 3.0g to about 0.1g of petrochemical material, about 2.5g to about 0.1g of petrochemical material, about 2.0g to about 0.1g of petrochemical material, about 1.5g to about 0.1g of petrochemical material, about 1.0g to about 0.1g of petrochemical material, and about 0.5g to about 0.1g of petrochemical material, including fractions and interpolations thereof. As previously mentioned, from a sustainability standpoint, it may be sought to exclude petrochemical materials from the exemplary feminine hygiene product 2600A or 2600B to the greatest extent possible. However, beyond the threshold, the structural and functional performance of the product is compromised at the expense of the wearer's experience. For at least this reason, too low or zero petrochemical quality can impair performance and result in greater size and weight, making feminine hygiene products bulky. Advantageously, examples 1 and 2 exhibited reduced mass of petrochemical material relative to comparative example 1 without introducing the same additional amount of cellulosic material as in comparative example 2. In this manner, it can be seen that the improved performance of the example feminine hygiene products 2600A and 2600B represent an improved method of converting from petrochemical materials to cellulosic materials, as performance improves significantly with a smaller increase in product quality.

Advantageously, as described in greater detail with reference to fig. 26A-26B and fig. 28A-28B, omitting dedicated ADL material from the example feminine hygiene products 2600A and 2600B may allow a larger portion of the absorbent structure to include cellulosic material without increasing the feature size, referred to as "caliper", at the expense of the wearer experience. Thinner gauge (where gauge describes the thickness of a component of the product) improves the wearer experience (e.g., during exercise, while stretched, while sitting, or while standing) by reducing the perception of wearing the product. However, reducing the caliper too much increases rewet and increases intake time by restricting lateral fluid movement between the backsheet 2605 and the topsheet 2615. In some embodiments, the example feminine hygiene products 2600A and 2600B have absorbent structure caliper, including fractions and interpolations thereof, of about 3.0mm to about 0.1mm, about 2.5mm to about 0.1mm, about 2.0mm to about 0.1mm, about 1.5mm to about 0.1mm, about 1.0mm to about 0.1mm, and about 0.5mm to about 0.1 mm. Thus, with respect to the materials and dimensional data described in Table 14, experiments conducted with the exemplary feminine hygiene product configurations resulted in the performance data described with reference to FIGS. 29-32. As shown in table 14, as described in more detail with reference to fig. 26A-26B and 28A-28B, the exemplary embodiments of the present disclosure exhibited comparable sizes and weights relative to comparative examples 1 and 2. Thus, the data in Table 16 below, and the graphs presented in FIGS. 29-32, present a direct comparison between comparable products. In this way, the reported improvements to the standard assay measurements represent a significant and unexpected improvement in the common properties of intake time, rewet, wicking distance, etc., in terms of average performance and consistency between products.

To this end, fig. 28A is a schematic view of a cross-section of an exemplary feminine hygiene product 2600A, showing a layer of material of the absorbent composite 2610A. As shown, instead of a conventional dedicated ADL layer in commercial products, the exemplary feminine hygiene product 2600A includes a core-wrap construction of a composite formed of a nonwoven layer 2810 and a crosslinked cellulose layer 2805 wrapped around an absorbent core 2815. In some embodiments, the composite is formed by physically entangling the nonwoven layer 2810 and the crosslinked cellulose layer 2805, which forms the interface region 2820 such that the nonwoven layer 2811 and the crosslinked cellulose layer 2805 are mechanically inseparable in the dry state. In some embodiments, the composite is at least partially wrapped around the absorbent core 2815. In some embodiments, the composite is at least partially folded to form a hollow core (e.g., the absorbent core 2815 is omitted) or folded such that the crosslinked cellulose layer 2805 contacts itself. The absorbent core 2815 can be or include cellulosic fluff pulp material, superabsorbent polymer, synthetic absorbent material or combinations thereof as described in more detail with reference to fig. 8A-8C. The composite material may be wrapped completely around the absorbent core 2815 or may be wrapped partially around the absorbent core 2815, thereby defining a gap that may be covered, as described in more detail with reference to fig. 5B-7B. Fig. 28A is not drawn to scale such that the relative thicknesses of layers 2805 and 2810 and interface region 2820 are shown for visual interpretation, rather than exhibiting precise or relative dimensions.

As described in greater detail with reference to fig. 26B, fig. 28B is a schematic diagram illustrating a cross-section of an exemplary feminine hygiene product 2600B comprising an absorbent composite 2610B formed from a plurality of stacked layers of a composite formed by physically entangling a crosslinked cellulosic layer 2805 with a nonwoven layer 2810, with an interface region 2820 formed therebetween. The exemplary feminine hygiene product 2600B is shown as comprising two layers of composite material. In some embodiments, the example feminine hygiene product 2600B includes one, two, three, four, five, six, or more layers of the composite. As described with reference to fig. 29-32, the absorbent capacity increases with increasing number of layers, making a greater number of layers beneficial until the caliper of the absorbent structure and the perceived size and weight of the exemplary feminine hygiene product 2600B affect the comfort of the wearer. For this reason, the number of layers is selected to provide improved performance in the series of standardized measurements described above, without increasing the gauge or mass to such an extent that would impair the wearer's experience.

In some embodiments, the exemplary feminine hygiene product 2600B comprises two layers of composite material, including two nonwoven layers 2810, two cellulosic layers 2805, and two interface regions 2820, and is superior to comparative example 1 and comparative example 2 in terms of intake time, rewet, and wicking distance measurement, as described in more detail with reference to fig. 29-32. As the composite layers increase, the perceived weight and size increases the likelihood of discomfort. As the number of layers decreases, the likelihood of performance impairment during liquid insults increases. As shown, the nonwoven layer 2810 is oriented toward the inner surface 2620 (e.g., toward the topsheet 2615) and the cellulosic layer 2805 faces the backsheet 2605. In this manner, the nonwoven layer 2810 can serve to distribute liquid to the cellulosic layer 2805 through the interface region 2820, absorbing liquid wicking away from the topsheet 2615, with improved performance compared to the comparative example. For layers closer to the backsheet 2605, liquid is received from layers closer to the topsheet 2615. In this way, while liquid insult may occur in a relatively concentrated region of the innermost layer of the composite fabric (relative to the inner surface 2620), the liquid transfer region may increase toward the backsheet 2605 with increasing number of layers, as the absorbency in each respective layer includes both a wicking component in the transverse direction and in the longitudinal direction. In some embodiments, the above orientation may be reversed such that the cellulosic layer 2805 may be oriented toward the inner surface 2620 and the nonwoven layer 2810 may be oriented toward the outer surface 2625.

In some embodiments, one or more layers of the composite material are oriented in an alternate or different configuration than that shown in fig. 28B. For example, the layers may be oriented such that at least one cellulosic layer 2805 contacts another cellulosic layer 2805, forming a two-layer composite with the nonwoven layer 2810 facing both the topsheet 2615 and the backsheet 2605. In some embodiments, when two or more layers of composite material are included, a combination of the two orientations described above may be included. For example, for three layers of a composite, a first layer and a second layer may be stacked, with the cellulosic layer 2805 of the first layer contacting the nonwoven layer 2810 of the second layer and the third layer oriented such that the cellulosic layers 2805 of the second and third layers contact each other.

Table 15 depicts comparative data for performance of exemplary feminine hygiene products 2600A and 2600B without topsheet 2615 in a series of determinations described above with reference to absorbent article testing procedures. Table 15 is provided to demonstrate that both structures exhibit comparable performance in a series of tests. The data in table 15 does not represent the performance of the composite fabric in a complete feminine hygiene product and thus the data is not directly comparable to those of fig. 29-32. Rather, the data in Table 15 demonstrates that including a composite fabric in one or more configurations can provide comparable performance of a feminine hygiene product in a range of assays representative of typical sanitary uses.

Table 15: performance data for exemplary absorbent composites 2610A-B

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Table 16: performance data of exemplary examples and comparative examples

Fig. 29 is a graph of inhalation time data showing improvement in the common properties among negative control products without cellulosic material, comparative example 1, comparative example 2, and examples 1 and 2, according to an embodiment of the present disclosure. The data of the graph in fig. 29 (reproduced in the first three columns of table 16) includes statistical measures from six repeated determinations of each product, such that bar height represents average intake time and error bars represent one standard deviation. As described above with reference to absorbent article testing procedures, the intake time measurement includes three consecutive intake time tests to simulate repeated liquid insults to the same feminine hygiene product. In this way, the performance of the product under typical and long-term wear conditions can be evaluated. In fig. 29, the control product represents a commercially available light weight feminine hygiene product that is constructed using synthetic materials, such as absorbent synthetic polymers, nonwoven acquisition distribution layers, and the like, excluding cellulosic materials. The data for the control product is provided as an indirect comparison of the improvement in the intake time performance of the embodiments of the present disclosure. Comparative examples 1 and 2, as described in table 14, included cellulosic material as part of the absorbent structure, but did not include a composite fabric as described in more detail with reference to fig. 1. Thus, comparative example products 1 and 2 represent a direct comparison of the common properties to demonstrate the improved performance of the examples of the present disclosure.

The shorter intake time reflects a quicker distribution of liquid insult from the inner surface of the product (e.g., topsheet 2615) to the absorbent material that receives and retains liquid, thereby allowing the wearer to remain drier and more comfortable. The negative control product exhibited comparable performance to comparative example 2, in which the intake time increased with each progressive insult, with a third intake reaching a peak intake time of about 500 seconds. In contrast, both comparative example 1 and examples 1 and 2 exhibited significantly reduced inhalation times relative to the negative control. Example 2 showed a significant improvement in the inhalation time per inhalation, including about 20-fold improvement in the second and third inhalations, relative to comparative example 2. In addition, example 2 is superior to comparative example 1, although additional internal structure is incorporated and has a different topsheet 2615 material.

In this manner, the intake time of the first intake of the exemplary feminine hygiene product 2600A or 2600B can be less than or about 30 seconds, less than or about 29 seconds, less than or about 28 seconds, less than or about 27 seconds, less than or about 26 seconds, less than or about 25 seconds, less than or about 24 seconds, less than or about 23 seconds, less than or about 22 seconds, less than or about 21 seconds, less than or about 20 seconds, less than or about 19 seconds, less than or about 18 seconds, less than or about 17 seconds, less than or about 16 seconds, less than or about 15 seconds, less than or about 14 seconds, less than or about 13 seconds, less than or about 12 seconds, less than or about 11 seconds, less than or about 10 seconds, less than or about 9 seconds, less than or about 8 seconds, less than or about 7 seconds, less than or about 6 seconds, less than or about 5 seconds, less than or about 4 seconds, less than or about 3 seconds, less than or about 2 seconds, and less than or about 1 second, including fractions and interpolations thereof. The intake time of the second intake of the exemplary feminine hygiene product 2600A or 2600B can be less than or about 250 seconds, less than or about 240 seconds, less than or about 230 seconds, less than or about 220 seconds, less than or about 210 seconds, less than or about 200 seconds, less than or about 190 seconds, less than or about 180 seconds, less than or about 170 seconds, less than or about 160 seconds, less than or about 150 seconds, less than or about 140 seconds, less than or about 130 seconds. Less than or about 120 seconds, less than or about 110 seconds, less than or about 100 seconds, less than or about 90 seconds, less than or about 80 seconds, less than or about 70 seconds, less than or about 60 seconds, less than or about 50 seconds, less than or about 40 seconds, less than or about 30 seconds, less than or about 20 seconds, less than or about 10 seconds, less than or about 9 seconds, less than or about 8 seconds, less than or about 7 seconds, less than or about 6 seconds, less than or about 5 seconds, less than or about 4 seconds, less than or about 3 seconds, less than or about 2 seconds, and less than or about 1 second, including fractions and interpolations thereof. The intake time for the third intake of the exemplary feminine hygiene product 2600A or 2600B can be less than or about 550 seconds, less than or about 525 seconds, less than or about 500 seconds, less than or about 475 seconds, less than or about 450 seconds, less than or about 425 seconds, less than or about 400 seconds, less than or about 375 seconds, less than or about 350 seconds, less than or about 325 seconds, less than or about 300 seconds, less than or about 275 seconds, less than or about 250 seconds, less than or about 225 seconds, less than or about 200 seconds, less than or about 175 seconds, less than or about 150 seconds, less than or about 125 seconds, less than or about 100 seconds, less than or about 75 seconds, less than or about 50 seconds, and less than or about 25 seconds, less than or about 10 seconds, less than or about 9 seconds, less than or about 8 seconds, less than or about 7 seconds, less than or about 6 seconds, less than or about 5 seconds, less than or about 4 seconds, less than or about 3 seconds, less than or about 2 seconds, and less than or about 1 second, including fractions and interpolations thereof.

Fig. 30 is a graph of performance measurement data for intake times of comparative example 1 and example 1, highlighting improved intake time performance of exemplary feminine hygiene products 2600A and 2600B relative to comparative products from the north american market, according to an embodiment of the present disclosure. As shown, example 1 is superior to comparative example 1 in all three inhalation tests. Advantageously, example 1 exhibited a reduced inhalation time at all three inhalations, which is lower than the average inhalation time of the first inhalation of comparative example 1. The data of fig. 30 shows that the inclusion of the composite fabric 110 described with reference to fig. 1 significantly improves intake time performance, which directly reflects an improved wearer experience, while also omitting the dedicated ADL layer included in comparative example 1.

Fig. 31 is a graph of data from rewet quality determinations of five products from the same group, in accordance with an embodiment of the present disclosure. As previously described, rewet quality measures the amount of liquid exuded from an absorbent article after application of a calibrated pressure. For this reason, lower rewet quality values reflect improved retention of liquid under body representative pressures, such as the average weight applied to a feminine hygiene product while sitting. In this manner, for example, the rewet mass of the feminine hygiene product 2600A or 2600B can be less than or about 1.5 grams, less than or about 1.4 grams, less than or about 1.3 grams, less than or about 1.2 grams, less than or about 1.1 grams, less than or about 1.0 grams, less than or about 0.9 grams, less than or about 0.8 grams, less than or about 0.7 grams, less than or about 0.6 grams, less than or about 0.5 grams, less than or about 0.4 grams, less than or about 0.3 grams, less than or about 0.2 grams, or less than or about 0.1 grams, including fractions and interpolations thereof. For improved rewet quality, examples 1 and 2, which are superior to both negative control and comparative examples 1 and 2, reflect an improved wearer experience while also omitting the dedicated ADL layer, which adds material between the absorbent component and the topsheet 2615 that can be used to retain a portion of the exuded liquid.

Fig. 32 is a graph of data from wicking distance determinations for five products from the same group, in accordance with an embodiment of the present disclosure. As previously described, the wicking distance measures the performance of a feminine hygiene product to accept and dispense liquid insults during a prescribed period of time. In this way, longer wicking distances reflect improved performance. Since examples 1 and 2 of the example feminine hygiene product 2600A or 2600B omit dedicated ADLs, one of ordinary skill would reasonably expect that examples 1 and 2 exhibit impaired performance relative to negative controls and comparative examples 1 and 2, both of which include dedicated ADLs. In contrast, fig. 32 shows that example 1 is superior to comparative example 1 in both the longitudinal and transverse directions, reflecting improved wicking properties in both characteristic directions. Similarly, example 2 is superior to comparative example 2 in both the longitudinal and transverse directions, reflecting improved wicking in both characteristic directions. The improved performance of the wicking distance measurement reflects an improved wearer experience due, at least in part, to improved distribution of localized liquid insults through the feminine hygiene product to increase retention capacity over a period of time that is characteristic of the period of time that the feminine hygiene product is worn. In some embodiments, for example, the feminine hygiene product 2600A or 2600B has a longitudinal wicking distance of greater than or about 0.5cm, greater than or about 1.0cm, greater than or about 1.5cm, greater than or about 2.0cm, greater than or about 2.5cm, greater than or about 3.0cm, greater than or about 3.5cm, greater than or about 4.0cm, greater than or about 4.5cm, greater than or about 5.0cm, greater than or about 5.5cm, greater than or about 6.0cm, greater than or about 6.5cm, greater than or about 7.0cm, greater than or about 7.5cm, greater than or about 8.0cm, greater than or about 8.5cm, greater than or about 9.0cm, greater than or about 9.5cm, greater than or about 10.0cm, greater than or about 10.5cm, greater than or about 11.0cm, greater than or about 11.5cm, greater than or about 12.5cm, greater than or about 13.5cm, and a score of the absorbent article. In some embodiments, for example, the feminine hygiene product 2600A or 2600B has a lateral wicking distance of greater than or about 0.5cm, greater than or about 1.0cm, greater than or about 1.5cm, greater than or about 2.0cm, greater than or about 2.5cm, greater than or about 3.0cm, greater than or about 3.5cm, greater than or about 4.0cm, greater than or about 4.5cm, greater than or about 5.0cm, greater than or about 5.5cm, greater than or about 6.0cm, greater than or about 6.5cm, greater than or about 7.0cm, greater than or about 7.5cm, greater than or about 8.0cm, greater than or about 8.5cm, greater than or about 9.0cm, greater than or about 9.5cm, greater than or about 10.0cm, including fractions and interpolations thereof. Advantageously, as shown in table 16 and fig. 29-32, the data for, for example, feminine hygiene products 2600A and 2600B, exhibit improved performance in terms of average and improved consistency reflected by variability in measured values. For example, the standard deviation values determined for each standard assay were lower for the example 1 and example 2 configurations relative to the corresponding comparative examples and negative controls. In this way, embodiments of the present disclosure exhibit an average improved performance and a more consistent performance, reflecting a significant improvement in the wearer experience over conventional absorbent products currently available on the market.

By way of example and not limitation, embodiments are disclosed in accordance with the paragraphs enumerated below:

A1. a composite fabric, comprising:

a nonwoven layer comprising polymeric fibers and/or filaments;

a crosslinked cellulosic layer comprising crosslinked cellulosic fibers; wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer; and

an interface region between the nonwoven layer and the crosslinked cellulosic layer, the interface region comprising physically entangled polymer fibers and/or filaments from the nonwoven layer and crosslinked cellulosic fibers from the crosslinked cellulosic layer,

wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in the dry state; and is also provided with

Wherein the composite fabric has a weight of 0.06g/cm ³ To 0.15g/cm ³ (e.g., 0.06 g/cm) ³ 、0.12g/cm ³ 、0.08g/cm ³ Or 0.06-0.08g/cm ³ ) Is a density of (3).

A2. The composite fabric of paragraph A1, wherein the nonwoven layer and the crosslinked cellulosic layer overlap each other and interpenetrate at the interface region.

A3. The composite fabric of paragraph A1 or paragraph A2, wherein the crosslinked cellulosic layer and the nonwoven layer are fully interpenetrating.

A4. The composite fabric of any one of the preceding paragraphs, wherein the nonwoven layer has a first thickness, the crosslinked cellulosic layer has a second thickness, and the interface region has a thickness less than or equal to the first thickness or the second thickness.

A5. The composite fiber of paragraph A1, wherein the polymer fibers and/or filaments comprise synthetic polymer fibers and/or filaments.

A6. The composite fabric of any of the preceding paragraphs, wherein the nonwoven layer comprises a bonded carded web fabric, a carded web, a spunbond fabric, a meltblown fabric, unbonded synthetic fibers, or any combination thereof.

A7. The composite fabric of any of the preceding paragraphs, wherein the crosslinked cellulosic fibers comprise polyacrylic crosslinked fibers.

A8. The composite fabric of any of the preceding paragraphs, wherein the crosslinked cellulosic layer is air-laid or dry-laid onto the nonwoven layer.

A9. The composite fabric of any of paragraphs A1-A7, wherein the crosslinked cellulosic layer is wet-laid onto the nonwoven layer.

A10. The composite fabric of any of paragraphs A1-A9, wherein crosslinked cellulosic fibers from the crosslinked cellulosic layer are hydroentangled into polymeric fibers and/or filaments from the nonwoven layer in the interfacial region.

A11. The composite fabric of any one of the preceding paragraphs, wherein the nonwoven layer has 15g/m in the composite fabric ² To 50g/m ² Is used as a dry basis of the (c) polymer.

A12. The composite fabric of any one of the preceding paragraphs, wherein the crosslinked cellulosic layer comprises 20g/m in the composite fabric ² To 185g/m ² Is used as a dry basis of the (c) polymer.

A13. The composite fabric of any one of the preceding paragraphs, wherein the composite fabric is embossed, folded, pleated, and/or perforated, and wherein the folded or pleated composite fabric optionally includes absorbent material in the folds or pleats.

A14. The composite fabric of any of the preceding paragraphs, wherein the composite fabric does not include latex, latex binder fibers, water saturated layers, pretreated nonwoven layers, lyocell fibers, rayon, or any combination thereof.

A15. The composite fabric of any one of the preceding paragraphs, consisting of the nonwoven layer and the crosslinked cellulosic layer and an interfacial region between the nonwoven layer and the crosslinked cellulosic layer.

A16. The composite fabric of any one of the preceding paragraphs, wherein the composite fabric neutralizes odors when subjected to biological fluids.

A17. An absorbent article comprising the composite fabric of any one of the preceding paragraphs.

A18. The absorbent article of paragraph a17, wherein the article comprises a personal care absorbent product.

A19. The absorbent article of paragraph a18, wherein the personal care absorbent product is selected from the group consisting of diapers, incontinence products, feminine hygiene products, wipes, towels, and tissues.

A20. The absorbent article of any of paragraphs a17 to a19, wherein the absorbent article comprises a fluid acquisition and distribution layer comprising the composite fabric.

A21. The absorbent article of any of paragraphs a17 to a20, wherein the composite web is disposed on an absorbent material, wherein the crosslinked cellulosic layer faces a surface of the absorbent material, and the absorbent material optionally comprises a superabsorbent polymer.

A22. The absorbent article of any of paragraphs a17 to a19, further comprising an absorbent core.

A23. The absorbent article of paragraph a22, wherein the absorbent core comprises a first layer of composite fabric overlying an absorbent material and a second layer of composite fabric underlying the absorbent material, wherein the absorbent material optionally comprises a superabsorbent polymer.

A24. The absorbent article of paragraph a22, wherein the absorbent core comprises the composite web encapsulating an absorbent material, wherein the absorbent material optionally comprises a superabsorbent polymer.

A25. The absorbent article of paragraph a24, wherein the composite fabric completely encapsulates the absorbent material, wherein the absorbent material optionally comprises a superabsorbent polymer.

A26. The absorbent article of paragraph a24 or paragraph a25, wherein the crosslinked cellulosic layer contacts the surface of the absorbent material.

A27. The absorbent article of paragraphs a 17-a 20 and a 22-a 25, wherein the absorbent article comprises an absorbent material, wherein the nonwoven layer or the crosslinked cellulosic layer contacts a surface of the absorbent material when the composite fabric is folded or pleated.

A28. The absorbent article of any of paragraphs a18 to a27, wherein the absorbent article is a diaper or an incontinence product.

A29. The absorbent article of any of paragraphs a20, a21, a26 and a27, wherein when the absorbent article comprises a fluid acquisition distribution layer comprising the composite fabric, the absorbent article reduces intake time from a first fluid exposure to a second subsequent fluid exposure in a flat acquisition test under load by at least 23%.

A30. The absorbent article of any of paragraphs a 24-a 28, wherein when the absorbent article comprises the composite fabric enveloping the absorbent core, the absorbent article reduces intake time from a first fluid exposure to a second subsequent fluid exposure in a flat acquisition under load test by at least 25%.

A31. The absorbent article of any of paragraphs a20, a21 and a28, wherein when the absorbent article comprises a fluid acquisition distribution layer comprising the composite fabric, the absorbent article reduces intake time from a second fluid exposure to a third subsequent fluid exposure in a flat acquisition under load test by at least 8%.

A32. The absorbent article of any of paragraphs a 24-a 28, wherein when the absorbent article comprises the composite fabric encapsulating the absorbent material, the absorbent article reduces intake time from a second fluid exposure to a third subsequent fluid exposure in a flat acquisition test under load by at least 12%.

A33. The absorbent article of any of paragraphs a20, a21 and a28, wherein when the absorbent article comprises a fluid acquisition distribution layer comprising the composite fabric, the absorbent article has a percentage wicking distance of at least 60% after a third fluid exposure in an unloaded saddle wicking test.

A34. The absorbent article of any of paragraphs a 24-a 28, wherein when the absorbent article comprises the composite fabric encapsulating the absorbent material, the absorbent article has a wicking distance percentage of at least 60% after a third fluid exposure in an unloaded saddle wicking test.

A35. The absorbent article of any of paragraphs a17 to a21 and a28, wherein the composite fabric comprises a dry basis weight of 20g/m ² To 50g/m ² (e.g., 30 g/m) ² To 40g/m ² ) Is 70g/m ² To 120g/m ² (e.g., 80 g/m) ² To 110g/m ² ) Is a crosslinked cellulosic layer.

A36. The absorbent article of any of paragraphs a17 to a19 and a22 to a28, wherein the composite fabric comprises a dry basis weight of 20g/m ² To 50g/m ² (e.g., 30 g/m) ² To 40g/m ² ) Is 40g/m ² To less than 70g/m ² (e.g., 40 g/m) ² To 60g/m ² Or 50g/m ² ) Is a crosslinked cellulosic layer.

A37. The absorbent article of paragraph a35, wherein when the absorbent article comprises a fluid acquisition distribution layer comprising the composite fabric, the absorbent article has a percent wicking distance of at least 60% after a third fluid exposure in an unloaded saddle wicking test.

A38. The absorbent article of paragraph a36, wherein when the absorbent article comprises the composite fabric encapsulating the absorbent material, the absorbent article has a percentage wicking distance of at least 60% after a third fluid exposure in an unloaded saddle wicking test.

A39. An absorbent article, comprising:

a liquid impermeable backsheet defining an inner surface and an outer surface;

an absorbent core disposed on an inner surface of the backsheet, wherein the absorbent core comprises:

an absorbent material defining an upper surface and a lower surface of the absorbent core; and

a composite fabric surrounding at least a portion of the upper surface and the lower surface, the composite fabric comprising:

a nonwoven layer comprising polymeric fibers and/or filaments;

a crosslinked cellulosic layer comprising crosslinked cellulosic fibers, wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer; and

wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in the dry state; and

a topsheet covering an upper surface of the absorbent core and contacting an inner surface of the backsheet.

A40. The absorbent article of paragraph a39, wherein the composite fabric completely surrounds the upper and lower surfaces of the absorbent core.

A41. The absorbent article of paragraph a39, wherein the composite web overlaps at least a portion of the width of the composite web on the upper or lower surface of the absorbent core.

A42. The absorbent article of paragraph a39, wherein the composite fabric defines a gap on an upper or lower surface of the absorbent core, the absorbent core further comprising a cover layer disposed over the gap.

A43. The absorbent article of paragraph a42, wherein the cover layer overlies at least a portion of the composite fabric, the composite fabric being disposed between at least a portion of the cover layer and the absorbent material.

A44. The absorbent article of paragraph a42, wherein the cover layer is positioned under the composite web and at least a portion of the cover layer is disposed between the composite web and the absorbent material.

A45. The absorbent article of any of paragraphs a42 to a44, wherein the cover layer is formed from the composite fabric.

A46. The absorbent article of any of paragraphs a42 to a45, wherein the cover layer comprises a Spunbond Meltblown Spunbond (SMS) material.

A47. The absorbent article of any one of paragraphs a42 to a45, wherein the cover layer comprises a Spunbond (SB) material.

A48. The absorbent article of any of paragraphs a39 to a47, wherein the absorbent material comprises an absorbent synthetic polymer and a high loft air permeable bonded carded web (TABCW).

A49. The absorbent article of any of paragraphs a39 to a47, wherein the absorbent material comprises an absorbent synthetic polymer (e.g., SAP), fluff pulp, or any combination thereof.

A50. The absorbent article of paragraph a49, wherein the absorbent material comprises 30% to 90% by weight of the absorbent synthetic polymer and 10% to 70% by weight of fluff.

A51. The absorbent article of any of paragraphs a39 to a50, wherein the polymer fibers and/or filaments of the nonwoven layer of the composite fabric comprise synthetic polymer fibers and/or filaments.

A52. The absorbent article of any of paragraphs a39 to a51, wherein the nonwoven layer and the crosslinked cellulosic layer of the composite fabric overlap each other and interpenetrate at the interface region.

A53. The absorbent article of any of paragraphs a39 to a52, wherein the crosslinked cellulosic layer and the nonwoven layer of the composite fabric are fully interpenetrating.

A54. The absorbent article of any of paragraphs a39 to a52, wherein the nonwoven layer has a first thickness, the crosslinked cellulosic layer has a second thickness, and the interface region comprises a thickness less than or equal to the first thickness or the second thickness.

A55. The absorbent article of any of paragraphs a39 to a54, wherein the nonwoven layer comprises a bonded carded web fabric, a carded web, a spunbond fabric, a meltblown fabric, or any combination thereof.

A56. The absorbent article of any of paragraphs a39 to a55, wherein the crosslinked cellulosic fibers comprise polyacrylic crosslinked fibers.

A57. The absorbent article of any of paragraphs a39 to a56, wherein crosslinked cellulose fibers from the crosslinked cellulose layer are hydroentangled into polymer fibers and/or filaments from the nonwoven layer in the interface region.

A58. The absorbent article of any of paragraphs a39 to a57, wherein the nonwoven layer has 15g/m in the composite fabric ² To 50g/m ² Is used as a dry basis of the (c) polymer.

A59. The absorbent article of any of paragraphs a39 to a58, wherein the crosslinked cellulosic layer has 20g/m in the composite fabric ² To 185g/m ² Is used as a dry basis of the (c) polymer.

A60. The absorbent article of any of paragraphs a39 to a59, wherein the composite fabric does not include latex, latex binder fibers, water saturated layers, pre-treated nonwoven layers, lyocell fibers, rayon, or any combination thereof.

A61. The absorbent article of any of paragraphs a39 to a60, wherein the article comprises a personal care absorbent product.

A62. The absorbent article of paragraph a61, wherein the personal care absorbent product is selected from the group consisting of diapers, incontinence products, and feminine hygiene products.

A63. The absorbent article of any of paragraphs a39 to a62, wherein the composite fabric completely encapsulates an absorbent material, wherein the absorbent material optionally comprises a superabsorbent polymer.

A64. The absorbent article of any of paragraphs a39 to a63, wherein the crosslinked cellulosic layer contacts a surface of the absorbent material.

A65. The absorbent article of any of paragraphs a39 to a64, wherein the absorbent article has a reduction in intake time from a first fluid exposure to a second subsequent fluid exposure of at least 25% in a flat acquisition under load test.

A66. The absorbent article of any of paragraphs a39 to a65, wherein the absorbent article has a reduction in intake time from a second fluid exposure to a third subsequent fluid exposure in a flat acquisition under load test of at least 12%.

A67. The absorbent article of any of paragraphs a39 to a66, wherein when the absorbent article comprises the composite fabric encapsulating the absorbent material, the absorbent article has a wicking distance percentage of at least 60% after a third fluid exposure in an unloaded saddle wicking test.

A68. The absorbent article of any of paragraphs a39 to a67, wherein the composite fabric comprises a dry basis weight of 20g/m ² To 50g/m ² (e.g., 30 g/m) ² To 40g/m ² ) Is 40g/m ² To less than 70g/m ² (e.g., 40 g/m) ² To 60g/m ² Or 50g/m ² ) Is a crosslinked cellulosic layer.

A69. A feminine hygiene product, comprising:

a composite fabric, the composite fabric comprising:

a nonwoven layer comprising polymeric fibers and/or filaments;

wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in the dry state.

A70. The feminine hygiene product of paragraph a69, further comprising an absorbent core comprising an absorbent material.

A71. The feminine hygiene product of paragraph a69 or paragraph a70, wherein the composite fabric, when subjected to fluid insult, distributes fluid to the front, middle, and rear portions of the feminine hygiene product.

A72. The feminine hygiene product of paragraph a71, wherein the front portion, the middle portion, and the rear portion each comprise an amount of fluid within 20wt% to 45wt% of each portion.

A73. The feminine hygiene product of any one of paragraphs a70 to a72, wherein the composite fabric is disposed on the absorbent core.

A74. The feminine hygiene product of any one of paragraphs a70 to a72, wherein the composite fabric encapsulates at least a portion of the absorbent material.

A75. A method of making the composite fabric of any one of paragraphs A1 to a15, comprising:

supplying polymer fibers and/or filaments;

supplying crosslinked cellulosic fibers;

air-laying or wet-laying the crosslinked cellulosic fibers to provide a crosslinked cellulosic layer on a nonwoven layer of polymeric fibers and/or filaments, wherein the crosslinked cellulosic layer is positioned opposite the nonwoven layer; and physically entangling the polymeric fibers and/or filaments from the nonwoven layer and the crosslinked cellulosic fibers from the crosslinked cellulosic layer to provide the composite fabric, wherein the composite fabric comprises an interfacial region between the nonwoven layer and the crosslinked cellulosic layer, wherein the nonwoven layer and the crosslinked cellulosic layer are mechanically inseparable in a dry state.

A76. The method of paragraph a75, wherein physically entangling the polymeric fibers and/or filaments from the nonwoven layer and the crosslinked cellulosic fibers from the crosslinked cellulosic layer comprises hydroentangling the crosslinked cellulosic fibers into the polymeric fibers and/or filaments.

A77. The method of paragraph a75 or paragraph a76, wherein the polymer fibers and/or filaments are in the form of a bonded carded web fabric, a carded web, a spunbond fabric, a meltblown fabric, unbonded synthetic fibers, or any combination thereof.

A78. The method of any one of paragraphs a75 to a77, wherein the polymer fibers are synthetic.

A79. The method of any one of paragraphs a75 to a78, wherein the nonwoven layer is a top layer and the crosslinked cellulose layer is a bottom layer.

A80. The method of any one of paragraphs a75 to a78, wherein the nonwoven layer is a bottom layer and the crosslinked cellulose layer is a top layer.

A81. The method of any of paragraphs a75 to a80, wherein the crosslinked cellulosic layer is preformed prior to entanglement with the nonwoven layer, and/or the nonwoven layer is preformed prior to entanglement with the crosslinked cellulosic layer.

A82. The method of any of paragraphs a 75-a 80, wherein the crosslinked cellulosic layer is not preformed prior to entanglement with the nonwoven layer, and/or the nonwoven layer is not preformed prior to entanglement with the crosslinked cellulosic layer.

A83. A feminine hygiene product, comprising:

a composite fabric, the composite fabric comprising:

a nonwoven layer comprising polymeric fibers and/or filaments;

A84. The feminine hygiene product of any one of paragraphs a83, further comprising:

an absorbent core comprising a superabsorbent polymer,

wherein the composite fabric is at least partially wrapped around the absorbent core, the crosslinked cellulosic layer physically contacting the absorbent core.

A85. The feminine hygiene product of any one of paragraphs a83 to a84, wherein the nonwoven layer is a first nonwoven layer, the crosslinked cellulosic layer is a first crosslinked cellulosic layer, and the interface region is a first interface region, the composite fabric further comprising:

a second nonwoven layer;

a second crosslinked cellulosic layer; and

a second interface region between the second nonwoven layer and the second crosslinked cellulosic layer, the second interface region comprising physically entangled polymer fibers and/or filaments from the second nonwoven layer and crosslinked cellulosic fibers from the second crosslinked cellulosic layer,

wherein the second nonwoven layer and the second crosslinked cellulosic layer are mechanically inseparable in the dry state, and wherein the second crosslinked cellulosic layer is mechanically coupled to the first nonwoven layer.

A86. The feminine hygiene product of any one of paragraphs a83 to a85, further comprising an average intake time at the first intake of less than or equal to about 15 seconds, as measured by the standardized intake time method.

A87. The feminine hygiene product of any one of paragraphs a83 to a86, further comprising an average intake time at a second intake of less than or equal to about 15 seconds as measured by the standardized intake time method.

A88. The feminine hygiene product of any one of paragraphs a83 to a87, further comprising an average intake time at a second intake of less than or equal to about 10 seconds as measured by the standardized intake time method.

A89. The feminine hygiene product of any one of paragraphs a83 to a88, further comprising an average intake time at a third intake of less than or equal to about 30 seconds as measured by the standardized intake time method.

A90. The feminine hygiene product of any one of paragraphs a83 to a89, further comprising an average intake time at a third intake of less than or equal to about 15 seconds as measured by the standardized intake time method.

A91. The feminine hygiene product of any one of paragraphs a83 to a90, further comprising an average rewet mass of less than or equal to about 0.75 grams as measured by the standardized rewet performance method.

A92. The feminine hygiene product of any one of paragraphs a83 to a91, further comprising an average rewet mass of less than or equal to about 0.20 grams as measured by the standardized rewet performance method.

A93. The feminine hygiene product of any one of paragraphs a83 to a92, further comprising an average wicking distance in the longitudinal direction of greater than or equal to about 9.2cm, as measured by the standardized liquid distribution method.

A94. The feminine hygiene product of any one of paragraphs a83 to a93, further comprising an average wicking distance in the longitudinal direction of greater than or equal to about 9.8cm, as measured by the standardized liquid distribution method.

A95. The feminine hygiene product of any one of paragraphs a83 to a94, further comprising:

a topsheet comprising a nonwoven material, the topsheet being mechanically coupled to the composite fabric and defining an interior surface of the feminine hygiene product; and

a liquid impermeable backsheet mechanically coupled with the composite web and defining an outer surface of the feminine hygiene product.

A96. The feminine hygiene product of any of paragraphs a83 to a95, wherein the topsheet comprises a perforated film material or a breathable bonded carded web (TABCW).

A97. The feminine hygiene product of any one of paragraphs a83 to a96, further comprising:

a first hydroentangled layer, said first hydroentangled layer being interposed between said topsheet and said composite fabric; and

a second hydroentangled layer, said second hydroentangled layer being interposed between said liquid impermeable backsheet and said composite fabric.

A98. The feminine hygiene product of any one of paragraphs a83 to a97, further comprising an average intake time at a second intake of less than or equal to about 225 seconds as measured by the standardized intake time method.

A99. The feminine hygiene product of any one of paragraphs a83 to a98, further comprising an average intake time at a third intake of less than or equal to about 490 seconds as measured by a standardized intake time method.

A100. The feminine hygiene product of any one of paragraphs a83 to a99, further comprising an average rewet mass of less than or equal to about 1.15 grams as measured by the standardized rewet performance method.

A101. The feminine hygiene product of any one of paragraphs a83 to a100, further comprising an average wicking distance in the longitudinal direction of greater than or equal to about 8.2cm, as measured by the standardized rewet performance method.

A102. The feminine hygiene product of any one of paragraphs a83 to a101, further comprising an average wicking distance in the transverse direction of greater than or equal to about 4.5cm, as measured by the standardized liquid distribution method.

A103. The feminine hygiene product of any one of paragraphs a83 to a102, further comprising a total mass of composite fabric of less than or equal to about 4.00 g.

A104. The feminine hygiene product of any one of paragraphs a83 to a103, further comprising a total mass of cellulosic material greater than or equal to about 1.50 g.

A105. The feminine hygiene product of any one of paragraphs a83 to a104, further comprising a total mass of petrochemical material of less than or equal to about 1.30 g.

Although exemplary embodiments have been shown and described, it should be understood that various changes may be made therein without departing from the spirit and scope of the disclosure.

Claims

1. A feminine hygiene product, comprising:

a composite fabric, the composite fabric comprising:

a nonwoven layer comprising polymeric fibers and/or filaments;

2. The feminine hygiene product of claim 1, further comprising:

an absorbent core comprising a superabsorbent polymer,

3. The feminine hygiene product of claim 1, wherein the nonwoven layer is a first nonwoven layer, the crosslinked cellulosic layer is a first crosslinked cellulosic layer, and the interface region is a first interface region, the composite fabric further comprising:

a second nonwoven layer;

a second crosslinked cellulosic layer; and

4. The feminine hygiene product of claim 1, further comprising an average intake time at a first intake of less than or equal to about 15 seconds as measured by a standardized intake time method.

5. The feminine hygiene product of claim 1, further comprising an average intake time at a second intake of less than or equal to about 15 seconds as measured by a standardized intake time method.

6. The feminine hygiene product of claim 4, further comprising an average intake time at a second intake of less than or equal to about 10 seconds as measured by a standardized intake time method.

7. The feminine hygiene product of claim 1, further comprising an average intake time at a third intake of less than or equal to about 30 seconds as measured by a standardized intake time method.

8. The feminine hygiene product of claim 7, further comprising an average intake time at a third intake of less than or equal to about 15 seconds as measured by a standardized intake time method.

9. The feminine hygiene product of claim 1, further comprising an average rewet mass of less than or equal to about 0.75 grams as measured by the standardized rewet performance method.

10. The feminine hygiene product of claim 9, further comprising an average rewet mass of less than or equal to about 0.20 grams as measured by the standardized rewet performance method.

11. The feminine hygiene product of claim 1, further comprising an average wicking distance in the longitudinal direction of greater than or equal to about 9.2cm, as measured by the standardized liquid distribution method.

12. The feminine hygiene product of claim 11, further comprising an average wicking distance in the longitudinal direction of greater than or equal to about 9.8cm, as measured by the standardized liquid distribution method.

13. The feminine hygiene product of claim 1, further comprising an average wicking distance in the transverse direction of greater than or equal to about 5.5cm, as measured by the standardized liquid distribution method.

14. The feminine hygiene product of claim 1, further comprising:

15. The absorbent article of claim 14, wherein the topsheet comprises a perforated film material or a breathable bonded carded web (TABCW).

16. The feminine hygiene product of claim 14, further comprising:

17. The feminine hygiene product of claim 16, further comprising an average intake time at a second intake of less than or equal to about 225 seconds as measured by a standardized intake time method.

18. The feminine hygiene product of claim 16, further comprising an average intake time at a third intake of less than or equal to about 490 seconds as measured by a standardized intake time method.

19. The feminine hygiene product of claim 16, further comprising an average rewet mass of less than or equal to about 1.15 grams as measured by the standardized rewet performance method.

20. The feminine hygiene product of claim 16, further comprising an average wicking distance in the longitudinal direction of greater than or equal to about 8.2cm, as measured by the standardized rewet performance method.

21. The feminine hygiene product of claim 16, further comprising an average wicking distance in the transverse direction of greater than or equal to about 4.5cm, as measured by the standardized liquid distribution method.

22. The feminine hygiene product of claim 1, further comprising a total mass of composite fabric of less than or equal to about 4.00 g.

23. The feminine hygiene product of claim 1, further comprising a total mass of cellulosic material greater than or equal to about 1.50 g.

24. The feminine hygiene product of claim 1, further comprising a total mass of petrochemical material of less than or equal to about 1.30 g.