KR20060012664A - Stabilized absorbent material and systems for personal care products having controlled placement of visco-elastic fluids - Google Patents

Abstract

There is provided a distribution material for personal care products which is a fabric which wicks artificial menses according to a horizontal wicking test a distance of about 1 inch in less than about 1.5 minutes. Materials meeting this performance criteria generally have a pore size distribution with a high percentage (usually more than 50 percent) of pore diameters between about 80 and 400 microns and a density below about 0.15 g/cc. There is also provided a personal care product system having a distribution/retention layer and a pad shaping layer wherein each layer has a stain length ratio of 0.5 or less and the distribution/retention layer has a saturation profile of 4 or less.

Description

Stabilized Absorbent Material and Systems for Personal Care Products Having Controlled Placement of Visco-Elastic Fluids}

1 is a graph of pore size distribution of 0.05 g / mm 3 material of Example 1, Repetition 1. FIG.

2 is a graph of pore size distribution of 0.05 g / mm 3 material of Example 1, Repetition 2. FIG.

3 is a graph of pore size distribution of 0.1 g / mm 3 material of Example 1, Repetition 1. FIG.

4 is a graph of pore size distribution of 0.1 g / mm 3 material of Example 1, Repeat 2. FIG.

5 is a graph of the pore size distribution of the unoriented 0.028 g / mm 3 material of Example 2. FIG.

6 is a graph of pore size distribution of 0.068 g / mm 3 material of Example 2. FIG.

7 is a graph of the pore size distribution of the oriented 0.028 g / mm 3 material of Example 2. FIG.

8 shows a multilayer design.

9 shows an example of a cover material.

10 shows the suction layer.

11 shows the distribution / retention layer.

12 shows the bottom or pad forming layer.

13 shows a two-layer design for feminine hygiene products.

14 illustrates a type of four layer design.

FIG. 15 is a bar graph of two systems with a top layer, a second layer as the distribution / retention layer and a third layer as the pad forming layer. FIG. The bar chart represents the liquid load in grams.

16 shows a design for a feminine hygiene product that includes a sine wave pattern.

FIG. 17 shows an embossing pattern for personal care products in a shell pattern. FIG.

The present invention relates to material structures and absorbent structures or systems useful in personal care products such as disposable sanitary napkins, diapers or incontinence guards. More specifically, the present invention relates to an absorption system that must treat complex viscous fluids such as physiological fluids.

Absorbent products such as feminine pads or sanitary napkins, diapers and incontinence guards are intended to inhale and retain body fluids. Current products have a flaw in this function, causing the leak to be higher than the desired leak level, causing stains on the garment. In addition, current products are not recognized as fully conveying characteristics such as dryness, fit, comfort and reliability to other consumers. Many of these properties are exhibited by product liquid handling performance. Women who have reduced leakage and improved comfort, despite the continued improvement in this field, for example, the introduction of "wings" to prevent part of the women's pads from leaking around the wearer's underwear. There is a need for hygiene products.

Most commercial pads have a relatively high leak rate. This pad can't work for 30% of the time and a defect rate of about 20% is quite common. Such defects are believed to be due to the high viscosity of menstrual blood and large variations in delivery capacity, resulting in overload and subsequent leakage of pads within the target surface. Insufficient distribution of menstrual blood is thought to be one of the important causes of target surface overload.

In the field of urine treatment in personal care products such as diapers, the distribution is often provided by a material having small pores of narrow pore size distribution. This material must move the high volume, low viscosity urine excretion off the target side within a time sufficient for the target side to accommodate the next excretion. Urine can be moved to a relatively distant portion of the diaper to overcome the actual hydrostatic pressure. In contrast, the volume of total excreta placed in feminine hygiene products is lower, but the viscosity of the fluid is greater so that it is more difficult to move the fluid. Distributors for feminine hygiene products should be very different from products primarily related to urine treatment.

Some examples of improved urine treatment can be found in commonly assigned US patent applications 08 / 754,414 and 08 / 755,136, which teach the use of advanced absorbent materials and system designs. Although the physical aspects of liquid treatment are somewhat similar to menstrual blood and urine, the complex nature of menstrual blood and the variability of the product usage conditions of menstrual blood require designs for absorbent materials and systems that are significantly different than those required for urine treatment. Previous attempts to provide less leaky feminine hygiene products include US Pat. Nos. 5,549,589 and 5,466,232 and 5,200,248, which discuss the distribution structure for menstrual blood. None of these references provided a unique combination of the properties of the present invention.

It is an object of the present invention to provide a feminine hygiene product with good distribution performance that moves menstrual blood from the target surface and provides comfort, dryness, and less leakage than typical pads.

It is an object of the present invention to improve feminine hygiene, which reduces leakage and improves comfort through the use of materials intended to accommodate the properties of menstrual blood and direct the menstrual fluid to the absorbent system so that it is substantially isolated within the local area of the absorbent system. To provide supplies. Another object of the present invention is to provide a feminine hygiene article having pores capable of using and maintaining an appropriate amount of liquid without disturbing suction and distribution.

Summary of the Invention

The object of the present invention is achieved by a distribution consisting of stabilized, high wettability fibers arranged to provide a capillary pore size and wettability that are ideally suited for wicking viscoelastic fluids. When exposed to viscoelastic fluids and the like, this material demonstrates improved fluid distribution performance in terms of wicked distance, wicking speed and moved fluid.

Dispensers for personal care products of the present invention are fabrics that draw artificial menstrual blood by a distance of about 2.54 cm (1 inch) in less than about 1.5 minutes according to a horizontal wicking test. Materials that meet this performance criterion generally have a high pore size distribution (typically greater than about 50%) and a density of less than about 0.15 g / cc, with a high percentage of pore diameters of about 80 to 400 microns.

In addition, a personal care product system is provided having a distribution / holding layer and a pad forming layer having a contamination length ratio of each layer of 0.5 or less and a saturation profile of the distribution / holding layer of 4 or less.

<Definition>

"Disposable" includes those which are not intended to be washed and reused and that can be discarded after use.

"Front" and "rear" are used throughout this specification to indicate a relative relationship to the garment itself rather than to suggest any location of the garment that is assumed when the garment is located on the wearer.

"Hydrophilic" refers to the fiber or surface of the fiber that is wetted by an aqueous solution in contact with the fiber. The degree of wetting of the materials can in turn be described in terms of the surface tensions and contact angles of the materials and liquids involved. Apparatus and techniques suitable for measuring the wettability of particular fiber materials may be provided by the Cahn SFA-222 Surface Force Analyzer System or a substantially equivalent system. Fibers with a contact angle of less than 90 °, as measured by this system, are marked "wettable" or hydrophilic, while fibers with a contact angle of 90 ° or more are labeled "non-wettable" or hydrophobic.

"Inner" and "outer" refers to a position relative to the center of the absorbent garment, specifically a position transversely and / or longitudinally and / or from the longitudinal and transverse centers of the absorbent garment.

"Layer" when used in the singular can have the dual meaning of one element or multiple elements.

By "liquid" is meant a substance and / or material that flows and can also take the internal form of a container in which a liquid is poured or poured.

"Liquid alternating current" means that liquid can move from one layer to another, or from one position in another layer to another.

"Longitudinal" and "lateral" have their usual meanings. The longitudinal axis is in the plane of the product when it is laid flat and fully unfolded and is generally parallel to the vertical plane that divides the wearer standing when wearing the product into half of the left and right body. The transverse axis is generally in the plane of the product perpendicular to the longitudinal axis. The illustrated product is longer in the longitudinal direction than in the transverse direction.

"Particle" means any geometric shape such as, but not limited to, spherical grains, cylindrical fibers or strands, flat surfaces or roughening, sheets, ribbons, strings, strands, and the like.

A "spray" and its variants include liquids that are strongly ejected as streams of spiral filaments, or spray particles, through orifices, nozzles, etc. by pressurization of air or other gases, by gravity or by centrifugal forces. The spray solution may be continuous or discontinuous.

As used herein, the term "nonwoven or nonwoven web" refers to a web that has a structure of individual fibers or yarns sandwiched between them, but not in an identifiable manner as in knitted fabrics. Nonwoven or nonwoven webs have been made from many methods, such as meltblowing methods, spunbonding methods, and bonded carded web methods. The basis weight of nonwovens is typically expressed in ounces (osy) or grams per square meter (gsm) of material per square yard, and useful fiber diameters are usually expressed in microns (33.91 in osy to convert from osy to gsm). Multiply).

As used herein, the term "spunbonded fiber" refers to a molten thermoplastic material extruded as a filament from a plurality of fine, generally circular parent ducts of the spinneret, after which the diameter of the extruded filament is for example Appel et al. U.S. Patent No. 4,340,563, U.S. Pat. By small diameter fibers that are formed to be rapidly reduced, as in US Pat. No. 3,502,763 to Hartman and US Pat. No. 3,542,615 to Dobo et al. Spunbond fibers are generally not tacky when they are deposited on a collecting surface. Spunbond fibers are generally continuous and have an average diameter (obtained from at least 10 samples) of more than 7 microns, more specifically about 10 to 20 microns. The fibers are described in US Pat. No. 5,277,976 to Hogle et al., US Pat. No. 5,466,410 to Hills and US Pat. No. 5,069,970 to Lagman et al. It may have a form as described in 5,057,368.

As used herein, the term “meltblown fibers” refers to the filaments of the molten thermoplastic material that are reduced in diameter through a plurality of fine, generally circular die capillaries. By generally meant fiber produced by extruding as a melt chamber or filament into a stream of hot, fast converging gas (eg, air) that allows for a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and deposited on the collecting surface to form a web of irregularly dispersed meltblown fibers. Such a method is described, for example, in US Pat. No. 3,849,241 to Butin et al. Meltblown fibers are microfibers that may be continuous or discontinuous, have an average diameter of generally less than 10 microns and are generally tacky when deposited on a collecting surface.

As used herein, the term “secondary molding” refers to a method of arranging one or more meltblown dieheads near a chute to add another material to the web while forming the web through the chute. Such other materials may be, for example, pulp, superabsorbent particles, natural polymers (eg rayon or cotton fibers) and / or synthetic polymers (eg polypropylene or polyester) fibers, the fibers being Staple length fibers. Auxiliary molding methods are shown in commonly assigned Lau, US Pat. No. 4,818,464, and in Anderson et al., US Pat. No. 4,100,324. Webs produced by auxiliary molding methods are generally referred to as auxiliary molding materials.

As used herein, the term "polymer" includes, but is not limited to, homopolymers, copolymers such as blocks, grafts, random and alternating copolymers, terpolymers, and the like and blends and modifications thereof. In addition, unless specifically limited, the term “polymer” shall include all possible geometries of the molecule. This shape includes, but is not limited to, the same, regular and irregular symmetry.

As used herein, the term "machine direction" or MD means the length of the fabric in the direction in which the fabric is made. The term "lateral machine direction" or CD means the width of the fabric, ie the direction generally perpendicular to the MD.

As used herein, the term "monocomponent" fiber refers to a fiber formed from one or more extruders using only one polymer. This does not mean that small amounts of additives exclude fibers formed from one polymer added for coloring, antistatic, lubrication, hydrophilicity, and the like. This additive for coloring, for example titanium dioxide, is generally present in an amount of less than 5% by weight, more typically about 2% by weight.

As used herein, the term “composite fiber” means a fiber formed from two or more polymers extruded from separate extruders but spun together to form one fiber. Composite fibers are also sometimes called multicomponent or bicomponent fibers. Although composite fibers can be monocomponent fibers, the polymers are generally different from one another. The polymers are arranged in separate zones positioned substantially uniformly across the cross section of the composite fibers and continuously spread along the length of the composite fibers. The coordination of such composite fibers can be, for example, a sheath / core arrangement in which one polymer is surrounded by another or side-by-side arrangement, pie arrangement or “islands-in-the-sea”. It can be an array. Composite fibers include U.S. Patent 5,108,820 to Kaneko, U.S. Patent 4,795,668 to Krueger, U.S. Patent 5,540,992 to Marcher, and U.S. Patent such as Strack. 5,336,552. Composite fibers are also taught in US Pat. No. 5,382,400 to Pike et al. And can be used to form wrinkles in fibers using different proportions of expansion and contraction of two (or more) polymers. Crimped fibers may also be produced by mechanical means and also by the method of DE 25 13 251 A1. In the case of bicomponent fibers, the polymer may be present in a ratio of 75/25, 50/50, 25/75 or any other desired ratio. The fibers are also described in US Pat. No. 5,277,976 to Hogle et al., US Pat. No. 5,466,410 to Hills and US Pat. No. 5,069,970 to Lagman, US Pat. It may have a form as described in 5,057,368.

As used herein, the term “bicomponent fiber” refers to a fiber formed from two or more polymers extruded as a blend from the same extruder. The term "blend" is defined below. Bicomponent fibers do not have a variety of polymer components arranged in separate zones located relatively uniform over the cross-sectional area of the fiber and the various polymers are generally not continuous along the entire length of the fiber, but instead generally start randomly Form fibrils or protofibrils that end. Bicomponent fibers are also sometimes called multicomponent fibers. Fibers of this general type are discussed, for example, in US Pat. Nos. 5,108,827 and 5,294,482 to Gesner. Bicomponent and bicomponent fibers are also described in textbook Polymer Blends and Composites by John A. Manson and Leslie H. Sperling, copyright 1976 by Plenum Press, a division of Plenum Publishing Corporation of New York, IBSN 0-306-30831- 2, at pages 273-277.

As used herein, the term "blend" refers to a mixture of two or more polymers, while the term "alloy" means a subclass of a blend that is commercially incompatible, although the components are immiscible. "Mixable" and "immiscible" are defined as mixtures that have negative and positive values, respectively, for the free energy of mixing. "Compatibility" is also a method of modifying the interfacial properties of an immiscible polymer blend to produce an alloy. Is defined.

As used herein, the term "bonded carded web" is directed through a combing or carding unit to separate or align the staple fibers in the machine direction to form a fibrous nonwoven web that is generally oriented in the machine direction. It means a web made from staple fibers. The fibers, which are placed in a picker that separates the fibers before the carding unit, are usually purchased in bundles. Once the web is formed, it is then joined by one or more of several known bonding methods. One such bonding method is a powder bonding method in which powder adhesive is distributed throughout the web and then generally activated by heating the web and adhesive with hot air. Another suitable bonding method is a pattern bonding method where heated calender rolls or ultrasonic bonding devices are generally used to bond the fibers together in a local bonding pattern, although the web may be bonded over its entire surface if desired. Another suitable known joining method, in particular when using bicomponent staple fibers, is a ventilation joining method.

"Airlaying" is a known method by which a fibrous nonwoven layer can be formed. In the airlaying process, small fiber bundles having a typical length of about 6 to about 19 mm are separated and entrained in the feed air, and then generally deposited on the forming screen with the aid of a vacuum feed. Thereafter, the irregularly deposited fibers are bonded to each other using, for example, hot air or spray adhesive.

"Personal hygiene goods" means diapers, training pants, absorbent underpants, adult incontinence products, bandages and feminine hygiene products.

<Test method>

<Material caliper (thickness)>

The caliper of the material is a measure of thickness and measured in mm at 344.7 Pa (0.05 psi) using a Starret type bulk tester.

<Density>

The density of the material is divided by the weight per sample area in grams per square meter (gsm) from 68.9 pascals to the bulk of the sample in millimeters (mm), and multiply the result by 0.001 to grams per cubic centimeter (g / ㏄). To be calculated. A total of three samples are evaluated and averaged for the density values.

Wicking time and horizontal liquid flux of absorbent structure

A sample strip of about 2.5 cm (1 inch) x 20 cm (8 inch) of material is placed horizontally so that the sample strip is in direct contact with the liquid surface when the sample strip is placed in the liquid reservoir at the start of the test. Relative humidity should be maintained at about 90 to about 98% during the evaluation. The sample strip was placed after a large amount (effectively infinite amount of liquid) and the stopwatch was activated as soon as the edges of the sample strip contacted the surface of the solution.

Record the horizontal distance of the liquid moving forward along the sample strip and the weight of liquid absorbed by the sample strip at various time periods. The weight of liquid absorbed by the sample strip up to about 1.3 cm (1½ inch), 2.54 cm (1 inch), 5 cm (2 inch) and 7.6 cm (3 inch) from the start of the evaluation is also obtained from the data. The liquid used in this test was a fluid intended to simulate the viscoelastic and other properties of menstrual blood and was prepared according to the procedure provided in the next test procedure.

Flat system test procedure

Purpose: To determine the fluid handling characteristics of various absorption systems through analysis of contamination lengths, saturation capacities and fluid loads of system components.

Apparatus: hourglass acrylic plate weighing approximately 330 g with a hole of 0.64 cm (0.25 inch) in the center; syringe; Tygon tubes with a 0.32 cm (⅛ inch) inner diameter; Pipette pumps; Physiological analogues; Laboratory balance or balance (precision to 0.00 g).

Preparation: 1. The ingredients are cut into the desired shape (generally 3.81 cm x 14.0 cm (1.5 inches x 5.5 inches) for intake and distribution layers); 4.45 cm x 14.0 cm (1.75 inches x 5.5 inches) for the transfer retardation layer; A 200 mm long hourglass for the perimeter layer).

2. Mark the 14.0 cm (5.5 inch) layer as a 2.8 cm (1.1 inch) piece and when it is in the center of the surrounding layer, mark the surrounding layer as the piece corresponding to the mark on the strip.

3. Weigh each ingredient and record the weight.

4. Assemble the individual components into the desired component system to keep the indicated fragments aligned. One cross section is labeled as top.

5. Fill the syringe with physiological analogues and attach the Tigon tube to the syringe.

6. Place the syringe in the pipette pump.

7. Program the pump (typically dispense 10 ml of the analog in 1 hour using a 30 mm syringe).

8. By the open end of the tube placed in the beaker, fuel is injected into the tube by the movable pump until all the air has come out of the tube and the like exits the tube at the end of the discharge.

9. Place the component system to be tested near the pipette pump, and place a (approximately) 5.08 cm x 15.24 cm (2 inch x 6 inch) piece of 25 gsm, 10d BCW on top of the center of the system and an acrylic in the top center of the system. Lay the plate.

10. Insert the open end of one tube into the hole in the acrylic plate. Repeat for the rest of the systems you want to test.

11. Start the discharge by operating the pipette pump.

12. At the end of the discharge cycle, remove the tube and acrylic plate. Carefully remove the BCW and dispose of it (without moving the subfloor).

13. Photograph and print component systems and layers.

14. Weigh each layer individually and record the weight.

15. Cut, weigh and record the first marked fragment starting at the end labeled as top. Repeat for the remaining fragments and layers.

16. Measure and record the contamination length for each layer.

17. Enter data into the spreadsheet for graphing and analysis.

This used physiological analogue was tested according to the following procedure.

In the case of fibrin depleted pig blood, blood was separated by centrifugation at 3000 rpm for 30 minutes, but other methods or speeds and times can be used if effective. Plasma was separated and stored individually, the leukocyte layer was removed and discarded, and the packed red blood cells were stored separately.

In the case of large chicken eggs, the eggs were separated, egg yolk and egg color were discarded and egg whites were left without discarding. The egg whites were filtered through a 1000 micron nylon mesh for about 3 minutes to separate the egg whites into thick and pale portions and discard the lighter portions. It should be appreciated that other mesh sizes may be used and the time or method may vary if the viscosity is at least as necessary. The dense portion of egg white retained on the mesh was collected and sucked with a 60 mm 3 syringe, which was then placed on a programmable syringe pump, drained 5 times and refilled to homogenize. In this case, the amount of homogenization was adjusted to a syringe pump speed of about 100 ml / min and a tube inner diameter of about 0.31 cm (0.12 inch). After homogenization, the dense egg white had a viscosity of at least 20 centipoises from 150 seconds ^-1 to about 3000 rpm for about 10 minutes, although any effective method of placing in a centrifuge and removing debris and bubbles could be used. Rotating in to remove debris and bubbles.

After centrifugation, the concentrated homogenized egg whites containing the hot slime were added to a 300 mm Fenwal® transfer pack using a syringe. Thereafter, 60 cc of pig plasma was added to the transfer pack. The transfer pack was fixed and placed in a Stomacher lab blender where all bubbles were removed and mixed at normal (or medium) speed for about 2 minutes. The transfer pack was removed from the blender, and 60 μg of porcine red blood cells were added and the contents mixed by manual kneading for about 2 minutes or until the contents appeared homogeneous. The hematocrit of the final mixture showed a red blood cell content of about 30% by weight and should generally fall within the range of at least 28-32% by weight for artificial menstrual blood prepared according to this example. The amount of egg white was about 40% by weight.

The components and devices used to make this artificial menstrual blood are readily available. The following is a list of sources of items used, but of course other sources may be used if they are almost equivalent.

Blood (pig): Cocaico Biologicals, Inc. (Cocalico Biologicals, Inc.) (449, Stevens Rd., Reamstown, PA 17567, (717) 336-1990).

Fenwal® transfer pack container, 300 ml, with coupler, code 4R2014: Baxter Healthcare, Fenwal Division (Deerfield, IL 60015).

Harvard Apparatus Programmable Syringe Pump Model No. 55-4143: Harvard Appratus (South Natick, MA 01760).

Stomacher 400 Laboratory Blender 400 Model No. BA 7021, Serial No. 31968: Seward Medical (London, England, UK).

1000 micron mesh, Item No. CMN-1000-B: Small parts, inks. Small Parts, Inc. (PO Box 4650, Miami Lakes, FL 33014-0650, 1-800-220-4242).

Hemata Stat-II device for measuring hemocret, serial no. 1194Z03127: Separation Technology, Inc. Separation Technology, Inc. (1096 Rainer Drive, Altamont Springs, FL 32714).

<Pore size distribution>

The pore size distribution of the material was measured using a device based on the porous plate method used by Burgeny and Kapur in The Textile Research Journal, volume 37 (1967), p. 356. It was. With this apparatus, the amount of fluid desorbed from the sample material at various pressures can be correlated with the radius of the pores in the provided material. This method is described in Chattterjee's Absorbency, Elsevier Science Publishers, B.V. 1985, pp. 36-40.

The deformation system used includes a programmable stepper motor and a moving stage interfaced with an electronic balance or scale controlled by a personal computer. The control program automatically moves the stage to the desired height, collects data at a certain sampling rate until equilibrium is reached, and then moves to the next planned height. The Plexiglas® support structure was used to maintain the material / porous plate in a vertical position during the entire test. Controllable parameters of the method include sampling rate, equilibration criteria, and measured pore size range. Data on the material tested was collected using mineral oil (0.82 g / dl, 32 dyne-cm, 0 ° fluid contact angle) as the test fluid. At the beginning of each test the sample material was completely saturated by placing the sample material on the porous plate and then lowering the porous plate structure. Thereafter, the mass data was collected when the pressure (ie the height of the stage) increased to determine the pore size. After four intervals of 60 seconds, equilibration is achieved if there is a change less than 0.05 g / min.

Plot the pore size on the x-axis and the incremental change in mass divided by the total mass change on the y-axis to represent the data as porosity versus pore radius in microns.

<Detailed Description of the Invention>

The present invention is a class of distributions consisting of stabilized, highly wettable fibers arranged to provide ideal capillary pore size and wettability for wicking viscoelastic fluids. Stabilization can be accomplished by using the liquid binder, binder fiber, thermally, or by any other method known to those skilled in the art. When exposed to viscoelastic fluids or fluid analogs, this material demonstrates improved fluid distribution performance in both wicked distances, wicking speeds, and moved fluids. The pore properties are minimal, preferably less than about 25%, more particularly 20%, even more particularly 15% when wet or dried with viscoelastic fluid analogs, swelling or bubble breaking. Stable. All these properties are important for the overall performance of the dispensing material placed on the target face of personal care products such as feminine pads.

Caliper (in cm) of material measured in dry state and wet after saturation with physiological analogs using a compressive strain meter with a base of 5.08 cm (2 inches) diameter at 137.9 Pa (0.02 psi) It is shown in Table 1 below.

Basis weight (gms) Density (g / ㏄) Pulp / Binder Percentage Dry caliper Wet Caliper  Bubble breaking 100 0.06 90/10 average 0.190 (0.075) 0.175 (0.069) 0.015 (0.006) 0.196 (0.077) 0.165 (0.065) 0.031 (0.012) 0.198 (0.078) 0.170 (0.067) 0.028 (0.011) 0.196 (0.077) 0.170 (0.067) 0.026 (0.010) 100 0.10 90/10 average 0.150 (0.059) 0.137 (0.054) 0.013 (0.005) 0.157 (0.062) 0.152 (0.060) 0.005 (0.002) 0.163 (0.064) 0.142 (0.056) 0.021 (0.008) 0.157 (0.062) 0.145 (0.057) 0.012 (0.005) 200 0.08 90/10 average 0.277 (0.109) 0.231 (0.091) 0.046 (0.018) 0.279 (0.110) 0.249 (0.098) 0.030 (0.012) 0.262 (0.103) 0.241 (0.095) 0.021 (0.008) 0.272 (0.107) 0.241 (0.095) 0.031 (0.013) 200 0.20 90/10 average 0.117 (0.046) 0.132 (0.052) -.015 (-.006) 0.127 (0.050) 0.119 (0.047) 0.008 (0.003) 0.107 (0.042) 0.112 (0.044) -.005 (-.002) 0.117 (0.046) 0.122 (0.048) -.005 (-.002)

Fluid distribution capacity requires proper capillary pore structure within the specific wettability range for the fluid. Distributors have been developed using several techniques to demonstrate the underlying material properties required for desirable performance. Examples of such materials are as follows.

<Example>

Example  One

In this example, the dispensing material is about 80% by weight fluff pulp (Sonan soft roll pulp treated with Rayonier R-9401 Mercer) and 20% by weight Danaklon short cut with S2 / B2 / 39 surface treatment. (5 mm) 2.2 denier polyethylene / polypropylene (PE / PP) shell / core composite binder fibers. This surface treatment can be seen as remaining hydrophilic after repeated excretion. The material was prepared at three different densities: 0.05 g / dl, 0.1 g / dl and 0.2 g / dl at a basis weight of about 100 to 250 gsm. Examples of 0.05 g / dl, 0.1 g / dl and 0.2 g / dl materials at a basis weight of about 125 gsm are shown for comparison.

The material was tested using a 2.54 cm x 20.32 cm (1 inch x 8 inch) sample according to the repeated equilibrium wicking test for a total of three tests. Table 2 below shows the results in seconds, expressed in grams of liquid retained by weight, and the DNR results did not reach the range.

Fluff pulp is Rayonian Inc. (Rayonier Inc .; Jessup, GA 31545). The binder fiber was from Danaklon a / s (Danaklon a / s, located at Engdraget 22, KD-6800 Varde, Denmark) and was a 2.2 denier composite PE / PP shell / core fiber cut to 5 mm length.

Dispensing materials were prepared by the Dan-Web airlaying method. The material was prepared using any other satisfactory procedure known in the art. A portion of the sample was tested for pore volume distribution. The results are shown graphically in FIGS. 1, 2 and 3 showing the pore volume distribution for 0.05 g / dV repeat 1, repeat 2 and 0.1 g / dV repeat 2. The results show that when the density is lowered and the pore size is increased, the wicking performance is greatly improved.

       Repeat 1        Repeat 2        Repeat 3 cm (inch)  Weight (g)  Time in seconds  Weight (g)  Time in seconds  Weight (g)  Time in seconds  0.05 g / ㏄ 1.27 (0.5) 2.54 (1.0) 5.08 (2.0) 7.62 (3.0)    1.26 1.80 1.56 1.02     50 161 633 DNR    1.15 1.77 1.71 0.89     50 170 611 DNR    1.13 1.55 1.48 0.72     54 170 714 DNR  0.1 g / ㏄ 1.27 (0.5) 2.54 (1.0) 5.08 (2.0) 7.62 (3.0)    0.86 1.14 0.95 0.32     20 155 811 DNR    0.68 1.07 0.91 0.16     24 123 868 DNR    0.76 1.03 0.9 0.23     18 139 810 DNR  0.2 g / ㏄ 1.27 (0.5) 2.54 (1.0) 5.08 (2.0)    0.79 1.11 0.62     56 253 DNR    0.83 1.03 0.96 0.21     43 174 1074 DNR    0.73 0.98 0.76     56 245 DNR

Example  2

In this embodiment, the distribution material is a bonded carded web consisting of 100% by weight eccentric shell / core composite fibers of polyethylene and polypropylene, commercially available from Chisso Chemical Co., Japan. The fiber is finished, known as HR6 applied to him. Table 3 below shows the wicking results for 0.028 g / dL samples, 0.068 g / dL samples and 0.028 g / dL samples with fibers oriented by the carding method. In Table 3 below, distances are expressed in cm (inch), weight in grams, and time in minutes and seconds as indicated. The pore volume distribution was tested and the results are shown in FIGS. 4, 5 and 6, respectively. This data indicates that better wicking results are obtained when large proportions of pores have pores in the range of about 200 to about 400 microns.

       density      Street      weight      time     0.028 g / ㏄ 2.54 (1.0) 5.08 (2.0) 7.62 (3.0)      1.7 1.1 0.9      50 seconds 10 minutes 17 minutes     0.068 g / ㏄ 2.54 (1.0) 5.08 (2.0)      0.6 0.1      1.5 minutes DNR     0.028 g / ㏄ oriented 2.54 (1.0) 5.08 (2.0) 7.62 (3.0) 10.16 (4.0)      1.7 1.2 0.9 0.1      1 minute 6.6 minutes 18 minutes 20+ minutes

Dispensers of the present invention must successfully draw artificial physiological fluids by a distance of 2.5 cm (1 inch) in less than about 1.5 minutes according to the horizontal wicking test. Materials meeting this performance criterion generally have a high pore size distribution (generally greater than 50%, more particularly greater than 60%, even more particularly greater than 70%) of the percentage of pore diameters of about 80 to 400 microns and Have a density of less than about 0.15 g / cc. Increasing the wettability of the pore surface is thought to result in a greater wicking drive force, allowing higher resistance and maintaining liquid movement within smaller pores.

The personal care system of the present invention is designed to regulate final liquid storage in a central region along the length of the pad. This functional behavior is highly desirable to prevent lateral leakage, which is the dominant form of leakage on female pads. Storage behavior is achieved by a layered absorber design that can include more than three layers. The bottom layer, ie the layer farthest from the wearer, has a larger x-y dimension than the other layers above it. This creates a raised surface photographic design that increases the likelihood of menstruation from the wearer reaching on a narrow strip as shown in FIG. 8. 8 shows a multi-layer design with a bottom layer 1, an upper or suction layer 3 and an intermediate layer 2.

The pores in each layer of material are designed with the geometry of the layer to cause a specific controlled filling method in the absorbent system. The average pore size of the second or middle layer is smaller than the average pore size in both the upper and lower layers. Therefore, the fluid is thought to be attracted to and distributed by the intermediate layer. The average pore size of the bottom layer is larger than the middle layer, which is believed to inhibit the transfer of fluid to the bottom layer early in the life of the product. The reduction of fluid in this lower layer is crucial to reducing leakage since it is believed that any fluid in this widest layer will begin to draw up softly and cause lateral leakage. In addition, each layer is stabilized to help maintain the intended pore size relationship during its use, in addition to having the microscopic integrity required for pad shaping.

In other embodiments, as high saturation causes transfer from the intermediate layer to the underlying layer, as may occur later in product life, the underlying layer is embossed, such as a longitudinal line, to help maintain fluid below the center of the underlying layer, or Can have densified fragments.

The top layer, also called the intake layer, is the layer closest to the wearer and has a low density at a basis weight of about 0.02-0.06 g / dl and about 25 to about 125 gsm. This allows for a pore size in the range of 80 microns to 1000 microns in diameter that is well suited to inhaling viscous physiological fluids.

The top or suction layer can be manufactured within the technical scope. Typical examples include airlaying mixtures of cellulose and synthetic binder fibers or 100% by weight synthetic fibers of bonded carded webs.

The layer below the top layer is designed to distribute and retain the fluid and is therefore called a dispense / retain layer or strip. It should have a density of about 0.1 g / dL to about 0.2 g / dL but higher than the suction layer. This increased density is believed to help desorb the suction layer into the distribution / retention layer. The distribution / retention layer should have a basis weight of about 175 gsm to about 300 gsm and an average pore size of about 40 to 500 μm diameter. Suitable materials for this layer include airlaying materials incorporating high concentrations of cellulose fibers (80-95% by weight) and synthetic binder fibers (5-20% by weight), which stabilizes the web performing this distribution function. However, it is assumed that the fibers constituting this layer are high wettability.

The bottom or pad forming layer has a lower density than the distribution / holding layer. Its primary function is to facilitate body wear, provide comfort to the wearer, and provide additional coverage. Its density is from about 0.03 to about 0.10 g / dL, so that it does not easily desorb the distribution / retention layer so that most of the fluid remains in the distribution / retention layer. In some designs, the pad forming layer may be an airlaying web of 80-90% by weight of cellulose pulp fluff mixed with 10-20% by weight of synthetic binder fibers. Although its primary purpose is pad molding, this layer can receive liquid from the dispensing / retaining strip, especially when the dispensing / retaining strip is heavily loaded with liquid. The pad forming layer may also include embossing patterns such as lines, sinusoids, acorn shapes, and the like.

Another aspect of the invention is a pad which allows the top two (suction and dispensing / holding) layers to be slit, preferably longitudinally (lengthwise) in the center so that they bend when lateral compression begins to occur in the underlying layer. It is a molding feature. This is the end to body wear, which is also crucial for reducing leaks.

Although the present invention is referred to as having "layers," it should be understood that this does not mean that separate materials must be made and laminated together. The term "layers" is meant to include a single monolithic material whose properties can be changed in such a way as to satisfy the functional and physical properties of the present invention. Thus, materials prepared in a one-step method and having properties that vary from the upper region to the lower region, for example in terms of satisfying the requirements of the present invention, are intended to be within the scope of the claims. A discussion of such materials can be found in the co-assigned patent application (Attorney docket number 14002) filed on the same day as this application.

The present invention can be modified in various forms to provide functional advantages over a wide range of product forms. 9, 10, 11 and 12 illustrate a typical component arrangement for the purpose of a very thin design for users who prefer that type of product form. 9 shows an example of a cover material to be in contact with the wearer, with a central width of the cover of about 80 mm, a widest point of about 90 mm, and a length of about 238 mm. 10 shows a suction layer 218 mm in length with a slit about 37 mm wide and about 101 mm long in the center. 11 shows a distribution / holding layer of the same dimensions as the suction layer. FIG. 12 shows the bottom or pad forming layer having the same general shape as the cover layer but with a center width of 60 mm and a width of the widest point of 70 mm. The bottom layer of FIG. 12 has five embossed lines of varying length equidistant in the center of the pad. The layers of Figures 10, 11 and 12 are detailed in Table 4.

The following examples were made to illustrate the distribution characteristics of the present invention.

Example  3

Nonwovens were prepared from pulp fluff and synthetic binder fibers according to the airlaying method. Other fluffs include Coosa 0054, 100 wt.% Softwood, Weihauser NB416 or NF405 100 wt.% Soft, Rayonier 9401, or any other fluff with similar properties. There is a number. The synthetic binder fibers were Hoechst-Celanese T-255 (H-C T-255) of 1.8 denier to 3 denier. Any other binder may be used that will impart similar binding properties to the complex.

Basis weight and density are shown in Table 4 below.

 drawing       function             Furtherance  Basis weight     density  10  inhale  Airlaying 90/10 fluff / binder   100 gsm   0.1 g / ㏄  11  Distribution / holding  Airlaying 90/10 fluff / binder   200 gsm   0.2 g / ㏄  12  Pad molding hold  Airlaying 90/10 fluff / binder   175 gsm   0.1 g / ㏄

Example  4

In this two-layer design shown in FIG. 13, the upper strip 4 is in a density range that can inhale, distribute and retain physiological fluids. The lower, or pad forming layer 5 has a lower density, thus inhibiting the transfer of fluid to itself until the upper strip is highly saturated. The design retains the thinness that some users want. The properties of the layers of the embodiment illustrated in FIG. 13 are shown in Table 5 below.

       function        Furtherance    Basis weight     density   Suction / dispensing / holding   Airlaying 90/10    250 gsm   0.1 g / cc   Pad forming / holding   Airlaying 90/10    175 gsm   0.05 g / cc

Example  5

In another variation, this absorption system may provide a thick product for users who prefer that product type. FIG. 14 illustrates the type of four layer design in which the intake layer 6 is over the dispensing / retaining layer 7 and the dispensing / retaining layer is over the delivery delay strip 8 and finally the pad forming layer 9.

In this embodiment as shown in FIG. 14, the suction layer 6 provides a suction function, while the next layer 7 is a higher density distribution / retention strip. The third layer 8 has a lower density than the dispensing / retaining strip 7 and thus delays fluid transfer to the wider and thicker pad forming layer 9, and also provides comfort and thickness requirements for this range of product types. To provide. Preventing fluid from entering the widest layer reduces wicking changes to the edges causing leakage. Once the liquid has permeated through the delivery retardation layer 8 at the end of the product life, the pad forming layer 9 may have an embossing pattern that prevents the liquid from being absorbed laterally.

Although these three examples illustrate the present invention, the present invention is not limited to these examples. The present invention includes an absorbent article that maintains a controlled placement of liquid below the center of the absorbent system to prevent lateral leakage.

 The following test data demonstrates a controlled fill pattern for the range of absorption system examples. In the following discussion, "upper layer" means intake layer, "middle layer" means distribution / retention layer, and "lower layer" means pad forming layer. The test procedure assembled the absorbent system components and discharged 10 ml of physiological analogs at the rate of 10 ml / hour as described in the test method paragraph above.

Both system designs were tested for fluid loading. The results are shown graphically in FIG. 15 with System I on the left and System II on the right. In FIG. 15, the first bar for each system is the top layer, the second bar is the distribution / retention layer, and the third bar is the pad forming layer. The left scale is the liquid load in grams. Fluid loading systems were made from coarse pulp and synthetic fibers described above and briefly below. In addition, some parts of Table 6 below refer to the “hourglass” form, in which it is noted that the form is an underlayer and the other layers are rectangular.

Bars in FIG. 15 represent mean data from fluid absorbed fragments of the raw material. Raw data for the graph of FIG. 15 is shown in Table 7 below.

Fluid load data      Dry weight      Wet weight     Absorbed fluid Upper layer Mezzanine Lower layer Upper layer Mezzanine Lower layer Upper layer Mezzanine Lower layer   System I    One  0.66  1.37  2.56  2.02  6.81  5.21  1.36  5.44  2.65    2  0.63  1.34  2.37  2.00  6.98  4.73  1.37  5.64  2.36    3  0.59  1.30  2.73  1.78  5.98  6.02  1.19  4.68  3.29  Average  0.63  1.34  2.55  1.93  6.59  5.32  1.31  5.25  2.77    System II    One  0.64  1.55  3.19  2.45  5.82  7.02  1.81  4.27  3.83    2  0.65  1.70  3.45  2.32  5.96  7.30  1.67  4.26  3.85    3  0.64  1.61  3.26  1.99  6.41  6.77  1.35  4.80  3.51    4  0.64  1.67  3.52  1.98  6.17  7.33  1.34  4.50  3.81    5  0.72  1.58  3.33  2.32  6.17  6.64  1.60  4.59  3.31    6  0.68  1.52  3.50  1.92  6.09  7.05  1.24  4.57  3.55  Average  0.66  1.61  3.38  2.16  6.10  7.02  1.50  4.50  3.64

Contamination size ratios are useful for describing the components and systems of the present invention. The contamination size ratio is defined as the width of contamination (w) divided by the length of contamination (l) after the contamination reaches equilibrium. The pad forming layer and the distribution / retaining layer should have a contamination size ratio of 0.5 or less, more particularly 0.375, even more particularly 0.1875. Although samples having a length of 22.1 cm (8.7 inches) for the pad forming layer and 15.24 cm (6 inches) for the dispensing / retaining layer were tested, longer or shorter products having this ratio fall within the scope of the present invention. It should be noted that. The following is a description of each layer of the system tested and the data immediately following the description. It should be noted that System I is identical to System I before.

Contamination length and rate data Pollution Length (cm (in.)) Pollution Width (cm (in.))       Pollution rain Upper layer Mezzanine Lower layer Upper layer Mezzanine Lower layer Upper layer Mezzanine Lower layer   System I    One 11.94 (4.70) 14.73 (5.80) 13.46 (5.30) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  0.32  0.26  0.28    2 11.94 (4.70) 14.73 (5.80) 14.48 (5.70) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  0.32  0.26  0.26    3 13.21 (5.20) 14.99 (5.90) 14.48 (5.70) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  0.29  0.25  0.26  Average 12.37 (4.87) 14.81 (5.83) 14.15 (5.57) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  0.31  0.26  0.27   System III    One 3.56 (1.40) 15.24 (6.00) 15.24 (6.00) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  1.07  0.25  0.25    2 3.56 (1.40) 15.24 (6.00) 15.24 (6.00) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  1.07  0.25  0.25    3 3.56 (1.40) 15.24 (6.00) 14.48 (5.70) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  1.07  0.25  0.26  Average 3.56 (1.40) 15.24 (6.00) 14.99 (5.90) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  1.07  0.25  0.25

The contamination width is 3.81 cm (1.5 ") for all samples.

In addition to the contamination length ratio, the saturation profile for the intermediate or distribution / holding layer is important. What the saturation profile means is the position of the liquid over the layer length. To determine the saturation profile, the distribution / retention strip can be divided into six equal length fragments and the ratio of (C + D) divided by (A + F) can be obtained.

   A    B    C    D    E    F

This corresponds to the amount of liquid (in grams) in approximately the middle third of the product divided by the sum of the liquids in the sixth of each end of the product. If the distribution / holding layer tested is not rectangular as in the case of the present specification, the product should be separated so that the dry weight of each piece is approximately the same. The saturation profile ratio of the present invention should be about 4 or less, more particularly less than about 2, even more particularly about 1.6 or less, more particularly less than 1.4 (using 6 fragments). Examples of materials used to test the saturation profile and the results of such tests are shown in Table 10 below.

Interlayer Saturation Profile                   snippet      ratio    A   B   C   D   E   F  (C + D) / (A + F)  System I    One  2.24  4.40  4.34  4.30  4.17  3.47      1.51    2  2.85  4.60  4.60  4.51  4.51  2.81      1.61    3  1.40  4.03  4.54  4.58  4.35  1.17      3.55  Average  2.16  4.31  4.49  4.46  4.34  2.48      2.22  System IV    One  2.83  3.91  4.04  3.85  3.60  1.74      1.73    2  2.61  4.25  4.39  4.39  4.32  2.89      1.60    3  2.47  4.05  3.99  4.24  4.05  2.85      1.55  Average  2.64  4.07  4.14  4.16  3.99  2.49      1.62  System V    One  3.32  3.94  4.09  4.28  4.23  2.94      1.34    2  3.20  3.77  3.91  4.06  4.15  2.87      1.31    3  3.61  4.33  4.57  4.47  4.04  2.07      1.59  Average  3.38  4.01  4.19  4.27  4.14  2.63      1.41

The design of the thick product was also tested for the saturation profile. Design information and saturation ratio data are shown in Tables 12 and 13, respectively.

Saturation Profile Data                   snippet        ratio    A    B    C    D    E    C / A    C / E    One   4.04   6.69   6.35   6.24   2.99   1.57   2.12    2   2.62   6.17   6.36   6.07   3.67   2.42   1.73   Average   3.33   6.43   6.35   6.15   3.33   2.00   1.93

Example 5 above describes a feminine hygiene pad with a delay in delivery function. In Example 5, the delivery retardation material has a lower density than the layer below, thus retarding the liquid delivery to the underlying layer. Although one method of causing the delivery of fluid to the lower material density layer to be delayed, other material properties can also cause delays in fluid delivery. Other material candidates effective for causing delay include nonwovens such as spunbond, composite spunbond or bonded carded webs. Perforated films can also be used to provide this function in absorbent systems.

When a nonwoven or film is used as the delivery delay material, it is desirable to make it non-wetting. In the case of spunbond, composite spunbond and film materials, the structure used in the following examples is slightly "flat". That is, it does not necessarily have a lower density than the layer below it in the absorption system design. It functions by providing a partially occluded, hydrophobic layer that begins to deliver fluid after the layer thereon is very highly saturated.

In embodiments using a bonded carded web, the propagation delay also works best when the web is hydrophobic. However, for this material both density and hydrophobicity play a role in retarding delivery.

The following example includes six thin absorption systems and seven thick absorption systems utilizing various propagation delay materials. Test data demonstrates that better saturation profile ratios can be obtained by using this material, and in some cases better contamination length ratios can be obtained compared to the original design based on density / pore gradients.

Although the test data uses certain materials, hydrophobic materials that have a lower density than other hydrophobic materials or materials below may provide a propagation delay function.

Another note about this data is that all previous data divided the distribution strip into six identical fragments, which is the method used in the claims below. The following data divides the strip into five identical fragments as illustrated below so that the excretion point is not exactly on the dividing line between the two fragments. Saturation profile ratios can be calculated from two sets of data. When five fragments are used, the saturation profile is calculated as the ratio of the amount of liquid in the central fragment to the sum of the terminal fragments.

Thin Saturation Profile with Transfer Retardation Layer

   A    B    C    D    E

C / ((A + E) / 2)

Top Layer Saturation Profile (g / g)                 snippet      ratio    A   B   C   D   E  C / ((A + E) / 2)  System 1    One  5.58  5.85  5.68  6.15  5.51      1.024    2  5.48  5.82  5.51  5.26  5.19      1.032  Average  5.53  5.83  5.59  5.70  5.35      1.028  System 2    One  5.90  5.97  6.01  5.65  5.62      1.043    2  5.04  5.36  5.56  5.23  5.07      1.099  Average  5.47  5.67  5.78  5.44  5.35      1.071  System 3    One  5.51  5.88  5.68  5.58  5.58      1.024    2  5.70  5.81  5.81  5.84  5.35      1.052  Average  5.61  5.84  5.74  5.71  5.47      1.038  System 4    One  4.99  6.41  5.74  5.88  5.42      1.103    2  5.57  6.03  5.68  5.96  5.47      1.028  Average  5.28  6.22  5.71  5.92  5.44      1.066  System 5    One  4.51  5.68  5.75  5.50  5.28      1.174    2  4.87  5.63  5.63  5.92  5.34      1.102  Average  4.69  5.65  5.69  5.71  5.31      1.138  System 6    One  5.88  6.06  6.38  5.91  5.81      0.874    2  5.78  6.37  6.04  6.15  6.30      1.000  Average  5.83  6.21  6.21  6.03  6.05      0.937

Thin Contamination Length Ratio with Transfer Retardation Layer Pollution Length (cm (in.)) Pollution Width (cm (in.))     Pollution Rain W / L   layer   T   M   B   T   M   B   T   M   B  System 1   One  6.00 No pollution 8.38 (3.30) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.45   2  6.00 No pollution 5.81 (2.00) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.75  Average  6.00 No pollution 6.73 (2.65) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.60  System 2   One  6.00 No pollution 6.60 (2.60) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.58   2  6.00 No pollution 10.92 (4.30) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.35  Average  6.00 No pollution 8.76 (3.45) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.47  System 3   One  6.00 No pollution 2.29 (0.90) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.67   2  6.00 No pollution 5.33 (2.10) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.71  Average  6.00 No pollution 3.81 (1.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.19  System 4   One  6.00 No pollution 3.81 (1.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.00   2  6.00 No pollution 3.56 (1.40) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.07  Average  6.00 No pollution 3.68 (1.45) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.03  System 5   One  5.80 No pollution 12.45 (4.90) 3.81 (1.5) No pollution 3.81 (1.5)  0.26 No pollution  0.31   2  6.00 No pollution 10.41 (4.10) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.37  Average  5.90 No pollution 11.43 (4.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.34  System 6   One  6.00 No pollution 0.00 (0.00) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  infinite   2  6.00 No pollution 0.00 (0.00) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  infinite  Average  6.00 No pollution 0.00 (0.00) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  infinite  T = upper M = middle B = lower

All thin systems are made as in Table 16 below.

   Basis weight       Pulp%    Binder%   density       size Upper layer  250 gsm  90% Weihauser NB416  10% 2.8 d H-C T-255 0.14 g / ㏄  38 mm x 140 mm Mezzanine  See description below  52 mm x 154 mm Lower layer  175 gsm  88% Weihauser NB416  12% 2.8 d H-C T-255 0.08 g / ㏄  Hourglass-60 mm ctr, 70 mm lobe, 200 mm length

Intermediate delivery delay layer for the above system:

System 1: 27 gsm (0.8 osy), 2.2 denier polypropylene spunbond,

System 2: 34 gsm (1.0 osy), 2.2 denier polypropylene spunbond,

System 3: 34 gsm (1.0 osy), 2.0 denier polypropylene / polyethylene side-by-side composite fiber,

System 4: 51 gsm (1.5 osy), 2.0 denier polypropylene / polyethylene side-by-side composite fiber,

System 5: 0.0254 mm (1.0 mil) perforated polyethylene film, and

System 6: 50 gsm bonded carded web.

Thick Saturation Profile with Transfer Retardation Layer

   A    B    C    D    E

C / ((A + E) / 2)

Top Layer Saturation Profile (g / g)                 snippet      ratio    A   B   C   D   E  C / ((A + E) / 2)  System 1    One  6.48  7.90  8.10  8.05  7.38      1.16    2  6.43  7.81  8.24  8.00  4.76      1.47  Average  6.45  7.86  8.17  8.02  6.07      1.32  System 2    One  7.24  7.90  8.24  8.05  7.52      1.12    2  6.98  8.13  8.09  8.18  7.46      1.12  Average  7.11  8.02  8.16  8.12  7.49      1.12  System 3    One  6.79  8.86  8.01  7.87  7.51      1.12    2  7.99  8.66  8.71  8.71  8.28      1.12  Average  7.39  8.76  8.36  8.29  7.90      1.12  System 4    One  7.59  8.22  7.93  8.66  8.17      1.00    2  8.01  8.55  8.11  8.50  7.91      1.02  Average  7.80  8.39  8.02  8.58  8.04      1.01  System 5    One  0.31  6.62  7.04  6.43  3.44      3.75    2  0.12  5.29  7.35  7.04  2.26      6.17  Average  0.21  5.96  7.19  6.73  2.85      4.96  System 6    One  5.31  5.35  5.22  5.03  5.57      0.96    2  4.82  5.27  5.01  5.11  5.27      0.99  Average  5.07  5.31  5.12  5.07  5.42      0.98  System 7    One  3.65  5.94  6.33  6.22  3.51      1.77    2  3.65  6.11  6.15  6.15  2.49      2.00  Average  3.65  6.03  6.24  6.19  3.00      1.89

Thick Contamination Length Ratio with Transfer Retardation Layer Pollution Length (cm (in.)) Pollution Width (cm (in.)) Pollution Rain W / L   layer   T   M   B   T   M   B   T   M   B  System 1   One 15.24 (6.00) No pollution 8.13 (3.20) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.47   2 14.22 (5.60) No pollution 9.65 (3.80) 3.81 (1.5) No pollution 3.81 (1.5)  0.27 No pollution  0.39  Average 14.73 (5.80) No pollution 8.89 (3.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.26 No pollution  0.43  System 2   One 15.24 (6.00) No pollution 3.81 (1.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.00   2 15.24 (6.00) No pollution 6.35 (2.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.60  Average 15.24 (6.00) No pollution 5.08 (2.00) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  0.80  System 3   One 15.24 (6.00) No pollution 1.27 (0.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  3.00   2 15.24 (6.00) No pollution 3.81 (1.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.00  Average 15.24 (6.00) No pollution 2.54 (1.00) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  2.00  System 4   One 15.24 (6.00) No pollution 3.81 (1.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.00   2 15.24 (6.00) No pollution 2.54 (1.00) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.50  Average 15.24 (6.00) No pollution 3.18 (1.25) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  1.25  System 5   One 13.46 (5.30) No pollution 10.67 (4.20) 3.81 (1.5) No pollution 3.81 (1.5)  0.28 No pollution  0.36   2 11.68 (4.60) No pollution 9.40 (3.70) 3.81 (1.5) No pollution 3.81 (1.5)  0.33 No pollution  0.40  Average 12.57 (4.95) No pollution 10.03 (3.95) 3.81 (1.5) No pollution 3.81 (1.5)  0.31 No pollution  0.38  System 6   One 15.24 (6.00) No pollution 1.27 (0.50) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  3.00   2 15.24 (6.00) No pollution 1.78 (0.70) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  2.14  Average 15.24 (6.00) No pollution 1.52 (0.60) 3.81 (1.5) No pollution 3.81 (1.5)  0.25 No pollution  2.57  System 7   One 11.94 (4.7) 11.18 (4.4) 5.81 (2.0) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  0.32  0.34  0.57   2 12.19 (4.8) 9.40 (3.7) 4.32 (1.7) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  0.31  0.41  0.88  Average 12.07 (4.75) 10.29 (4.05) 4.70 (1.85) 3.81 (1.5) 3.81 (1.5) 3.81 (1.5)  0.31  0.38  0.82

All thick systems are made as shown in Table 19 below.

   Basis weight       Pulp%    Binder%   density       size Upper layer  250 gsm  90% Weihauser NB416  10% 2.8 d H-C T-255 0.12 g / ㏄  38 mm x 140 mm Mezzanine  See description below  52 mm x 154 mm Lower layer  435 gsm  100% Coot 0054 sine wave embossed  0%  Hourglass-60 mm ctr, 70 mm lobe, 200 mm length

Intermediate delivery delay layer for the above system:

System 1: 27 gsm (0.8 osy), 2.2 denier polypropylene spunbond,

System 2: 34 gsm (1.0 osy), 2.2 denier polypropylene spunbond,

System 3: 34 gsm (1.0 osy), 2.0 denier polypropylene / polyethylene composite fiber,

System 4: 51 gsm (1.5 osy), 2.0 denier polypropylene / polyethylene composite fiber,

System 5: 0.0254 mm (1.0 mil) perforated polyethylene film,

System 6: 50 gsm bonded carded web, and

System 7: 100 gsm, 0.03 g / dl, 50/50 blend of Weihauser NB 416 pulp and H-C T-255 binder fibers, prepared according to the airlaying method.

Embodiments of personal care products encompassed by the present invention include feminine hygiene pads having a bodyside liner, a dispensing / retaining layer, a delivery retardation layer, a pad shaping or second absorbent layer, and a backsheet. The material can be held together by various means, for example with an adhesive, mechanically and with thermal bonding means.

The liner may be a nonwoven or a laminate of nonwovens and a film. In the case of laminates, the liner must be perforated by means of allowing the passage of fluid. Suitable nonwovens for such laminates are made from air-bonded composite polypropylene / low density polyethylene, 50/50 cores / shells, concentric 6 to 10 denier fibers that are finished to show wettability. Suitable nonwovens can have a density of about 0.03 g / dL and a basis weight of about 24 gsm (0.7 osy). Examples of suitable films for such laminates include 94% Rexene® low density polyethylene and 6% Ampacet® titanium dioxide concentrate having a melt index of 5.5 and a density of 0.923 g / dL. There is a commercially available film from Edison Plastics (Edison Plastics). Films and nonwovens may be laminated and perforated, for example, in a thermal bond pattern having a bonding area of 8-12% to form an open area of about 27% for the passage of fluid.

The liner layer may be connected to the dispensing / retaining layer with an adhesive, for example National Starch NS34-5610 or equivalent, in an additional amount of about 5 gsm. Any adhesive or other joining method should of course not block the fluid flow between the layers.

The dispensing / retaining layer can be produced by an airlaying method, for example 90% of Weihauser NB-416 or NF-405 Southern softwood pulp and 10% of Hoechst-Celanes T-255 polyethylene terephthalate / Co-polyolefin, 50/50 core / shell, concentric 2.8 denier fibers. The basis weight of the distribution layer may be about 250 gsm when having a density of about 0.14 g / dl. The dispensing / retaining layer will be slit longitudinally as described above so that the product will bend upward during use and thus improve fitness. Such slits may be continuous or discontinuous and located at the product center.

Suitable delivery retardation layers can be polyolefin fibers having about 2.7 denier fibers at a basis weight of about 27 gsm (0.8 osy), for example fabrics produced by the spunbond method from polypropylene. This layer has a larger x-y plane than the distribution layer and has a color other than white to indicate to the wearer whether fluid has moved beyond the edge of the distribution / retaining layer. One such color may be rose, which gives the product an aesthetic feel.

Once the fluid retention is maximized in the dispensing / retaining layer and / or compressive force is applied to the product, the delivery delay layer will cause the fluid to move in the Z direction (downward) to the pad forming layer.

The pad forming or second absorbing layer can be made from the same material at the same ratio as the distribution layer, but at a lower density of, for example, about 0.08 g / dl and a lower basis weight, for example of 175 gsm. Suitable pad forming layers have a longitudinal embossing pattern that can direct and direct the fluid in the longitudinal direction so that it does not deviate laterally and body fitness is improved.

Alternative suitable pad forming layers may have two layers of pulp. One such layer is Kusa 0054, Weihauser NB-416 or NF-405 or Georgia Pacific Golden Isles grade 4821 pulp, about 200 mm long and about 60-70 mm wide. It may have a 100% Southern serial 500 gsm, for example the sine wave pattern shown in Figure 16 or another longitudinal embossing pattern. Another layer may be 400 gsm of the same material about 160 mm long and about 45 mm wide and have an acorn shape or other embossing pattern.

The pad forming layer may be attached to the backing layer or baffle layer with an adhesive such as National Starch NS34-5610 in an amount of less than about 15 gsm.

The back layer or baffle layer of the article can be made from a low density, 0.254 mm (1 mil) polyethylene film, such as Edison Plastic XP 746A, a rose colored, fine embossed film. In addition, any other color may be selected for the back layer.

A more extensive discussion of the methods and apparatus to be used to practice the present invention can be found in co-assigned, co-pending patent application (Attorney docket no. 13817).

As already discussed, the entire material can be embossed from the bodyside liner side. Embossing may emboss only the bodyside liner or may include other layers. The embossing pattern can be selected to maximize material densification, which increases fluid intake and dispersion throughout the product and fluid distribution along the front to back axis. Embossing may also provide the wearer with a visible signal that should be discarded because the product capacity is almost full and may also be used to provide an aesthetic benefit. Examples of suitable embossing patterns are shown in the figures. FIG. 16 is an embossing pattern for personal care products referred to as a sine wave pattern and FIG. 17 is an embossing pattern for personal care products referred to as a shell pattern.

Women's personal hygiene systems, such as women's hygiene products having the characteristics required for the present invention, it is clear that the feces develop very well. This development requires more efficient use of the entire product prior to leakage, thus providing excellent comfort to the wearer.

Although only a few exemplary embodiments of the invention have been described in detail above, those of ordinary skill in the art will recognize that many modifications can be made in the exemplary embodiments without materially departing from the novel teachings and advantages of the invention. It is easily understood that it is possible. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, the means plus functional claims are intended to include equivalent structures as well as the structures and structural equivalents described herein that perform the recited functions. Thus, although the nails use cylindrical surfaces to hold the wooden parts together, the screws and screws may not be structural equivalents in that the screws use spiral surfaces, but in terms of fastening the wooden parts, the nails and screws It may be an equivalent structure.

The above arrangement of the present invention results in a feminine hygiene product with good distribution performance that moves menstrual blood from the target surface and provides comfort, dryness, and less leakage than a typical pad. In addition, improved feminine hygiene products have been obtained that reduce leakage and improve comfort through the use of materials intended to accommodate the properties of menstrual blood and direct the physiological fluid to the absorbent system to substantially isolate it within the local area of the absorbent system. .

Claims (37)

A distribution / holding layer and a pad forming layer, each layer having a contamination length ratio of 0.5 or less, a saturation profile of the distribution / holding layer of 4 or less, and a density of the distribution / holding layer of 0.1 g / cc to 0.2 g / kPa Personal care products with an average pore size of from 40 to 500 microns. The personal care article of claim 1 wherein the contamination length ratio of each of the distribution / retention layer and the pad forming layer is no greater than 0.375. The personal care article of claim 1 wherein the contamination length ratio of each of the distribution / retention layer and the pad forming layer is no greater than 0.1875. The personal care article of claim 1 wherein the saturation profile ratio of the dispensing / retaining layer is 2 or less. The personal care article of claim 1 wherein the saturation profile ratio of the distribution / retention layer is 1.4 or less. The personal care product of claim 1 wherein the basis weight of the dispensing / retaining layer is between 175 and 300 gsm. The personal care product according to claim 1, wherein the pad forming layer has a density of 0.03 g / dl to 0.1 g / dl. The personal care article of claim 1 wherein the pad forming layer has a larger pore size than the dispensing / retaining layer. The personal care product of claim 1 further comprising a suction layer. 10. The personal care article of claim 9 wherein the pad forming layer has a larger pore size than the dispensing / retaining layer and the dispensing / retaining layer has a smaller pore size than the suction layer. 10. The personal care article of claim 9 wherein the layers are regions of monolithic material. 10. The personal care article of claim 9 wherein at least one of the layers has a slit. 10. The personal care article of claim 9 wherein the one or more layers are prepared according to a method selected from the group consisting of airlaying, wetlaying and bonded carded web methods. The personal care article of claim 13, wherein the one or more layers are made of a material selected from the group consisting of cellulose fibers, foams, synthetic fibers, and mixtures thereof. 10. The personal care article of claim 9 further comprising a delivery delay layer. 10. The personal care article of claim 9 wherein at least one layer is embossed. 17. The personal care article of claim 16 wherein the pad forming layer is embossed in a sine wave pattern. 17. The personal care article of claim 16 wherein all the layers are embossed together in a shell shell pattern. The personal hygiene product according to claim 1, which is a feminine hygiene product. Suction layer having a density of 0.02 to 0.06 g / dL, a basis weight of 25 to 125 gsm, a pore size of 80 to 1000 microns and at least one longitudinal slit at the center, A dispensing / retaining layer having a density of 0.1 to 0.2 g / dL, a basis weight of 175 to 300 gsm, a pore size of 40 to 500 microns and at least one longitudinal slit centered, and Embossed Pad Formation Layer with Density of 0.03 to 0.2 g / dl Feminine hygiene products comprising a. A bodyside liner, a dispensing / retaining layer, a delivery retardation layer, a pad forming layer and a backsheet, The liner is selected from the group consisting of nonwovens and perforated laminates of nonwovens and films, The dispensing / retaining layer is adhesively attached to the liner layer and comprises pulp and binder fibers, The delivery retardation layer comprises a fabric made of polyolefin fibers and is larger in x-y plane than the distribution / retention layer and tinted to indicate to the wearer that fluid has moved beyond the edge of the distribution / retention layer, The pad forming layer has an embossing pattern for directing and directing fluid in the longitudinal direction, The rear layer includes a low density film attached to the pad forming layer with an adhesive, The contamination length ratio of the distribution / retention layer and the pad forming layer is 0.5 or less, and the saturation profile of the distribution / retention layer is 4 or less. 22. The method of claim 21, wherein the liner is 6-10 denier wettability, composite, polypropylene / low density polyethylene, 50/50 cores / shell, air-bonded web of concentric fibers, the web having a density of 0.03 g / dl And a laminate having a basis weight of 24 gsm (0.7 osy) and a film comprising 94% low density polyethylene and 6% titanium dioxide concentrate having a melt index of 5.5 and a density of 0.9 g / dL. . The feminine hygiene article of claim 22 wherein the liner is a laminate of film and nonwoven, laminated and perforated with a thermal bond pattern of 8 to 12% bond area to form a 27% open area for passage of fluid. The feminine hygiene article of claim 21 wherein the liner is connected to the dispensing / retaining layer with an adhesive in an additional amount of 5 gsm. 22. The method of claim 21 wherein the distribution / retention layer is prepared by an airlaying method and comprises 90% softwood pulp and 10% polyethylene terephthalate / co-polyolefin, 50/50 cores / shell, concentric 2.8 denier fibers. And the dispensing / retaining layer has a basis weight of 250 gsm and a density of 0.14 g / dL. 27. A feminine hygiene product as set forth in claim 25 wherein said dispensing / retaining layer is slit longitudinally such that the product is bent upward during use. 27. A feminine hygiene product as in claim 26, wherein said slit is continuous or discontinuous and is located at the center of the product. The feminine hygiene article of claim 21 wherein the delivery retardation layer is a spunbonded web of 2.7 denier polyolefin fibers and the basis weight of the web is 27 gsm (0.8 osy). 29. A feminine hygiene product as in claim 28, wherein said delivery retardation layer has a color other than white. The method of claim 21 wherein the pad forming layer is prepared by an airlaying method and comprises 90% softwood pulp and 10% polyethylene terephthalate / co-polyolefin, 50/50 cores / shell, concentric 2.8 denier fibers, and Feminine hygiene article having a basis weight of 175 gsm and a density of 0.8 g / dl. 22. The two pulp layers of claim 21 wherein the pad forming layer comprises 500 gsm softwood pulp and a first layer having a sinusoidal embossing pattern, and a second pulp layer comprising 400 gsm softwood pulp and having an embossing pattern. Feminine hygiene products having. The feminine hygiene article of claim 21 wherein the backing layer comprises a low density 0.0254 mm (1 mil) polyethylene film. 22. The feminine hygiene article of claim 21, wherein said back layer is a rose index. A bodyside liner, a dispensing / retaining layer, a pad forming layer and a backsheet, The liner is 6-10 denier wettable, composite, polypropylene / low density polyethylene, 50 laminated and perforated with a thermal bond pattern of 8-12% bond area to form a 27% open area for the passage of fluid. / 50 core / shell, air-bonded web of concentric fibers, the web having a density of 0.03 g / dl and a basis weight of 24 gsm (0.7 osy), a melt index of 5.5 and a density of 0.9 g / dl A laminate with a film comprising 94% low density polyethylene and 6% titanium dioxide concentrate having The dispensing / retaining layer is adhesively connected to the liner, prepared by an airlaying method, 90% softwood pulp and 10% polyethylene terephthalate / co-polyolefin, 50/50 cores / shell, concentric 2.8 denier fibers Wherein the dispensing / retaining layer has a basis weight of 250 gsm and a density of 0.14 g / mm 3, discontinuous or continuous, with longitudinal slits at the center, The pad forming layer was prepared by an airlaying method and comprises a web having 90% softwood pulp and 10% polyethylene terephthalate / co-polyolefin, 50/50 cores / shell, concentric 2.8 denier fibers, based on 175 gsm Has a weight and a density of 0.08 g / dL, and has a longitudinal embossing pattern that directs and directs the fluid in the longitudinal direction, And said back layer comprises 0.0254 mm (1 mil) polyethylene low density, rose-colored film adhesively attached to said pad forming layer. 35. The method of claim 34, wherein the xy plane is larger than the distribution / retention layer and comprises a spunbonded web of 2.7 denier polyolefin fibers, wherein the web has a basis weight of 0.8 osy (27 gsm) and is other than white. Feminine hygiene further comprising an index delivery retardation layer between the dispensing / retaining layer and the pad forming layer. A bodyside liner, a dispensing / retaining layer, a pad forming layer and a backsheet, The liner is 6-10 denier wettable, composite, polypropylene / low density polyethylene, laminated and perforated in a thermal bond pattern having a bond area of 8-12% to form a 27% open area for the passage of fluids, 50/50 core / shell, air-bonded web of concentric fibers, the web having a density of 0.03 g / dl and a basis weight of 24 gsm (0.7 osy), a melt index of 5.5 and 0.9 g / dl A laminate with a film comprising 94% low density polyethylene having a density and 6% titanium dioxide concentrate, The dispensing / retaining layer is adhesively connected to the liner, prepared by an airlaying method, and made of 90% softwood pulp and 10% polyethylene terephthalate / co-polyolefin, 50/50 cores / shell, concentric 2.8 denier fibers. Including a basis weight of 250 gsm and a density of 0.14 g / dl, The pad forming layer is a web having two pulp layers of another layer comprising 500 gsm softwood pulp and having a sinusoidal embossing pattern, and another layer containing 400 gsm softwood pulp and having an embossing pattern, And said back layer comprises 0.0254 mm (1 mil) polyethylene low density, rose-colored film adhesively attached to said pad forming layer. 37. The method of claim 36, wherein the xy plane is larger than the distribution / retention layer and comprises a spunbonded web of 2.7 denier polyolefin fibers, the web having a basis weight of 27 gsm (0.8 osy) and other than white. Feminine hygiene further comprising an index delivery retardation layer between the dispensing / retaining layer and the pad forming layer.

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