PT84973B - COATING MATERIAL WITH INCREASED RESISTANCE OF STAINS AND PROCESS FOR ITS PRODUCTION - Google Patents

Abstract

Facing materials for absorbent prods., partic. clean dry facings for sanitary napkins, are produced by (a) forming a web of hydrophobic staples fibres; (b) rearranging the fibres of the web to form yarn-like bundles with a pattern of apertures in it; (c) applying an absorbent binder material to the rearranged web of fibres, in an intermittent pattern; (d) curing the absorbent binder material; (e) applying a fluorochemical repellent material to the web; and (f) curing the repellent material to form a repellent treated fabric. The web comprises 88 wt. percent of polyester fibres and 12 wt. percent of rayon staple fibres. The repellent material is a fluorochemical repellent material.

Description

The present invention relates to coating materials for absorbent products, and specifically to dry and clean coatings for sanitary towels.

Background of the Invention

Coating layers have long been embedded in absorbent products to retain the absorbent core media and provide a surface for skin contact. Initially coatings were developed in the sense of softness, absorbency and volume or damping effect. Coatings have also been developed, which has improved fluid transfer properties. These coatings have been characterized by a reduced degree of absorbency, and have reduced the fluid return from the absorbent core. Such a coating is disclosed in a ^'is. 4,391,869, of the United States 1

America, which describes a low density fabric of synthetic polyester fibers bonded with resin. The fabric is saturated bonded, and can be subjected to conventional foot-treatments, including a repellent coating. Due to the total bonding coating, this fabric, if coated with repellency, would not exhibit the increased repellency or stain resistance of the present invention coating.

Plastic Tapes with orifices have Tam been used in coatings to reduce retor however, they have been employed, typically in conjuns to convey the coating are plastic obstansensação "a coating, * '* ^Ί" as well, in ;

with strata of fabric, a sensation of surface similar to a fabric and if one does not want one when plastic tapes with holes have been used, the upper surface of a coating, the coatings require a dry and clean surface due to the repellent or hydrophobic properties of the plastic. Such a coating is described in Patent 1Ϊ2. 4,324,246, from the United States of America.

The coating of the present invention is a fibrous, repellent coating that exhibits a dry and clean surface, without the plastic sensation of a plastic tape coating arranged with holes. The enhanced repellency of the coating is achieved by an upper repellent cover over a fibrous layer, with a single intermittent bonding cover.

Hesumo of the Invention

The present invention comprises a non-woven coating material, with increased resistance to stains, and a process for producing the same, a coating material is useful as a coating for absorbent products, and particularly for hygienic products. The coating material of the present invention comprises a fabric of hydrophobic fibers, of suitable length for spinning, intermittently bonded to an absorbent bonding material, and topped with a repellent material, preferably a fluorochemical repellent material.

A preferred embodiment of the invention, the fabric of the hydrophobic fibers 6 is arranged with holes before the application of the binding agent and the repellent. The fabric arranged with holes can be produced by the fluid re-arrangement process, described in Patent Π2 .....

2,862,251, from the United States of America, where the fibers are rearranged into a matrix of thread-like bundles, defining a matrix of holes between them, when the fabric is arranged with holes in this way, it is preferable that the fabric contains about 5% to 20%., and more preferably 12%, by weight, of rayon fibers, of suitable length for spinning. The coatings of the present invention exhibit repellency. increased and increased resistance to stains, in terms of both the area of the stains and the intensity of the stains.

Concise Description of the Drawings _4.s Figures 1 to 7 are photomacrographic, in a 5-fold scale, of the different fibrous coating materials.

Pe rition. detail! The coating material of the present invention is made of a starting fabric, comprising hydrophobic fibers, such as polyester, acrylic, cotton or nylon fibers, of suitable length for spinning. The fabric may comprise carded fibers, fibers arranged irregularly as in an air-exposed fabric, or a combination of them. The fiber fabric is intermittently bonded with an absorbent bonding material, and is topped with a repellent material. As used in this patent application, intermittent bonding refers to a bonding matrix, in the final tissue, in which, after curing, the bonding areas are well separated from each other. Such a matrix can be carried out with a gravure drum, with a diamond matrix or with diagonal print wings, with 6 lines by 2.54 cm (inch). As is well known, the matrix of cured binding areas in the tissue can depend on many factors, including the matrix of the application of the binding agent, the amount of the binding agent added and the degree of migration of the binding agent; however, one skilled in the art is easily able to design and make an intermittent matrix of the cured binding agent on a fabric. In general, the areas of the bonding agent in the lining fabric of the present invention should comprise about 20% to 50% of the surface area of the fabric. The absorbent bonding agent employed may be any of the absorbent bonding agents obtainable on the market, such as the acrylic bonding agent of Iational Starch 4260 ", the acrylic bonding agent of" B. F. Goodricn 2671, or the Hational Starch 125-2873 vinyl acetate / acrylic copolymer absorbent binding agent. The repellent can be any of the repellent materials obtainable on the market, such as solutions or emulsions, based on the wax, but is preferably a fluorochemical repellent material.

In a preferred embodiment of the invention, the fabric is arranged with holes, for increased fluid return through it. According to a preferred embodiment of the process of the present invention, the starting fabric can be arranged with holes, by the process of new fluid arrangement, described in Patent H2. 2,862,251, from the United States of America, which produces a fabric, which comprises bundles similar to fiber threads, with an array of holes between them, when the holes are produced in this way, it is preferable that the fabric comprises about 5 / to 20 /, and more preferably 12 /, by weight, of rayon fibers, of suitable length for spinning, for increased clarity of the holes. A loss, from the clarity of the holes,

- 4 V with the fibers extending in, and through the holes, reduces the return of fluids through them, and can result in increased stains of the coating, despite the rayon / polyester fabrics of 25, 75 fibers and 100% polyester, showing a resistance to stains, gradually increasing, a fabric, with 88% polyester and 12% rayon, eni be another increase, in the clarity of the holes and in the resistance to stains.

The coatings of the present invention are repellent and have increased stain resistance in terms of reduced stain area and stain intensity. Surprisingly, this increased stain resistance is achieved with the use of an absorbent bonding agent. As set out in the Table, which follows, the coating of the present invention exhibits a greatly increased stain resistance on fabrics made with repellent binding agents and on fabrics made with a full application of the absorbent binding agent.

ha Table, which follows, the fabric of sample 1, represented in Figure 1, in the 5-fold scale, has a stain area of 28.38 cm2 (4.4 sq. in.) and a stain intensity of 23.4, measured in a liunter colorimeter, as described below. Sample 1 is a 16.85 mg / 8353.9o cm2 card (260 grains / yd *) and a bonding fabric, consisting of 1.8 mg / cm2 (220 grains / yd) of a blend of fiber 50% ^ vtex SN 1913 rayon fibers, with suitable length for spinning, and 50% polyester fibers of Oelanese 417, with suitable length for spinning, with a total coating of 3 mg / cm2 (40 grains / yd.) of BF Goodrich 2671 acrylic absorbent bonding agent. As can be seen from Figure 1, this fabric exhibits a large, intensely colored stain and is therefore not stain resistant.

Sample 2, represented in Figure 2, on a 5-fold scale, is 2.5 mg / cm2 tissue

2 (325 grains / yd), consisting of 1.5 mg / cm2 (212 grains / yd)

- 5 of a carded fabric from a mixture of 50 / 3.81 cm Lenzing Lenzesa rayon of 1.7 denieres and 50 / 3.81 cm DuPont 372 polyester fibers ( 1.5 inches) of 1.7 denieres, rearranged, according to the process of Patent N2. 2,862,251, from the United States of America, at a pressure of 120 to 130 psi of water, in a drum with 25 holes / cm2 (165 holes / inch). Then, 0.9 mg / cm2 (113 grains / yd) of a solution of the binding agent is foamed onto the fabric, to provide a full coating of the binding agent. The bonding agent employed is the self-crosslinking vinyl acetate / acrylic copolymer bonding agent of Hational Starch 125-2873, with 713 mg (11 grains) of microcrystalline wax repellent emulsion, with zirconium salts, which makes the binding agent solution repellent. Sample 2 shows only a slight increase, 11th spot area and spot intensity, over sample 1.

Sample 3, represented in Figure 3, on a 5-fold scale, is a tissue of 2.2 mg / cm2 (285 grains / yd), consisting of 1.8 mg / cm2 (228 grains / yd ^) of a carded fabric of a mixture of 88 /, by weight, polyester fibers of 3.81 cm (1.5 inch) of 1.2 denier Uelanese D-244, with suitable length for spinning, and 12 /, in weight, of 2.9 cm (1 1/8 inch) Rayon fibers of 1.5 denier Avtex SN 1913, with suitable length for spinning, with 4.3 mg / cm2 (56 grains / yd) of a Ifational Starch 4260 acrylic absorbent bonding agent solution, made repellent with ICI fluorochemical repellent F-31X> The fibers were rearranged with 120 to 130 psis of water, at 49 ° - 54 ° 0 (120-130 ° F), using a 73.4x 73.4 belt and a drum with 22 , 3 holes / cm2 (144 holes / in ^), before adding the bonding agent solution, applied with a gravure tube, at 9 lines per cm, (23 lines per inch), to achieve the bonding total saturation. After the bonding agent had cured, the fabric was topped with ΙΟΙ P-31A repellent in a compensating operation, resulting in a repellent coating of 0.08 mg / cm2 (1 grains / yd). The sample has a spotting area and an inten- 6

stains, similar to those in sample 2.

Sample 4, shown in Figure 4, on a 5-fold scale, is a tissue of 2.7 mg / cm2 (350

2 grains / yd), consisting of 1.9 mg / cm2 (242 grains / yd) of a 1.81-cm 1.81 denier Hoechst T-221 polyester fiber carded fabric , rearranged as in sample 3, with 0.7 mg / cm2 (97 grains / yd) of a Rohm & Haas 1.6 / -1285 repellent acrylic bonding agent solution, to which TiOg is added for the opacity of the fabric. The bonding agent solution is applied with a 9 line per inch (23 line per inch) rotogravure drum to achieve full bonding agent saturation. After curing, the fabric is coated with a 3M PC-824 fluorochemical repellent in a compensating operation, resulting in a repellent coating of 0.08 mg / cm2 (1 grain / yd). The sample shows a certain improvement in the area of the stains and in the intensity of the stains, but it is difficult to produce, since TiOg is difficult to keep in solution and dries quickly, polluting the tracks of the gravure drum.

Sample 5, represented in Figure 5, on a 5-fold scale, and a tissue of 2.1 mg / cm2 (280 grains / yd), consisting of 1.8 mg / cm2 (229 grains / yd) of a tissue carded from a mixture of 88%, by weight, of polyester fiber of 3,81 cm (1,5 inch) of 1,2 denieres, d © Celanose D-244, with suitable length for the spinning, containing 1,5 % TiOg and 12% by weight of 2.9 cm (1 1/8 inch) rayon fiber from Avtex SH-1913 denieres, suitable for spinning length, rearranged as in sample 3, with 0.4 mg / cm2 (50 grains / yd) of an ITational Starch 4260 acrylic absorbent bonding agent, applied with a 9 lines / cm (23 lines / in) gravure drum to achieve a full saturation bond . After the bonding agent has cured, the fabric 6 is coated with I.G.I. P-31X, in a clearing operation, resulting in a repellent coating of 0.08 mg / cm2 (1 grain / yd). This sample reveals a spotty area and spotty intensity, similar

those in sample 4.

Sample 6 is a 2.1 mg / cm2 tissue

2 (280 grains / yd), consisting of 1.8 mg / cm2 (229 grains / yd) of a carded tissue from the fiber mixture of sample 5 © of 0.4 mg / cm2 (50 grains / yd) of the Acrylic absorbent bond of Libational Starch 4260, rearranged, as in sample 3 · The bonding agent is applied with a ruptured engraving drum, in a diamond matrix of 2.4 lines / cm (6 lines / / in), to an angle of 30 °, the print drum paths are 0.03556 cm (0.014 ”) wide and 0.010016 cm (0.004”) deep. After the bonding agent has cured, the fabric is coated with I.O.I.

F-31X, in a clearing operation, resulting in a repellent coating of 0.08 mg / cm2 (1 grain / yd). The sample exhibits unexpected stain resistance, with a stain area of only 22.58 cm2 (3.5 sq.in.) and a stain intensity of only 4.8.

Sample 7 is a 2.1 mg / cm2 (280 grains / yd) tissue of a 1.8 mg / cm2 (229 grains 2 / yd) carded tissue from the fiber mix of samples 5 and 6, arranged in no. same as in sample 3, with 0.4 mg / cm2 (50 grains / yd) of the Hohm and Eaas 1715 repellent bonding agent, applied with the same gravure drum as the one used when sample 6 was made. if the bonding agent had cured, the fabric was topped with the IOI repellent, D-31Z, in a compensating operation, resulting in a 0.08 mg / cm2 (1 grain / yd) aerial coating. The sample shows an area of stains and an intensity of stains, similar to that of amostia 5.

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1. The spot area was measured by the following test:

The coating material was bonded to an absorbent core made of wood pulp fibers, spraying the bottom surface of the coating with a hot melted H.B. Fuller, before adding the coating to the absorbent core. The sanitary napkin was fixed to a smooth surface, with the coating layer covering the exposed coating material. A 25.4 cm x 7.62 cm (10 ”x 3”) mold of plexiglass, with a central and oval opening, 3.31 cm (1 1/2) in length and 1.9050 cm ( 3/4) wide, it was placed on the sanitary napkin, and 15 cm3 of synthetic menstrual fluid was poured into the oval opening. The mold was removed, a 2.2 kg drum was placed on top of the stain, it was rotated to a longitudinal end of the sanitary napkin and back through the stain to the other end, and again to the other end, to cross the sanitary napkin 10 times. The drum was then removed and the coating was allowed to dry. The spot area was measured using a device for analyzing the image of Aikon hicro-plan II, manufactured by the Computer Device Laboratories (Laboratories Computer Systems Inc.,), Main Street (^ ain Street) 139, Cambridge, massachusetts . The average of ten measurements of the area was recorded. The synthetic menstrual fluid employed was an electrolytically active solution, with a surface tension about that of menstrual fluid, and containing a red ink.

2. The intensity of the stain was measured with an optical D-25-2 ilunter Color Difference Adder sensor from hunter associates Laboratory Inc., hunter, Fairfax, Virginia.

The preceding Table demonstrates the unexpected stain resistance of the coating of the present invention, comprising the hydrophobic fibers, intermittently bonded with an absorbent bonding agent, and coated with a repellent finish. The coating material of the present invention can be used as the coating layer for absorbent products, such as sanitary towels. When used as a coating layer, the coating material can be juxtaposed to the upper surface of the sanitary napkin absorbent core, with or without an intermediate fibrous layer, such as fabric, and can be glued in place, or placed simply about the hygienic dressing. The coating material can be wrapped around the absorbent core, and a fluid-impervious layer can be placed on the sanitary napkin under the absorbent core.

Claims (1)

non-woven lining material, with increased resistance to stains, characterized in that it consists of a fabric of hydrophobic fibers, of suitable length for spinning, intermittently connected by means of an absorbent bonding agent, the fibers and the bonding agent coated with an absorbent material. - Non-woven lining material according to claim 1, characterized in that the material re. It must be a fluorochemical repellent material. Non-woven fabric according to claim 1 or 2, characterized in that said lining material has a variety of holes through it. - 4 * - Non-woven fabric according to claims 1, 2 or 3, characterized in that the hydrophobic fibers are polyester fibers. - ₅ to _ Non-woven lining material according to claim 3, characterized in that the fibers of the fabric are arranged in yarn-like bundles, defining a matrix with holes between them. - 6- · - Non-woven fabric according to claim 5, characterized in that the fabric comprises 88% by weight of polyester fibers and 12% of rayon fibers of suitable length for spinning. - 7th - Product for the absorption of body fluids, characterized in that it comprises an absorbent core and a coating material to cover the absorbent core, comprising the coating material The coating material according to claims 1, 2, 3, 4, 5 or 6 . - 8 ^ - Product according to claim 7, - 12 X characterized in that the product is a sanitary napkin. - - Product according to claim 7, characterized in that the product is a diaper. 10. A product according to claim 7, characterized in that the product is a bandage. A product according to claim 7, characterized in that the coating material is glued to the surface of the absorbent core. 12. The product of claim 7 wherein the coating material and the absorbent core contain thermoplastic material and the coating material is hot bonded to the absorbent core. 13. ^A product according to claim 7, characterized in that the coating material is bonded to the absorbent core by means of a hot melt adhesive. 14. ^A product according to claim 11, characterized in that the coating material is adhered to the absorbent core by means of an emulsion adhesive. - 13 15 ^The product according to claim 11, characterized in that the coating material is glued to the absorbent core according to the total matrix. -16a _ Product according to claim 12, characterized in that the coating material is glued to the number | absorbent core according to a striped matrix. -173 Process for the manufacture of a non-woven coating material, with an increased resistance to stains characterized by comprising the phases of: The. Formation of a tissue of hydrophobic fibers, with suitable length for spinning; B. Application of an absorbent bonding material to the fabric in an intermittent matrix; ç. Gold of the bonding material; and d. Application of a repellent material to the fabric. —Lt- ^L— Process according to claim 17, characterized in that the repellent material is a fluorochemical repellent material. -l ₉ to _ Process according to claim 17, or 18, characterized in that the fabric is perforated prior to the application of the bonding material. Attachment process with claims 17, 18 or 19, characterized in that the hydrophobic fibers are polyester fibers. -213 Process for the manufacture of a non-woven coating material with increased resistance to stains, characterized by comprising the phases of: The. Formation of a tissue of hydrophobic fibers, with suitable length for spinning; B. Rearrangement of the fabric fibers to form yarn-like bundles with an array of holes; ç. Application of an ab sorbent bonding material to the rearranged fiber tissue according to an intermittent matrix; d. Gold of the absorbent bonding material; and. Application of a fluorochemical repellent material to the fabric; and f. With the repellent material, a treated repellent fabric can be formed. 22. The method of claim 21, wherein the fabric comprises 88% by weight of polyester fibers and 12% by weight of polyester fibers ^. 'rayon' with suitable length for wiring. -233 Process according to claim 21 or 22, characterized in that the repellent material is a fluorochemical repellent material. Non-woven lining material, with increased resistance to stains, characterized in that it comprises a fabric of hydrophobic fibers connected by a bonding agent, the fabric having a variety of holes throughout and the same being coated with a repellent material. —25- _ Body fluid absorption product characterized in that it comprises an absorbent core and a coating material covering the absorbent core, the coating material comprising the coating material according to claim 24, the coating material being fixed to the absorbent core surface. 26. The product of claim 25, characterized in that it is a sanitary napkin. 27. The product of claim 25, characterized by a diaper. 28. The product of claim 25, characterized in that it is a bandage. 29. The product of claim 25, wherein the coating material is glued to the surface of the absorbent core. A product according to claim 25, characterized in that the coating material and the absorbent core contain thermoplastic material, and that the coating material is hot bonded to the absorbent core. A product according to claim 29, characterized in that the coating material is glued to the absorbent core by means of a hot melt adhesive. Product according to claim 2, characterized in that the coating material is bonded to the absorbent core by means of an emulsion adhesive. -33a _ Product according to claim 29, characterized in that the coating material is glued to the absorbent core according to a total matrix. -34a _ Product according to claim 29, characterized in that the coating material is glued to the absorbent core according to a striped matrix.