JP2009542929A - Non-woven structure and manufacturing method thereof - Google Patents

Abstract

A nonwoven material that exhibits a highly desirable unique combination of visual pattern and high wear resistance for use in various products.
A laminated non-woven fabric structure comprising a fibrous water-permeable fixed layer and a fiber layer having fibers entangled with the fixed layer and having a structure in which a pattern is formed and a structure in which the pattern is not formed is provided. . Also provided are personal care products including the structure and methods of manufacturing the structure.
[Selection] Figure 2

Description

Disclosure details

(Field of the Invention)
The present invention relates generally to laminated composite materials. Specifically, the present invention provides advantageous laminating strength and one or more other advantageous such as drape, loftiness, abrasion resistance, liquid absorbency, flexibility, and / or visual appeal. And a laminated composite material exhibiting properties.

BACKGROUND OF THE INVENTION
Nonwoven materials are widely used in various commercial personal care products, including, for example, wipes and feminine hygiene products such as napkins, liners, and tampons. In many of these applications, it is desirable for the nonwoven material to have sufficient strength to maintain its integrity during use. For example, in certain uses it is often desirable to reduce the delamination that can occur between the various material layers of the nonwoven.

  Applicants have also recognized that it is desirable for such materials to have other advantageous properties with relatively high strength / integrity. For example, it may be desirable to have such a material with abrasion resistance and / or “draping” to provide comfort to the user. As used herein, the term “draping” refers to the property of a material that hangs substantially vertically due to gravity when one end of the material is held like a cantilever. A material exhibiting high drapability, for example, has a property of matching the shape with the shape of a contact surface such as the user's skin, and therefore tends to improve the user's comfort of a product made of a material with high drapability. . Applicants have also recognized that for certain applications, relatively strong nonwovens with bulkiness (ie, low density) and / or patterns are desirable.

  Accordingly, Applicants have recognized a desire for a nonwoven material that exhibits a highly desirable unique combination of high drape and / or low density and / or high laminate strength / high integrity for use in a variety of articles. ing. In addition, Applicants have recognized the need for unique methods of manufacturing such materials, including but not limited to methods of manufacturing such materials by non-woven hydroentanglement and novel patterning methods. ing.

[Summary of the Invention]
Applicants respond to the above needs by producing a fibrous composite structure having a unique and desired combination of relatively high laminate strength combined with high drape and / or low density properties.

  According to one aspect, the present invention is directed to a laminated composite material. The laminate composite includes a fibrous fluid permeable anchoring layer and a fiber layer comprising fibers entangled with the anchoring layer, the composite material having a laminate strength greater than about 20 g and a drape greater than about 4 gsm / g. Have sex.

  According to another aspect, the present invention is directed to a laminated composite material. The laminated composite material includes a fibrous fluid permeable anchoring layer and a fiber layer comprising fibers entangled with the anchoring layer, the composite material having a laminate strength greater than about 20 g and less than about 0.15 g / cc. Having a density of

  The composite material of the present invention can be used to provide significant benefits to various personal care articles. Accordingly, in another embodiment, the present invention is directed to a personal care article comprising the composite material of the present invention.

  Exemplary embodiments of the present invention will be described with reference to the accompanying drawings.

[Description of Preferred Embodiment]
According to certain embodiments, the present invention is directed to a laminated composite material comprising a fibrous fluid permeable anchoring layer and a fiber layer having fibers entangled with the anchoring layer. This laminate composite has a unique combination of relatively high laminate strength combined with one or more properties of relatively high drape and / or low density (high bulkiness or “bulk”) than conventional nonwoven structures. Show. Such unique materials advantageously also have wear resistance, durability, flexibility, comfort, and / or absorbency in certain embodiments. In certain embodiments, such materials are further useful to provide a variety of other benefits, including fluid absorbency or separability, cleanability, and peelability, in various products.

  Specifically, Applicant measured the laminate strength of a composite material according to a specific embodiment of the present invention according to a “Lamination Strength Test”, described in detail below. As can be appreciated by those skilled in the art, the high lamination strength values obtained resist the fiber layer having a fixed layer of composite material and fibers entangled with the fixed layer being separated from each other with the applied force. A low capacity value indicates a relatively high capacity, and a low lamination strength value indicates that these two layers have a relatively low capacity to withstand being separated by an applied force. In addition, Applicants have recognized that relatively high laminate strength tends to correlate with the “durability” of the laminate composite that consumers desire. According to certain embodiments, the composite material exhibits a laminate strength value of about 20 g or more, preferably about 50 g or more, more preferably about 100 g or more.

  Applicants have also measured the drapability of this structure by a “drapability test” which will be understood by those skilled in the art and described in detail below. Applicants have found that in certain embodiments, the structure not only exhibits the desirable high lamination strength described above, but also exhibits a relatively high drape along with this high lamination strength. Specifically, according to certain embodiments, the structure has about 4 basis weight / g (gsm / g) or more, preferably about 6 basis weight / g (gsm / g). More preferably, the draping property (basis weight / MCB) is about 8 basis weight / g (gsm / g) to 16 basis weight / g (gsm / g).

  Applicants have also determined the density of the composite material of certain preferred embodiments of the present invention according to a “density test”, which is understood by those skilled in the art and described in detail below. Applicants have found that in certain embodiments, the structure not only exhibits the desirable high lamination strength described above, but also exhibits a relatively low density in conjunction with this high lamination strength. According to certain embodiments, the structure has a density that is about 0.15 g / cc or less, more preferably about 0.12 g / cc or less, and even more preferably about 0.12 g / cc to about 0.03 g / cc. Show.

  According to certain embodiments, Applicants have determined that in addition to the combination of relatively high lamination strength and relatively high drape and / or relatively low density, the composite structure of the present invention has relatively high absorbency, It further includes one or more properties selected from relatively high tensile strength, desired thickness, and combinations of two or more thereof. For example, in certain embodiments of the present invention, the laminated composite material has an absorbency greater than about 3 g / g, preferably greater than about 4 g / g, more preferably greater than about 5 g / g. In certain embodiments, the composite material has a tensile strength in the machine direction of about 10 N / 5 cm or greater, preferably about 15 N / 5 cm or greater, more preferably about 20 N / 5 cm or greater (as those skilled in the art (Measured by “tensile strength test” described later). The thickness of the composite material of the present invention can be optimized for use in a variety of articles, and any suitable / desired thickness can be used for a particular article. In certain preferred embodiments, the composite material of the present invention has a thickness of less than about 10 mm, preferably less than about 5 mm, more preferably less than about 2 mm, and even more preferably from about 0.3 mm to about 2 mm.

  FIG. 1 is a cross-sectional view illustrating an embodiment of a laminated composite material 100 consistent with the embodiments of the invention described herein. The laminated composite material 100 includes a fibrous fluid-permeable fixed layer 110 and a fiber layer 122 having fibers 120 that are at least partially entangled with the fixed layer 110.

  The fluid permeable pinned layer 110 can comprise any suitable fibrous material that is permeable to fluid. Fluid permeable means that a liquid or gas, such as water (and the like), can pass through the cross section of the fluid permeable pinned layer 110, i. It means coming out from the inner surface 114 of the fluid-permeable pinned layer 110. In certain preferred embodiments, the fluid permeable anchor layer 110 includes a network of interconnected pores 116 to facilitate fluid movement through the fluid permeable anchor layer 110. In certain preferred embodiments, the pinned layer has a pore area ratio of about 25% or greater. Preferably, the fluid permeable pinned layer 110 normally resists degradation and mechanical degradation that can be caused by the passage of high pressure fluids such as water and gas through the interior.

  In certain embodiments, the fluid permeable pinned layer 110 is relatively thin, for example, having a thickness of less than about 2000 μm, more preferably from about 3 μm to about 2000 μm. The fluid permeable pinned layer 110 can have any suitable basis weight. In certain preferred embodiments, the anchoring layer has a basis weight of from about 5 gsm to about 20 gsm, more preferably from about 5 gsm to about 15 gsm. Further, the fluid permeable pinned layer 110 is preferably mechanically integrated so as to have a tensile strength of at least about 5 N / 5 cm. In addition, the fluid permeable anchoring layer is preferably selected to have a relatively flexible (ie, not hard) Applicant recognizes that it is advantageous for the drapeability of the material incorporated in the anchoring layer. Is desirable.

  In a preferred embodiment, the fluid permeable anchoring layer 110 includes bonded fibers, including spun-bond materials or thermobonded materials, such as through-air bonded materials. It comprises or consists essentially of a polymeric material such as a material. “Through air bond” means fibers that are oriented by various means such as carding and passed through a heated air stream and bonded together. "Spunbond" is a spinneret having a diameter of the extruded fiber, which is melt-spun by extruding the molten thermoplastic polymer as fibers from normally circular capillaries, then rapidly thinned by drawing and then cooled. Means fiber. Spunbond fibers are usually continuous fibers. Suitable spunbond materials are formed from fibers having a diameter of about 3 μm to about 20 μm and a length greater than about 200 mm. The fibers of the fixed layer can include heterophasic fibers formed from materials such as polyolefins such as polypropylene and polyethylene, polypropylene, polyethylene, or combinations thereof. Subsequently, the spunbond fibers can be compressed to increase strength and reduce thickness. In a preferred embodiment, the fluid permeable pinned layer 110 comprises or consists essentially of a spunbond material.

  The outer surface 112 of the fluid permeable pinned layer 110 is typically a wear resistant surface. “Abrasion resistance” usually means that the outer surface 112 is not deteriorated by an elastic material such as a hand rubbing the outer surface 112 or the surface of another body.

  The laminated composite material 100 includes fibers 120 that are at least partially entangled with a fluid-permeable pinned layer 110. Such fibers are preferably bonded to the fiber layer 122. Preferably, the fibers entangled with the fluid permeable anchor layer 110 include a plurality of fibers or filaments that are bonded to each other and to the fluid permeable anchor layer 110, such as by entanglement. Thus, the fluid permeable pinned layer 110 effectively functions as the “skeleton” of the laminated composite material 100.

  Entanglement of the fibers to the fluid permeable pinned layer 110 typically results in a bond at the contact surface 124 between the fiber layer 122 and the fluid permeable pinned layer 110. Although the contact surface 124 is shown as a substantially line in FIG. 1, the contact surface 124 typically has an associated thickness. The essence of the contact surface 124 is a fiber that is twisted, tied, tied, or otherwise entangled in the fluid permeable pinned layer 110.

  In certain preferred embodiments, the fibers of the anchoring layer 110 and the fiber layer 122 entangled with the anchoring layer 110 are bonded and / or chemical adhesives formed by melting the fibers and / or anchoring layer 110. Is substantially free of bonds formed using As used herein, the phrase “bonds formed by melting fibers and / or pinned layers 110 and / or bonds formed using chemical adhesives” is fixed by melting or chemical adhesives. It means a material in which less than 10 wt% of the fibers of the fiber layer 122 bonded to the layer 110 are bonded. Preferably, this material contains less than 5% of the fibers of the fiber layer 122 that are bonded to the anchoring layer 110 by melt or chemical adhesive, more preferably none. Applicant does not wish to be bound or limited by any theory of operation, but the bond between the fibers of the fiber layer 122 and the fluid permeable pinned layer 110 is not a melt bond or a chemical adhesive, but a physical bond. It is considered that the laminated composite material 100 obtained tends to have a better drape by limiting to the general entanglement.

  A wide variety of fibers can be selected for use in the fiber layer 122. Examples of suitable fibers include fibers derived from cellulose, polyester, rayon, polyolefin, polyvinyl alcohol, or polyamide, or other synthetic fibers, and combinations of two or more thereof. Examples of certain suitable fibers may include only one type of cellulose, polyester, rayon, or polyolefin, or a combination of two or more types. Examples of suitable commercially available fibers include “Galaxy” rayon fibers sold by Kelheim Fibers, Kelheim, Germany, or ranging AG (Lenzing), Lenzing, Austria. And Tencel lyocell fibers sold by AG).

  In certain embodiments of the invention, the fibers include, for example, cellulose such as wood pulp. In one embodiment of the invention, the fiber layer 122 comprises about 0% to about 100% pulp, more preferably about 5% to about 50% pulp.

  In certain preferred embodiments of the present invention, the wood pulp has a reduced hydrogen bonding capacity. Wood pulp with reduced hydrogen bonding capacity is a liquid suspension of pulp with a water-soluble alkali metal salt solution having an alkali metal salt concentration of about 2 wt% to about 25 wt% at 15 ° C. to about 60 ° C. It can be formed by a process that includes processing for 5 minutes to about 60 minutes. Suitable reagents for caustic treatment include, but are not limited to, hydroxides such as sodium hydroxide, potassium hydroxide, calcium hydroxide, and rubidium hydroxide, lithium hydroxide, and benzyltrimethylammonium hydroxide. Mention may be made of alkali metals. Sodium hydroxide is a particularly preferred reagent for use in caustic treatment to produce cellulose fibers suitable for forming superabsorbent cellulose fibers according to the present invention. The wood pulp is about 4 wt% to about 30 wt%, more preferably about 6% to about 20%, most preferably about 12 wt% to about 16 wt% sodium hydroxide (or any other suitable amount) based on the weight of the aqueous solution. It is preferable to treat with an aqueous solution containing a caustic substance). Caustic treatment can be performed during or after bleaching, purification, and drying. Preferably, the caustic treatment is performed during the bleaching and / or drying process. Pulp produced in this way is sometimes referred to as “caustic pulp” or “mercelized pulp”. Examples of commercially available caustic extracted pulp suitable for use in the present invention include, for example, Polozania-J sold by Rayonier Performance Fibers Division, Jesup, Georgia. -HP (Porosanier-J-HP), Buckeye's HPZ sold by Buckeye Technologies, located in Perry, Florida, and Federal Way, Washington The TRUCELL marketed by Weyerhaeuser company in can be mentioned.

  In another preferred embodiment of the invention, the pulp with reduced hydrogen bonding capacity is crosslinked. “Crosslinked fibers” refer to cellulose fibers that have chemical crosslinks primarily within the fibers. That is, this cross-linking is primarily between the cellulose molecules of one fiber, not between the cellulose molecules of separate fibers.

  Cross-linked fibers are notably described in FH Steiger, published March 22, 1966, which produces individual cross-linked fibers by cross-linking fibers in an aqueous solution containing a cross-linking agent and a catalyst. The process disclosed in granted U.S. Pat. No. 3,241,553, or (2) immersing the expanded fiber in an aqueous solution containing a crosslinker to dehydrate and defiberize the fiber by mechanical manipulation; US patent granted to LJ Bernardin on December 21, 1965, where individual fibers are produced by drying and crosslinking the fibers at elevated temperatures at substantially elevated temperatures. It can be formed by various processes such as those disclosed in US Pat. No. 3,224,926. Commercially available crosslinked pulp suitable for use in the present invention is, for example, a Columbus Modified Fiber grade sold by Weyerhaeuser Corporation, Federal Way, Washington. : CHB416 is included.

  In certain embodiments, the laminated composite 100 is preferably substantially free of woven, knitted, tufted, or stitch-bonded fibers. That is, the laminated composite material preferably includes a fiber material made directly from fibers, not from yarns.

  In addition to the fibers, the fiber layer 122 can include a variety of other materials well known in the field of manufacturing nonwovens for use in absorbent articles. For example, the fiber layer 122 promotes a polymer or other chemical fiber finish, or particulate material, such as a superabsorbent that can be dispersed in fibers used to improve fluid absorbency, or a specific appearance. Pigments or other light reflectors. The fiber layer 122 is preferably substantially free of chemical binders that can improve the stiffness of the composite or reduce the drapeability of the composite.

  The fiber layer 122 can have the same or different fiber composition throughout its thickness. In certain preferred embodiments, the fiber layer 122 includes a heterogeneous mixture including, for example, cellulose fibers and synthetic fibers. In certain other preferred embodiments, the fiber layer 122 is a homogeneous layer, eg, consisting essentially of cellulose fibers or consisting essentially of synthetic fibers.

  In certain preferred embodiments of the invention, 50 wt% or more of the fibers of the fiber layer 122 are formed from fibers having a length to diameter ratio of greater than about 300. Such fibers can be staple fibers or continuous filaments, but preferably the fibers are staple fibers. Such fibers can be, for example, cellulose fibers such as wood pulp or cotton; synthetic fibers such as polyester, rayon, polyolefin, polyvinyl alcohol, multicomponent (core sheath) fibers, and combinations of two or more thereof. . Such fibers can be bonded together by any suitable method, including methods described in detail below.

  The fiber layer of the present invention can have any appropriate basis weight. In certain preferred embodiments, the fiber layer 122 can have a basis weight of from about 20 gsm to about 200 gsm, preferably from about 20 gsm to about 150 gsm.

  In an alternative embodiment, as shown in FIG. 2, the fiber layer 122 may itself include multiple layers or hierarchies. FIG. 2 shows the uppermost fiber layer 210 and the lower fiber layer 220. In one embodiment, the uppermost fiber layer 210 comprises or consists essentially of one or more synthetic fibers or heterophasic fibers, such as olefins or polyesters, and the lower fiber layer 220 comprises cellulosic fibers. Or substantially consisting of cellulose fibers. Further, while FIG. 2 shows a fiber layer 122 consisting of only two layers, it is contemplated that additional layers having various compositions may be added.

  In addition, FIGS. 1 and 2 show one fluid permeable anchoring layer 110 at the end of the laminated composite 100, but a second fluid permeable anchoring layer 110 at the opposite end of the laminated composite 100. It is within the scope of the present invention to include, thereby creating a “sandwich” structure in which one or more fiber layers are generally sandwiched between two fluid permeable anchoring layers. In such a structure, there are two separate wear resistant surfaces.

  The properties of the laminated composite material can be adjusted based on the desired properties. For example, in order to obtain a low density and a high drapability, it is usually possible to select mainly polyester, rayon, and mixtures thereof. When it is desired to achieve high absorption capacity and low cost, wood pulp can be mainly selected. In order to balance all such properties, the fiber layer 122 may itself comprise a separate layer of such material.

  In certain embodiments of the invention, the laminated composite material comprises a visible pattern. FIG. 3 is a plan view of a laminated composite material consistent with embodiments of the present invention disclosed herein. The laminated composite 100 includes individual ridges 300 surrounded by a lower portion of the substrate 310. FIG. 4 is a cross-sectional view taken along line 3-3 ′ of FIG. 3 showing various structures of the laminated composite material 100. The raised portion 300 and the lower portion 310 look different from each other. For example, an uncorrected average visual acuity observer should be able to easily identify the difference or contrast between the ridge and the lower portion 310 when viewing the laminated composite 100 from a distance of 12 inches (304.8 mm). It is. In one embodiment of the present invention, the ridge 300 has a height 320 of about 0.1 mm to about 5 mm, more preferably about 0.5 mm to about 2 mm, and a length or width of at least about 0.5 mm. More preferably, it is at least about 1 mm, and most preferably at least about 3 mm.

  In one embodiment of the present invention, the ridge 300 is not entangled and bonded, ie, there is a significant bond at the contact surface 330 between the fluid permeable anchoring layer 110 and the fiber layer 122 in the ridge 300. do not do. In this embodiment of the present invention, significant bonding between the fluid permeable anchoring layer 110 and the fiber layer 122 exists only within the lower portion 310, for example, along the contact surface 340. Therefore, the cross section of the entangled portion 360 and the cross section of the non-entangled portion 350 (the boundaries thereof are indicated by a one-dot chain line in FIG. 4) exist in the laminated composite material 100.

  FIG. 4 illustrates a laminated composite 100 having a continuous cross section (base material) of the interlaced portion 360 and a plurality of separate cross sections of the unentangled portion 350 positioned substantially within the continuous cross section of the interlaced portion. Show. This structure is often desirable for imparting sufficient tensile strength to the laminated composite material 100. However, other structures of ridges and lowers are also contemplated. For example, the ridges are not disposed as separate unentangled portions 350 surrounded by, or substantially disposed within, the lower portion 360, but over the entire width or length of the laminated composite material 100. Can do. Further, the sense of the entangled portion and the unentangled portion can be “opposite” from the material shown in FIG.

  In certain preferred embodiments, the laminated composite of the present invention is a spunlace structure. That is, the laminated composite material is preferably a material obtained from the hydroentanglement or “spunlace” process, which is the process described herein. Applicants have shown that the structure of the present invention provides superior wear resistance and surprisingly good laminate strength and / or drape, and / or density compared to conventional fiber nonwoven structures, particularly conventional spunlace materials. I found out that Such a novel surprising combination of properties provides significant advantages to the structure in a variety of applications, including but not limited to personal care products such as feminine hygiene products and wipes.

  In one embodiment of the present invention, the laminated composite material is used as a constituent material of a sanitary pad such as a sanitary napkin or a panty liner. For example, the laminated composite can be a top sheet such as a panty liner or sanitary napkin or an integrated top sheet / absorbent core layer.

  In certain preferred embodiments, in a laminated composite material, the fluid permeable anchoring layer 110 can be directed to a user's body so that the fluid permeable anchoring layer 110 faces the body of the sanitary pad. Become part of the surface. In certain preferred embodiments, the laminated composite functions as an integrated top sheet / absorbent core layer of a sanitary napkin or panty liner. Such an integrated top sheet / absorbent core layer comprising the laminated composite material of the present invention is such that the integrated top cover contributes to improved user comfort, wear resistance, flexibility, This is advantageous in terms of improving absorbency and drape.

  In one embodiment of the present invention, the fibrous nonwoven material may be, for example, “infant wipes”, personal care / beauty wipes or wipes (wet or dry) useful for personal cleansing, or inanimate surfaces. Used as a constituent material for wiping products such as cleansing wiping products. The laminated composite material of the present invention can be used as a single layer wipe product or as one or more layers of a multilayer wipe product. Preferably, the wear-resistant surface of the laminated composite is located on the outer surface of the wipe product so as to contact the user's skin. Wipe product materials comprising the laminated composite of the present invention are advantageous in that they have excellent wear resistance (and hence durability) as well as flexibility, compressibility and absorbency.

[Method of the present invention]
The laminated composite material of the present invention can be produced by any of a variety of novel methods found by the applicant. For example, according to certain embodiments, the structure can be manufactured by a method that includes contacting a fluid flow with the laminated structure. Such a laminated structure includes fibers and a fluid permeable anchoring layer. The fluid permeable anchoring layer is positioned to at least partially shield the fiber layer from fluid flow.

  FIG. 5 illustrates one embodiment of a method for performing a hydroentanglement step according to the present invention. The hydroentanglement step includes providing a layer of fibers 520 disposed on a screen 590 (eg, a metal or plastic screen) supported on a movable conveyor (not shown). The term “layer” refers to a collection of fibers having a much smaller thickness dimension compared to length and width 205. For example, the layer 520 can have a thickness of less than about 10% of the width, eg, less than about 2% of the width. In a preferred embodiment, the thin layer of fibers 200 is substantially planar and has a thickness of less than about 20 mm, preferably less than about 5 mm. The thin layer of fibers has a composition and properties as described above in connection with the fiber layer 122 shown in FIGS. 1 and 2 above.

  The fibers of layer 520 need not be bonded to each other. “Unbonded” means that the fibers of the thin layer 520 are weakly bonded to each other and have a low tensile strength of less than about 5 N / 5 cm. In an alternative embodiment, the fibers of layer 520 are weakly bonded together, for example, prior to spunlacing.

  A fluid permeable pinned layer 110 is located on the fiber layer 520. Thereby, the fiber layer 520 and the fluid permeable anchoring layer 110 form a target web 550 that is entangled. During operation, the target web 550 is moved in a machine direction within a series of jets 530 that release a fluid 508, preferably a fluid, more preferably water. It is contemplated that the fiber layer 520 can be applied to the target web 550 in any direction and at any pressure suitable for forming a stable target web. Preferably, the fluid flow 508 is oriented to impinge the layer of fibers in a substantially vertical direction, for example, at a pressure of about 500 psi to about 5000 psi (about 3.4 MPa to about 34.5 MPa). The term “substantially vertical” as used herein is about 20 degrees to about 0 degrees, preferably about 10 degrees to about 0 degrees, more preferably about 5 degrees to about 0 degrees, and most preferably about 0 degrees.

  The target web 550 can be moved in the machine direction before, during, and / or after contacting the fluid stream 508 at any speed suitable to entangle the target web. In certain embodiments, the stabilized web 210 is at least about 3.05 m / min (about 10 fpm (feet per minute)), for example, about 15.24 m / min to about 76.20 m / min (about 50 fpm to about 50 fpm). It is moved in the machine direction at a speed of 250 fpm).

  When the entanglement step is completed, the fluid permeable anchoring layer is entangled with the fiber layer, and the laminated composite material of the present invention is formed as described above, as depicted in the examples shown in FIGS.

  FIG. 6 shows a target web hydroentanglement similar to the hydroentanglement shown in FIG. 5 except that the fluid flow 508 passes through a mask 600 that moves relative to the jet 530. The mask 508 can be rotated around a series of guides or rollers 660 to align various portions of the mask 600 with the fluid flow 508 at various times.

  The mask 600 has spatially different permeability to the fluid flow 508. Specifically, as shown in FIGS. 6 and 7 (perspective view of mask 600), spatially different transparency is created by including a pattern of highly permeable portions 620 and less permeable portions 630. Yes. The highly permeable portion 620 can be, for example, an open space (substantially all of the fluid can pass through the highly permeable portion 620). Alternatively, the highly permeable portion 620 can include a support screen such as the screen 650 shown in FIG. 7 that provides sufficient mechanical support to the mask 600 but does not significantly interfere with the fluid flow 508. In one embodiment, the highly permeable portion 620 has an open area of at least about 50%, more preferably at least about 65%.

  In contrast, the low permeability portion 630 of the mask 600 typically prevents most, preferably all, of the fluid flow 508 that contacts the mask from contacting the target web 550.

  Initially, when the jet 530 is positioned over the highly permeable portion 620 of the mask, the portion of the target web 550 below the jet 530 is entangled in contact with the fluid flow 508. In contrast, when the jet 530 is positioned over the low-permeability portion 630 of the mask at the second time, the portion of the target web 550 below the jet 530 does not contact the fluid flow 508 (or As an alternative, touch minimally) and remain relatively unentangled.

  At a time interval in which the mask is fully rotated (ie, a complete pattern cycle), the pattern of the high permeable portion 620 and the low permeable portion 630 in the mask 600 is transferred to a predetermined length of the target web 550 and the pattern The formed laminated composite material is formed. FIG. 8 shows an example of a laminated composite material 810 in which a pattern having a length of 800 is formed. This process can then be repeated to form a series of equal length laminated composites that can later be separated from each other (eg, by cutting).

  Note that in FIG. 8, an unentangled raised flower pattern is shown against a uniform flat background. If the low-permeability portion 630 of the mask 800 is not fully open (eg, if it includes a screen as shown in FIG. 7), a portion of the screen's blocking portion may be pulled into, for example, a laminated composite material. Note that as a raised small portion 850 of the background structure, such as thin lines and grids distributed over the majority 860 of the entangled portion imparting, can be effectively transferred to the laminated composite material.

  The length 800 of the laminated composite with repeated patterns (ie, the length of the mask when placed on a flat surface) can be varied, for example, from about 50 cm to about 10 m. The boundary of length 80 is indicated by an imaginary line in FIG.

  The mask 800 can be formed by various methods known in the art. For example, the mask 800 can be formed by selectively etching a metal plate. The plate may be formed from a flexible sheet of aluminum, stainless steel, or copper, or from a polymeric material including plastic or rubber (which may be reinforced), for example from about 0.05 mm to about 0. It can have a thickness of 5 mm.

  6-8 illustrate one process for making a laminated composite with a visible pattern formed, other processes are contemplated. For example, rather than using a mask that moves relative to the jet, the jet is selectively blocked at a specific location, adjacent to the entangled lows, or unentangled ridges interspersed with the lows Lines or stripes can be formed.

  In yet another embodiment of the invention, a visible pattern is formed using a topographic forming surface. In this embodiment of the invention, the fluid flow is brought into contact with a target web supported on the shape-forming surface. Shape support members typically include a peak and valley structure as well as an open structure, for example, U.S. Pat. Nos. 5,827,597 and 5, which are hereby incorporated by reference in their entirety. 674, 587 (both granted to James et al.). The peak and valley structure can be formed by any suitable technique, such as mechanical drilling, laser drilling, laser ablation, raster scanning, and laser modulation, among others.

  In an embodiment of the method of the present invention, a laminated structure comprising a layer of fibers and a fluid permeable anchoring layer is positioned on a shape support member. The fluid flow is oriented in a laminated structure, the laminated structure is molded into the shape of a shape support member, and the fiber layer is entangled with the fluid permeable fixed layer.

  In a preferred embodiment shown in FIG. 9, the fluid permeable anchoring layer 900 is positioned in direct contact with the shape support member 910 and the fiber layer 920 is positioned over the fluid permeable anchoring layer. Accordingly, the fiber layer 920 at least partially shields the fluid permeable anchoring layer from the fluid. The fiber layer 920 can comprise a variety of materials as described in connection with the fiber layer 122.

  In another preferred embodiment, the fiber layer comprises wood pulp, preferably cellulose such as mercerized pulp or crosslinked pulp as described above. In yet another preferred embodiment, the fiber layer 920 comprises a synthetic fiber layer 930 positioned directly on the fluid permeable anchoring layer 900 and a cellulosic fiber layer positioned directly on the long fiber layer 930. It includes at least two different layers, such as layer 940 (eg, pulp). In this embodiment, fluid flow 508 is impinged in the order of cellulose fiber layer 940, long fiber layer 930, fluid permeable anchoring layer 900, and shape support member 910. In this embodiment of the invention, the synthetic fiber layer 930 and the fluid permeable anchoring layer 900 function as a barrier that prevents relatively short cellulose fibers from flowing toward the discharge opening 960 formed in the shape support member 910. To do. Therefore, there is little possibility that the short cellulose fibers that make this process difficult will clog the discharge opening 960.

[Example]
The following examples are illustrative of the present invention and are not intended to be limiting in any way.

<Example 1>
In each example shown below, the target web was placed on an 80 mesh metal screen forming surface on a rotating cylindrical drum. The target web consists of a layer of fibrous material and a fluid permeable pinned layer. The fluid permeable fixation layer used was a 12 gsm spunbond polypropylene layer sold by BBA Fiberweb. The fiber material was a mixture of 70% rayon fibers and 30% polyester fibers of various basis weights. The drum was rotated to move the fiber layer at a linear velocity of 30.48 m / min (100 fpm). The jet was oriented so that the pressurized water stream impinged perpendicular to the target web. The jets were placed in a single row of jets spaced at a density of 30 jets per inch. Before an initial stabilization treatment is performed on all fiber layers to release water from each of a number of jets having a diameter of 0.127 mm (0.005 inches) at 4.14 MPa (600 psi) and entangled with spunbond polypropylene Loosely bonded to the fiber. The drum was rotated six complete revolutions, passing a given point in the fiber layer through the jet row six times. The pressure of the water discharged from the jet can be changed.

  The laminate strength of each sample was measured using a laminate strength test performed as follows (to obtain a laminate strength value (LSV)).

  A sample of the 1 inch x 1 inch (25.4 mm x 25.4 mm) material to be measured (including a fixed layer and a fiber layer having fibers entangled with the fixed layer) was cut. Using double-sided adhesive tape (Scotch double-coated tape, model number: 666), the sample was surfaced in two stainless steel cubes (approximately 1 inch x 1 inch (25.4 mm x 25.4 mm)). The sample was sandwiched between two cube surfaces. The mounted sample was squeezed between the cubes at a pressure of 5 psi (about 34.5 kPa) or more for at least 6 seconds. The cube is then pulled apart at a crosshead speed of 50.8 mm / min (2 inches / min) using a crosshead and the force at this time is measured with an Instron force-measurement gauge. did. The lamination strength value is equal to the peak load recorded for the sample (related to the first peak in the Instron output graphics display).

In order to determine the drapeability (basis weight / MCB) according to the present invention, the following drapeability tests were conducted on various fiber nonwoven fabric structures. Modified Circular Bend Stiffness (MCB) is determined by tests modeled after the ASTM D 4032-82 Circular Bend PEOCEDURE. This circular bending method has been considerably modified and is performed as follows. The circular bending method is a simultaneous multi-directional deformation of a material in which one surface of a test piece is concave and the other surface is convex. The circular bending method averages the stiffness in all directions while applying a value of force related to bending resistance. The equipment required for the circular bending method is a modified Circular Bend Stiffness Tester having the following parts:
1. A 102.0 mm × 102.0 mm × 6.35 mm smooth polished steel plate with an orifice having a diameter of 18.75 mm. The orifice wrap edge should be at a 45 degree angle to a depth of 4.75 mm.
2. 0.88 mm extended from the ball nose with a ball nose with a total length of 72.2 mm, a diameter of 6.25 mm, a radius of 2.97 mm, and a base diameter of 0.33 mm and a tip with a radius of less than 0.5 mm A plunger having a needle tip. This plunger is mounted concentrically with the orifice and has equal clearance on all sides. Note that the needle tip simply prevents the specimen from moving laterally during the test. Therefore, the needle tip should not be used if the needle tip has a significant adverse effect on the specimen (e.g., ruptures the inflated structure). The bottom of the plunger should be set well above the top of the orifice plate. The downward stroke of the ball nose is from this position to the very bottom of the orifice plate.
3. Force measuring gauge, specifically Instron reverse compression load cell. The load cell has a load range of about 0.0 g to about 2000.0 g.
4). Instron (model number: 1122) with actuator, specifically a reverse compression load cell. Instron 1122 is manufactured by Instron Engineering Corporation, Canton, Massachusetts.

  To perform this test procedure, three samples are required for each article, as will be described later. The position of the nonwoven structure to be tested is selected by the operator. Cut into 37.5 mm x 37.5 mm specimens from corresponding positions on each of the three samples. Prior to cutting the sample, remove any release paper or packaging material and cover all exposed adhesive, such as adhesive for attachment to clothing, with non-adhesive powder, such as talc. Talc should not affect BW or MCB measurements.

  Specimens should not be folded or bent by the tester, and handling on the test should keep the edges to a minimum so as not to adversely affect bending resistance.

  The procedure of the circular bending method (CIRCULAR BEND PROCEDURE) is as follows. The specimens are conditioned by leaving them at room temperature of 21 ° C. ± 1 ° C. and 50% ± 2.0% relative humidity for 2 hours. The weight of each cut specimen is measured in grams and divided by a factor of 0.0014. This is the basis weight (gsm) in grams per square meter. The average basis weight (BW) is calculated by averaging the values obtained for the basis weight of each test piece. This average basis weight (BW) can be used in the above equation.

  The specimen is positioned in the center of the orifice platform below the plunger so that the body facing the specimen layer faces the plunger and the barrier layer of the specimen faces the orifice platform. The plunger speed was set to 50.0 cm / min with a full stroke length. Check and adjust the zero display as necessary. Operate the plunger. Avoid touching the specimen during the test. The maximum force is read to the nearest gram and recorded. Repeat the above steps until all three specimens have been tested. The three recorded test values are then averaged to obtain the average MCB stiffness. This average MCB value can be used in the above equation. Drapeability is calculated by dividing the basis weight by the average MCB determined above.

  In order to measure the thickness, the following density tests were performed on thin layers of various fibers and fibrous nonwoven structures according to the present invention.

Cut into strips of material 5 cm wide. In order to measure the tensile strength in the machine direction, the strip was placed so that the machine direction was the longitudinal direction. In order to measure the tensile strength in the cross-machine direction, the strip was placed so that the cross-machine direction was the longitudinal direction. This test was performed using an Emveco gauge with a pressure of 482.7 Pa (0.07 psi) applied to a foot size of 2500 mm ² . This digital display was exactly 0.0025 cm. The average of the five measurements was recorded as the thickness. The product sample was placed in the anvil so that the gauge foot was raised and the gauge foot was approximately centered with respect to the desired location of the product sample. When lowering the foot, care must be taken that the foot does not fall on the product sample or excessive force is applied. The foot was lowered at a speed of 2.54 mm / sec (0.1 in / sec). A load of 482.7 Pa (0.07 psig) is applied to the sample to stabilize the measurement for about 10 seconds. The thickness measurement was read. This procedure was repeated for at least three product samples and the average thickness was calculated. The density was then calculated by dividing the mass of the sample by the volume (length x width x average thickness as described above).

Example 1A
A spunbond material layer was placed on the underside of the fiber layer (ie, the fiber layer was located between the jet and the fluid permeable anchoring layer). The jet pressure was 10.34 MPa (1500 psi). The web was passed through the jet four times. The obtained laminated composite material had a lamination strength (LSV) of 25 g, a thickness of 0.77 mm, a basis weight of 85 gsm, a density of 0.11 g / cc, and a drape property of 7.9 gsm / g.

Example 1B
A spunbond material layer was placed under the fiber layer. The jet pressure was 10.34 MPa (1500 psi). The web was passed 8 times through the jet. The obtained laminated composite material had a lamination strength of 65 g, a thickness of 0.73 mm, a basis weight of 88 gsm, a density of 0.12 g / cc, and a drapability of 8.6 gsm / g.

Example 1C
A spunbond material layer was placed over the fiber layer. The jet pressure was 10.34 MPa (1500 psi). The web was passed through the jet four times. The obtained laminated composite material had a lamination strength of 32 g, a thickness of 0.90 mm, a basis weight of 90 gsm, a density of 0.10 g / cc, and a drape property of 9.1 gsm / g.

Example 1D
A spunbond material layer was placed over the fiber layer. The jet pressure was 10.34 MPa (1500 psi). The web was passed 8 times through the jet. The obtained laminated composite material had a lamination strength of 106 g, a thickness of 0.85 mm, a basis weight of 83 gsm, a density of 0.10 g / cc, and a drapability of 11.8 gsm / g.

Example 1E
A spunbond material layer was placed at the bottom of the fiber layer. The jet pressure was 13.79 MPa (2000 psi). The web was passed through the jet four times. The obtained laminated composite material had a lamination strength of 47 g, a thickness of 0.79 mm, a basis weight of 86 gsm, a density of 0.11 g / cc, and a drapability of 8.5 gsm / g.

Example 1F
The spunbond material layer was placed at the bottom of the fiber layer. The jet pressure was 13.79 MPa (2000 psi). The web was passed 8 times through the jet. The obtained laminated composite material had a lamination strength of 281 g, a thickness of 0.78 mm, a basis weight of 89 gsm, a density of 0.12 g / cc, and a drape property of 10.3 gsm / g.

Example 1G
The spunbond material layer was placed on top of the fiber layer. The jet pressure was 13.79 MPa (2000 psi). The web was passed through the jet four times. The obtained laminated composite material had a lamination strength of 205 g, a thickness of 0.86 mm, a basis weight of 83 gsm, a density of 0.10 g / cc, and a drapability of 12.5 gsm / g.

Example 1H
A spunbond material layer was placed on top of the fiber layer. The jet pressure was 13.79 MPa (2000 psi). The web was passed 8 times through the jet. The obtained laminated composite material had a lamination strength of 341 g, a thickness of 0.92 mm, a basis weight of 83 gsm, a density of 0.10 g / cc, and a drapability of 11.8 gsm / g.

<Example 2>
In each example shown below, the target web was placed on an 80 mesh metal screen forming surface on a rotating cylindrical drum. The target web consists of a layer of fibrous material between two separate fluid permeable anchoring layers. The fluid permeable fixation layer used was a 12 gsm spunbond polypropylene layer sold by BBA Fiberweb. The fiber material was either a mixture or pulp of 70% rayon fibers and 30% polyester fibers of various basis weights. The drum was rotated to move the fiber layer at a linear velocity of 30.48 m / min (100 fpm). The jet was oriented so that the pressurized water stream impinged perpendicular to the target web. The jets were placed in spaced rows at a density of 30 jets per inch. An initial stabilization process that discharges water at a number of 0.005 inches (0.127 mm) from each of the jets at 4.14 MPa (600 psi) is performed on all fiber layers of the synthetic fiber except the pulp layer, It was loosely bonded to the fiber before it was entangled with the spunbond polypropylene (listed as a prebond in Table 2). The drum was fully rotated at various times. The pressure of the water discharged from the jet can be changed.

Comparative Example 2A
The fiber layer is made of pulp. The jet pressure was 4.14 MPa (600 psi). The web was passed through the jet four times. The resulting laminated composite material has a lamination strength of 1 g at the upper boundary (closest to the jet) and 1 g at the bottom boundary (farthest from the jet), a thickness of 1.65 mm, a basis weight of 204 gsm, and a density. Was 0.124 g / cc, and the drapability was 1.47 gsm / g.

Comparative Example 2B
The fiber layer is made of mercerized pulp. The jet pressure was 4.14 MPa (600 psi). The web was passed through the jet seven times. The resulting laminated composite material has a laminate strength of 2 g at the upper boundary (closest to the jet), 1 g at the bottom boundary (farthest from the jet), a thickness of 1.69 mm, a basis weight of 197 gsm, density Was 0.117 g / cc, and the drapeability was 1.35 gsm / g.

Example 2C
The fiber layer is made of mercerized pulp. The jet pressure was 8.27 MPa (1200 psi). The web was passed through the jet four times. The resulting laminated composite material has a laminate strength of 41 g at the upper boundary (closest to the jet), a laminate strength of 6 g at the bottom boundary (farthest from the jet), a thickness of 1.42 mm, a basis weight of 195 gsm, density Was 0.137 g / cc, and the drapability was 1.40 gsm / g.

Example 2D
The fiber layer is made of mercerized pulp. The jet pressure was 8.27 MPa (1200 psi). The web was passed 8 times through the jet. The resulting laminated composite material has a lamination strength of 100 g at the upper boundary (closest to the jet), a lamination strength of 31 g at the bottom boundary (farthest from the jet), a thickness of 1.58 mm, a basis weight of 207 gsm, density Of 0.131 g / cc and drapability of 1.25 gsm / g.

Example 2E
The fiber layer is made of mercerized pulp. The jet pressure was 8.27 MPa (1200 psi). The web was passed 16 times through the jet. The resulting laminated composite material has a lamination strength at the top boundary (closest to the jet) of 225 g, a lamination strength at the bottom boundary (farthest from the jet) of 109 g, a thickness of 1.32 mm, a basis weight of 192 gsm, a density Was 0.145 g / cc, and the drapeability was 1.39 gsm / g.

Example 2F
The fiber layer is made of a mixture of synthetic fibers. The jet pressure was 10.34 MPa (1500 psi). The web was passed through the jet four times. The resulting laminated composite material has a laminate strength of 23 g at the top boundary (closest to the jet), a laminate strength of 11 g at the bottom boundary (farthest from the jet), a thickness of 0.95 mm, a basis weight of 98 gsm, and a density. Was 0.103 g / cc, and the drapeability was 4.90 gsm / g.

Example 2G
The fiber layer is made of a mixture of synthetic fibers. The jet pressure was 10.34 MPa (1500 psi). The web was passed 8 times through the jet. The resulting laminated composite material has a lamination strength of 35 g at the top boundary (closest to the jet), a lamination strength at the bottom boundary (farthest from the jet) of 24 g, a thickness of 0.89 mm, a basis weight of 97 gsm, density Was 0.109 g / cc, the density was 0.109 g / cc, and the drapability was 5.39 gsm / g.

<Example 3>
In each of the following examples, a “tricot” pattern peak and valley structure similar to the pattern described in US Pat. No. 5,827,597, and a shape-forming surface that also includes raised flower patterns (acetal sleeve) Placed on top. The fluid permeable anchoring layer used is a layer of 10 gsm spunbond fabric sold by BBA Fiberweb. The drum was rotated to move the fiber layer at a linear velocity of 30.48 m / min (100 fpm). The jets were oriented in a direction perpendicular to the layer of fibers and placed in rows spaced at a density of 30 jets per inch. The drum was rotated six full revolutions, passing a row of jets six times through a given point in the fiber layer.

Example 3A
The fiber layer 920 is a pre-bonded layer of a mixture of 30% polyester fiber and 70% rayon fiber having a total basis weight of 60 gsm. The resulting laminated composite material had excellent lamination strength, wear resistance, and a clear image.

Example 3B
The experiment of Example 2A was repeated, except that a layer of 90 gsm mercerized pulp (sold by Porosanier, Rayonier Corporation) was placed on top of the prebonded synthetic fiber layer. Lamination strength and image clarity were excellent.

  Table 1 shows the materials made and tested in the above example, their density, lamination strength, and drapeability. Such values clearly illustrate the advantageous and surprising unique combination of one or both of high drapability or low density and high lamination strength associated with the materials of the present invention. It should also be noted that Table 1 shows that by placing a fluid permeable pinned layer on the fiber layer, the lamination strength is improved and high drape is maintained.

  Others are similar test conditions, but note that the laminate strength between the fluid permeable anchor layer and the fiber layer is significantly higher when the fluid permeable anchor layer is disposed over the fiber layer. Such a high lamination strength can be achieved without sacrificing drape or density.

In addition, Table 2 surprisingly makes it possible to form strong wear resistant “sandwich” materials that have both high drape and low density at the same time and are resistant to delamination. This is illustrated. It should also be noted that it is possible to make such a high laminate strength material with a relatively low jet pressure, especially for high basis weights.

Embodiment
(1) In laminated composite materials,
A fibrous fluid-permeable fixed layer;
A fiber layer comprising fibers entangled in the fixed layer;
Including
The composite material has a laminate strength value (LSV) greater than about 20 g and a drapeability greater than about 4 gsm / g.
(2) In the composite material according to Embodiment 1,
The material has a LSV greater than about 50 g.
(3) In the composite material according to Embodiment 1,
The material has a LSV greater than about 100 g.
(4) In the composite material according to Embodiment 1,
The composite material has a drapability greater than about 8 gsm / g.
(5) In the composite material according to Embodiment 1,
The composite material has a drapability greater than about 16 gsm / g.

(6) In the composite material according to Embodiment 1,
The composite material has a density of less than about 0.15 g / cc.
(7) In the composite material according to Embodiment 1,
The fixed layer is a composite material selected from the group consisting of spunbond materials, through-air bonded materials, and combinations of two or more thereof.
(8) In the composite material according to embodiment 7,
The fixed layer comprises a composite material comprising a spunbond material comprising one or more polyolefin fibers.
(9) In the composite material according to Embodiment 1,
A composite material, wherein at least some of the fibers of the fiber layer having fibers entangled with the fixed layer include cellulose fibers.
(10) In the composite material according to embodiment 9,
The cellulose fiber is a composite material including wood pulp.

(11) In the composite material according to embodiment 10,
The wood pulp is a composite material including mercerized pulp.
(12) In the composite material according to embodiment 10,
The wood pulp is a composite material including a crosslinked pulp.
(13) In the composite material according to Embodiment 1,
A composite material comprising a cross-section of an entangled portion and a cross-section of an unentangled portion, wherein the entangled portion and the non-entangled portion are clearly different from each other visually.
(14) In the composite material according to Embodiment 1,
A continuous cross section of the entangled portion, and a plurality of separate cross sections of the unentangled portion substantially located within the continuous cross section of the entangled portion;
Including composite materials.
(15) In the laminated composite material,
A fibrous fluid-permeable fixed layer;
A fiber layer comprising fibers entangled in the fixed layer;
Including
The composite material has an LSV greater than about 20 g and a density less than about 0.15 g / cc.

(16) In the composite material according to embodiment 15,
The material has a LSV greater than about 50 g.
(17) In the composite material according to embodiment 15,
The material has a LSV greater than about 100 g.
(18) In the composite material according to embodiment 15,
The composite material has a density of less than about 0.12 g / cc.
(19) In the composite material according to embodiment 15,
The fixed layer is a composite material selected from the group consisting of spunbond materials, through-air bonded materials, and combinations of two or more thereof.
(20) In the composite material according to embodiment 19,
The fixed layer comprises a composite material comprising a spunbond material comprising one or more polyolefin fibers.

(21) In the composite material according to embodiment 15,
The composite material in which at least some of the fibers of the fiber layer having fibers entangled with the fixed layer include cellulose fibers.
(22) In the composite material according to embodiment 21,
The cellulose fiber is a composite material including wood pulp.
(23) In the composite material according to embodiment 22,
The wood pulp is a composite material including mercerized pulp.
(24) In the composite material according to embodiment 22,
The wood pulp is a composite material including a crosslinked pulp.
(25) In the composite material according to embodiment 15,
A composite material comprising a cross-section of an entangled portion and a cross-section of a non-entangled portion, wherein the entangled portion and the non-entangled portion are clearly different from each other visually.

(26) In the composite material according to embodiment 15,
A composite material comprising a continuous cross section of an entangled portion and a plurality of separate cross sections of unentangled portions substantially located within the continuous cross section of the entangled portion.
(27) A personal care product comprising the material of embodiment 1.
(28) In the personal care product according to embodiment 27,
The product is a personal care product, including a sanitary pad or wipe product.
(29) In the personal care product according to embodiment 28,
A personal care product, wherein the product is a sanitary pad comprising a top sheet comprising the material of embodiment 1.
(30) In the personal care product according to embodiment 29,
The anchoring layer is a personal care product including a body facing surface of the sanitary pad.

(31) A personal care product comprising the material according to embodiment 15.
(32) In the personal care product according to embodiment 31,
The product is a personal care product, including a sanitary pad or wipe product.
(33) In the personal care product according to embodiment 32,
A personal care product, wherein the product is a sanitary pad comprising a top sheet comprising the material of embodiment 1.
(34) In the personal care product according to embodiment 33,
The anchoring layer is a personal care product including a body facing surface of the sanitary pad.

It is sectional drawing of one Embodiment of the laminated composite material of this invention disclosed here. It is sectional drawing of another embodiment of the lamination | stacking composite material of this invention disclosed here. FIG. 6 is a plan view of another embodiment of a laminated composite material of the present invention disclosed herein, showing an additional structure. FIG. 4 is a cross-sectional view of the laminated composite material taken along line 3-3 'of FIG. FIG. 6 is a cross-sectional view illustrating the formation of a laminated composite material according to a process consistent with an embodiment of the invention disclosed herein. FIG. 6 is a cross-sectional view illustrating the formation of a laminated composite material according to another process consistent with an embodiment of the invention disclosed herein. 1 is a perspective view of a mask that can be used to form a laminated composite material consistent with embodiments of the present invention disclosed herein. FIG. It is a top view of the lamination | stacking composite material 810 in which the pattern of the predetermined length corresponding to embodiment of this invention disclosed here was formed. 2 is a cross-sectional view illustrating patterning of a laminated composite material according to an embodiment of the present invention disclosed herein. FIG.

Claims (14)

In laminated composite materials,
A fibrous fluid-permeable fixed layer;
A fiber layer comprising fibers entangled in the fixed layer;
Including
The composite material has an LSV of greater than about 20 g and a drape of greater than about 4 gsm / g. The composite material according to claim 1, wherein
The material has a LSV greater than about 50 g. The composite material according to claim 1, wherein
The material has a LSV greater than about 100 g. The composite material according to claim 1, wherein
The composite material has a drapability greater than about 8 gsm / g. The composite material according to claim 1, wherein
The composite material has a drapability greater than about 16 gsm / g. The composite material according to claim 1, wherein
The composite material has a density of less than about 0.15 g / cc. The composite material according to claim 1, wherein
The pinned layer is a composite material selected from the group consisting of spunbond materials, through air bond materials, and combinations of two or more thereof. The composite material according to claim 7, wherein
The fixed layer comprises a composite material comprising a spunbond material comprising one or more polyolefin fibers. The composite material according to claim 1, wherein
A composite material, wherein at least some of the fibers of the fiber layer having fibers entangled with the fixed layer include cellulose fibers. The composite material according to claim 9, wherein
The cellulose fiber is a composite material including wood pulp. The composite material according to claim 10.
The wood pulp is a composite material including mercerized pulp. The composite material according to claim 10.
The wood pulp is a composite material including a crosslinked pulp. The composite material according to claim 1, wherein
A composite material comprising a cross-section of an entangled portion and a cross-section of an unentangled portion, wherein the entangled portion and the non-entangled portion are clearly different from each other visually. The composite material according to claim 1, wherein
A continuous cross section of the entangled portion, and a plurality of separate cross sections of the unentangled portion substantially located within the continuous cross section of the entangled portion;
Including composite materials.

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