MXPA00001908A - Breathable barrier composite - Google Patents

Abstract

A composite material adapted for mechanical fastener use as a loop fastener component with a complementary hook component is made by laminating a film (10) with an amorphous polymer layer to a prebonded nonwoven web (34) under conditions producing laminate bonds corresponding to the prebond locations, and loose filaments or fibers between the bonds. The composite also desirably has a MVTR of at least about 100 g/m2/24 hours and a hydrohead of at least about 50 mbar. In use as a component of a disposable personal care product such as a disposable diaper, the loop fastener component may be substantially the entire backing, providing comfort, protection andhighly variable fit.

Description

BARRIER COMPOSITE WITH BREATHING CAPACITY BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to composite materials having barrier applications with a capacity to breathe and particularly useful as a component of the hook-and-loop type fasteners typified by that marketed extensively by Velero International and now available from numerous sources of lace-up applications. for shoes up to golf gloves and many others where a non-permanent grip is desired. These fasteners fundamentally include a hook member and a curl member which, when pressed together, become entangled in a manner that resists the cutting forces but that can be separated when subjected to a desired level of peel force. The design of these members has become very sophisticated and provides a wide range of properties obtainable by varying the factors such as the shape, size and flexibility of the hook as well as other similar curl characteristics. For many low-cost applications such as fasteners for disposable garment applications such as diapers and adult incontinent garments, it has been necessary to develop inexpensive manufacturing techniques and materials for fasteners that nevertheless meet the operating requirements. Particularly for such applications where the curl component also serves as the backing material it is highly desirable that it be breathable for comfort and serve as a barrier to prevent runoff. The present invention provides an ideal curl fastener component particularly suitable for such disposable product applications.

Background The art is replete with references to hook-and-loop type fasteners and components for such fasteners that are intended to be used and disposable product applications such as disposable diapers and the like. By way of example, reference may now be made to United States Patent No. 5,614,281 issued jointly to Jackson, which, in itself, provides much background information and for this purpose is incorporated here by reference in its whole. Other fastener materials are disclosed in, for example, U.S. Patent No. 4,761,318 issued to Ott and others, U.S. Patent No. 5,032.12, to Noel et al., The patent. United States of America No. 5,326,612 issued to Goulait, United States Patent No. 5,595,567 issued to King et al., and United States Patent No. 5,647,864 issued to Alien et al. Briefly, a particularly economical curl component can be formed using nonwoven manufacturing techniques such as yarn bonding processes that result in significant areas of the fabric between the joined points where the filaments are not attached to one another and available for hooking the hooks of a member of complementary hooks. The factors, such as the configuration, number and area coverage of the joints in the nonwoven as well as the section of a particular ganch member, can be varied to achieve a desired level of peel strength and other properties within a range d designated cost. In addition, the selection of the polymer or other composition ingredient for the nonwoven and / or the hook component may affect the performance and / or cost of the fastener in a given application. There is still a need for a curl fastener component that can have ready-made properties such as peel strength, resilience cut resistance as well as barrier functions with ability to breathe at a cost consistent with use as a backing component. disposable products. Other uses for breathable barrier materials having cloth-like attributes such as surgical suits and surgical covers, for example, will be apparent to those skilled in the art.

SYNTHESIS OF THE INVENTION The present invention is directed to a non-woven barrier composite with breathability particularly adapted for use as a curl fastener component that includes a laminate of a film layer and a pre-woven non-woven layer wherein the laminate bonds. they occur at the binding sites of the pre-joined nonwoven, leaving fibers or filaments between such bound sites unbound. For improved comfort and utility as a backing component of a personal care product such as a disposable diaper, for example, the laminate has the ability to breathe with a moisture vapor transmission rate of up to about 100 g / l. square meter / 24 hours and has a hydro head value of at least 50 mbar of water. In use with a complementary hook component a curl fastener formed from this composite provides the ability to hold on either side on the back of the product and a consistent resilience over a period of time and for the number of opening and closing cycles. closure that is suitable for many limited use and disposable applications. The woven layer n contains a bond pattern of either uniform or non-uniform bond impressions resulting in a non-bonded area of at least 70 percent, taken on any 10 square centimeters of non-woven surface. In addition, the bonding frequency provides a pattern density in the range of from about 50 to about 200 joints / square inch with an area coverage of from about 5 percent to about 30 percent, advantageously from about 50 percent. 10 percent to around 25 percent. The film cap is either a multi-layer structure co-extruded with an exposed layer of an amorphous and soft polymer or a monolayer and, in any case, is a microporous liquid barrier predominantly that is comfortable and compatible with nonwoven. The lamination can be achieved by a heat and pressure application taking advantage of the amorphous polymer properties either in the multilayer film, or as the bonding cap applied separately in the monolayer film mode, for example. To improve the cloth type aesthetics and hooking of the hook elements for the curl component applications, a retracted laminate can be formed by stretching the film prior to lamination to the nonwoven subsequently allowing the laminate to relax or retract, producing a textured surface of curls formed by fibers or inner junction filaments not joined between the bonded areas where the film and the nonwoven remain securely fastened. The invention also includes the method for making the curl fastener component.

DETAILED DESCRIPTION Definitions As used herein the following terms have the specified meanings unless the context demands a different meaning, or a different meaning is also expressed, the singular generally includes the plural, and the plural usually includes the singular unless otherwise indicated. way .

The phrase "non-woven" means a fiber or filament fabric that is formed by means other than woven fabric and that contains bonds between some or all of the fibers or filaments; such joints can be formed, for example, by thermal, adhesive or mechanical means such as entanglement.

"Fiber" means an elongated yarn of defined length, such as the short fibers formed by cutting a continuous yarn into stretches of, for example, 2 to 5 centimeters. The collections of fibers can have the same or different lengths.

"Filament" means a generally continuous strand having a large mu to length ratio, e.g., 1,000 or more.

"Spunbonded" means a non-woven filament formed by extrusion of polymer melt into yarns that are cooled and pulled, usually p means of air at high speed, to reinforce the filaments which are collected on a forming surface and are frequently joined by the application with heat pressure pattern. Spunbond processes are described, for example, in the following patents to which reference may be made for additional details: United States Patent No. 4,340,563 issued to Appel and other US Pat. No. Pat. 3,802.81 issued to Matsuki et al., And United States Patent No. 3,692,618 issued to Dorschner et al.

The "curl" means an area of separation of at least one fiber or filament from others in a nonwoven and includes but is not limited to configurations where the same filament fiber intersects itself; For example, you do not need to form a complete circle or oval.

The phrase "complementary hook" means a structure adapted to be used as a mechanical fastening component and having projections of a profile, height, geometry density and orientation so as to releasably join the terry fastening material of the invention and provide the intended level of properties of resistance to the cut and peeling of hook. The projections do not need to be a "hook" but may have other configurations such as mushroom shape, for example, suitable hook materials may be unidirectional or bidirectional, for example, they often comprise from about 16 to about 620 hooks per square centimeter and desd hook heights around 0.00254 centimeters to around 0.19 centimeters These are available, for example from Velero International of Manchester, NH, and of 3M of San Paul MN.

The "amorphous polymer" when used herein to describe a binding layer either as a multilayer film component or a separately applied layer means a thermoplastic polymer such as certain polyolefins with a density in the range of from about 0.85 to about d 0.89 and of low crystallinity, for example, of less than about 30 percent such as those which are often used as adhesive components and have limited hot melt properties.

The "thermal point union" involves passing a fabric or fabric of fibers that are to be joined between a heated calender roll and an anvil roller. The calendered roll d has a pattern in some way so that the entire phone does not fit through its entire surface. As a result of this, many models or patterns have been developed for calendering rolls for functional reasons as well as aesthetics. As will be understood by those skilled in the art the percentages of bonded area are, by necessity, described in ranges or approximations since the joint bolts are normally tapered and wear out over time. As those skilled in the art will recognize, the references to "square bolt / inch" and "square joints / inch" are interchangeable since the anvil bolts will create joints in the substrate in essentially the same sizes and surface area as the bolts. on the anvil. An example of a pattern has points and is the Hansen Pennings pattern "H &P" with about 30 percent area bonded with about 200 joints / square inch as taught in the United States Patent Number 3,855,046 issued Hansen and Pennings. The H &P model has a square point or bolt of joint areas where each bolt can have a lateral dimension of 0.038 inches (0.965 millimeters), for example, resulting in a model or pattern having a bonded area of about 30 hundred. Another typical point union model is the Hansen and expanded Pennings junction model or "EHP" which produces a joint area of about 15 percent at 18 percent which can have a square bolt having a side dimension of 0.037 inches ( 0.94 millimeters), for example, and a bolt density of around 100 bolts / square inch. In another typical point union model designated "714" has square bolt joint areas where each bolt can have a side dimension of 0.023 inches for example, for the joint area of 15 percent to 20 percent and around 270 bolts / square inch. Other common patterns include a "Ramisch" diamond pattern with repeating diamond having a bound area of 8 percent at 14 percent and 52 bolts / square inch as well as a wire knit pattern that looks like its name suggests, for example, with a window grid and having a joined area of 15 per cent to 20 percent and 302 joints / square inch. Typically, the percentage of bond area varies widely from about 10 percent to about 30 percent of the area of the laminated fabric and the number of bolts / square inch can also vary over a wide range. Of the combinations of practically limitless binding configurations, only the binding patterns selected according to the invention are useful. These will have a united area in the range of about 5 percent to about 30 percent, desirably in the range of about 10 percent around 25 percent and a frequency of union in the rang from about 50 to about 200 per square inch, desirably in the range of from about 75 to about 125 per square inch. When used herein, the term "pre-bonded" non-woven means those non-wovens having been bonded with a pattern defined as useful according to these parameters. As is well known in the art, point bonding keeps the laminate layers together as well as imparting integrity to each individual layer by joining the filaments and / or fibers within each layer.

Test Procedures Hydrohead: A measure of the liquid barrier properties of a cloth is the hydro head test. The hydro head test determines the height of water (in mbars) which will support the fabric before a predetermined amount of liquid passes through it. A higher hydro head reading indicates that a cloth is a better barrier to liquid penetration than a cloth with a lower hydro head. The hydrohead test is carried out according to the federal test standard 191A, method 5514.

Grip Tension Test: The gripping tension test is a measure of the resistance to breakage and to the elongation or tension of a fabric when it is subjected to unidirectional tension. This test is known in the art and conforms to the specifications of method 5100 of the federal testing method standard 191A. The results are expressed in pounds or grams at the break and percentage of stretch before breaking. The upper numbers indicate a more stretchable and stronger fabric. The term "load" means the maximum load or force, expressed in units of weight, required to break or tear the specimen in a stress test. The term "total energy" means the total energy under a load curve against elongation, as expressed in a weight-length unit. The term "elongation" means the increase in length of a specimen during a stress test. The grip tension test uses two clamps, each having two jaws with each jaw having a face and contact with the sample. The clamps hold the material in the same plane, usually vertically, separated by three inches (76 mm) and move apart at a specified length of extension. The values for grip strength and elongation of grip were obtained using a sample size of 4 inches (102 millimeters) per inch (152 millimeters), with a jaw face size of an inch (25 millimeters) per 1 inch, and a constant rate d extension of 300 mm / min. The sample is wider than the clamp jaws to give representative results of the effective fiber strength in the clamped width combined with the additional strength contributed by the adjacent fibers in the fabric. The specimen is held in, for example, a tested Sintech 2 available from Sintech Corporation, 1001 Sheldon Dr., Cary, North Carolina 27513, an Instron TM model, available from Instron Corporation, 2500 Washington Street, Canton M 02021, or a Thwing-Albert INTELLECT II model available from the Thwing-Albert Instrument Company, 10960 Dutton Road, Philadelphia, PA 19154. This closely simulates fabric tension conditions in actual use. The reported results are the average of three tested specimens and can be carried out with the specimens in the transverse direction (CD) or in the machine direction (MD).

Strip Tension: The strip tension test is similar to the grip tension and measures the peak and d breaking loads and the percentages of peak elongations and d breaking of a fabric. This test measures the load (resistance in grams and elongation in percent.) In the tension test strip two clamps, each having two jaws with each jaw having a load in contact with the sample hold the material in the same plane, usually in vertical form, separated by three inches and moving and separating a specified rate of extension.The values of the strip tensile strength and strip elongation are obtained using a sample size of 3 inches per inch, with a jaw face size of 1 inch in height by 3 inches in width, and a constant extension rate of 30 mm / min.The Sintech 2 tester, available from Sintec Corporation, 1001 Sheldon Dr., Cary, North Carolina 27513, the Instron TM model, available from Instron Corporation, 250 Washington Street, Canton MA 02021, or an INTELLECT II Thwing-Alber model available from the Thwing-Albert Instrument Company, 10960 Dutton Road, Philadelphia, PA 1915 4 can be used for this test. The reported results are the average of three tested specimens and the test can be carried out with the specimen in the transverse direction (CD) or in the machine direction (MD).

Peel Test: In the peeling delamination test, a laminate is tested with respect to the amount of tension force that will pull apart the laminate layers. The values for peel strength were obtained using a cloth width, a clamp jaw width and a constant ta of specified extension. For samples with a film side, the film side of the specimen should be covered with protective tape, or some other suitable material, to prevent the film from tearing apart during testing. The protective tape is only on one side of the film. laminated and contributes to the peel resistance of the sample. This test uses two clamps, each having two jaw jaws with one face in contact with the sample, to hold the material in the same plane, usually in vertical, separated by two inches to start. The sample size is 4 inches wide for as long as is necessary to delaminate a sufficient sample length. The face size of the jaw is 1 inch in height by at least 4 inches in width, and the constant rate of extension is 300 mm / min. The sample is delaminated by hand by a sufficient amount to allow it to be embraced and position, and the clamps move apart at the specified extension rate to pull the laminate apart. The sample specimen is pulled apart at 180 degrees d separation between the two layers, and the reported peel strength is an average of three tests, peak load in grams The force measurement begins when 16 millimeters of laminate have been pulled and have separated, and this continues until a total of 170 millimeters have been delaminated. The proven Sintech 2 available from Sintech Corporation, 1001 Sheldo Drive, Cary, North Carolina 27513, the TM Instron model available from Instron Corporation, 2500 Washington Street, Canton MA 02021, or the INTELLECT II model from Thwing-Alber available from Thwing-Albert Instrument Company, 10960 Dutto Road, Philadelphia, PA 19154 may be used for this test. The test can be carried out with the specimen in the transverse direction (CD) or in the machine direction (MD).

Martindale Abrasion Test: This test measures the relative resistance to abrasion of a fabric. The results of the test are reported on a scale of 1 5, with 5 being the least wear and 1 the highest, after 12 cycles with a weight of 1.3 pounds per square inch. The test was carried out with a wear tester and abraded Martindale such as model 103 or model number 403 available from James H. Heal & Company, Limited of West Yorkshire, England. The abrasive used is a 36-inch by 4-inch by 0.05-inch silicon rubber wheel reinforced with glass fiber having a surface hardness of 81 A durometer, Shore A of 81 plus or minus 9. Abrasive is available from Flight Insulation, Inc., a Connecticut Hard Rubber dealer, 925 Industrial Park, NE, Marietta Georgia 30065.

Base Weight: The base weights of various materials described here were determined in accordance with federal test method number 191A / 5041. The sample size for the sample materials was 15.24 by 15.24 centimeters, and s obtained three values for each material and then s averaged. The values reported below are the averages.

Peeling of Hook: The 180 degree peel strength test is attempted to measure how well the hook and loop components engage, and this involves fastening the hook material to a loop material of a hook and loop fastening system. curl, then peel the material of the hook from the curl material at an angle of 180 degrees. The maximum load was recorded in grams as an average of the three highest peak load values needed to disengage or peel the materials. To carry out the test, a continuous extension rate voltage tester with a full scale load of 5 is required., 000 grams, such as an integrated Sintech System 2 computer test system available from Sintec Inc., having offices in Research Triangle Park, North Carolina. A sample of the curl material of 3 inches (7.6 centimeters) by 6 inches (15.2 centimeters) was used. A 2.5 inch (6.3 cm) wide sample of hook material which is adhesively and ultrasonically secured to essentially elastic nonwoven material, was placed with the hook ladder down on the upper surface and applied to it to cover the sample of curl material, with about 1 inch of overlap. To ensure a proper uniform hooking of the hook material with the loop material, a juicer, model LW 1, part number 14-9969 of Atla Electric Devices Company, of Chicago, Illinois, is used to squeeze the combined hook and loop materials by a cycle, with a cyclone equaling one pass through a juicer using a total of 40 pounds of weight. One end of the ded appendage material that holds the hook material is secured within the upper jaw of the tension tester, while the end of the loop material directed towards the upper jaw is bent downward and secured within the lower jaw of voltage tester. The placement of the retive materials within the jaws of the tension tester should be adjusted so that there is minimum clearance in the retive materials and the length of markers is 3 inches (7. centimeters) before activation of the tension tester. The hook elements of the hook material are oriented in the direction generally perpendicular to the intended directions of movement of the tension tester jaws. The tension tester is activated at a constant rate of separation of 500 millimeters per minute and the peak load in grams is then recorded to disengage or peel the material from the hooks of the curl material at an angle of 180 degrees based on the average of the three highest peaks.

Hook Cut: The dynamic cut resistance test involves hooking a hook material with a loop material of a hook and loop fastening system then pulling the hook material through the surface of the loop material. The maximum load required to unhook the hook from the loop was measured in grams. To perform this test, a constant rate of extension voltage testing was required with a full scale load of 5.00 grams, such as a computer-integrated Sintech 2 system. A sample of the 3-inch curl material was attached by inches with protective tape to a planar support surface and then cut in half in the shortest direction. A sample of a 2.5 inch by .7 inch hook material, which is adhesively and ultrasonically secured to an essentially inelastic nonwoven material, was placed on the upper surface and applied to the sample of the curl material centered in the sample. the direction shorter and 2 inches in from the cutting edge. To ensure a proper and even hooking of the hook material with the d rizo material, a juicer, model LW 1, part number 14-9969 of the Atla Electric Devices Company of Chicago Illinois was used to squeeze the combined hook and loop materials for a cycle, with a cycle equaling one MD pass (larger dimension), through the juicer using a total of 40 pounds of weight. A tip of the non-woven material holding the hook material was secured within the upper jaw of the tension tester, the end of the loop material directed towards the lower jaw was secured within the lower jaw of the tension tester. The placement of the respective materials within the jaws of the tension tester should be adjusted so that there is minimum clearance in the respective materials before activation of the voltage tester. The hook elements of the hook material are oriented in a direction generally perpendicular to the intended directions of movement of the tension tester jaws. The tension tester is activated at a marker length of 3 inches and a crosshead speed of 250 millimeters per minute and the peak load to disengage the hook material from the curl material was then recorded in grams as the average of the highest peaks. high for 3 specimens.

Brief Description of the Drawings Figure 1 is a schematic illustration of a process for making the terrycloth fastener material of the present invention.

Figure 2 is a cross section of an embodiment of a terrycloth fastener material of the present invention.

Figure 3 is an illustration of a terrycloth fastener material of the present invention in use as a backing component of a personal care product.

Figure 4 is an illustration of a useful joining pattern according to the present invention.

Figure 5 is an illustration of a second attachment pattern useful in accordance with the present invention.

Figure 6 is a photograph taken at an amplification of about 20 X showing a composite material according to the invention after the peel-peel test and bending over an edge to expose the loose filaments.

Figure 7 is a photograph similar to that of Figure 6 of a different composite material according to the invention.

Detailed additions The invention will be described with reference to the drawings and the examples which illustrate certain embodiments. It will be apparent to those skilled in the art that these embodiments do not represent the full scope of the invention which is broadly applicable in the form of variations and equivalents as may be encompassed by the claims appended hereto. It is intended that the scope of claims extend to all those equivalent variations.

Referring to Figure 1, the illustrated process begins with a filled film 10 that is unrolled from roll 12 and is preheated, for example, by contact with two heated rotating drums 14 and 16. The temperature at which the film 10 is heated will depend on the constitution of the film as well as the ability to breathe and other final properties desired of the composite material. Po For example, like a curl bra, the amount of retraction will affect the size of the curls. In many cases the film will heat to a temperature not higher than 10 degrees centigrade below its melting point. The purpose for heating the film is to allow it to stretch quickly without causing defects of the film. The heated film is stretched in the direction of the machine in a »*, Orientation section in the machine direction 1 comprising the rotating rollers 20 and 22 and the associated pressure rollers. The roller 22 is driven faster than the roller 20, with the result that the film is stretched in the direction of travel ("machine direction" or "MD") The amount of stretch will depend on the desired final properties of the fastener However, in general, the film will stretch at least about 300 percent of its original length but less than the amount that tends to result from film defects. For many polyolefin-based film applications, for example, the stretch will be at least 200 percent of the length of the original film and will often be in the range of about 250 percent to 500 percent. The stretched film 24 is supported on the support rolls 26 and 28 through an optional bonding station 27 where the applicator 30 applies amorphous polymer, for example, the polyolefin resin 32 if desired. As will be explained in more detail below, the amorphous polymer application is not necessary for certain embodiments of the invention where this is a film component layer, and, in those cases, this station can be removed and the laminate thermally bonded at the point 35. A face layer 34 of a prebonded nonwoven is unwound from the roll 36 and combined with a stretched film 24 in front of the pressure roll 38. After the pressure point 35, the two layers are allowed to relax, with or without heating, and the laminate is wound at a reduced speed, for example, from 80 percent to 90 percent of the pressure point velocity passing over the rotating roller 40 which is driven at a speed qu allowing the film 24 the retracting to cause withdrawal of the front layer 34. After the roller 40 the combined layers are hardened by contact with the heated roller 42 which is driven around the Roller 40 speed to avoid a significant additional stretch. The tempering temperature will vary according to the desired final properties of the fastener material and according to the composition of the layers, but it can be for example within 15 degrees centigrade of the temperature used in the stretch. After tempering, the combined layers can be cooled, for example, by contacting the air from the air knife 43 or the cooling rollers, if desired, or collecting directly as the roll 44 or going to a conversion line. to incorporate into a product for personal care. Although not shown, an etching step may be used, if desired, to impart an attractive pattern or pattern to the composite by, for example, passing it between the etching rolls in a manner well known to those skilled in the art.

As will be apparent to those skilled in the art, the aforementioned process can be adapted to many films and front layers to produce a restrained material with barrier curl capable of breathing having widely varying properties. To work effectively as a curl fastening material according to the invention, however, the selection of these components desirably took into account a number of factors. The film, for example at low weights, must be robust enough to withstand the process steps necessary to provide the desired flexibility and smoothness as well as to maintain the low cost. In addition, the film must be capable of effectively joining the front layer and maintaining barrier properties and moisture vapor transmission rates. For many applications it will be desirable for the stretched film to also provide opacity to the composite.

Films that meet these requirements include polymers, such as polyethylene, polypropylene, blends including polyolefins and copolymers such as ethylene and propylene copolymers, for example generally having a basis weight in the range of from about 10 grams per square meter at about 50 grams per square meter, advantageously for curl component applications in the range of from about 15 grams per square meter to about 30 grams per square meter. Specific examples include linear low density polyethylenes such as Dowlex® 2535, 3347 and 3310, Affinity® 5200 available from the Dow Chemical Company of Midland, Michigan. Film compositions desirably contain up to about 40 percent by weight of a filler such as calcium carbonate especially about 45 percent to about 65 percent by weight of such filler. Examples include calcium carbonate Supercoat® from English Chine Clay of Sylacauga, Alabama which contains a coating of about 1.5 percent by weight of either stearic or acidic acid to improve dispersion of the filler. Particularly advantageous film examples include the co-extruded films having on one or both sides a thin extern layer of an amorphous polymer such as a terpolymer copolymer of propene-rich polyalphaolefin which allows attachment to the front layer without requiring an applied tie layer. separately. One example is the Catalloy polymer from Montel USA, Inc. of Wilmington Delaware which is an olefinic multi-pass reactant wherein a random amorphous ethylene propylene copolymer is molecularly dispersed in a continuous matrix of low ethylene monomer / monomer predominantly semicrystalline propylene, an example of which is described in U.S. Patent No. 5,300,365 issued to Ogale. In addition, the amorphous polymer layer may also include hot melt adhesives or other amorphous polyalphaolefin resins, which desirably have a melt viscosity of 100,000 mPa sec or greater, for example, up to about 50 weight percent. of the polymer fraction, as long as the barrier properties with the ability to breathe described above are retained. Commercially available amorphous polyalphaolefins, such as those used in hot melt adhesives, are suitable for use with the present invention and include, but are not limited to, REXTAC® ethylene-propylene APAO E-4 and E-5 butylene-propylene BM-4 and BH-5, and REXTAC® 2301 from Rexen Corporation of Odessa, TX, and VESTOPLAST® 792 from Huís AG de Mari Germany. These amorphous polyolefins are commonly synthesized on a Ziegler-Natta sustained catalyst and an aluminum alkyl co-catalyzed, and the olefin, such as propylene, polymerized in combination with varying amounts of ethylene, 1-butene, 1-hexane or other materials for produce a predominantly atactic hydrocarbon chain. Also useful are certain elastomeric polypropylenes as described, for example, in U.S. Patent No. 5,539,096 issued to Yang et al. And in U.S. Pat. No. 5,596,092 issued to Resconi et al. incorporated herein by reference in their entireties, and polyethylenes such as Affinity®, EG 8200, from Do Chemical of Midland, Michigan as well as EXACT® 4049, 4011 and 404 from Exxon of Houston, Texas, as well as blends including one or more adhesives and KRATON® from Shell Chemical Company of Houston Texas. A compound with the tie layer on one side can only have the advantage of a higher moisture vapor transmission rate if desired. Such films are described in detail in the co-pending United States of America patent application serial number 08 / 929,562 (subject of pleading No. 13257) filed on the same date herewith in the name of McCormack and Haffner and entitled "Laminate of Filled Films with Breathing Ability "(express mail number R 879 662 575 US) Whose contents are incorporated herein in their entirety by reference. Other film layers will be apparent to those skilled in the art in light of the examples provided herein.

The pre-joined face layer will be selected as being compatible with the film or the bonding layer and will have properties such as base weight, volume and strength suitable for the intended use. Primarily for economic reasons, non-woven fabrics are preferred, especially spunbonded nonwovens having a weight generally in the range of from about 10 grams per square meter to about 50 grams per square meter, for example, frequently within of the range from about 1 gram per square meter to about 25 grams per square meter. The composition of the front layer will be selected to be compatible with the film layer while providing the desired properties in the curl fastener component. Synthetic polymers such as polyolefins are generally useful, for example, polypropylene, polyethylene, blends and copolymers including propylene and ethylene. Such non-woven fabrics are described above and in the references provided herein, and their manufacture is known to those skilled in the art. Specific examples include spunbonded non-woven ACCORD available from Kimberly-Clar Corporation of Dallas, Texas. The pattern, or pair pattern, for the front face, as mentioned above, will provide the ridge between the joints to provide the attachment areas for the complementary hooks. Useful examples include an expanded RHT pattern as illustrated in U.S. design patent number 239,566 issued Vogt, an EHP pattern, a Delta dot pattern which comprises rows of off-center circular joints having about 102 d pins. square inch for a joint area of 9 per cent to 20 percent, and a Ramish pattern as described above. An advantageous bonding pattern for a hilad-faced face fabric is an "S" weave pattern as described in the patent application of the United States of America filed at the same time as this and also assigned series No. 08 / 929,808 (Attorney's case number 13,324) on behalf of Messrs. McCormack, Fuqua and Smith, and entitled "Non-Woven Union Patterns Producing Fabrics with an Abrasion Resistance and Improved Stamina (express mail number EM 331 625 424 United States d North America) which is incorporated herein by reference in its entirety. In all cases the percentage of bonded area will be less than about 30 percent and the bonding density will be from about 50 to about 200 / square inch. In addition, for the application for the curl fastener component, the face It will desirably have a tensile strength measured as described above, of at least about 3,000 grams taken in the machine direction, and at least about 1,500 grams taken in the transverse direction to the machine, and advantageously a Martindale abrasion, measured as described above, of at least about 3.

When used, the amorphous polymer bonding layer applied separately will be compatible with both the film and front layers d and will provide a bond between them if the moisture vapor transmission is prevented. Advantageously the joining layer is applied by melt blowing, for example of an amorphous polyolefin such as REXTAC® 2730 or 2330 available from Huntsman Corporation, of Salt Lake City, Utah. The meltblown layer d when applied at low weights, for example, of less than 10 grams per square meter, advantageously less than 5 grams per square meter, is capable of breathing is cost effective. Other examples include Huís Vestoplast 703, 704 and 508 of Huís AG de Mari, Germany and National Starch N 5610 of the National Starch Chemical Company of Bridgewater, Ne Jersey, and the elastomeric compositions described above.

Whether it is bonded with or without the bonding layer applied separately, the bonding strength between the face and the film as measured by the laminate peel test described above, will desirably exceed the peel strength between the hook face and the complementary hook as measured by the peel test described above, as to avoid undesirable delamination. Advantageously, the difference is at least about 100 g. In addition, for many applications and particularly as a backing for the personal care item such as a diaper, for example, the composite will have a hydro head as measured by the hydro head test described above, of at least about 50 mbar of water and advantageously of at least about 90 mbar. Especially when used as a backing for disposable personal care products, the compound will have a moisture vapor transmission rate of at least about 100 g / square meter / 24 hours and advantageously at least about «Of 800 g / square meter / 24 hours. For these applications, a hook peel strength will desirably exceed 100 g and a hook cut resistance, as measured by the hook cut test described above, will desirably exceed 1,500 g.

Referring to Figure 2, there is shown in cross section an embodiment of a curl fastener component of the present invention. The loops 110 between the joined areas 112 are formed in a spun-bonded front layer 114 which is attached to a co-extruded film 116 containing an outer tie layer 118 and a base layer 120 in each of the pre-joined points coinciding with a joined laminate area 112. As shown, the curl areas 110 are composed of unbonded fibers or filaments available to entangle the hook members 122 of the complementary hook member 124. As shown, the hook and riz layers are partially spaced apart. for clarity.

Referring to Figure 3, an example of the terryclip fastener component of the present invention is shown in the form of a backing material for a disposable personal care cloth product. The diaper 210 comprises the liner 212, the absorbent 214 and the backing 216. As is generally known, the liner 212 allows the urine to pass through and is absorbed by the absorbent 214 while the backing 216 (shown partially in section showing the layers 118 and 120 (Figure 2) for clarity) is impermeable to urine to help prevent runoff. In this case the complete backing is formed of a terry fastening material of the present invention and is described in relation to Figure 2, with the nonwoven loops on the outside. This provides an essentially infinite degree of adjustment when combined with the hook fastener elements 218. In use, the hook elements 218 can be pulled to a comfortable fit and fixed on either side on the backing 216. Also, if desired a fit in the notch, the hook elements 218 can simply be peeled and reattached on either side on the backing 216. In advantageous embodiments, the backing is permeable to moisture vapor for increased comfort dryness.

Figures 4 and 5 illustrate the representative pre-assembled patterns useful in accordance with the pre-woven non-woven component of the compound of the present invention. Figure 4 shows an "S-tissue" as described above with the prearranged areas 400, and Figure 5 shows the "expanded Hansen-Pennings" as described above with the bonded areas 500.

Figures 6 and 7 are edge view photographs of composite materials according to the invention with a "S-tissue" pre-pattern (Figure 7) and with a EHP pre-pattern (Figure 6) after the peel test. hook. As shown, the EHP comparative material, still, as discussed, has a good performance from a hook peel point of view, has a higher degree of filaments pulled out of the nonwoven compared to the "woven" composite material. S "of the present invention. Both photos were taken at an amplification of around 20X and while the samples were bent over a straight edge to expose the loose filaments.

Examples For the following examples, the process was used as shown in Figure 1 to form a curl fastener component, except as otherwise indicated.

Example For this example the front material was a bonded cap by 2.0 denier filament yarn made of a propylene copolymer with 3.5 percent ethylene (from Unio Carbide 6D43 available from Union Carbide Corporation of Danbury, Connecticut) and having a basis weight of about 0.7 ounces per square yard (about 24 grams per square meter) having been joined with a Hansen Pennings expanded pattern (with a bond density of 100 bolts / inch and 16.8 po cent of actual measured jointed area). The film used was a 45 percent by weight blown monolayer of LLDPE (Dowlex® N 3347A, 0.917 g / cc density, melt index at 190 degrees Celsius of 2.3 g / 10 min available from Dow Chemical Company of Midland, Michigan), 50 percent Supercoat ™, a CaC03 coated with ground stearic acid (available from English China Clay), and 5 percent LDPE (Dow 6401 0.922 g / cc, Melt Index at 190 degrees Celsius 2.0 g / 10 min available from Dow Chemical) having an initial caliber of 1.5 thousand. This film is described in detail in commonly assigned U.S. patent application serial number 773,826 filed December 27, 1996 in the name of Haffne et al., Which is hereby incorporated by reference in its entirety. A melt-blown amorphous polyolefin fusion layer (Rextac 2715, available from Huntsman Corporation of Salt Lake City, Utah) was applied to the spun bonded surface at a base weight of about 3.5 grams per square meter at a melting temperature of 177. degrees centigrade and a separation distance of about 10 centimeters. Before the lamination, the film was stretched to 4 X on an orienter in the direction of the machine to make it microporous at a temperature of 71 degrees centigrade. The film was kept under tension when pressed between a rubber roller.

(Shore A 40) and a smooth steel roller to the junction with spinning PLI. After rolling, the compound was allowed to relax by tempering it at a temperature of 116 degrees centigrade while allowing it to retract 10 per cent (speed of the quencher roll: 100 fpm, reel: 90 fpm) and then cooled with a current of air at 15 degrees centigrade. The resulting laminate had a base weight of 49 gsm, an unsupported hydro head of 220 mbar, and a water vapor transmission rate (WVTR) of 1326 g / square meter / 24 hours. When tested with a member of complementary hooks using a hook fastener component Velero 858 from Velero International of Manchester, NH, a hook-peel strength of 402 grams and a hook-shear strength of 2919 grams were obtained, based on an average of 10 tests Employ For this example, the front material was a spun-bonded yarn of about 2.0 denier of propylene copolymer with 3.5 percent ethylene (Unio Carbide 6D43 of Union Carbide Corporation) and having a base weight of about 0.65 ounces per square yard (about 20 grams per square meter) having been bonded with a "S-woven" pattern with a binding density of 111 bolts / inch and 17. percent actual measured unit area) as described in the patent application of the United States of North America still pending and commonly assigned series number 08 / 929,808 filed on September 15, 1997 in the name of McCormack others and entitled "Union Patterns of Non-Woven Fabrics for Improved Abrasion and Resistance ( attorney's issue number 13,324), whose full contents are incorporated herein by reference.The film was a 47-percent weight-forged monocap of LLDPE (Dowlex® NG 3310 0.91 8 g / cc density, melt index at 190 degree Celsius of 3.5 / 10 min available from Dow Chemical Company), 4 percent Supercoat ™, a CaC03 coated with ground stearic acid (available from English China Clay), and percent of LDP (Dow 4012, density of 0.916 g / cc, melt index at 19 degrees Celsius of 12.0 g / 10 min, available from Dow Chemica Company) (case: 12,441 filed 12/96) having an initial calibration of 1.5 one thousand. An amorphous polyolefin meltblown linker layer (Rextac 2730, from Huntsman Corporation of Salt Lake City, Utah) was applied to the spun bonded surface at a base weight of about 3.0 grams per square meter, and at a melting temperature of 177. degrees centigrade and at a separation distance of about 11.5 centimeters. Before the lamination the film was stretched to 4 X on one oriented in the direction of the machine to make it microporous at a temperature of 71 degrees centigrade. The film was kept under tension as it was placed at a pressure point between smooth rubber roll (Shore A 40) and a smooth steel roll at the junction with spinning at 15 PLI. After lamination, the composite was allowed to relax by tempering it at a temperature of 110 degrees centigrade while the retract was allowed to e laminate 10 percent (temper roller speed: 30 fpm, reel: 270 ft / minute) and then it was cooled with a current of air at 15 degrees centigrade. The resulting laminate had a basis weight of 51 grams per square meter, an unsustained hydrohead of 170 mbar, and a water vapor transmission rate (MVTR) of 2429 g / square meter / 24 hours. When tested with a complementary hook member using the Velero 51-1003 hook fastener component, a hook peel strength of 174 g and a hook cut resistance of 2960 grams were obtained, based on an average of 10 tests.

Axis plo For this example, the film used was a co-extruded "AB" film having a basis weight of 45 percent LLDPE (Dowlex® NG 3310, density 0.918 g / cc, Melt Index at 190 degrees Celsius from 3.5 g / 10 min available from Dow Chemical Company), 50 percent Supercoat ™, a CaC03 coated with ground stearic acid (available from English China Clay), and 5 percent LDPE (Dow 4012, density 0.916 g / cc, melt index at 190 degrees Celsius 12.0 g / 10 min, available from Dow Chemical Company) and a 60 percent side layer of CaC03 Supercoat ™, 20 percent amorphous propene-rich polyalphaolefin ("APAO"), (Huís Vestoplast®, density 0.865 g / cc, melt viscosity at 190 degrees centigrade of 125,000 mPa according to DIN 53 019, available from Huís America, Inc., of Somerset, New Jersey) and 20 percent elastomeric polyethylene (Dow Affinity® EG8200 of catalyzed constricted geometry, density 0.87 g / cc, melt index at 190 degrees Celsius of 5.0 g / 10 min, available from Dow Chemical Company). base layer constituted 90 percent by weight, and binding layer 10 percent by weight. stretch of film included a heating step at 50 degrees centigrade, stretching in a single zone 3.8 X in machine direction to 60 degrees Celsius and tempering to 9 degrees Celsius. total basis weight of coextruid film was 58 grams per square meter (about 1.5 thousand). This coextruded film was successfully bonded at 204 feet / minute (6 m / min) - without a separate meltblown bonded layer - to front layer of Example 2 using a pressure of 15 PLI Shore A4 pressure point of smooth steel / rubber to 93 degrees Celsius. E laminate was allowed to relax to 10 percent (speed of pressure point: 204 feet / min, furling speed: 180 feet / min) resulting laminate had a basis weight of 44 grams per square meter, a hydro head of 60 mbar, and an MVTR of 42 grams / square meter / 24 hours. When tested with complementary hook member of Example 2, Sailboat 51-1003, obtained a hook-peel strength of 238 g and a hook-cut resistance of 3141 g, based on an average of 10 tests.

For comparison, conventional film / nonwoven laminate diaper backing samples were tested with the same hook components used in the preceding Examples. The following results were obtained: outer film / non-woven laminate product sold by Huggies® Ultratrim ™ 1996 from Kimberly-Clark Corporation (attached by 2.5 denier polypropylene yarn bonded with a woven wire pattern: 302 bolts / square inch) , 18 percent d united area) when tested with a 858 Sailboat hook, s obtained a hook peel of 29 grams and a hook cut of 171 grams over an average of 10 tests. With the Velero 51-1003 ganch, a hooked peel of 71 g and a hook cut of 589 g were obtained on an average of 10 tests. It has been determined with the consumer use tests that are desired or peeled from a hook of at least 100 g and a hook cut of at least 1,500 g for primary support of the products for active children who start walking.

Those skilled in the art will recognize that the invention can be subject to many variations, modifications and equivalents within the scope of the foregoing description. S intends that all such modifications, variations and equivalents be included as encompassed by the appended claims. For these purposes the equivalents include functional as well as structural and compositional equivalents. For example, a screw and a nail are functional equivalents of a fastener even though these may have different structures.

Claims (24)

R E I V I N D I C A C I O N S

1. A liquid barrier compound for breathing capacity comprising: a pre-assembled nonwoven having a pattern of spaced apart and separated joints with fibers or filaments not joined between said joints; a film bonded to said nonwoven in place corresponding to said pattern of spaced apart joints and otherwise not essentially bonded to said nonwoven; wherein said compound has a moisture vapor transmission rate of at least about 100 g / square meter / 24 hours and a hydro head value of at least about 50 mbar of water.

2. The compound as claimed in clause 1 characterized in that said separate spaced joints comprise about 5 percent to about 3 percent of said prewoven nonwoven surface area and a binding frequency in the range of from about 50. around 200 per square inch.

3. The compound as claimed in clause 2 characterized in that said film-to-fabric bonds comprise an amorphous polymer.

4. The compound as claimed in clause 3 characterized in that said film comprises a plurality of layers and said amorphous polymer comprises a d said layers that is in contact with said nonwoven.

5. The compound as claimed in clause 3 characterized in that said amorphous polymer comprises a layer applied separately to said film before contact with said nonwoven.

6. The compound as claimed in clause 2 characterized in that said fibers or filaments between said spaced apart joints are crimped, forming latching areas for a complementary hook fastener component.

7. The compound as claimed in clause 6 characterized as a curl component of a hook and loop fastening system wherein the resistance to peeling of the hook is in the range of from about 100 g to about 800 g.

8. The compound as claimed in clause 7 characterized in that said hook cutting resistance is in the range of from about 1,000 g to about 6,000 g.

9. An article for personal care that comprises the compound as claimed in clause 1

10. A personal care item that comprises the compound as claimed in clause 8

11. The article for personal care as claimed in clause 10, characterized in that said compound comprises a backing material that provides a clamping essentially on either side on said backrest.

12. The article for personal care as claimed in clause 11, characterized in that it selects from the group consisting of diapers, underpants for learning, products for the care of women and for incontinent use.

13. A process for making a sweeping compound to the breathing-able liquid comprising the steps of: a) providing a pre-woven nonwoven having a pattern of spaced apart joints with unbonded filament fibers between said unions, b) provide a breathable film, c) providing a layer of amorphous polymer between said film and the nonwoven, and d) combining said nonwoven, amorphous polymer layer and film under conditions such that said fabric is attached to said film essentially only at said spaced apart locations.

14. The process as claimed in clause 13 characterized in that said film is stretched retracted after bonding to said non-woven by causing the fibers or filaments to curl between said spaced apart and spaced apart area providing fastening areas for a component of complementary hook.

15. A mechanical fastener comprising hook and loop components wherein the curl component comprises the compound as claimed in clause 1.

16. A mechanical fastener comprising hook and loop components wherein the curl component comprises the compound as claimed in clause 3

17. The compound as claimed in clause 8 characterized in that the spaced apart joints comprise about 10 percent to about 2 percent of said prewoven nonwoven surface area.

18. The compound as claimed in clause 17 characterized in that said binding frequency is in the range of from about 75 to about 125 po of square inch.

19. The compound as claimed in clause 18 characterized in that it has a Martindale abrasion of at least about 3.

20. The compound as claimed in clause 19, characterized in that it has a water vapor transmission rate of at least about 800 g / square meter / 24 hours.

21. A laminate comprising a film layer and a nonwoven layer wherein said nonwoven layer contains a pattern of bonded areas and said film has a superior degree of fastening to said nonwoven in said joined areas that provides a laminated hydro head. of at least about 50 mbar of water and a moisture vapor transmission rate of at least about 100 g / square meter / 24 hours.

22. The laminate as claimed in clause 1, characterized in that said film comprises an amorphous polymer and is a joining layer in a face contact with the prebonded nonwoven.

23. A surgical gown comprising laminate as claimed in clause 22.

24. A surgical cover comprising the laminate as claimed in clause 22. SUMMARY A composite material adapted for use as a mechanical fastener is made as a curl fastener component with a complementary hook component by laminating a film with a layer of amorphous polymer to a prewoven nonwoven fabric under conditions that produce laminate joints. they correspond to the preunited locations, and loose filaments or fibers between the joints. The compound also desirably has an MVTR of at least about 100 g / square meter / 24 hours and a hydro head of at least about 50 mbar. In use as a component of a disposable personal care product such as a disposable diaper, the curl fastener component can essentially be the complete backing, providing comfort, protection and a highly variable notch.