CN1968664A - Compression resistant nonwovens - Google Patents

Abstract

A sanitary napkin comprising a topsheet comprising a plurality of discrete tufts of fibrous material, wherein the topsheet has a density of less than 0.027 g/cc under a load of 0.02756Kla (0.004 psi), and a density of less than 0.0688/cc at a load of 1.5847Kla (0.23 psi).

Description

Compression resistant nonwovens

Technical field

The present invention relates to be suitable for use as the fibrous nonwoven webs of the top flat in the disposable absorbent article.Specifically, the present invention relates to handle to strengthen the fleece of compressive property with mechanical molding.

Background technology

Disposable absorbent article such as baby diaper, adult-incontinence articles, sanitary towel, Pantiliner, hemorrhoid treatment pad, binder etc. is well-known in the art.This based article has the top flat of fluid penetrable and the egative film of fluid impermeable usually, and is clipped in the absorbent cores that is used between described top flat and the described egative film to absorb with the receiving body fluids exudate.

In some application scenarios of disposable absorbent article for example in sanitary towel and the Pantiliner, it would be desirable not only absorb body fluids but also make the fluid on the wearer's body minimum.Can be by guaranteeing fluid to enter absorbent article no longer reflux and come out for example to be pressed or be extruded the mode of coming and farthest reduce liquid on the health.Farthest reduce the bleeding back of health although carried out a large amount of effort, but still need a kind of can help to keep user clean body and dry and comfortable disposable absorbent article.

Therefore, there be a kind of can help to provide the disposable absorbent article that cleans the health beneficial effect in sanitary towel and Pantiliner field.

In addition, still need a kind ofly can be manufactured on the method that sanitary towel and Pantiliner field help to provide the disposable absorbent article of cleaning health beneficial effect relatively inexpensively.

Summary of the invention

A kind of sanitary towel, described sanitary towel comprises top flat, described top flat comprises the discrete tufts of a plurality of fibrous materials, wherein top flat have under the load of 0.028kPa (0.004psi) during less than the density of 0.027g/cc and load at 1.59kPa (0.23psi) less than 0.068 density.

Description of drawings

Fig. 1 is the fibroreticulate perspective view of the present invention.

Fig. 2 is a fibroreticulate guide wire of alternative shape shown in Figure 1.

Fig. 3 is the profile in the 3-3 cross section of Fig. 2.

Fig. 4 is the plane graph of a fibroreticulate part shown in the 4-4 among Fig. 3.

Fig. 5 is the perspective view that is used to form the fibroreticulate device of the present invention.

Fig. 6 is the cross-sectional view of the part of device shown in Figure 5.

Fig. 7 is the perspective view of a part that is used to form the device of the fibroreticulate embodiment of the present invention.

Fig. 8 is the enlarged perspective that is used to form the part of the fibroreticulate device of the present invention.

Fig. 9 is the guide wire of alternative shape of fibroreticulate another embodiment of the present invention.

The plane graph that Figure 10 partly excises for sanitary towel of the present invention.

The specific embodiment

The present invention can be used for any known disposable absorbent products.In preferred embodiments, the present invention includes the sanitary towel of planning to be used as menopad.Sanitary towel of the present invention comprises at least three parts: top flat, the absorbent cores that is administered to the lotion on the described top flat and is communicated with described top flat fluid.Find unexpectedly, the fleece of the application of the invention, sanitary towel of the present invention can provide the beneficial effect of ideal cleaning health.Specifically, sanitary towel of the present invention provides and can compare better compressive property with the sanitary towel that known shaping membrane fleece is made, and described known shaping membrane fleece has for example by Procter ﹠amp; Gamble Co. sells on market is used for ALWAYS ^The DRI-WEAVE of sanitary towel ^Top flat.Improved compressive property strengthens the ability that bleeds back of sanitary towel, makes that still less absorbed liquid is returned and extrudes described product and flow on wearer's the health.

The conversion factor of unit used herein: 1 inch=25.4mm; 1psi=6.89kPa; 1 foot=304.8mm.

Fig. 1 shows a kind of laminate web 1 of the present invention, and it is suitable for use as the resistance to compression top flat in the disposable absorbent article of the present invention.Fleece 1 can comprise one deck, but comprises two-layer at least in a preferred embodiment.This paper is called precursor web general plane, two dimension, for example first precursor web 20 and second precursor web 21 with each layer.In preferred embodiments, two precursor web all are non-woven webs.Precursor web 20 and 21 (and any accessory fibers net) can engage by binding agent, hot adhesion, ultrasonic bonding etc., but does not preferably use binding agent or other adhesive form to engage.As hereinafter disclosed, the component precursor fleece of fleece 1 can engage by the interlocked mechanical engagement that is produced by forming of tuft 6.

Fleece 1 has first side 3 and second side 5, and term " side " is used in the common usage of two-dimensional fiber net (as have two lateral paper and thin film when being in flat condition roughly) of general plane.Each precursor web 20 and 21 has first surface 12 and 13 respectively, and has second surface 14 and 15 (as shown in Figure 3) respectively.Fleece 1 has as vertical (MD) and horizontal (CD) of web manufacture field known to usually.Although the present invention can implement with thin polymer film and woven web, two precursor web non-woven webs that basic randomly oriented fiber constitutes of all serving as reasons in preferred embodiments." basic random orienting " is meant the processing conditions owing to described precursor web, and the amount of possible MD (vertically) orientation fibers is higher than the amount of CD (laterally) orientation fibers, or vice versa.For example, spunbond and melt and spray that the continuous fiber thigh is deposited in the support that vertically moves in the processing.Although attempt to allow spunbond or the fibroreticulate fibre orientation of melt-blown non-woven real " at random ", the percentage ratio of common machine-direction oriented fiber with horizontal compare high slightly.In a preferred embodiment, first precursor web 20 is that the hydrophilic relatively non-woven webs and second precursor web 21 are hydrophobic relatively non-woven webs.For all non-woven webs, hydrophobicity or hydrophilic can obtain by the fiber that use has a proper characteristics, perhaps can handle precursor web and make it have required characteristic.

In one embodiment, yet first side 3 of fleece 1 is limited by the expose portion of the first surface 13 of second precursor web 21 and at least one preferably a plurality of discrete tuft 6, and tuft is at least the first precursor web 20 and the integral extensions of the fiber of two precursor web preferably.As shown in Figure 3, each tuft 6 can comprise and runs through second precursor fiber 21 and from the fibrae circulares 8 of its first surface 13 outwardly directed a plurality of alignment.In another embodiment, each tuft 6 all can comprise a plurality of from first surface 13 outward extending non-looped fibers 18 (as shown in Figure 3).In one embodiment, tuft 6 can comprise the fiber that is derived from two precursor web.In such embodiments, the fiber of first precursor web 20 covers at the fiber of second precursor web under the situation of tuft outside substantially in the inner molding of tuft.

Term used herein " non-woven webs " refer to have interlaced but there is no weave or braided fabric in the individual fibers of such repeat patterns or the fleece of silk thread structure, described weave or braided fabric does not typically have randomly oriented fiber.Non-woven webs or fabric have been formed at several different methods, and for example meltblown, spun-bond process, water twine method, air lay and bonded carded web method, comprise the carded thermal.Fiber can be bi-component, multicomponent, multicomponent or the like, as known in the art.Basis weight of nonwoven fabrics is represented with gram every square metre (gsm) usually.The basic weight of laminate web is each total basic weight of forming layer and any other optional feature.Fibre diameter is represented with micron usually; Fiber size can represent that also it is the unit of every fibre length weight with the dawn.The basic weight that is applicable to laminate web of the present invention can be in the scope of 10gsm to 500gsm.

Nonwoven precursor web 20 or 21 composition fiber can be made of the polymer such as polyethylene, polypropylene, polyester and their blend.Described fiber can comprise the blend of cellulose, artificial silk, cotton thread or other natural material or polymer and natural material.Fiber also can comprise superabsorbent material, as any combination of polyacrylate or suitable material.Fiber can be one pack system, bi-component and/or double elements, non-circular (for example, capillary pipe fiber), and the major cross-sectional dimension that can have (for example, the diameter of cylindrical fibre) is 0.1 to 500 micron.For example, a kind of fiber of non-woven webs that is applicable to comprises nanofiber.Nanofiber is described to average diameter less than 1 micron fiber.Nanofiber can comprise all fibres in the non-woven webs or the part fiber in the non-woven webs.The composition fiber of nonwoven precursor web also can be the mixture of different fiber types, and these different fiber types are inequality on some features as chemistry (for example PE and PP), component (single-and two-), dawn (little dawn and 20 dawn), shape (being capillary tube and circle) etc.The scope of forming fiber can be about 0.1 dawn to about 100 dawn.

" spun-bonded fibre " used herein is meant the fiber of the minor diameter that forms with following method: molten thermoplastic material from a plurality of meticulous of spinning head and be generally circular capillary tube and be extruded as long filament, is reduced the filament diameter of extruding then fast.When being deposited on the collection surface, spun-bonded fibre is not clamminess usually.Spun-bonded fibre be generally successive and the average diameter (from least 10 samples) that has greater than 7 microns, more particularly between about 10 and 40 microns.

Term used herein " meltblown " is meant the method for following formation fiber: with molten thermoplastic material by a plurality of meticulous and be generally circular punch die capillary tube and be extruded as fusion silk thread or long filament, convergence high-speed gas (as the air) stream that enters common heating then weakens the long filament of molten thermoplastic, so that its variation in diameter, even may diminish to the microfibre diameter.Thereafter, meltblown fibers is delivered and is deposited on by high velocity air and collects on the surface, when still being clamminess, forms the fleece of the meltblown fibers of random distribution usually.Meltblown fibers is continuous or discontinuous microfibre, and common average diameter is less than 10 microns.

Term " polymer " used herein " generally include but be not limited to homopolymer, copolymer, for example block, grafting, random and alternate copolymer, terpolymer etc. and their blend and modifier.In addition, unless otherwise specifically limited, term " polymer " " comprise all possible geometrical configuration of described material.Described configuration includes but not limited to isotaxy, atactic, syndiotaxy and symmetrical at random.

Term used herein " one pack system " fiber is meant the fiber that only uses a kind of polymer to be shaped by one or more extruders.This and do not mean that by a kind of polymer formation, wherein add that a small amount of additive is used to dye, the fiber of antistatic property, lubricated, hydrophilic etc. forecloses.The amount that these additives (for example be used for painted titanium dioxide) exist usually is less than about 5% weight and more typical about 2% weight.

Term " bicomponent fibers " used herein " be meant and extrude from extruder separately by at least two kinds of different polymer but be spun the fiber that forms a fiber.Bicomponent fibre is also referred to as conjugate fibre or multicomponent fibre sometimes.Described polymer is arranged in the constant distinct zone of basic fixed position, and these regional cross sections with bicomponent fibre intersect and extend continuously along the length of bicomponent fibre.For example, the configuration of this bicomponent fibre can be that skin/core pattern is arranged, and wherein a kind of polymer is centered on by another kind of polymer, or parallel type is arranged, the cake formula is arranged or " fabric of island-in-sea type " arranged.

Term used herein " biconstituent fibers " is meant by same extruder extrudes fiber as at least two kinds of polymer formation of blend.Biconstituent fibers does not have the various polymers compositionss in the basic fixed position of being arranged on completely different zone constant, that intersect with fiber cross section, and various polymer are not successive along the whole length of fiber usually, but are generally the shaping fibril of random start and end.Biconstituent fibers also refers to multicomponent fibre sometimes.

Term used herein " non-circular fiber " is to describe to have the fiber of non-circular cross sections, and comprises " shaped fibers " and " capillary pipe fiber ".Such fiber can be solid or hollow, and they can be trilobal, δ shape, and preferably its outer surface has the fiber of capillary channel.Capillary channel can be various shape of cross sections, as " U-shaped ", " H shape ", " C shape ", " V-arrangement ".A preferred capillary pipe fiber is T-401, and called after 4DG fiber is available from the Fiber Innovation Technologies of Tennessee State JohnsonCity.The T-401 fiber is polyethylene terephthalate (a PET polyester).

Term used herein " integral extensions " refers to the fiber of the tuft 6 of the fiber with the precursor web of being derived from when being used for tuft 6.For example, the fiber in the tuft 6 can be an one with first precursor web 20, promptly is derived from first precursor web 20.Therefore, the fibrae circulares 8 of tuft 6 and non-looped fibers 18 can be plastic deformation and the fiber that stretch out of first precursor web 20, and are one with first precursor web 20 therefore." one " used herein is different from the fiber that is incorporated into or joins independent precursor net in order to make tuft, for example, and as general doing in the conventional carpet manufacturing.

The number of tuft 6, spacing and size can change so that the texture variation of first side 3 of fleece 1.For example, if tuft 6 is enough near at interval, then first side 3 of fleece 1 can have the sensation of terry cloth-like.Alternatively, tuft 6 can have stronger texture, flexibility, loft, absorbability or visual pattern captivation with a part that causes laminate web with the arranged in patterns as linear or filling shape.For example, when tuft 6 during with straight line or microgroove arranged in patterns, tuft can have the outward appearance of embroidery.Tuft 6 also can be arranged and form specific shape, for example style, letter or logo.For example, these shapes can be used to can have the title or the logo in hotel in the above on the used laminated material of hotel bath towel or bathing gown.Similarly, the size of single tuft 6 also can change as height, length and width.Single tuft can be about 3cm, and can make separately or be dispersed among the tuft of various sizes.

First precursor web 20 can be fiber weaving or non-woven webs, and it fiber that comprises has enough elongation characteristics so that its part forms as the following tuft of describing more comprehensively 6.Tuft is by forming fiber releasing outside the plane on the Z-direction in fibroreticulate discrete, the partial part of precursor.Releasing can be owing to the cause of fiber displacement outside the plane, that is, fiber can move and we can say and be drawn out outside the plane with respect to other fiber.Yet for most of nonwoven precursor web, releasing outside the plane is because the fiber of tuft 6 is plastically stretched to small part and for good and all is out of shape to have formed the cause of tuft 6 usually.Therefore, in one embodiment, the height required according to tuft 6, the component fibre of nonwoven precursor web can show the elongation at break that has at least about 5%, more preferably at least about 10%, more preferably at least about 25%, more preferably at least about 50%, and more preferably at least about 100%.Elongation at break can be by simple extension test for example by using Instron extension test equipment determine, and be found in usually on the material data file from this fibrid or fleece supplier.

Should be appreciated that suitable precursor web should comprise can stand enough plastic deformations and tensile elongation or have the ambulant fiber of enough fibers, makes it can form fibrae circulares 8.Yet recognize that the fiber of some percentage ratio outside the plane of release first surface 12 will can not form looped pile, will rupture and form loose end but replace.This fibrid is called as " loose " fiber or " loose fiber ends " 18 in this article, as shown in Figure 3.Loose fiber ends 18 is not necessarily undesirable for the present invention, and in some embodiments, the great majority of tuft 6 or whole fiber can be loose fiber ends 18.Loose fiber ends 18 also can be served as reasons and be comprised or comprise the result that the non-woven webs that cuts staple fiber is made tuft 6.In this case, some artificial staple fiber ends may be projected among the tuft 6, and this depends on these situations such as height as the quantity of staple fiber in the fleece, staple fiber cut length and tuft.In some instances, may in precursor web, use the blend of different length fiber or in different layers, use the blend of different length fiber.Can optionally long fibre and short fiber be separated like this.Long fibre can mainly form tuft 6, and short fiber mainly is retained in the fleece part that does not form tuft 6.The mixture of an exemplary fiber length can comprise the long fibre that is approximately 2 to 8 centimetres and less than the fiber of about 1 centimetre short fiber.

First precursor web 20 can be fiber weaving net or the non-woven webs that comprises elastic fiber or elastomeric fibre.Elastic fiber or elastomeric fibre can be stretched its original size at least about 50% and can return to its original size 10% in.If owing to the mobility of fiber, fiber is simply shifted, or is stretched above their elastic limit and plastic deformation as fruit fiber in non-woven material, tuft 6 can be formed by elastic fiber.

Second precursor web 21 can be any web material in fact, and unique requirement is that it has enough integrity to make laminated material by method described below.In one embodiment, with respect to first precursor web 20, it can have very little elongation characteristics, make when standing to be derived from the fiber strain that on the direction of second precursor web 21, is pushed out planar first precursor web 20, second precursor web 21 will be broken, for example tear owing to extending failure, the part of the precursor web 20 of winning can be passed (that is, we can say " dashing saturating ") second precursor web 21 is to form tuft 6 on first side 3 of fleece 1.In one embodiment, second precursor web 21 is a thin polymer film.Second precursor web 21 also can have enough extensibilities and make fibrae circulares, and is as above according to first precursor web 20.

The representative tuft 6 of the embodiment of fleece 1 shown in Figure 1 (wherein second precursor web 21 " is passed " by first precursor web) is shown among Fig. 2 with the view of further amplification.Shown in Fig. 2 or 3, tuft 6 comprises a plurality of fibrae circulares 8, and it aligns substantially and makes tuft 6 have tangible linear direction and longitudinal axes L.Tuft 6 also has the axis T that roughly is orthogonal to longitudinal axes L in the MD-CD plane.In the embodiment shown in Fig. 1 and 2, longitudinal axes L is parallel to MD.In one embodiment, all isolated tufts 6 have the longitudinal axes L of almost parallel.Tuft 6 numbers of fleece 1 per unit area, i.e. the area density of tuft 6, can from 1 bunch of per unit area for example every square centimeter change to up to every square centimeter 100 bunches.Every square centimeter can have at least 10 or at least 20 tufts 6, and this is decided by final use.Usually, do not require unanimity, but tuft 6 can only exist at some region memory of fleece 1, for example have reservation shape, as the zone of linear, bar shaped, band shape, circle etc. in the whole area inner area density of fleece 1.

As can understanding by this paper explanation, in a lot of embodiments of fleece 1, the opening 4 of second precursor web 21 will have tangible rectilinear direction and longitudinal axis, determine that its direction is parallel to the longitudinal axes L of the tuft 6 of its correspondence.Equally, opening 4 also will have the axis of pitch that roughly is orthogonal to longitudinal axis in the MD-CD plane.

Shown in Fig. 1 to 4, tuft 6 can run through the opening 4 in second precursor web 21.Opening 4 forms by make second precursor web, 21 partial fracture with the method that describes in detail below.Breaking can relate to just splitting and open second precursor web 21, makes opening 4 stay the simple two-dimensional slit.Yet for example for the thin polymer film, the part of second precursor web 21 can be deflected or release and form the wings that this paper is called fin 7 outside the plane (that is the plane of second precursor web 21) for some material.The form of fin 7 and structure height depend on the material behavior of second precursor web 21.The wing 7 can have the general structure of one or more wings, as shown in each figure.In other embodiment, fin 7 can have the structure that more resembles the volcano shape, comes out from fin 7 eruptions as tuft 6.In other embodiments, fin 7 in fact can cover tuft 6 fully, makes them form " medicated cap " on tuft 6.

In one embodiment, fin 7 can significantly stretch out outside the plane, even we can say the same high with tuft 6 itself.In this embodiment, fin 7 can cause tuft 6 more to be added with elastic force and be not easy more flattening owing to the effect of compression or bending force.Therefore, in one embodiment, laminate web 1 comprises two-layer at least (being precursor web 20 and 21), and two-layer tactile qualities and the compressive property that all influences tuft 6.

Tuft 6 preferably includes the fibrae circulares that is derived from two precursor web.Therefore, tuft 6 can be or " passing " second precursor web 21 in some sense, or the tuft of " propelling " second precursor web 21.Both one of arbitrary situation in, can say first and second precursor web can by with the frictional engagement of opening 4 by " pinning " in suitable position.For example, in some embodiments, the transverse width of opening 4 (that is the measured size of axis of pitch that, is parallel to it) can be less than the Breadth Maximum (via method described below) of the tooth bar that forms opening.This shows the answer that certain size is arranged at opening part, and it is tending towards suppressing tuft 6 and retracts by opening 4.The frictional engagement of tuft and opening is provided at the laminate web structure that has permanent tufting on the side, and permanent tufting can need not binding agent or hot adhesion and form.

Because one of them layer (for example in certain embodiments, the thin polymer film of relatively low percentage elongation or tissue paper second precursor web 21 among Fig. 1 to 4) be not significantly contribution material (for example in the embodiment shown in Fig. 1 to 4) of tuft 6, the fleece 1 that comprises non-woven first precursor web 20 can have in the dominant feature of the biateral fibre of fleece 1, and fiber is only by 20 contributions of non-woven first precursor web.Therefore, can make tuft 6 enough near at interval to cover first side 3 of fleece 1 effectively.In such embodiment, two sides of fleece 1 look like non-woven material, and wherein the difference between two sides 3 and 5 is the difference on the surface texture.Therefore, in one embodiment, this invention can be described as the laminated material of two or more precursor web, and two sides of wherein said laminate web are all covered by the fiber from a precursor web only basically.

Shown in Fig. 1 to 4, a feature of tuft 6 can be the advantage orientation alignment of fiber 8 or 18.For example, fiber 8 cyclic, alignment can be described to have and is parallel to the planar remarkable or main vector component of Z-CD, and fibrae circulares 8 has the basic alignment uniformly with respect to axis T when plane graph is for example observed among Fig. 4.So-called " ring-type " fiber 8 is meant that fiber 8 and first precursor web 20 are one wholely also to begin and stop within it, but its first surface 13 from second precursor web 21 extends outwardly along the Z-direction.Fibrae circulares 8 " alignment " with respect to tuft 6 is meant that fibrae circulares 8 is all directed so basically, if make when on as the plan view among Fig. 4, observing, each fibrae circulares 8 has the effective vector component that is parallel to axis T, and the master vector component that preferably is parallel to axis T.

As a comparison, the non-looped fibers 18 and first precursor web 20 are one, but only start from first precursor web 20, and have from the first surface 13 of second precursor web 21 at the Z outwardly directed free end that makes progress.Free end 18 also can have to be described as and has that to be parallel to Z-CD planar effectively or the roughly consistent alignment of master vector component.

For fibrae circulares 8 and staple in bulk 18 for both because when making goods and when use be wound on the roller or compression, described alignment is the feature of tuft 6 before any manufacturing after strain.

When observing in the plane graph as Fig. 4, used herein being oriented in apart from the angle of longitudinal axes L has an effective vector component that is parallel to axis T greater than 45 fibrae circulares 8 of spending.When observing in the plane graph as Fig. 4, used herein being oriented in apart from the angle of longitudinal axes L has a master vector component that is parallel to axis T greater than 60 fibrae circulares 8 of spending.In a preferred embodiment, at least 50%, more preferably at least 70%, and more preferably the fiber 8 of at least 90% tuft 6 has an effective vector component that is parallel to axis T, and more preferably be parallel to a master vector component of axis T.If desired, the orientation of fiber can use amplifier unit to determine, the microscope of suitable measurement scale for example is housed.Usually, to observed non-linear segment of fiber in plane graph, longitudinal axes L and fibrae circulares 8 are all made the approximate angle that can be used to determine fibrae circulares 8 and longitudinal axes L of straight line.For example, as shown in Figure 4, a fiber 8a shows emphatically with heavy line, and the approximate 8b of its straight line shows with dotted line.This fiber becomes the angle (measuring counterclockwise from L) of about 80 degree with longitudinal axis.

The orientation of fibrae circulares 8 is used for ining contrast to the orientation of the fibre composition and first precursor web 20 in the tuft 6, is described as having the alignment of fibers of basic random orientation best for its orientation of non-woven webs.In a woven web embodiment, the orientation of fibrae circulares 8 can be same as described above in the tuft 6, but the fiber of first precursor web 20 will have and be used for making the relevant orientation of fibroreticulate concrete Weaving method (as, plain weave pattern).

In the embodiment depicted in fig. 1, the longitudinal axes L of tuft 6 is roughly alignd on the MD of tuft 6 direction.Therefore, tuft 6 and longitudinal axes L in principle can be along aliging on any direction with respect to MD or CD.Therefore, we can say usually that the fibrae circulares 8 of alignment roughly is orthogonal to the longitudinal axes L alignment makes them have the effective vector component that is parallel to axis T, and more preferably has the master vector component that is parallel to axis T for each tuft 6.

In some embodiments, because the method for optimizing of formation tuft 6 as described below, another characteristics that mainly comprise the tuft 6 of ring-type, aligned fibers 8 are its common open structures, and this structure is characterised in that the unlimited void area 10 that is limited to tuft 6 inside, shown in Fig. 2 and 3.Interstice coverage 10 can have at far-end 31 place's broads of tuft 6 or big and in the narrower shape in pedestal 17 places of tuft 6.This shape with the gear piece that is used to form tuft 6 is just in time opposite.So-called " interstice coverage " also do not mean that complete district without any fiber, and this term means the common description to the general appearance of tuft 6.Therefore, in some tuft 6, staple in bulk 18 or a plurality of staple in bulk 18 can be present in the void area 10." open wide " void area meaning be two vertical ends of tuft 6 be roughly open wide and do not have fiber, make tuft 6 can form something, as shown in Figure 3 as " passage " structure at uncompressed state.

In addition, owing to make a method for optimizing of fleece 1, second side 5 of fleece 1 shows to have is interrupted 16, the tooth that it is characterized in that being generally linear breach (this breach is limited by the original random fiber of the second surface 14 of the first precursor web 20) equipment that has been formed directionally (promptly, as shown in figs. 1 and 3, usually be orthogonal to MD-CD planar " Z direction ") be advanced in the tuft 6, will describe in detail below.The direction that original randomly oriented fiber of first precursor web 20 demonstrates sharply changes to define is interrupted 16, and its demonstration has the feasible longitudinal axis that can be described to have the longitudinal axes L that is roughly parallel to tuft 6 of rectilinearity.Owing to be used as the person's character of a lot of non-woven webs of first precursor web 20, being interrupted 16 can be high-visible unlike tuft 6.Just because of this, unless very near-earth check fleece 1, the interruption 16 on second side 5 of fleece 1 can not observe and detect usually less than.For this reason, the outer harmony in the exterior sensation of second side 5 of fleece 1, first precursor web 20 that can have bunch.Therefore, in some embodiments, fleece 1 can have harmony in the exterior sensation outside the napping of towelling on first side 3, and on second side 5, have more slick, softish outside harmony in the exterior sensation, two sides by be derived from same non-woven webs promptly the fiber of first precursor web 20 constitute.In other embodiments, be interrupted 16 and can appear as perforate, and can be the perforate of passing fleece 1 by the end of tunnel-like tufts 6.

From the explanation of the fleece 1 that comprises non-woven first precursor web 20 as seen, the fiber 8 of tuft 6 or 18 can from first precursor web 20 or first surface 12 or second surface 14 origin or stretch out.Certainly, the fiber 8 or 18 of tuft 6 also can stretch out from the inside 28 of first precursor web 20.As shown in Figure 3, the fiber 8 of tuft 6 or 18 is owing to extending (that is, go up at as shown in Figure 3 " Z to " and release) outside the roughly two-dimensional plane that is extended first precursor web 20.Usually, the fiber 8 of tuft 6 or fiber 18 comprise that the fiber with first precursor web 20 is one and the fiber that extends from it.

Therefore, be understood that from the above description in one embodiment, fleece 1 can be described as the laminate web that is formed by the selectivity mechanically deform of at least the first and second precursor web, at least described first precursor web is a non-woven webs, described laminate web has first side and second side, described first side comprises second precursor web and a plurality of discrete tufts, and each discrete tufts comprises that a plurality of is the first precursor fiber integral extensions and the clustered fiber that extends through second precursor web; Described second side comprises first precursor web.

Because the plastic deformation and the Poisson's ratio effect of fiber, fiber 8 or 18 elongation may be accompanied by totally reducing of the fiber cross sectional dimension diameter of circular fiber (for example, for).Therefore, the fiber diameter of the fibrae circulares 8 of tuft 6 alignment can be less than the fiber diameter of the fiber of first precursor web 20.According to the material behavior of first precursor web 20, it is believed that reducing on this fibre diameter helps the perception pliability of first side 3 of fleece 1, the pliability that can compare with cotton towel cloth.Have been found that on the fiber cross sectional dimension to reduce between the bottom 17 of tuft 6 and tip part 31 be maximum.Believe that this is because the cause of preferred manufacture method, as following disclosed in detail.In simple terms, as shown in Figure 3, it is believed that tuft 6 bottom 17 and not taper divide the fiber at 31 places contiguous below the top of the gear piece 110 of roller 104 in greater detail, and in the course of processing, locked and fix by frictional property.Therefore, the mid portion of tuft 6 is more free to stretch, or prolongs, and therefore can experience reducing of corresponding fiber cross sectional dimension.The fiber of some first precursor web 20 may laterally push the base portion 17 of tuft 6.The base portion 17 of tuft 6 even can be closed (if from the fiber close enough of tuft 6 together to contact) or keep opening wide.Usually, any opening at base portion 17 places all is narrow.Can help to stablize the tuft 6 and second precursor web 21 in the closure of base portion 17 other fibers of place or constriction or extruding.

Referring to Fig. 5, its demonstration is used to make a kind of apparatus and method of fleece 1 of the present invention.Device 100 comprises a pair of intermeshing roller 102 and 104, and all around axis A rotation, axis A is parallel in same plane for each.Roller 102 comprises a plurality of protruding 106 and corresponding grooves 108, and they intactly stretch along the whole circumference of roller 102.Roller 104 is similar to roller 102, but do not have the projection that intactly stretches along whole circumference, many rows that roller 104 comprises have been improved to the gear piece of in a row opening along the circle spacing 110 along the projection of circumferential extension, and this gear piece stretches in the spaced around of at least a portion roller 104.The individual rows of teeth 110 of roller 104 is separated by corresponding grooves 112.In operation, roller 102 and 104 engagements make the projection 106 of roller 102 extend in the groove 112 of roller 104, and the gear piece 110 of roller 104 extends in the groove 108 of roller 102.Being meshing with each other is illustrated in greater detail in the cross sectional representation of Fig. 6, hereinafter can be discussed. Roller 102 and 104 both or one of them can heat by methods known in the art, for example use deep fat to fill roller or electric heating roller.

In Fig. 5, device 100 illustrates with preferred structure, and it has a patterned roll for example roller 104 and a non-rollet roller 102.Yet, in certain embodiments, use two patterned roll 104 may be for preferably, these two rollers have identical or different decorative pattern in the identical or different corresponding region of roller separately.Such device can be produced the fleece with tuft 6, and described tuft 6 stretches out from the both sides of fleece 1.Also can design a device, described device has the gear piece of directed in opposite directions on same roller.This will cause all producing in fibroreticulate two sides the fleece of tuft 6.

The method of making fleece 1 of the present invention with the continuation method of viable commercial is depicted among Fig. 5.Fleece 1 is made as first and second precursor web 20 and 21 by mechanically being out of shape precursor web, its each all can be described as by device first being processed shown in Figure 5 be generally planar and two-dimentional.So-called " planar " and " two dimension " only is meant that fleece begins processing with the state of general planar for finished fiber net 1, and described finished fiber net 1 is because the shaping of tuft 6 has three-dimensional tangible, out-of-plane, the Z-direction." planar " and " two dimension " do not infer any specific plane, smoothness or dimension.

Method and apparatus of the present invention is similar to the United States Patent (USP) 5 of called after " Web MaterialsExhibiting Elastic-Like Behavior " in many aspects, 518,801 described methods, and in patent documentation afterwards, be called as " SELF " fleece, " SELF " representative " Structural Elastic-like Film ".Yet, have marked difference between the disclosed apparatus and method in apparatus and method of the present invention and ' 801 patents, thereby difference is obvious in the fleece of making separately.As described below, the gear piece 110 of roller 104 has concrete how much character relevant with leading edge and trailing edge, and its leading edge allows basic " wearing " the relative excessively precursor web 20,21 of gear piece with trailing edge, comes down to make the fleece distortion.In a two-layer laminate web 1, gear piece 110 is released outside the plane simultaneously fiber from first precursor fiber 20 and is passed second precursor web 21 (it we can say that the gear piece 110 that fiber 8 was pushed away dashes saturating) to form tuft 6.Therefore, fleece 1 of the present invention can have and runs through and away from " passage shape " tuft 6 of the fibrae circulares 8 of the tuft 6 of the loose fiber ends 18 on the surface 13 of first side 3 and/or alignment, different with SELf fibroreticulate " tent like " rib linear element, each all has coupled continuous side walls SELf fibroreticulate " tent like " rib linear element, and it does not show to have the perforation that one deck penetrates another layer.

Precursor web 20 and 21 or by their web manufacture methods separately directly or by supply volume indirectly (all not shown) provide and move in the vertical in the roll gap 116 of be meshing with each other roller 102 and 104 of counter-rotating.The well-known process that precursor web is preferably handled with this area fleece keeps enough web tension so that enter roll gap 16 with roughly straight state.When each precursor web 20,21 during by roll gap 116, simultaneously the part of first precursor web 20 to be released the plane of first precursor web 20 outer and pushed away second precursor web 21 with formation tuft 6 with the gear piece 110 of the groove 108 intermeshing rollers 104 of roller 102.In fact, gear piece 110 " pushed away the fiber of first precursor web 20 " or " breaking through " second precursor web 21.

When the top of gear piece 110 pushed away first and second precursor web 20,21, with gear piece 110 intersect by advantage be oriented in the precursor web of CD direction the part of fiber released outside the plane of first precursor web 20 by gear piece 110.Fiber can be pushed out outside the plane owing to fiber mobility, and perhaps they can be pushed out outside the plane by upwards stretching at Z and/or carrying out plastic deformation.Also can be promoted the fiber of planar second precursor web 21 by the part of planar first precursor web 20 of gear piece 110 releases, perhaps they can push away second precursor web 21 (if it has relatively low ductility), caused tuft 6 to be formed on first side 3 of fiber 1 thus.Be to be launched and remain on substantially their initial random orientation states mainly by gear piece 110 being roughly parallel to longitudinal axes L (promptly on precursor web 20MD as shown in Figure 1) precursor web 20 of direction orientation and/or 21 fiber.Here it is why in embodiment (this as shown in Fig. 1 to 4) fibrae circulares 8 can show reason with unique fiber alignment, this fibrae circulares 8 accounts for the significant percentage of each tuft 6 fiber, and described tuft 6 has the effective vector component or the master vector component of the axis T that is parallel to tuft 6.

Be appreciated that when preparing fleece 1 that by above-mentioned explanation precursor web 20,21 can have with precursor web destroys the relevant differing material properties of (as owing to tensile stress is destroyed) preceding elongation ability with apparatus and method of the present invention.Specifically, non-woven first precursor web 20 can have than bigger fiber mobility of second precursor web 21 and/or bigger elongation characteristics relative, make its fiber can fully move or extend to form tuft 6, second precursor web 21 is broken simultaneously, promptly is not elongated to form the necessary degree of tuft.Yet in other embodiments, two precursor web all have enough percentage elongations, make its fiber can move fully or extend to form tuft 6.

The fiber of nonwoven precursor web can stretch out outside the plane and plastic-less deformation's degree can be depending on the degree of precursor web inter-fiber.For example, if the fiber of nonwoven precursor web only is that very loosely is entangled to each other, they will be easier slide (promptly moving with respect to adjacent fibre by reptation) between mutually so, and therefore easier stretching out with the formation tuft on the plane outside.On the other hand, the fiber of the nonwoven precursor web of more bonding (for example by a large amount of thermal point bond, water entanglement method etc.) will more may need to stretch out out-of-plane tuft and has plastic deformation greatly.Therefore, in one embodiment, first precursor web 20 can be to have the adherent non-woven webs of relatively low fibrous inside, and second precursor web 21 can be to have the adherent non-woven webs of relative high inter-fiber, make the extended plane of fiber of the precursor web of winning like this, and the fiber of second precursor web 21 can not stretch out the plane.When enough power was applied to first precursor web 21, fiber wherein was tending towards stretching, and the not tensible of fiber of second precursor web, and be tending towards breaking.

Number, spacing and size that can be by changing gear piece 110 and if necessary pair roller 104 and/or roller 102 carry out number, spacing and the size that corresponding change in size changes tuft 6.This change adds may change in the precursor web 20,21, can allow to prepare to be used for multi-purpose many various fleeces 1.For example, by comprise have MD and CD weave the extending line of plasticity the higher basis weights Woven fabric first precursor web 20 and comprise that the fleece 1 that higher basis weights, second precursor web 21 of low ductile synthetic polymer non-woven material are made can be made into firm, porous mulch film, as be used for reducing the erosion protection system that ramp way damages and the native country vegetation can be grown at unsettled soil.

What Fig. 6 showed is the roller 102 and 104 of part engagement, and the cross section of projection 106 and gear piece 110.As shown in the figure, gear piece 110 has tooth height TH and (notices that TH also can be applicable to height of projection; Tooth height equates with height of projection in preferred embodiments), and the spacing of gear piece and gear piece (or spacing of projection and the projection) section of being called is apart from P.As shown in the figure, depth of engagement E is measuring of roller 102 and 104 mesh degrees, and is to measure from top to the top of gear piece 110 of projection 106.According to the characteristic of the character of precursor web 20,21 and required fleece 1, the degree of depth of engagement E, tooth depth TH and section change as required apart from the P shell.For example, generally speaking, the level of engagement is big more, and flowability is big more between percentage elongation of necessity that the fiber of first precursor web 20 must have or fiber and fiber.Equally, the required density (tuft 6 on the per unit area fleece 1) of tuft 6 is big more, and section is apart from should be more little, and the long TL of tooth and tooth pitch TD should be more little, and is as described below.

Fig. 7 represents to have an embodiment of the roller 104 of a plurality of gear pieces 110, this roller can be used for by basic weight between about 60gsm and 100gsm, preferably non-woven first precursor web 20 of about 80gsm and density be about 0.91 to 0.94 and basic weight be about 20gsm polyolefin film (as, polyethylene or polypropylene) second precursor web 21 makes terry cloth-like fleeces 1.

The zoomed-in view of tooth 110 as shown in Figure 8.In this embodiment of roller 104, tooth 110 has consistent circumferential length size TL, and 111 tailing edge TE is measured as about 1.25mm from forward position LE to tooth top usually, and mutual spacing is identical, is about 1.5mm apart from TD.For making terry-cloth web 1 at about 60 fleeces 1 to about 100gsm scope by total basic weight, the length T L scope that the gear piece 110 of roller 104 can have is from about 0.5mm to about 3mm, and spacing TD is that about 0.5mm is to about 3mm, tooth depth TH scope for about 0.5mm to about 5mm, and section apart from P between about 1mm (0.040 inch) and about 5mm (0.200 inch).Depth of engagement E is that about 0.5mm is to about 5mm (equaling tooth height TH up to maximum).Certainly, E, P, TH, TD and TL can change size, spacing and the area density (tuft 6 numbers of per unit area fleece 1) to obtain required tuft 6 independently of each other.

As shown in Figure 8, each gear piece 110 has top 111, leading edge LE and trailing edge TE.Tooth tip 111 is elongated and has with tuft 6 and be interrupted the corresponding roughly direction longitudinally of 16 longitudinal axes L.It is believed that the looped tufts 6 (this fleece can be described to terry cloth-like) for obtaining 1 bunch of fleece, LE and TE should almost completely be orthogonal to the local periphery surface 120 of roller 104.Equally, from the top 111 and the transition of LE or TE should be acute angle (for example right angle), and have enough little radius of curvature and make gear piece 110 push through second precursor web 21 at LE and TE place.Be not bound by theory, it is believed that the top transition that has into relative acute angle between the top of gear piece 110 and LE and the TE make gear piece 110 can " neatly ", that is to say, local and clearly penetrate precursor web 20,21, make first side 3 of gained fleece 1 can be described as " bunch shape " rather than " shapeless " like this.When adding man-hour like this, except that the elasticity that precursor web 20 and 21 may have at first, fleece 1 is not endowed any special elasticity.

Not bound by theory, it is believed that if the fiber of precursor web has the altitude curve shape as crimped fibre, compare with more linear fiber conformation so, gained tuft 6 will have more fibrae circulares 8 and less broken fiber 18.The chance that it is believed that the bridging between two adjacent teeth of this fiber conformation is less, and because they and be not easy stretch to surpass its breakaway poing, the chance that therefore forms complete circulus is bigger.In addition, these curvilinear-shaped fibers also can be made by using eccentric bicomponent fibers or side-by-side bicomponent fibre (as the bicomponent fibre of being made up of polyethylene and nylon).

In preferred embodiments, first and second precursor web are for wherein existing the non-woven webs of minimum fiber and inter-fibre-bond.For example, precursor web can be the non-woven webs with pattern of discrete thermal point bonds, and this is generally known in the non-woven webs field.Yet, generally speaking, it would be desirable that the number that makes bounding point is minimum and make the spacing maximum to allow maximum fiber mobility and displacement during tuft 6 forms.Generally speaking, utilize fiber to cause the formation of tuft 6 better and more obvious with higher diameter and/or higher fracture elongation and/or higher fiber flowability.

Although fleece 1 is disclosed in the two layer web of being made by two precursor web in preferred embodiments, it need not be confined to two-layer.For example, can make three layers or more laminated material, as long as one of precursor web is extending and push through the formation tuft from the opening of another layer by three precursor web.For example, fleece 1 can comprise top flat, second top flat and the core of feminine hygiene article.Usually, needn't utilize binding agent or other adhesive bonding method to make laminate web 1.

The component layers of fleece 1 (for example, precursor web 20 and 21 and any other the layer) can utilize " pinning " effect of the tuft 6 of the opening 4 that runs through second precursor web 21 to keep with face-to-face laminated relation.In some embodiments, use optimal binding agent or hot adhesion or other adhesive bonding method of being to use according to the final use of fleece 1.For example, the fleece 1 that comprises the bicomponent fibre non-woven webs can carry out through-air bonded after tuft 6 forms provides bigger layer of peel strength and layer adhesion.In addition, it would be desirable at least a portion that binding agent is applied to one of precursor web.For example, in certain embodiments, the specific region that binding agent, chemical adhesion, resin or powder-stuck between the layer or thermal optionally are applied to precursor web or whole.For example, using under the situation of binding agent, binding agent can be used in a continuous manner, as by the slot type coating, or uses in discontinuous mode, as by spraying, extrude etc.The discontinuous forms such as can be bar, band, droplet of using of binding agent.

When as the top flat in the disposable absorbent article such as sanitary towel, in a multi-layered web 1, each precursor web can have different material behaviors, thereby useful characteristic is provided for fleece 1.For example, comprise two-layer (or multilamellar) precursor web for example the fleece 1 of first and second precursor web can have useful flow handling feature.For example, for good fluid treatment, first precursor web 20 can be by hydrophilic relatively fibrous.Second precursor web 21 can be by hydrophobic relatively fibrous.A kind of so fibroreticulate tuft 6 can form has the hydrophobic relatively top flat towards body surface, and wherein hydrophilic tufts is dragged fluid health away from and seen through top flat.Depositing fluid on superincumbent, the hydrophobic relatively tuft can be transferred to goods apace away from relative hydrophobic layer and be in part (for example absorbent cores) below second precursor.Be not bound by theory the fiber 8,18 of the approximate vertical alignment that a reason that it is believed that the compressive property of viewed fleece 1 is a tuft 6. Fiber 8,18 forms the support column of the directivity alignment of impedance compression.

Figure 10 represents sanitary towel's plane graph of part excision, and described sanitary towel is with the parts one of of fleece 1 of the present invention as it.Generally speaking, sanitary towel 200 comprise egative film 202, top flat 206 and be arranged on top flat 206 and egative film 202 between absorbent cores 204, they can 210 engage around periphery.Sanitary towel 1 can have the lateral side extension in crotch district that is used for covering sanitary towel's 1 user medicated underpants, is commonly referred to " flap " 208.Sanitary towel comprises as its top flat towards body surface, is well-known in the art and need not the detailed description of various alternative and optional patterns.Except sanitary towel, fleece 1 also can be used in diaper or adult incontinence products or other disposable sanitary product.Yet, notice that fleece 1 can be used as one or more in egative film, core, top flat, second top flat or the flap material, or as their parts.Fleece 1 also can have multilamellar, and comprises top flat, second top flat, core, egative film or any several target zone.

Fleece 1 is particularly suited for the top flat 206 as sanitary towel 200.Because the combined effect of its good fluid acquisition performance and compressive property can prevent that fluid from bleeding back to the surface towards health of top flat 206 when using, fleece 1 especially is of value to the top flat 206 as sanitary towel.The reason that bleeds back has two at least: (1) is because the pressure in the sanitary towel 200 is extruded the fluid that is absorbed; And/or (2) at top flat 206 inner or above collected humidity.In preferred top flat 206, its two kinds of performances, fluid acquisition performance and compressive property all are maximized, and are minimized and bleed back.Different is that preferably top flat has high rates of fluid acquisition and low-level bleeding back with demonstration.

In sanitary towel of the present invention, top flat 206 can have the detergent composition that is administered on it.Detergent composition can be any known lotion, for example comprises the lotion of vaseline, and described lotion can provide the effect of skin-friendly to user.In a preferred embodiment, lotion also provides the beneficial effect of cleaning health to user.That is to say that lotion preferably applies health and makes menstruation be not easy to adhere on the health that comprises hair and skin.Therefore, preferably lotion is hydrophobic, and causes hair and skin hydrophobic.

Can lotion be administered to the online any way lotion application of non woven fibre with known in the art being used for.Lotion can be applied on the top (that is far-end) of tuft 6.Have been found that lotion is administered on the top and can be transferred to effectively on wearer's the skin.Be not bound by theory, it is believed that tuft plays acting on of small brushes and during motion is for example taken a walk lotion wiped on the health.

Lotion of the present invention can comprise following patent disclosed those: US 5,968,025, US6,627,787, US 6,498,284, US 6,426, and 444, US 6,586,652, US 3,489, and 148, US6,503,526,6,287,581, US 6,475,197, US 6,506, and 394, US 6,503,524, US6,626,961, WO 2000038747 or EP-A 927,050.

Except lotion-treated (or replacing lotion-treated), available other material of top flat 206 (or its part) or compositions are handled to give its sufficient hydrophobicity.For example, top flat can be handled with siloxanes inorganic agent, low-surface-energy inorganic agent, fluorinated hydrocarbons inorganic agent.Generally speaking, the hydrophobic relatively contact angle of material or compositions and water that is meant is at least about 70 degree, preferably at least about 90 degree.Generally speaking, low-surface-energy is meant and is lower than about 5.5Pa (every square centimeter of 55 dyne), is preferably to be lower than about 2.6Pa (every square centimeter of 26 dyne), more preferably about 3.0 to about 5.0Pa (30 to every square centimeter of about 50 dyne).

In a preferred embodiment, fleece 1 is used as the top flat 206 with core 204 combination of high power capacity and high absorption.Generally speaking, preferred absorbent cores is the air lay core, and its type is disclosed in US 5,445,777; Or among the US 5,607,414.In preferred embodiments, absorbent cores 204 for example is disclosed in US 5,550 for being commonly called the type of hipe foam, those types in 167, US5,387,207, US 5,352,711 and 5,331,015.In preferred embodiments, absorbent cores 204 has himself the free absorbability less than about 10% after the desorbing of 30cm; From about capillary absorption pressure of 3 to 20cm; Capillary tube desorption pressures from about 8 to about 25cm; From about 5 to about 85% compression deflection resistance capabilities when under the confined pressure of 5.10kPa (0.74psi), measuring; And from the free absorbability of about 4 to 125 gram/grams.In these parameters each all can be as being determined of being stated among the US that authorizes DesMarais 5,550,167 that announces on August 27th, 1996 like that.It is very thin that an advantage utilizing air lay as disclosed or hipe foam core is that absorbent cores can make.For example, absorbent cores of the present invention can have less than about 20mm, and preferably less than the average thickness (thick) of about 10mm, and thickness can be less than about 5mm.

Table 1 shown below shows the fibroreticulate packed data of the present invention, also shows the contrast fleece.In table 1,1 to 3,5 and No. 7 sample is the contrast sample, and 4,6 and 8 to No. 13 sample is a fleece of the present invention.

Sample 1 be can be used for ALWAYS ^The DRI-WEAVE of sanitary towel ^The polyethylene film of the molding that top flat is compared is available from Tredegar Film Products, Terre Haute, IN.

Sample 2 for the professor of US 4,629,643 that is pursuant to December in 1986 and authorized people such as Curro on the 16th by Tredegar Film Products, Terre Haute, the polyethylene film of the molding that IN makes.

Sample 3 is the 30gsm spun-bonded fibre net of 50/50PE/PP bicomponent fibre, available from BBA, and Simpsonville, SC.

Sample 4 is a fleece of the present invention, is processed into according to method as herein described by the fleece of sample 3.

Sample 5 is the combing non-woven webs, and it comprises 50%6 dawn (dpf) PE/PP bicomponent fibre and 50%6 dawn pet fibers, available from BBA, and Simpsonville, SC.

Sample 6 is made by method as herein described by the fiber of sample 5.

Sample 4 and 6 is for to make by method as herein described with a precursor web.Sample 8 to 13 is for precursor web is manufactured according to the present invention as described herein with two, and wherein two precursor web are all contributed fiber with the configuration (so to say that) of intussusception to tuft.Therefore, the fiber of second precursor web is not " passing " but be shaped in the tuft with the fiber of first precursor web, and two fleeces are all to tuft contribution fiber.

Sample 8 is to be made by method as herein described by the laminated material of the double-deck fibrous nonwoven webs of sample 7.The ground floor of sample 7 comprises the 30gsm fleece of 50/50PE/PP bicomponent fibre, and the second layer is the 45gsm fleece, and it comprises 50%6 dawn 50/50PE/PP bicomponent fibres and 50%9 dawn PP fibers.Two kinds of fleeces are all available from BBA, Simpsonville, SC.

Sample 9 is for to be made by methods described herein by a kind of twin-layered laminate, wherein the ground floor and the second layer comprise the 30gsm fleece of PE/PP bicomponent fibre, and such as known in the art, the second layer be through surfactant handled to give its higher relatively hydrophilic.Described 30gsm fleece is available from BBA, Simpsonville, SC.

Sample 10 is for to be made by methods described herein by a kind of laminated material of double-deck fibrous nonwoven webs, wherein ground floor comprises the 30gsm fleece of PE/PP bicomponent fibre, and the second layer is the 45gsm fleece, and it comprises 50%6 dawn PE/PP bicomponent fibres and 50%6 dawn pet fibers.Two kinds of fleeces are all available from BBA, Simpsonville, SC.

Sample 11 is for to be made by methods described herein by a kind of laminated material of double-deck fibrous nonwoven webs, wherein ground floor comprises and is derived from Pegas, the 30gsm fleece of the PE/PP bicomponent fibre of Czech Republic, and the second layer is the 45gsm fleece, it comprises 50%6 dawn PE/PP bicomponent fibres and 50%6 dawn pet fibers, available from BBA, Simpsonville, SC.

Sample 12 and 13 each all be to make by methods described herein by a kind of laminated material of double-deck fibrous nonwoven webs, wherein ground floor comprises the 30gsm fleece of 50/50PE/PP bicomponent fibre, and the second layer is the 45gsm fleece, and it comprises 50%6 dawn 50/50PE/PP bicomponent fibres and 50%6 dawn pet fibers.Two kinds of precursor web are all available from BBA, Simpsonville, SC.

In the sample of the present invention shown in the table 1 each all is that the roll gap by roller in the mesh as described above processes according to the present invention, its section is 1.5mm (about 0.060 inch) apart from P, the high TH of gear piece is about 3.7mm (about 0.145 inch), and gear piece spacing TD is that 1.6mm (about 0.063 inch) and the long TL of gear piece are 1.25mm (about 0.050 inch).The depth of engagement DOE and the linear velocity of each sample of the present invention all are shown in the table 1.

As shown in table 1, have good density and specific volume characteristic under the simulation load of fleece of the present invention experience in sanitary towel's dress.For example, the pressure that 0.028kPa (0.004psi) can be experienced when standing, and the pressure that 1.586kPa (0.23psi) can be when being seated on the soft surface, and the situation that 0.75se can be when being seated on the hard surface.

Table 1: each fibroreticulate contrast of the present invention

Sample	1	2	3	4	5	6
							First precursor web	Formed film	Formed film	30gsm 50/50 PE/PP bi-component	30gsm 50/50 PE/PP bi-component	45gsm carding 50%6dpf PE/PP-50%6 dpf polyethylene terephthalate	45gsm carding 50%6dpf PE/PP-50%6 dpf polyethylene terephthalate
Second precursor web	Inapplicable	Inapplicable	Inapplicable	Inapplicable	Inapplicable	Inapplicable
							Total basic weight (gsm)	25	25	30	30	45	45
The depth of engagement (cm (inch))	N/A	Inapplicable	Inapplicable	0.254 (0.100)	Inapplicable	0.254(0.100)
							Linear velocity (rice (foot) per minute)	N/A	Inapplicable	Inapplicable	366(1200)	Inapplicable	366(1200)
0.028kPa the density in the time of (0.004psi) (g/cm3)	0.020	0.026	0.088	0.021	0.029	0.017
							1.59kPa the density in the time of (0.23psi) (g/cm3)	0.047	0.053	0.158	0.068	0.065	0.040
5.17kPa the density in the time of (0.75psi) (g/cm3)	0.061	0.119	0.231	0.094	0.096	0.088

0.028kPa the specific volume in the time of (0.004psi) (cm3/g)	50.4	38.4	11.3	47.7	34.9	57.3
							1.59kPa the specific volume in the time of (0.23psi) (cm3/g)	21.2	18.8	6.3	14.7	15.3	25.1
5.17kPa the specific volume in the time of (0.75psi) (cm3/g)	16.4	8.4	4.3	10.7	10.4	11.3
							0.028kPa the voidage in the time of (0.004psi) (cm3/g)	49.3	37.3	10.2	46.6	34.0	56.5
1.58kPa the voidage in the time of (0.23psi) (cm3/g)	20.1	17.7	5.2	13.6	14.5	24.2
							5.17kPa the voidage in the time of (0.75psi) (cm3/g)	15.3	7.3	3.2	9.6	9.6	10.5

Conversion: 1 inch=25.4mm; 1psi=6.89kPa; 1 foot=304.8mm.

Table 1, continuous

Sample	7	8	9	10	11	12	13
								First precursor web	30gsm 50/50 PE/PP bi-component	30gsm 50/50 PE/PP bi-component	30gsm 50/50 PE/PP bi-component	30gsm 50/50 PE/PP bi-component	30gsm 50/50 PE/PP bi-component	30gsm 50/50 PE/PP bi-component	30gsm 50/50 PE/PP bi-component
Second precursor web	45gsm 50%6 dpf PE/PP-50%6 dpf PETGs	45gsm 50％6 dpf PE/PP/ 50％9 dpf PP	30gsm 50/50 PE/PP bi-component w/ surfactant	45gsm 50%6 dpf PE/PP-50%6 dpf PETGs	45gsm 50%6 dpf PE/PP-50%6 dpf PETGs	45gsm 50%6 dpf PE/PP-50%6 dpf PETGs	45gsm 50%6 dpf PE/PP-50%6 dpf PETGs
								Total basic weight (gsm)	75	75	60	75	75	75	75
The depth of engagement (cm (inch))	N/A	0.3429 (0.135)	0.3429 (0.135)	0.3429 (0.135)	0.254 (0.100)	0.254 (0.100)	0.254 (0.100)
								Linear velocity (rice (foot) per minute)	N/A	7.62(25)	7.62(25)	152.4 (500)	365.7 (1200)	15.24 (50)	7.62 (25)
0.028kPa the density in the time of (0.004psi) (g/cm3)	0.039	0.025	0.027	0.026	0.027	0.025	0.027
								1.58kPa the density in the time of (0.23psi) (g/cm3)	0.081	0.042	0.076	0.061	0.053	0.043	0.042
5.17kPa the density in the time of (0.75psi) (g/cm3)	0.110	0.084	0.125	0.100	0.107	0.077	0.066
								0.028kPa the specific volume in the time of (0.004psi) (cm3/g)	25.7	39.7	37.3	38.3	37.2	40.7	37.6
1.58kPa the specific volume in the time of (0.23psi) (cm3/g)	12.4	24.0	13.2	16.3	18.8	23.3	24.0
								5.17kPa the specific volume in the time of (0.75psi) (cm3/g)	9.1	11.9	8.0	10.0	9.3	13.1	15.2
0.028kPa the voidage in the time of (0.004psi) (cm3/g)	24.8	38.6	36.2	37.3	36.2	39.7	36.6
								1.58kPa the voidage in the time of (0.23psi) (cm3/g)	11.4	22.9	12.1	15.3	17.8	22.4	23.0
5.17kPa the voidage in the time of (0.75psi) (cm3/g)	8.1	10.8	6.9	9.0	8.4	12.1	14.2

Conversion: 1 inch=25.4mm; 1psi=6.89kPa; 1 foot=304.8mm.

Method of testing

Voidage and specific volume can be determined with following method:

Voidage

Compression voidage usefulness MTS tensile tester down is with 0.028,1.58 and the calculation of pressure of 5.17kPa (0.004,0.23 and 0.75 pound per square inch).Tensile tester is measured the resistance when material is compressed between moveable platen and fixed pedestal.Material is compressed to the power of 1000g with constant rate of speed.Power and platen position go on record.

Voidage during given platen position is calculated with this formula:

Wherein:

VV=is in the voidage of the material of the every gram of cubic centimetre

x ₀=sentence the initial platen position that millimeter is counted from pedestal

X=is from the platen position of initial position in millimeter

A _m=in the area of the material of square centimeter

M=is in the quality of the material of gram

ρ _Fiber=to restrain every cubic centimetre fibre density

For the fleece of being made by multiple fiber type, fiber net fiber density is each single weighted mean of planting fibre density.

ρ _{Fiber, total amount}=(wt% _{Fiber 1}) (ρ _{Fiber 1})+(wt% _{Fiber 2}) (ρ _{Fiber 2})+... ..

Wherein:

In the wt%=fleece percentage by weight of fiber type or:

The suitable device of this test can comprise tensile tester (MTS model Alliance RT/1 tape test working software and 50N force cell).Checker must have fixed pedestal bigger than platen on the size.Zero elevation between platen and the pedestal is set till first fundamental force is measured to by reducing platen, and platen is subsequently by the incremental change that gos up, and clip position is made zero.For each sample, sample spaces and is higher than fixed pedestal to and sets greater than the distance of material original depth by raising platen.The masterpiece that is lowered up to 1gf from this position platen is used for sample.Go on record from this position of zero elevation metering and to be used as initial platen position (x ₀), and clip position is made zero again.

In this test, the circular platen of a 4.9cm diameter be used to relative pedestal with the speed of 0.51cm/min from 1 to 1000gf compression material (0.75 pound pressure per square inch).For each sample, platen is retracted into initial platen position subsequently with identical speed.Initial platen position or test are spaced and are changed according to the thickness of material described above.Repeat to do five times for isolating exemplar, get five results' meansigma methods.Every tested sample of material on area all greater than platen, but on area less than fixed pedestal.

Specific volume

Compression specific volume usefulness MTS tensile tester down is with 0.028,1.58 and the calculation of pressure of 5.17kPa (0.004,0.23 and 0.75 pound per square inch).Tensile tester is measured the resistance when material is compressed between moveable platen and fixed pedestal.Material is compressed to the power of 1000g with constant rate of speed.Power and platen position go on record.

Specific volume during given platen position calculates with this formula:

SV=l/ ρ _Fleece

Fleece density during given platen position is calculated with this formula:

Wherein:

SV=is in the space specific volume of the material of the every gram of cubic centimetre

ρ _Fleece=non-woven webs to restrain every cubic centimetre density

x ₀=sentence the initial platen position that millimeter is counted from pedestal

X=is from the platen position of initial position in millimeter

BW=is to restrain the quality of every square metre material

The suitable device of this test can comprise tensile tester (MTS model Alliance RT/1 tape test working software and 50N force cell).Checker must have fixed pedestal bigger than platen on the size.Zero elevation between platen and the pedestal is set till first fundamental force is measured to by reducing platen, and platen is subsequently by the incremental change that gos up, and clip position is made zero.For each sample, sample spaces and is higher than fixed pedestal to and sets greater than the distance of material original depth by raising platen.The masterpiece that is lowered up to 1gf from this position platen is used for sample.Go on record from this position of zero elevation metering and to be used as initial platen position (x ₀), and clip position is made zero again.

In this test, the circular platen of a 4.9cm diameter be used to relative pedestal with the speed of 0.51cm/min from 1 to 1000gf compression material (0.75 pound pressure per square inch).For each sample, platen is retracted into initial platen position subsequently with identical speed.Initial platen position or test are spaced and are changed according to the thickness of material described above.Repeat to do five times for isolating exemplar, get five results' meansigma methods.Every tested sample of material on area all greater than platen, but on area less than fixed pedestal.

From the description of above fleece of the present invention 1 and device 100, be appreciated that the structure that can under the situation that does not deviate from protection scope of the present invention, produce many various fleeces 1, as in additional claims, being subjected to those of claims protection.For example, top flat 206 can apply or handle with medicine, cleaning fluid, antiseptic solution, emulsion, aromatic or surfactant in addition.Similarly, device 100 can be configured as and only form tuft 6 on the part of fleece 1, or forms the tuft 6 of different size or area density.

Another advantage of the fibroreticulate method of described production the present invention is that described fleece can be with other web production equipment online production or with the online production of disposable absorbent article production equipment.In addition, also existing can be in first being processed of the present invention or other solid molding method of using afterwards.For example, fleece can be processed as described herein, uses the drawing process perforate then, as authorizes the method described in people's such as Curro the United States Patent (USP) 5,658,639.Alternatively, material can be made composite by the whole bag of tricks, as authorizes U.S.'s announcement 2003/028 of people such as Curro, method described in the 165A1, or as authorize people's such as Weber United States Patent (USP) 5,167, annular roll-in in 897 is processed then as described herein.Therefore the gained fleece can show all beneficial effects that these many material improvement are brought.

The relevant portion of all documents of quoting in detailed Description Of The Invention is incorporated herein by reference; Quoting of any document can not be understood that it is to its approval as prior art of the present invention.

Although illustrated and described specific embodiments of the present invention, it will be apparent to those skilled in the art that and to make many other variation and improvement in the case of without departing from the spirit and scope of protection of the present invention.Therefore, in additional claims, comprise all these variations and the improvement that belongs in the scope of the invention consciously.

Claims (10)

1. sanitary towel, described sanitary towel comprises:

A. top flat, described top flat comprise the discrete tuft of fibrous nonwoven webs and a plurality of fibrous materials,

B. be characterised in that described top flat have under the load of 0.004psi during less than 0.027 density and load at 0.23psi less than the density of 0.068g/cc.

2. sanitary towel as claimed in claim 1, wherein said top flat comprises first and second nonwoven precursor web.

3. sanitary towel as claimed in claim 1 or 2, wherein said top flat comprises at least two precursor web, and described discrete tuft comprises the fiber that is derived from each described precursor web.

4. the described sanitary towel of each claim as described above, the tuft of wherein said material comprises many fibrae circulares.

5. the described sanitary towel of each claim as described above, wherein said top flat comprises two sides and two or more precursor web, two sides of wherein said top flat all are derived from the only fiber-covered of a described precursor web basically.

6. the described sanitary towel of each claim as described above, wherein said top flat comprises every square centimeter of 1 to 100 described discrete tuft, preferred every square centimeter of 20 to 40 described discrete tufts.

7. sanitary towel is characterised in that:

A. top flat, described top flat have towards bodyside and comprise the discrete tuft of every square centimeter of 10 to 50 fibrous materials;

B. semi-solid lotion composition, described detergent composition is applied to the described at least a portion of bodyside of described top flat; With

C. wherein said top flat have under the load of 0.004psi during less than 0.027 density and load at 0.23psi less than the density of 0.068g/cc.

8. sanitary towel as claimed in claim 7, wherein said lotion comprises vaseline.

9. as claim 7 or 8 described sanitary towels, wherein said top flat comprises first precursor web and second precursor web, and wherein at least one described precursor web has more hydrophobicity relatively with respect to described another of described precursor web.

10. sanitary towel is characterised in that:

A. top flat, described top flat comprises first precursor web and second precursor web, wherein at least one described precursor web has more hydrophobicity relatively with respect to described another of described precursor web, and wherein said top flat also comprises and is derived from described first or the discrete tuft of the fibrous material of second precursor web

B. wherein said top flat have under the load of 0.004psi during less than 0.027 density and load at 0.23psi less than the density of 0.068g/cc and

C. absorbent cores, described absorbent cores is communicated with described top flat fluid, and described absorbent cores has the average thickness less than about 7mm; With

D. egative film, described egative film joins on the described top flat.

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