RU2209863C2 - Superlight nonwoven material suitable for reprocessing into article - Google Patents

Abstract

FIELD: textile industry. SUBSTANCE: superlight material comprises nonwoven web of fibrous structure composed of separate fibers or filaments. Weight of basic portion of material is less than 13.5 g/sq.m. Pattern of connected zones is formed on surface of basic portion of material. Web has dimensional stability characterized by factor calculated by multiplying Puasson coefficient of nonwoven material at 10% elongation in direction of advancement of semi-finished product in machine for reprocessing it into article by basic weight of nonwoven web, with said factor being equal to 40.5 g/sq. m. Two other versions of nonwoven material are characterized by different methods of manufacture of web surface pattern: according to one version, pattern on web surface is made in the form of continuously connected zones and, according to other version, pattern is made in the form of zones connected along intermitted lines. Article for individual care comprises said nonwoven material used as facing. Method involves providing nonwoven material of fibrous structure comprising disconnected separate fibers or filaments with basic weight of 23.5 g/sq.m; forming connected zone pattern on material web surface for providing dimensional stability. EFFECT: improved quality of nonwoven superlight material and wider range of articles produced from such materials. 28 cl, 11 dwg, 13 tbl

Description

FIELD OF THE INVENTION
The invention relates to ultralight non-woven materials that have adequate strength and aesthetic characteristics for use as protective coatings or facings on fabric-like laminates. The linings of the present invention can be used on absorbent articles for personal care, such as diapers.

BACKGROUND OF THE INVENTION
Lightweight nonwovens are often used as external liners on both absorbent and protective laminate materials. Examples of such nonwoven materials include spunbond nonwovens, meltblown nonwovens, and carded nonwovens. Such webs may form body-cladding linings on absorbent articles, such as diapers and diapers. Claddings function as an inner shell of pulp for personal care products, such as diapers.

 In the diaper, the lining is a lining that is located between the baby’s skin and the absorbent material of the diaper. In this case, the lining should be permeable to liquids that must be absorbed by the absorbent material so that the liquids are removed as quickly as possible by capillary from the skin of the child. Such claddings in such products play the role of an abrasion resistant, but fabric-like “protective coating” on the absorbent material. In addition, spunbond linings are used on products such as CREW brand wipes (manufactured by Kimberly-Clark) for clean rooms. In these special wiping materials, the absorbent properties are provided by means of the melt-blown inner layer with a liner of a spunbond method of manufacture, and the liner of the spunbond method of production imparts abrasion resistance and a fabric feel.

 In three-layer protective materials, in which the outer layers are obtained by the spinneret method of production, and the inner layer is obtained by aerodynamic method from the melt, claddings of the spinneret method of production are used to provide the same function as in CREW brand wipers. Carded webs or spunbond webs are often used in connection with film protective materials to provide a fabric-like protective coating on the protective material. Examples of such protective film materials are back coverings on surgical tables and the outer layers of personal care products.

 The claddings described above are partly similar to the veneer used in furniture manufacturing. Also, as in the manufacture of furniture, from an economic point of view, it is desirable to use as lightweight veneer as possible. An additional advantage of using less material in disposable products is the reduction of waste after its use.

 Machines for the manufacture of personal care products, such as diapers, must process many continuous webs. Such processing is known in the industry as “conversion”. Large production lines of machines carry out conversion, which provides for the implementation of various technological operations, for example, combining canvases one on top of the other, joining combined canvases, applying glue to combined canvases, cutting connected canvases to the desired product configurations. Such technological processes of multilayer duplication of materials may include unwinding of the lining for laminating onto another substrate, as in the case of the production of three-layer structures with outer layers obtained using a spunbond production method, and internal - aerodynamic method from a melt, or unwinding in a machine for processing into a product for peripheral lamination by connecting over an absorbent layer of a personal care product.

 In the process of performing these various technological operations, the web conversions should be stretched and wound onto rolls and stretched both in the direction of movement of the semi-finished product in the machine for processing onto the product and in the transverse direction perpendicular to the direction of movement of the semi-finished product in the machine. If one or more webs breaks down during such processing, then this breakdown will tend to clog the various devices of the machine and stop the production process until the blockages are cleared and the machine is restarted. Thus, the tensile strength of the webs during such conversion technological operations must be adequate to withstand such processing without continuous fracture.

 In addition, each sheet should be capable of undergoing such stretching, while still being supported in combination with other sheets, so that technological operations such as applying glue, gluing and cutting can be properly performed to obtain a product that will be aesthetically acceptable to the consumer. Thus, the canvas should have adequate dimensional stability for resistance to constant deformation in the process. For example, the web should have adequate dimensional stability in order to resist the tendency to "transverse narrowing" when stretching the web in the direction of movement of the semi-finished product in the conversion machine. Typically, materials that taper in the transverse direction will deform, becoming longer in the direction of movement of the semi-finished product in the conversion machine and shorter in the transverse direction perpendicular to the direction of movement of the semi-finished product in the conversion machine, when converting semi-finished products into products.

 As indicated above, lightweight webs are desirable since they reduce the weight of the entire product and the amount of material required for cladding, thereby reducing the cost of the entire product. Although lower masses are desirable, known fabric-like nonwovens lose dimensional stability as mass decreases. In particular, they have a tendency to transverse narrowing in the transverse direction, perpendicular to the direction of movement of the semi-finished product in the machine during unwinding and applying a pulling force during the conversion process. Such a tendency of the cladding to transverse narrowing creates difficulties in controlling the process, especially when the required cladding width of the final layered structure is achieved.

 One solution to the problem of transverse narrowing was to increase the degree of bonding of the cladding. Another potential solution is the transition from typical point bonding to general fiber bonding. Lightweight non-woven nylon material (sold under the trademark Cerex) obtained by the spinneret production method, and non-woven polyester material (sold under the trademark Reemay) obtained by the aerodynamic method from melt, have dimensional stability and are manufactured on an industrial basis. In these products, bonding typically takes place at each point of contact between the fiber and the fiber, thereby providing dimensional stability. The polyolefin non-woven spunbond production method, produced on an industrial basis by the company AMOKO (AMOSO), also has such characteristics. Providing the desired dimensional stability, these materials do not have the surface mobility of the fibers, which is necessary to give the feeling of fabric similarity, which is desirable for most linings of products for personal care.

To date, the aforementioned tensile strength and dimensional stability requirements have prevented the use of linens that are lighter than approximately 0.40 ounces / square yard (13.5 g / m ² ) for linings. Canvases that are lighter than 0.40 ounces / square yard (13.5 g / m ² ) often do not have the required tensile strength and / or do not have dimensional stability and, therefore, are not considered favorable for conversion processes.

 Non-woven fabrics that are not favorable for conversion can be used in standard products manufactured on an industrial basis, but their dimensional stability is not enough to allow them to be converted into products without significant production waste and downtime of the technological equipment during the implementation of the process itself.

OBJECTS AND SUMMARY OF THE INVENTION OF THE PRESENT INVENTION
An object of the present invention is to provide a lightweight nonwoven material that can be used to form a liner.

 Another object of the present invention is to provide a personal care product or other product, for example a product of a laminate with a lining formed from a light non-woven material.

 Another objective of the present invention is to obtain an ultra-light non-woven material having a bulk of 0.40 ounces / square yard (13.5 g / m2) and which is suitable for forming a lining for a personal care product or other product, for example a product of laminate .

 Other objectives and advantages of the present invention will be set forth in part of the description of the present application below, and in part will become apparent from the description or may be discovered in the practical application of the present invention. The objectives and advantages of the present invention can be realized and achieved by instrumentation and combinations described, in particular, in the attached claims.

 To solve these problems and in accordance with the purpose of the present invention, the embodiments of which are described in detail in this application, an ultra-light non-woven fabric is obtained that has dimensional stability comparable to heavier materials. The ultra-light non-woven lining, which is resistant to lateral tapering during lamination or processing, provides the mobility of surface fibers, which leads to the fact that the material feels like fabric to the touch. The lining may be wettable for use in absorbent products or non-wettable for use in protective products.

Characteristically, the present invention is directed to a non-woven fabric that has a bulk of less than 0.40 ounces / square yard (13.5 g / m ² ) and which uses either a continuous joint pattern or a high-density discrete joint pattern. A continuous joint pattern is obtained by calendering the web so as to obtain a continuous pattern of the joint region as opposed to a discrete, intermittent point joint. A high-density intermittent joint pattern has many point junctions, typically resulting in a dot density corresponding to at least 400 dots / square inch (60 dots / cm ² ).

The ultra-light materials of the present invention will generally retain their shape during stretching and will not result in significant “transverse narrowing” under tension. The ultra-lightweight material of the present invention minimizes such “transverse narrowing” and has dimensional stability that is comparable to dimensional stability of materials that are much heavier (with a bulk of more than 0.40 ounces / square yard (13.5 g / m ² ) )

 The materials of the present invention can be obtained from various types of fibers, including meltblown fibers, spunbond fibers, bicomponent fibers, and crimped fibers described, for example, in US Pat. No. 5,418,045 (issued to Pike et al.), Which fully incorporated into this application by reference. The ultra-lightweight materials of the present invention can be used as linings and lining materials in disposable absorbent articles (for personal care), such as diapers, training pants, incontinence clothing, feminine hygiene products, such as sanitary napkins, bandages and the like. products, as well as various absorbent and protective products for medical purposes, such as clothing for surgeons, surgical sheets or napkins, sterile wraps accurate materials and similar products. In addition, in accordance with the present invention can be obtained various layered materials, such as elastic and film laminated materials, bedspreads, side panels, earbands, absorbent linings, wipes and various other products, for example three-layer materials, in which the outer layers are spunbond production method, and the inner layer is obtained aerodynamically from a melt.

 The accompanying drawings, which are included in the description of this application, are an integral part thereof and illustrate one embodiment of the present invention, and together with the description are intended to explain the principles of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS
A full and comprehensive description of the present invention, including a description of the best option for its implementation, is more specifically set forth for the ordinary person skilled in the art in the rest of it, with reference to the accompanying drawings, in which
FIG. 1 is a plan view of a nonwoven fabric with a pattern of unconnected zones in accordance with the present invention;
figure 2 is a side section of a nonwoven material with a pattern of unconnected zones shown in figure 1;
FIG. 3 is a plan view of an alternative embodiment of intermittently connected nonwoven fabric;
4 is a schematic side view of a device for producing non-woven material with a pattern of unconnected zones, corresponding to the present invention;
5 is a partial isometric image forming a picture of the roll, which can be used in accordance with the method and device shown in figure 4;
FIG. 6 is an isometric view of a disposable hygiene article made of a material in accordance with the present invention, the article comprising a lining or lining that covers an absorbent core;
FIG. 7 is a graphical illustration of the values of the Poisson's ratio of various materials with drawings of unconnected zones for given sizes (denier) of fibers and for given masses in units of ounces / square yard;
FIG. 8 is a graphical illustration of the values of the Poisson's ratio of various materials with drawings of unconnected zones and various control materials for given sizes (denier) of fibers and for given masses in units of ounces / square yard;
FIG. 9 is a graphical illustration of the values of the Poisson's ratio of various intermittently connected materials for given sizes (denier) of fibers and for given masses in units of ounces / square yard;
figure 10 is a graphical illustration of the values of the Poisson's ratio of various intermittently connected materials and various control materials at given sizes (denier) of fibers and at given masses in units of ounces / square yard;
11 is a graphical illustration of the values of the Poisson's ratio of various materials with drawings of unconnected zones, various intermittently connected materials and various control materials for given sizes (denier) of fibers and for given masses in units of ounces / square yard.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE PRESENT INVENTION
Preferred embodiments of the present invention are described in detail with reference to the accompanying drawings, illustrating one or more examples thereof. Each example is intended to illustrate the present invention without limiting its scope and nature. In fact, it will be apparent to those skilled in the art that various modifications and changes can be made without departing from the scope and spirit of the present invention. For example, the elements illustrated and described as part of one embodiment may be used in another embodiment to provide another embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims or their equivalents. Similar reference numbers in the drawings and in the description indicate similar components.

Definitions
"Fibers of a spunbond production method" are small diameter fibers that are obtained by extruding molten thermoplastic material in the form of filaments through a plurality of small, typically round, capillaries of a spinneret, and the diameters of the extruded filaments are rapidly reduced. Examples of spunbond fibers are described in US Pat. No. 4,340,563 (issued to Appel et al.), US Pat. No. 3,692,618 (issued to Dorschner et al.), US Pat. No. 3,802,817 (issued to Matsuki et al.), And US Pat. , in U.S. Patent 3,341,394 (issued to Kinney), in U.S. Patent 3,502,763 (issued to Hartmann) and in U.S. Patent 3,542,615 (issued to Dobo et al.). The fibers of the spunbond production method are typically continuous and have average diameters (for example, at least 10 μm) of more than seven μm, more specifically in the range of 10-40 μm. Such fibers may also take the forms described in US Pat. No. 5,277,976 (issued to Hoogl et al.), US Pat. No. 5,466,410 (issued to Hills), US Pat. No. 5,069,970 (issued to Largman et al.) And US Pat. etc.), in which fibers of an unusual shape are described.

 “Melt-derived fibers” are fibers obtained by extruding molten thermoplastic material through a variety of small, typically round, capillaries of the extruder head in the form of fibers or filaments into converging high-speed (usually hot) gas (eg, air) streams, in which the fibers of the molten thermoplastic material are prompted to reduce their diameter, which after such processing may correspond to the diameter of the microfiber. After that, the fibers obtained by the aerodynamic method from the melt are transferred by a high-speed gas stream and deposited on the trapping surface to form a web with randomly distributed fibers obtained by the aerodynamic method from the melt. Such a method is described, for example, in US Pat. No. 3,849,241 (issued to Buntin et al.). The meltblown fibers are microfibers (continuous or intermittent) having an average diameter of typically less than ten microns.

 "Conjugate fibers" are fibers that are formed from at least two polymer resins extruded from separate extruders, but twisted together to form one fiber. Conjugate fibers are sometimes also called multicomponent or bicomponent fibers. Polymers, which, as a rule, differ from each other by being conjugated, can become monocomponent fibers. Polymers located essentially in constantly positioned different zones of the cross section of the conjugate fibers, continuously extend along the length of the conjugate fibers. The configuration of such a conjugate fiber may be, for example, a shell-core arrangement in which one polymer surrounds the other, or a side-by-side arrangement or an island in the ocean. Conjugate fibers are described in US Pat. No. 5,108,820 (issued to Kaneko et al.), US Pat. No. 5,336,552 (issued to Straket and others) and US Pat. No. 5,382,400 (issued to Pike et al.). For bicomponent fibers, the polymers can be taken in ratios 75/25, 50/50, 25/75, or any other desired ratio. The fibers may take the forms described, for example, in US Pat. No. 5,277,976 (issued to Hoagl et al.), In US Pat. No. 5,069,970 (issued to Largman et al.) And in US Pat. reference in which fibers of non-standard shapes are described. Polymers suitable for producing conjugated fibers include polymers, for example, various polyolefins, nylons, polyesters, and others that are commonly used in processes for producing fibers of a spunbond production method and an aerodynamic method for producing from a melt.

 "Bioelement fibers" are fibers that have been prepared from at least two polymers extruded from a single extruder as a mixture. Bioelement fibers do not have different polymer components located in relatively permanently positioned zones in the cross-sectional area of the fiber, and different polymers are generally not continuous along the entire length of the fiber instead of typically forming fibrils or protofibrils that begin and end arbitrarily. Bioelement fibers are sometimes also called multi-element fibers. Fibers of this type are described, for example, in US Pat. No. 5,108,827 to Hessner. Bicomponent and bio-element fibers are also described in the book "Polymer blends and composite materials" by John A. Manson and Leslie X. Sperlink, copyright 1976 Plenum Press, division of Plenum Publishing Corporation of New York, IBSN 0-306-308831-2, pp. 273-277.

 “Jointed carded webs” are webs that are made from staple fibers that have passed through a device that separates or tears and combines staple fibers in the direction of movement of the semi-finished product in a machine for manufacturing a nonwoven fabric to form a nonwoven fabric with fibers oriented generally in the direction moving the semi-finished product in the machine for the manufacture of non-woven fabric. Such fibers are typically purchased in bales that are placed in a baking powder / mixer or pickling unit that separates the fibers before carding. Once the web is formed, it is joined by one or more of several known joining methods. One such bonding method is a powder bonding method in which a powdery adhesive is distributed in the web and then activated, typically by heating the web and the adhesive with hot air. Another suitable bonding method is a group bonding over an area in which heated calendars or ultrasonic welding equipment are used together to connect the fibers, usually in a localized bonding pattern, whereby the web can optionally be bonded over its entire surface. Another suitable and well-known method of bonding, in particular when using bicomponent staple fibers, is bonding by air circulating through the product layer.

 "Air laying" is a well known method of forming a fibrous nonwoven layer. In the process of air laying, bundles of small fibers having lengths, typically in the range of from about 3 mm to about 19 mm, are separated and entrained in the air supply and then deposited on the forming screen, usually by applying a vacuum. After that, arbitrarily deposited fibers are interconnected using, for example, hot air or spraying glue.

 As used in this application, the term “bonding by means of air circulating through the product layer” means a process for bonding a non-woven bicomponent fibrous web in which air that is sufficiently heated to melt one of the polymers from which the web fibers are made is fed under pressure through the web. The air speed is 100-500 ft / min (30-150 m / min), and the exposure time can be, for example, 6 s. Melting and re-hardening of the polymer provides a connection. The connection by means of air circulating through the product layer has a relatively limited possibility of change, and since this method of connection requires the melting of at least one component to make the connection, it is limited for use with webs made with bicomponent fibers, like conjugate fibers, or with canvases that separately contain glue, for example a fiber with a low melting point, or an adhesive additive. In the device for connecting by air circulating through the product layer, air having a temperature higher than the melting temperature of one of the components and lower than the melting temperature of the other component is directed to a perforated shaft supporting the web. Alternatively, a device for connecting by air circulating through the product layer may have a planar configuration in which air is directed downward to the web in a vertical direction. The operating conditions of both of these configurations are similar, and the main difference is the geometry of the web during the connection. Hot air melts the polymer component with a lower melting point and for this reason forms bonds between the fibers to integrate the web.

 As used in this application, the term “pattern of unconnected zones” or “unconnected spaces” means a pattern of material having continuous connected zones defining a plurality of discrete unconnected zones. Such a pattern is shown in FIGS. 1 and 2. Fibers or filaments in discrete unconnected zones are dimensionally stabilized by continuous connected zones that surround each unconnected zone. Unconnected zones are specifically designed to provide gaps between fibers or threads in unconnected zones.

 As used in this application, the term “intermittent joint pattern” means a pattern of material having discrete joint zones that are not continuous. Unlike a pattern with unconnected points, a discontinuous connection pattern has many separate point connections surrounded by unconnected zones.

 For aesthetic reasons, various calendaring configurations have been developed, but such configurations did not, as a rule, result in high-density intermittent patterns used in the present invention, as defined below. As described in US Pat. No. 3,855,046 (issued to Hansen and Pennings), which is incorporated herein by reference in its entirety, an example of such a configuration has points and is a Hansen Pennings or ChiP configuration having approximately 30% of the connection area with approximately two hundred connections per square inch (30 dots / sq.cm). The Hansen Pennings configuration has square point connections in which each point has a lateral size of 0.038 inches (0.965 mm), the spacing between the points is 0.070 inches (1.778 mm), and the connection depth is 0.023 inches (0.584 mm). The resulting configuration has a joint area of approximately 29.5%. Another typical point connection configuration is the expanded Hansen Pennings connection configuration, which gives 15% of the connection area with square dots having a lateral dimension of 0.037 inches (0.94 mm), a gap between the points of 0.097 inches (2.464 mm) and a connection depth of 0.039 inches (0.991 mm). Another typical point connection pattern, designated “714”, has square point connection areas in which each point has a lateral dimension of 0.023 inches (0.584 mm), a spacing of 0.062 inches (1.575 mm) between the points, and a connection depth of 0.033 inches (0.838 mm) . The resulting pattern has a combined area of approximately 15%. Another common pattern is a C-Star pattern, which has a joint area of approximately 16.9%. Other standard patterns include a rhomboid configuration with repeating and slightly offset rhombuses having a joint area of approximately 16%, and a wire mesh configuration having a shape corresponding to its name, for example, like a window mesh, with a joint area of approximately 19%. Typically, the percentage of area of the connection varies from about 10% to about 30% of the area of the canvas non-woven laminate. As is well known in the art, a point bonding holds together layers of a laminate and also gives integrity to each individual layer by combining filaments and / or fibers in each layer.

Used in this application, the expression "high-density intermittent connection pattern" is an intermittent connection pattern that has a total connection density of approximately 400 dots / square inch (60 dots / cm ² ).

 Used in this application, the expression "direction of movement of the semi-finished product in the machine for processing into products" means the direction along the length of the material obtained in the machine. The expression "transverse direction perpendicular to the direction of movement of the semi-finished product in the machine for processing into a product" means the direction along the width of the material, that is, the direction generally perpendicular to the direction of movement of the semi-finished product in the machine.

 Used in this application, the expression "dimensionally stable" refers to a material that resists deformations, for example, the transverse narrowing described above, which occur during processing. “Dimensionally stable” is a relative characteristic and distinguishes a particular material from other materials having comparable bulk and / or fiber sizes. Dimensional stability is quantified in this application by determining the Poisson's ratio when elongating in the direction of movement of the semi-finished product in a machine for processing into an article of 10%.

Test methods
The following methods were used to obtain the data presented in the tables given in this application.

 Bulk: The bulk of the various materials described in this application was determined using the federal test method 191A / 5041. The dimensions of the material sample were 15.24 x 15.24 cm, and for each material three values of this parameter were obtained and then averaged. The values shown are arithmetic mean values.

 Denier: Denier is a measure of the size of the fiber, and specifically the fineness of the fibers that make up the fabric, and represents the mass, measured in grams, of 9,000 meters of yarn. It is expressed in denier / thread.

 Material Thickness: The thickness of a textile material is defined as the distance between the upper and lower surfaces of the material, measured in inches under a specific pressure. The average thickness of the textile material is usually determined by measuring the distance by which the movable plate is offset from a plane parallel to the textile material under a certain pressure. In this procedure, the thickness of a 4 x 4-inch (101.6 x 101.6 mm) material sample is measured using a dial comparator equipped with a 5 × 5-inch (127 x 127 mm) Lusite support plate. The pressure applied by the weight of the support plate, the weight of the attachment bar, and additional weights is 0.4 ± 0.01 pounds (182 ± 5 g). (If a sample of a sufficiently large size is not available, then the faceplate may be replaced with a round contact surface with a diameter of 1 inch (25.4 mm). In this case, the sample should have a diameter of at least 1 inch (25.4 mm)). The thickness of the samples is measured to the nearest thousandths of an inch. For each sample, the thickness of five samples is determined and the arithmetic average of their thicknesses is calculated.

 Breathability: The breathability of a material, measured in cubic feet of air per square foot of material per minute passing through the material, is a measure of the permeability of the material to air. During the test, in order to guarantee the prescribed pressure drop between the two surfaces of the material in the test area, the air flow rate through the known area of the material is controlled. The breathability of the material is determined based on this flow rate. To perform such a test, a Textest FX-3300 breathability tester manufactured by Benninger Corporation of Spartanburg, South Carolina can be used. When carrying out such a test, samples of 8 x 8 inches (203.2 x 203.2 mm) are generally used, although other sizes larger than the minimum size of 4 x 4 inches (101.6 x 101.6 mm) may be used. ) The sample is clamped in the crimping head in the device to determine air permeability, while the vacuum pump is automatically started. The air permeability of the test sample will be displayed in the selected units of measurement (typically in cubic feet per square foot per minute).

 Cup Crush: The softness of the nonwoven material can be measured in accordance with the Cup Crush Test. By testing the "crushing the glass" evaluate the stiffness of the material by measuring the maximum load (also called "load crushing the glass" or simply "crushing the glass") and energy using a tensile tester at a constant speed of movement of the working part. Stiffer materials will have higher maximum loads. The measured maximum load is the load that a hemispherical support with a diameter of 4.5 cm is required to crush a piece of material approximately 23 x 23 cm in size, which is shaped like an inverted cup with a diameter of approximately 6.5 cm and a height of 6.5 cm, while the material to which the shape of the cup is shaped, is surrounded by a cylinder having a diameter of approximately 6.5 cm, in order to maintain uniform deformation of the material to which the shape of the cup is shaped. The support and the glass are combined to prevent contact interaction between the walls of the glass and the support, which may affect the reading of the test results. The maximum load is measured in grams (or pounds) when lowering the support at a speed of 400 mm / min.

 The test "crushing the glass" gives the value of all the energy (crushing the glass) required to crush the sample. The energy of crushing the cup is the energy spent from the start of the test until the maximum load is applied, that is, the area under the curve formed by the load in grams on one axis and the distance in millimeters that the bearing passes along the other axis. For this reason, the glass crushing energy is expressed in g / mm (or lb / in). Smaller glass crush energies indicate a softer non-woven fabric.

 A suitable apparatus for measuring cup crushing is a constant velocity test apparatus manufactured by Sintech Corporation of Cary, North Carolina. This device is a measuring device in which the rate of increase in the length of the test sample is constant during the test.

 Drapeability: Drapeability of the material expresses the bending stiffness of the material. To determine the bending length of the material, a bend test is performed on the cantilever part of the test sample, using the principle of bending the cantilever part of the test material sample under the action of its own mass. Bending length is a measure of the interaction between the mass of material and the stiffness of the material, manifested in how the material bends under its own weight. When performing the test, samples measuring 10-1 x 8 inches (254-25.4 x 203.2 mm) are slidable at a speed of 4.75 inches / min (120.65 mm / min) in a direction parallel to their large sizes so that the leading edges protrude from the edge of the horizontal surface. The length of the cantilever part is measured when the ends of the samples are deflected by their own mass to the point at which the line connecting the ends to the edge of the platform forms an angle of 41.5 degrees with the horizontal platform. The longer the cantilever part, the slower the bending of the specimen, and thus the stiffer the material. The procedure used is in accordance with ASTM D 1388 standard test except that instead of 1 x 6 inch (25.4 x 152.4 mm) samples, 1 x 8 inch (25.4 x 203.2 mm) samples are used ) In this test, equipment is used, for example, a cantilever test device for the cantilever part of the test sample (Model 79-10 manufactured by Testing Machines Inc. Of Amityville, New York). For non-polypropylene-based materials, the American Society for Testing Materials or TAPPI conditions must be used. In addition, 5 samples should be cut in the direction of movement of the semi-finished product in the machine for processing into the product and 5 samples should be cut in the transverse direction perpendicular to the direction of movement of the semi-finished product in the machine for processing into the product. The lengths of the cantilever parts of various samples are recorded from the linear scale of the bending test apparatus. The results are presented as bending lengths, and samples cut in the direction of movement of the semi-finished product in the machine for processing into a product should be presented separately from samples cut in the transverse direction to the movement of the semi-finished product in the machine for processing into a product. Drapeability is expressed in inches and corresponds to a bend length divided by two.

где W_o - исходная ширина образца (как правило, 75 мм или 3 дюйма);
W_i - ширина образца при длине образца L_i при данном удлинении;
L_o - исходная длина образца (как правило, 300 мм или 12 дюймов), причем значение L_o минимум в четыре раза больше значения W_o;
L_i - длина образца при данном удлинении.The Poisson's ratio at 10% elongation in the direction of movement of the semi-finished product in the machine for processing into the product: "The Poisson's ratio at 10% elongation in the direction of movement of the semi-finished product in the machine for processing into the product" is a measure of the dimensional stability of the material. The lower the Poisson's ratio, the better the dimensional stability of the material. In particular, the Poisson's ratio is a measure of the relative change in width with a change in length. The better the dimensional stability of the material, the less the tendency of the material to transverse narrowing during the process of processing into a product. Poisson's ratio is a dimensionless quantity obtained using the formula

where W _o - the initial width of the sample (usually 75 mm or 3 inches);
W _i - the width of the sample with the length of the sample L _i at a given elongation;
L _o - the initial length of the sample (usually 300 mm or 12 inches), and the value of L _o at least four times the value of W _o ;
L _i is the length of the sample at a given elongation.

 Such tests require a Sintech-type device (or similar Instron-type equipment), as the following illustrates.

1. For the distance between the clamps of the sample corresponding to 300 mm or 12 inches, the length (L _o ) of the sample is reduced to a minimum of 38 cm (380 mm or 15 inches) with a width (W _o ) of the sample of 75 mm or 3 inches. When using a different distance between the clamps of the sample, the width of the sample should be no more than 0.25 of the distance between the clamps of the sample.

 2. A line is drawn across the middle of the sample in the transverse direction. All measurements of the width of the sample are carried out on this line with an accuracy of 0.50 mm or 0.02 inches.

 3. The specimen is placed between the clamps of the specimen on a Sintech device with minimal sagging or tension in the specimen.

4. Measure and record the initial width (W _o ) of the sample with an accuracy of 0.5 mm or 0.02 inches. The original length of the sample (or the initial distance between the clamps of the sample) is also recorded.

 5. The length of the sample is increased by increasing the distance between the clamps of the sample manually. As a rule, this is carried out stepwise with an elongation of 1% at each stage (i.e., from 300 mm to 303 mm; from 303 mm to 306 mm; from 306 mm to 309 mm and so on) to an elongation of a maximum of 10%.

 6. The width of the sample is measured at first tension with an accuracy of 0.5 mm or 0.02 inches along with the length of the elongated sample (current distance between the clamps of the sample). This operation is repeated for all subsequent extensions.

 Tensile test with unidirectional force: Tensile test with unidirectional force is a measure of the tensile strength or elongation or deformation of a material when subjected to unidirectional force. Such a test is known in the art and meets the specifications of Method 5100 of the Federal Standard 191A Test Methods. The "maximum unidirectional tensile force", measured in pounds, is the breaking load before breaking the material subjected to elongation in one direction at a constant speed, usually in the transverse direction of the material, perpendicular to the movement of the semi-finished product in the machine for processing into the product or in the direction of movement of the semi-finished material in a machine for processing into a product. “The maximum percentage of tensile strain when unidirectional force is applied” is a measure of the relative elongation of the material before failure, that is, the elasticity of the material at a constant elongation speed in one direction, usually in the transverse direction of the material perpendicular to the movement of the semi-finished product in the machine for processing into the product or in the direction of movement prefabricated material in a machine for processing into a product. The term “elongation” or “deformation” means an increase in the length of a specimen during a tensile test and is given as a percentage. Higher values indicate a stronger, more flexible material. The term "total energy" means the total energy, expressed in units of mass-length as the area under the curve of the dependence of the elongation of the material from the load. The term "maximum tensile energy upon application of unidirectional force" means the total energy immediately before fracture.

The following is an example of a tensile test with unidirectional force. The unidirectional tensile test procedure closely follows the standards of D-5034-92 and D-5035-92 and INDA 1ST 110.1-92 of the American Society for Testing Materials using a constant-speed tensile testing apparatus at which the speed of length increase sample is constant in time. The tensile test with unidirectional force is carried out in standard laboratory conditions at a temperature of 73 ± 3.6 ^o F (23 ± 2 ^o C) and a relative humidity of 50 ± 5%. In case of mismatch tolerance should be ± 1.8 ^o F (1 ^o C) and ± 2% relative humidity. In special cases, for example, in a control test, when the conditioning requirements cannot be met and the data can still be direct help for work, other conditioning procedures can be used, provided that these amended conditions are indicated in the protocol. Material is measured only after sufficient time is needed for the samples to reach a significant equilibrium with the surrounding atmosphere. The values of tensile strength when applying unidirectional forces and elongation when applying unidirectional forces are obtained when using a material of a certain width, usually 4 inches (102 mm), the width of the clamp and a constant speed of elongation. The sample has a width that must be greater than the width of the clamp to obtain results characterizing the effective strength of the fibers in the width of the clamp in combination with additional strength, which is the contribution of adjacent fibers in the material. A 4-inch (100 mm) specimen is centered when a tensile tester is installed in the clamps, for example, Instron Model TM manufactured by Instron Corporation, 2500 Washington Street, Canton, Massachusetts 02021, or Thwing-Albert Model INTELLECT II manufactured by Thwing-Albert Instrument Co., 10960 Dutton Road, Philadelphia, PA 19154, which have 3 inch (76 mm) parallel clamps. This very accurately simulates the stress conditions of the material in practical applications. The force is applied until the sample is destroyed. The value of the destructive force and the elongation of the test specimen are read from scales, dials, tapes of the recorder or computer connected to a tensile test device. The tensile test procedure with unidirectional force determines the effective strength of the material, that is, the strength of the fibers in a specific width together with the material from adjacent fibers. The breaking force obtained from the tensile test procedure with unidirectional force is not a reflection of the strength of the fibers actually trapped between the clamp surfaces and cannot be used for direct comparison with fiber strength determinations. In addition, there is no direct correlation between tensile tests with unidirectional force and strip tests, since the amount of material aid depends on the type of material and design parameters.

 The "maximum tensile strip load", measured in pounds, is the breaking load before breaking the strip of material at a constant tensile speed in one direction, usually in the transverse direction perpendicular to the direction of movement of the semi-finished product in the machine for processing into the product, or in the direction of movement of the semi-finished product in the machine for processing into a product. “Percentage of maximum tensile strain of a strip” is a measure of the relative elongation of a strip of material before failure, that is, the elasticity of the strip of material, at a constant tensile speed in one direction, usually in the transverse direction, perpendicular to the direction of movement of the semi-finished product in the machine for processing into the product, or in the direction the movement of the semi-finished product in the machine for processing into the product. The following is an example of a strip test. A 4 inch (100 mm) wide specimen is mounted centrally in the clamps of the tensile testing apparatus and a force is applied until the specimen breaks. The values of the breaking force and elongation of the test specimen are read from scales, dials, tapes of the recorder or computer connected to the device for tensile testing. The strip test procedure determines the effective strength of the material, that is, the strength of the fibers in a specific width together with the material from adjacent fibers.

Detailed description
A typical disposable personal care absorbent product includes a lining that encloses a fluid permeable body. As, for example, shown in Fig.6, the diaper 60 contains a lining 64, fitting the body, permeable to liquid. For the lining or lining 64, various nonwoven materials according to the present invention can be used. For example, a fabric containing a lining that encloses a body may be a nonwoven fabric obtained from a melt aerodynamic method, or a spunbond production method from synthetic fibers similar to thermoplastic fibers, for example polyolefin fibers, melt-derived yarns, staple fibers, multicomponent yarns obtained by the aerodynamic method from the melt.

 Fibers can be formed from a variety of thermoplastic polymers, the term "thermoplastic polymer" refers to a long-chain polymer that softens when heated and returns to its original state when cooled to ambient temperature. Examples of thermoplastics include (without limitation) polyvinyl chloride, polyesters, polyamides, polyfluorocarbons, polyolefins, polyurethanes, polystyrenes, polyvinyl alcohols, caprolactams and copolymers of the above chemical compounds, as well as elastomeric polymers, for example, elastic polyolefins, copolyesters, block copolyesters, block copolyesters, block copolyesters ethylene vinyl acetate, block copolymers having the general formula ABA or AB like styrene / ethylene butylene copolymer, styrene-poly (ethylene-propylene) -styrene, styrene-poly (ethylene-butylene ) -styrene, (polystyrene / poly (ethylene-butylene) / polystyrene, poly (styrene / ethylene-butylene / styrene), ABA, AB tetrablock copolymers and similar chemical compounds.

 As is well known in the prior art, the fibers or filaments used to make the nonwoven fabric can have any suitable morphology and can contain hollow or monolithic, straight or crimped, single-component, bicomponent or bio-element fibers or filaments and mixtures of such fibers or filaments. All such nonwoven webs can be pre-connected or otherwise combined using known technologies for joining non-woven webs, for example with a hot air knife, sealing rolls, joining by air circulating through the product layer, ultrasonic welding and stitching, or subsequently connected using methods and devices, corresponding to the present invention, or alternatively, such non-woven fabrics can only be joined using methods and devices of the present invention.

 A variety of poly-olefins are available for industrial fiber production, for example, suitable polymers are linear low density polyethylene PE XU 61800.41 and high density polyethylene 25355 and 12350, manufactured on an industrial basis by Dow Corning. Fiber-forming polypropylenes include Escorene PD 3445 polypropylene manufactured by Exxon Chemical Company and PF-304 and PF-015 polypropylene manufactured by Monteil Chemical Co. Many other standard polyolefins are produced on an industrial basis, which include polybutylenes and other chemical compounds.

 Examples of polyamides and methods for their synthesis can be found in the book of Don E. Floyd's "Polymer Resins" (Library of Congress 66-20811, Reinold Publishing, New York, 1966). Particularly suitable industrial grade polyamides are nylon-6, nylon-6.6, nylon-11 and nylon-12. These polyamides can be purchased from a number of sources, for example, Ember Industries of Summer, South Carolina (Grilon and Grilamid nylons), Atochem Inc. Polimers Division of Glen Rock, New Jersey (Rilsan Nylon), Nytech of Manchester New Hampshire (2169, Nylon 6 and Custom Resins of Henderson, Kentucky (Nylene 401-D) and others.

Suitable elastomeric resins include block copolymers having the general formula ABA, where A and A 'are polymer end blocks, each of which contains a styrene component, for example polyvinylarene, and B, an elastomeric polymer midblock, for example a conjugated diene double bonds or
lower alkene polymer. Block copolymers for blocks A and A 'and the available block copolymers are intended to encompass linear, branched and radial block copolymers. In this case, the radial block copolymers can be represented by the formula (AB) _m -X, in which X is a multifunctional atom or molecule, and (AB) _m is emitted from X so that A is an end block. In a radial block copolymer, X may be an organic or inorganic multifunctional atom or molecule, am an integer having the same meaning as the functional group originally represented in X. This is an integer, usually at least 3, and often 4 or 5 but not limited to these values. Thus, in the present invention, the expression "block copolymer" and in particular the block copolymer "ABC" and "AB" are intended to encompass all block copolymers having such elastomeric blocks and thermoplastic blocks as described above that can be extruded (for example, aerodynamically from a melt). An elastomeric non-woven fabric can be formed, for example, from elastomeric block copolymers (polystyrene / poly (ethylene-butylene) / polystyrene). Examples of such commercially available elastomeric copolymers are, for example, materials known as KRATON materials manufactured by Shell Chemical Company of Houston, Texas. KRATON block copolymers are available in several different compositions, a number of which are identified in US Pat. Nos. 4,663,220, 4,323,534, 4,834,738, 5,093,422 and 5,305,599.

 In practical applications of the present invention can also be used polymers consisting of an elastomeric ABA AB tetrablock copolymer. Such polymers are described in US Pat. No. 5,332,613 to Taylor et al. In such polymers, A is a thermoplastic polymer unit and B is an isoprene monomer unit hydrogenated to a substantially poly (ethylene-propylene) monomer unit. An example of such a tetrablock copolymer is styrene-poly (ethylene-propylene) -styrene-poly (ethylene-propylene) or the SEPSEP elastomeric block copolymer manufactured by Shell Chemical Company of Houston, Texas on a commercial basis under the trade name KRATON G-1657.

 Other examples of elastomeric materials that can be used in practical applications of the present invention are polyurethane elastomeric materials, for example, those manufactured under the trade name ESTANE by B.F. Godrich & Co., or under the trade name MORTHANE by Mortjn Thiokol Corp., polyester elastomeric materials sold under the trade name HYTREL by E.I. DuPjnt De Nemour & Company, or known under the trade name ARNITEL, previously available from Akzo Plastics of Amhem, Holland, and now from DSM of Sittard, Holland.

где n - положительное целое число, РА представляет полиамидный полимерный сегмент, а РЕ представляет полиэфирный полимерный сегмент. В частности, полиэфирный блок-амидсополимер имеет температуру плавления от приблизительно 150^oС до примерно 170^oС, измеренную в соответствии с ASTM D-789; показатель плавления - от приблизительно 6 г в течение 10 минут до примерно 25 г в течение 10 минут, измеренный в соответствии с ASTM D-1238, условие Q (235 С/1 кг нагрузки); модуль упругости при изгибе - от приблизительно 20 МПа до примерно 200 МПа, измеренный в соответствии с ASTM D-790; сопротивление растяжению при разрушении - от приблизительно 29 МПа до примерно 33 МПа, измеренное в соответствии с ASTM D-638, и конечное удлинение при разрушении от приблизительно 500 процентов до примерно 700 процентов, измеренное в соответствии с ASTM D-638. Конкретный вариант осуществления полиэфирного блок-амидсополимера имеет температуру плавления около 152^oС в соответствии с ASTM D-789; показатель плавления - приблизительно 7 г в течение 10 минут, измеренный в соответствии с ASTM D-1238, условие Q (235 С/1 кг нагрузки); модуль упругости при изгибе - от примерно 12,50 МПа, измеренный в соответствии с ASTM D-790; сопротивление растяжению при разрушении - приблизительно 29 МПа, измеренное в соответствии с ASTM D-638 и конечное удлинение при разрушении - примерно 650 процентов, измеренное в соответствии с ASTM D-638. Аналогичные материалы с торговым названием РЕВАХ различного качества производятся на промышленной основе в компании ELF Atochem Inc. Of Glen Rock, New Jersey. Примеры практического применения таких полимеров описаны в патентах США 4724, 4820772 и 4923742, выданных Киллиану.Another suitable material is a polyester block amide copolymer having the formula

where n is a positive integer, RA represents a polyamide polymer segment, and PE represents a polyester polymer segment. In particular, the polyester block amide copolymer has a melting point of from about 150 ^{° C.} to about 170 ^{° C.} , measured in accordance with ASTM D-789; melting index - from about 6 g in 10 minutes to about 25 g in 10 minutes, measured in accordance with ASTM D-1238, condition Q (235 C / 1 kg load); flexural modulus from about 20 MPa to about 200 MPa, measured in accordance with ASTM D-790; tensile strength at break - from about 29 MPa to about 33 MPa, measured in accordance with ASTM D-638, and final elongation at break from about 500 percent to about 700 percent, measured in accordance with ASTM D-638. A particular embodiment of the polyester block amide copolymer has a melting point of about 152 ^{° C.} in accordance with ASTM D-789; melting point - approximately 7 g for 10 minutes, measured in accordance with ASTM D-1238, condition Q (235 C / 1 kg load); flexural modulus from about 12.50 MPa, measured in accordance with ASTM D-790; tensile strength at fracture is approximately 29 MPa, measured in accordance with ASTM D-638, and ultimate elongation at fracture is approximately 650 percent, measured in accordance with ASTM D-638. Similar materials under the trademark REVACh of various quality are manufactured on an industrial basis by ELF Atochem Inc. Of Glen Rock, New Jersey. Examples of practical applications of such polymers are described in US Pat. Nos. 4,724, 4,820,772 and 4,923,742 to Killian.

 Elastomeric polymers also include copolymers of ethylene and at least vinyl, such as vinyl acetates, unsaturated aliphatic monocarboxylic acids and esters of such monocrabic acids. Elastomeric copolymers and the formation of elastomeric nonwoven webs from such elastomeric polymers are described, for example, in US Pat. No. 4,803,117.

где G - выбран из группы, содержащей полиоксиэтилен-альфа, омега-диол, полиоксипропилен-альфа, омега-диол, полиоксиметилен-альфа, омега-диол; а и b - положительные целые числа, имеющие значение 2, 4 и 6; a m и n - положительные целые числа, имеющие значение 1-20. Такие материалы, как правило, имеют удлинение при разрушении от приблизительно 600 процентов до примерно 700 процентов, измеренное в соответствии с ASTM D-638, и температуру плавления - от приблизительно 350^oF (176^oС) до примерно 400^oF (205^oС), измеренную в соответствии с ASTM D-2117.Thermoplastic copolyesters include copolyesters having the following general formula

where G is selected from the group consisting of polyoxyethylene alpha, omega diol, polyoxypropylene alpha, omega diol, polyoxymethylene alpha, omega diol; a and b are positive integers with values 2, 4 and 6; am and n are positive integers with a value of 1-20. Such materials typically have a fracture elongation of from about 600 percent to about 700 percent, measured in accordance with ASTM D-638, and a melting point of from about 350 ^o F (176 ^o C) to about 400 ^o F (205 ^o C) measured in accordance with ASTM D-2117.

 Examples of such commercially available copolyesters are known, for example, as ARNITEL materials, previously available from Akzo Plastics of Amhem, Holland, and now from DSM of Sittard, Holland, or known as HYTREL, which are available from E. I. DuPont de Nemours of Wilmington, Delaware. The preparation of an elastomeric nonwoven web from polyester elastomeric materials is described, for example, in US Pat. No. 4,741,949 to Morman et al. And US Pat. No. 4,707,398 to Boggs.

 Elastomeric olefin polymers are industrially manufactured by Exxon Chemical Company of Baytown, Texas under the trade name ACHIEVE for Polypropylene Polymers and under the trade names EXACT and EXEED for Polyethylene Based Polymers. The Dow Chemical Company of Midland, Michigan has polymers commercially available under the trade name ENGAGE. It is believed that these materials are produced using non-stereoselective metallocene catalysts as “one-way” catalysts, while specialists at the Dow Chemical Company of Midland, Michigan refer them to “limited geometry” catalysts under the trade name INSIGT to distinguish them from traditional Siegel-Matt catalysts that have many chemically active sites.

According to an embodiment of the present invention, an ultralight material can be obtained from a non-woven fabric having a fibrous structure consisting of individual fibers or threads. The nonwoven webs of the present invention, with materials both with a pattern of unconnected zones and intermittent materials, will be ultra-lightweight materials that have higher relative dimensional stability compared to materials of a similar mass that were not obtained in accordance with the present invention. In particular, the materials of the present invention will have a bulk of approximately 0.40 ounces / square yard (13.5 g / m ² ) or less. More specifically, the materials of the present invention will have a bulk of approximately 0.30 ounces / square yard (10.125 g / m ² ) or less. In addition, these materials may have a bulk of approximately 0.20 ounces / square yard (6.75 g / m ² ) or less. The minimum bulk of the materials of the present invention will depend on the particular application of the lighter weight material of the present invention. For example, webs having a small base mass of 0.20 ounces / square yard (6.75 g / m ² ) can be used in the present invention, although any lightweight material having characteristics having features of the present invention is within the scope of the invention.

 The connection zones of the present invention, materials with a pattern of unconnected zones or intermittent connections will occupy no more than 50% of the entire contact area. More specifically, the connection zones corresponding to the present invention will be in the range of approximately not more than 30% of the entire contact area and may be in the range of not more than 15% of the entire contact area. Generally, to obtain lightweight fabric-like nonwoven webs according to the present invention, a minimum joint area of at least about 10% may be acceptable, although other common joining areas will be within the scope of the present invention, depending on the specific properties that the final product should have . Generally speaking, the lower limit of the relative bonding area acceptable for producing the nonwoven ultra-light material of the present invention is the point at which the fiber deflection unduly reduces surface integrity and material durability. A number of factors will affect the value of the required relative bonding area, including the type (s) of polymeric materials used in the production of fibers or filaments of a nonwoven fabric, whether the nonwoven fabric has a single or multilayer fibrous structure, and so on. It was found that acceptable are the connection area in the range of 15-50%, and more specifically in the range of 15-40%.

 Various methods can be used to connect the webs of the present invention. Such methods include bonding through air circulating through a spot thermal bonding product layer, as described in US Pat. No. 3,855,046 to Hansen et al., Which is incorporated herein by reference in its entirety. In addition, in some applications, other means of connection may be used, for example, furnace connection, ultrasonic welding, hydro-entangling, or a combination thereof.

 As shown in figures 1 and 2, one particular material corresponding to the present invention can be obtained as material 4 (with a pattern of unconnected zones), in which continuously connected zones 6 limit a lot of discrete dimensionally stabilized unconnected zones 8 in non-woven material 4.

 A suitable method for producing non-woven fabric with a pattern of unconnected zones, corresponding to the present invention, as further illustrated in this application, provides for a non-woven material or fabric, providing first and second calender rolls opposing each other, limiting the contact zone between them, at least one of these rolls heats up and has on its outer surface a joint pattern containing a continuous configuration of contact pads that limit the a number of discrete holes, apertures or channels, and the transmission of non-woven material or web in the contact zone formed by these rolls. Each of the openings in said roll (or rolls) bounded by continuous contact pads forms a discrete unconnected zone in at least one surface of the nonwoven fabric or fabric in which the fibers or filaments of the fabric are substantially or completely not connected. In other words, a continuous pattern of contact pads in said roll (or rolls) forms a continuous pattern of connected zones that define a plurality of discrete unconnected zones on at least one surface of said non-woven fabric or web. Alternative embodiments of the above method include pre-bonding or reinforcing the non-woven fabric or fabric before passing the material or fabric into the contact area formed by the calender rolls, or providing a plurality of non-woven fabrics to form a laminate with a pattern of unconnected zones. Materials with a pattern of unconnected zones are described in US patent application 08/754419, and are shown in FIGS. 1 and 2, where continuously connected zones 6 limit a plurality of discrete dimensionally stabilized unconnected zones 8 in non-woven fabric 4.

With reference to FIGS. 4 and 5, one embodiment of a method and apparatus for producing a nonwoven fabric with a pattern of unconnected zones in accordance with the present invention will be specifically described. A device for producing a nonwoven fabric with a pattern of unconnected zones according to the present invention is indicated by a common reference number 34. The device 34 may comprise unwinding means 36 of the first web and a pattern receiving unit 40 of unconnected zones. As shown in FIG. 4, for example, an ultra-lightweight nonwoven fabric web 38 having a bulk of less than 0.40 ounces / square yard (13.5 g / m ² ) is removed from the unwinder 36 and passed through assembly 40 (to obtain a pattern of unconnected zones), which comprises a first pattern-forming roll 42 and a second or back-up roll 44 which are driven by a conventional drive, for example by electric motors (not shown). If it is necessary to obtain multilayer layered materials corresponding to the present invention, additional unwinding means (not shown) for the materials can be used. In addition, it is obvious that the nonwoven material can be directly fed from the machine that produces the material itself, instead of being unwound from the unwinding means.

 The forming pattern roll 42 is a round cylinder, which can be made of any suitable durable material, for example steel, to reduce the wear of the rolls during their operation. The pattern forming roll 42 has on its outer surface a pattern of contact pads 46 that define a plurality of discrete holes or apertures 48. The contact pads 46 are designed to form a contact zone 50 with a smooth or flat outer surface of the opposing backup roll 44, which is also a round cylinder, which can be made of any suitable durable material.

 As shown in FIG. 4, a nonwoven ultra-light material or web 38 is passed through a contact zone 50 formed by rolls 42, 44. Each of the holes 48 in the patterning roll 42 (or rolls), bounded by continuous contact pads 46, forms a discrete unconnected zone 8 (FIG. 1 and 2) in at least one surface of the nonwoven fabric or material 4 (FIGS. 1 and 2), in which the fibers or filaments of the fabric are substantially or completely not connected. In other words, the continuous pattern of the pads 46 in the pattern-forming roll 42 (or rolls) forms a continuous pattern of connected zones 6 (FIGS. 1 and 2), which limit the plurality of discrete unconnected zones 8 (FIGS. 1 and 2) to at least one nonwoven fabric or web surface 4.

 As shown in FIG. 5, upon receipt of the nonwoven fabric 4 with a pattern of unconnected zones according to the present invention, the holes 48 may have an average diameter in the range of 0.050-0.25 inches (0.127-0.635 cm), and more particularly 0.100-0.160 inches (0.330-0.406 cm) and a depth measured from the outer surface of the patterning roll 42 of at least about 0.020 inches (about 0.051 cm), and more specifically at least about 0.060 inches (0.152 cm). In addition, although the holes 48 in the patterning roll 42, as shown in FIG. 5, are round, other shapes, for example, ovals, squares, rhombs and similar configurations, may be used.

The number or density of holes 48 in the patterning roll 42 can also be selected to provide the desired dimensional stability of the ultralight material. Forming the rolls 42, having a hole density in the range of 1.0-25.0 holes / cm ² , and more particularly 5.0-7.0 holes / cm ² , can be used to obtain material 4 with a pattern of unconnected zones, corresponding to the present invention. In addition, the distances between the center lines of the individual holes 48 can be selected in the range of 0.13-0.22 inches (3.30-5.59 mm) in the direction of movement of the semi-finished product in the machine for processing non-woven material into the product and in the transverse direction, perpendicular to the movement of the semi-finished product in a machine for processing non-woven material into a product.

 The particular arrangement or configuration of the holes 48 in the patterning roll 42 is chosen so that, in combination with the size, shape and density of the holes, the desired levels of dimensional stability are achieved. For example, as shown in FIG. 5, the individual holes 48 are staggered (see also in FIG. 1). Other configurations are also contemplated within the scope of the present invention.

 A portion of the outer surface of the pattern-forming roll 42 occupied by the continuous contact pads 46 can likewise be modified to meet the requirements of the end use of the material with the pattern of unconnected zones. The degree of bonding communicated to the nonwoven ultra-light material with a pattern of unconnected zones can be expressed as the relative area of the joint, which refers to the part of the entire area of at least one surface of the nonwoven fabric 4 with a pattern of unconnected zones (see FIG. 1), which is occupied by the connected zones 6.

 The temperature of the outer surface of the patterning roll 42 can be changed by heating or cooling relative to the support roll 44. Heating and / or cooling can affect the properties of the web (s) being treated and the degree of connection of one or a plurality of webs passing through the contact zone, formed between the opposing rolls 42 and 44. In the embodiment shown in FIG. 4, for example, both rolls 42 and 44 are heated, preferably to the same compound formation temperature. When receiving a nonwoven material with a pattern of unconnected zones, the specific temperature range used depends on a number of factors, including the types of polymeric materials used to obtain a nonwoven material with a pattern of unconnected zones, the input or linear speed (speeds) of the nonwoven fabric (s) passing through the contact zone formed between the patterning roll 42 and the support roll 44, and the pressure in the contact zone between the patterning roll 42 and the support roll 44.

 As shown in FIG. 4, the back-up roll 44 has a much smoother surface than the pattern-forming roll 42, and is preferably smooth or flat. However, it seems possible that the back-up roll 44 has a shallow pattern on its outer surface and is considered smooth or flat for the purposes of the present invention. Such surfaces are collectively referred to in this application as "flat." The support roll 44 provides a basis for the patterning roll 42 and the web or webs of material for contact interaction. Typically, the pattern-forming roll 42 and the back-up roll 44 will be made of steel.

 In an alternative embodiment, the back-up roll 44 may be replaced by a roll to form a pattern (not shown) having a pattern of continuous contact pads delimiting a plurality of discrete apertures or holes made in the roll, as in the above-described forming roll 42. In this case, the receiving unit the pattern of unconnected zones will contain a pair of counter-rotating rolls forming a pattern, which will form a pattern of continuously connected zones that limit the set of discrete unbonded areas on the top and bottom surfaces of the nonwoven fabric with pattern-unbonded. The rotation of the opposing rolls can be synchronized so that the resulting unconnected zones on the surfaces of the material with the pattern of unconnected zones are aligned or located side by side in the vertical direction.

 As follows from figure 4, the patterning roll 42 and the support roll 44 are rotated in opposite directions so as to provide traction to the nonwoven ultra-light web 38 through the contact zone formed between them. The pattern-forming roll 42 has a first rotation speed measured on its outer surface, and the back-up roll 44 has a second rotation speed also measured on its outer surface. In the shown embodiment, the first and second rotational speeds are substantially identical. However, to create a difference in speeds between the rolls rotating in opposite directions, the rotation speeds of the pattern-forming roll and the back-up roll can be changed.

As shown in the alternative embodiment illustrated in FIG. 3, the ultralight material 5 can be obtained as point-connected ultralight material, in which continuously connected zones 7 (less dark) limit a lot of discrete dimensionally stabilized point-connected zones 9 (darker) in non-woven material 5. Material 5 is obtained from a non-woven fabric having a fibrous structure of individual fibers or threads. The nonwoven fabric is an ultra-lightweight material 5 and thus has a bulk of less than 0.40 ounces / square yard (13.5 g / m ² ). The pattern of point-connected zones 9 can have different configurations (rectangular configurations are shown in FIG. 3), in which the density of point-connected zones 9 relative to unconnected zones 7 is not to the extent that it could be illustrated. To show the point-connected zones 9 on a scale for the high densities of the present invention, the point-connected zones 9 must be sealed so that it is difficult to distinguish them from the continuously connected zones 7 located between them.

 In the formation of intermittent joining patterns of the present invention, a material or web of fibers to be joined is passed between the heated calender and the back-up roll. The calender is shaped in the same way as the unconnected material zones, and the back roll is generally left flat.

As in the case of the embodiment of material 4 with a pattern of unconnected zones, material 5 has dimensional stability characterized by a calculated indicator obtained by multiplying the Poisson's ratio of the web (at ten percent elongation in the direction of movement of the semi-finished product in the machine for processing into a product) by the bulk of the web, and this indicator should be no more than 1.2 ounces / square yard x Poisson's ratio (40.5 g / m ² x Poisson's ratio).

 In an additional embodiment of the present invention, an ultralight material, as described, can be used to provide a liquid-permeable liner 64 adjacent to the body for a personal care product, such as a diaper 60 (shown in FIG. 6). In the embodiment of the diaper shown in Fig.6, the absorbent inner layer 66, formed, for example, from a mixture of hydrophilic cellulose fibers of paper pulp of wood pulp and particles of a gelling agent having a high degree of absorption (for example, superabsorbent). Elastic elements can be positioned adjacent to each longitudinal edge 68 of the diaper 60 to divert and hold the transverse lateral edges 68 of the diaper against the legs of the user. In addition, the elastic elements can also be adjacent to one or both end edges 70 of the diaper 60 to provide an elastic waistband. The diaper may additionally contain optional valves 72 for localization of fluid, made or attached to the lining 64 adjacent to the body. Suitable designs and devices of such valves for fluid localization are described, for example, in US Pat. No. 4,704,116 (issued to Enloy), the disclosure of which is incorporated herein by reference. The means for attaching the diaper 60 around the user may be a hook and loop fastener comprising hooks 74 attached to the inner and / or outer surface of the outer shell 62 at the back of the diaper belt 60, and one or more loops or pads 76 of material with a pattern of unconnected zones having loops attached to the outer surface of the outer shell 62 in the front region of the diaper belt 60.

As shown in the tables, the abbreviation "PU" means "materials with a pattern of unconnected zones", and "DB" means "intermittently connected materials." Control samples (all of which are intermittently connected materials) in the series of tables A have the following connection figures
Control # 1 - connection area 15-20%, 302 dots per square inch;
Control # 2 - connection area 9-20%, 102 dpi;
Control # 3 - connection area 15-20%, 302 dots per square inch;
Fitessa control - connection area 18%, 204 dots per square inch;
Kami control - connection area 18%, 204 dots per square inch;
Polybond control - connection area 18%, 204 dpi.

 The material Control # 1 has a pattern of weaving a wire of spunbond production method. Material Control # 2 has a dot matrix pattern, and the points are triangular in shape. Material Control # 3 has a weave pattern. The remaining three control samples are industrial-grade materials manufactured by Fitessa, KAMI and Polybond, respectively.

As follows from the tables below, samples of materials corresponding to the present invention, the indicated "intermittently connected material having the features of the invention" in a series of tables B, has a dense diamond-shaped pattern with a joint area in the range of 15-18%, but with connection points, very closely spaced to provide a density of 460 dots / sq. inch (69 dots / cm ² ). The lateral dot size in this figure is 0.018 inches (0.457 mm). The distance between the centers of neighboring points in the transverse direction perpendicular to the movement of the semi-finished product in the machine for processing into a product is 0.086 inches (2.184 mm), and in the direction of movement of the semi-finished product in the machine for processing into a product is 0.050 inches (1.27 mm), when measured in one row, with alternating rows in a checkerboard pattern. The connection depth in this figure is 0.024 inches (0.61 mm). This material is an example of a material with a pattern of connected zones, corresponding to the present invention. Samples of “materials (with a pattern of unconnected zones) having features of the invention” are examples of materials (with a pattern of unconnected zones) corresponding to the present invention.

 Below are the polymers used to obtain the materials of the control samples mentioned above, and materials possessing the features of the invention (intermittently connected and with the pattern of unconnected zones).

Control # 1 - Polypropylene 35 MFR Union Carbide E5D47 with 2% TiO ₂ .

Control # 2 - Polypropylene 35 MFR Union Carbide E5D47 with 2% TiO ₂ .

Control # 3 - Polypropylene 35 MFR Exxon 3445 with 2% TiO ₂ .

The intermittently connected material possessing the features of the invention is polypropylene 35 MFR Union Carbide E5D47 with 2% TiO ₂ .

Material # 1 with a pattern of unconnected zones, having the features of the invention is polypropylene 35 MFR Exxon 3445 with 2% TiO ₂ (samples 10, 11, 12, 13, 15, 16, 18, 19, 20, 21).

Material # 2 with a pattern of unconnected zones, having the features of the invention is polypropylene 35 MFR Exxon 3445 with 2% TiO ₂ (samples 9, 14, 17).

 In FIG. 7-11 illustrate graphs obtained on the basis of the data given in the tables. In accordance with the present invention, the Poisson's ratio for ultralight material 5 with a pattern of connected zones, presented in Table II-B, and material 4 with a pattern of unconnected zones (Figs. 1 and 2), presented in Table II-C, is less than in the control samples shown in table II-A. Poisson's ratio is lower in the range of masses for denier of all fibers. Thus, the materials of the present invention have higher dimensional stability than control samples. The tables illustrate the effect of denier on the Poisson ratio. The materials of the present invention are superior to the materials of the control samples with similar bulk materials, even with large deniers of materials of the present invention.

 For standard materials, it is normal that the Poisson's ratio increases when the bulk of the material decreases with constant denier / thread. Such an increase is to be expected since fewer fibers per unit area of material. This will be the case, as more fibers will be per unit area. One way to correct the Poisson's ratio with a constant bulk is to decrease the denier / thread. However, in some cases, the web designer cannot reduce the denier / thread due to factors controlled by denier. For example, a decrease in denier also leads to a decrease in permeability or porosity, which may be undesirable for some applications, for example, in the case of lining for personal care products or cladding absorbent layered structures for wiping materials, where the tasks of liquid absorption are better solved at more high permeability. Surprisingly, materials of the present invention with a higher denier / thread are superior to control materials with equal weights, although control samples had a lower denier / thread than materials of the present invention. From this fact, we can conclude that materials possessing the features of the invention not only provide higher dimensional stability at low base weights, these materials corresponding to the present invention also surpass comparable materials in that they have a smaller denier / thread with optimized dimensional stability.

In the table. V summarizes the results of measurements of the Poisson's ratio of various materials with the bulk of less than 0.40 ounces / square yard (13.5 g / m ² ). The materials for which these data are obtained are materials having the lowest Poisson's ratios at a particular compound temperature in a particular application. The connection temperatures are the surface temperatures of the pattern-forming roll and the back-up roll, if only one temperature is given, if the two temperatures are given, the first number indicates the surface temperature of the pattern-forming roll, and the second number indicates the surface temperature of the back-up roll. In addition, Table V illustrates the product obtained by multiplying the bulk of the materials by Poisson's ratios. The entries in Table V are arranged in increasing order of such factors.

The present invention can be quantitatively limited by the use of an indicator obtained by multiplying the bulk of the non-woven fabric by the Poisson's ratio with ten percent elongation of the material in the direction of movement of the semi-finished product in the machine for processing into a product. This metric can be expressed in units of ounces / square yards x Poisson's ratio. Nonwoven webs according to the present invention, whether they are high-density intermittently connected materials or materials with a pattern of unconnected zones, will have such an indicator equal to not more than 1.20 ounces / sq. yard x Poisson's ratio (40.5 g / m ² x Poisson's ratio).

 Although a preferred embodiment of the present invention has been described using specific terms, devices, and methods, this description is for illustrative purposes only. The words used are words for description rather than limitation. It should be obvious that a person skilled in the art can, without deviating from the essence and scope of the present invention, make various changes and modifications that are set forth in the claims. In addition, it should be obvious that aspects of various embodiments may be replaced in whole or in part.

Claims (28)

1. An ultra-light dimensionally stable non-woven material containing a non-woven fabric of fibers or threads, said non-woven fabric having a bulk of less than 0.40 ounces / square yard (13.5 g / m ² ), and on its surface is a pattern of connected zones, the specified non-woven fabric has dimensional stability, characterized by an indicator calculated by multiplying the Poisson's ratio of the non-woven material at ten percent elongation in the direction of movement of the semi-finished product in the machine for processing it into an article for the bulk of the non-woven lot, while the specified indicator is not more than 1.20 ounces / square yard • Poisson's ratio (40.5 g / m ² • Poisson's ratio).  2. The material according to claim 1, wherein said pattern of connected zones is continuous. 3. The material of claim 1, wherein said nonwoven fabric has a bulk of less than 0.30 ounces / square yard (10.125 g / m ² ). 4. The material of claim 1, wherein said nonwoven fabric has a bulk of less than 0.20 ounces / square yard (6.75 g / m ² ).  5. The material according to claim 1, wherein said connected zones comprise no more than 50% of the total surface area of said surface.  6. The material according to claim 1, wherein said connected zones comprise not more than 40% of the total surface area of said surface.  7. The material according to claim 1, wherein said connected zones comprise no more than 30% of the total surface area of said surface.  8. The material according to claim 1, wherein said connected zones comprise no more than 15% of the total surface area of said surface.  9. The material of claim 1, wherein said pattern of connected zones comprises a plurality of intermittent point connections. 10. The material according to claim 1, wherein said joined zones result in a web having a connection point density of approximately 400 point connections / square inch (60 dots / cm ² ).  11. The material according to claim 1, wherein said non-woven fabric contains yarn obtained by the aerodynamic method from a melt.  12. The material according to claim 1, wherein said non-woven fabric contains spunbond fibers.  13. The material according to claim 1, wherein said non-woven fabric contains multicomponent threads.  14. The material of claim 1, wherein said non-woven fabric contains thermoplastic fibers.  15. The material according to claim 1, wherein said non-woven fabric contains polypropylene fibers.  16. A product for personal care, containing as a lining material according to claim 1.  17. The product for personal care under item 16, in which the specified non-woven fabric contains polyolefin fibers spunbond production method.  18. A personal care product according to claim 16, which is an adult incontinence product.  19. The product for personal care under item 16, which is a product for the hygiene of women.  20. The product for personal care under item 16, which is a diaper. 21. An ultra-light dimensionally stable non-woven fabric comprising a non-woven fabric of fibers or threads, said non-woven fabric having a bulk of less than 0.40 ounces / square yard (13.5 g / m ² ), and a pattern of continuously connected zones on its surface , the specified non-woven fabric has dimensional stability, characterized by an indicator calculated by multiplying the Poisson's ratio of the non-woven material at ten percent elongation in the direction of movement of the semi-finished product in the machine for processing it into a bulk product etkanogo web, said indicator is not more than 1.20 oz / square yard • Poisson ratio (40.5 g / m ² • Poisson's ratio). 22. An ultra-light dimensionally stable non-woven fabric comprising a non-woven fabric of fibers or threads, said non-woven fabric having a bulk of less than 0.40 ounces / square yard (13.5 g / m ² ), and on its surface is a pattern of intermittently connected zones , said non-woven fabric has dimensional stability, characterized by an indicator calculated by multiplying the Poisson's ratio of the non-woven material at ten percent elongation in the direction of movement of the semi-finished product in the machine for processing it into an article, to the bulk non-woven fabric, while the specified indicator is not more than 1.20 ounces / square yard • Poisson's ratio (40.5 g / m ² • Poisson's ratio). 23. A method of producing an ultralight non-woven fabric, providing for a non-woven fabric having a fibrous structure of unconnected individual fibers or threads, with a bulk of less than 0.40 ounces / square yard (13.5 g / m ² ), and creating on the surface of the specified non-woven fabric a pattern of connected zones giving dimensional stability, characterized by an indicator calculated by multiplying the Poisson's ratio of the nonwoven material, at ten percent elongation in the direction of movement of the semi-finished product in the processing machine of a product on the basis weight of the nonwoven web, wherein said component is not more than 1.20 oz / square yard • Poisson ratio (40.5 g / m ² • Poisson's ratio).  24. The method according to p. 23, in which the pattern of connected zones created on the specified surface of the specified non-woven fabric, is continuous.  25. The method according to p. 23, in which the pattern of connected zones created on the specified surface of the specified non-woven fabric is intermittent. 26. The method according to p. 25, in which the specified pattern of connected zones created on the specified surface of the specified non-woven fabric, resulting in a fabric having a density of connection of at least approximately 400 point connections / square inch (60 dots / cm ² ).  27. The method according to p. 23, in which to create the specified pattern of connected zones on the specified surface of the specified non-woven fabric using a roll with many recesses formed in it.  28. The method according to p. 23, in which to create the specified pattern of connected zones on the specified surface of the specified non-woven fabric using a roll with many protrusions formed on it.

Images