US20120100772A1 - High barrier nonwoven - Google Patents

High barrier nonwoven Download PDF

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Publication number
US20120100772A1
US20120100772A1 US13/380,095 US201013380095A US2012100772A1 US 20120100772 A1 US20120100772 A1 US 20120100772A1 US 201013380095 A US201013380095 A US 201013380095A US 2012100772 A1 US2012100772 A1 US 2012100772A1
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Prior art keywords
nonwoven
layer
surface tension
web
nonwoven web
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English (en)
Inventor
Lone Kondrup Hummelgaard
Brian Udengaard
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Fibertex AS
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Fibertex AS
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Assigned to FIBERTEX A/S reassignment FIBERTEX A/S ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: UDENGAARD, BRIAN, HUMMELGAARD, LONE KONDRUP
Publication of US20120100772A1 publication Critical patent/US20120100772A1/en
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/10—Esters; Ether-esters
    • C08K5/101—Esters; Ether-esters of monocarboxylic acids
    • C08K5/103—Esters; Ether-esters of monocarboxylic acids with polyalcohols
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
    • D04H3/033—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random reorientation immediately after yarn or filament formation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2432/00—Cleaning articles, e.g. mops, wipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2535/00—Medical equipment, e.g. bandage, prostheses, catheter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00—Personal care
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00—Personal care
    • B32B2555/02—Diapers or napkins
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]

Definitions

  • the present invention relates to a nonwoven web or nonwoven layer made of fibers, obtainable from a mixture of one or more thermoplastic polymers and an additive component.
  • Hygiene applications such as baby diapers, feminine hygiene products, adult incontinence products, wipes, bandages and wound dressing as well as medical isolation gowns, surgical gowns, surgical drapes and covers, surgical scrub suits, surgical caps and other hygiene products such as panty liners or sanitary napkins or pads are well-known and used on a daily basis.
  • meltblown nonwovens have limited tensile strength they are usually combined with layers of spunbound nonwovens so as to reinforce the fabric. The resulting two or more layers are e.g. thermally bonded.
  • layer products may be industrially produced in a continuous process.
  • Common layering patterns include the SMS pattern, as well as patterns with more layers, such as e.g. SMMS, SMMMS or SSMMS patterns.
  • a further common approach already known from the state of the art is to increase the barrier properties of a nonwoven fabric with respect to liquid permeability by increasing the basis weight of the material. This is the obvious approach, however it is not very sophisticated since other properties like softness and weight of the respective products are altered in an unfavourable way.
  • a potential solution is to develop a material that has a lower intrinsic surface energy than the commonly used polymers. For the intended applications, such a lower intrinsic surface energy results in a significant improvement in low surface tension liquid strike through.
  • fluorine chemicals are an improvement over materials made from pure polypropylene with regard to the achievement of a lower intrinsic surface energy of the material and thus, for example, an increase in the barrier towards low surface tension liquids.
  • fluorine chemicals are generally frowned upon in the hygiene industry due to the risk of skin irritations resulting from the addition of some types of the respective chemicals, regardless their efficiency in lowering surface energy and thus in improving low surface tension liquid strike through.
  • the additive component comprises one or more lipid esters.
  • melt additive Due to this specific melt additive, a low intrinsic surface energy can be imparted to polymer material. Consequently, these melt additives can also impart an improved low surface tension liquid strike through to nonwovens that are fabricated with such a material.
  • the present invention encompasses a high barrier polymer nonwoven, characterized in that the surface energy of the polymer material is decreased by the use of lipid esters as melt additives.
  • the lipid esters are triglycerides, representatives of some common triglycerides being triglycerides with either one, two, or all three hydroxy functional groups esterified with the same or different members of e.g. the group arafflec, stearic, palmitic, myristic, myristoleic, oleic, linoeic or arachidonic acid, as non-limiting examples, and other carboxylic acids or combinations thereof.
  • said triglyceride is glycerol tristearate (CAS No 555-43-1), also known by such names as tristearin or 1,2,3-Trioctadecanoylglycerol.
  • glycerol tristearate also known by such names as tristearin or 1,2,3-Trioctadecanoylglycerol.
  • the name glycerol tristearate will be used, and in case of doubt the CAS No shall be seen as the primary identifier.
  • glycerol tristearate has a surface energy of 34.2 mJ/m 2 .
  • a reduction in surface tension is achieved by the addition of chemicals with a lower surface energy than the respective polymer, e.g. fluorine chemicals.
  • the addition of lipid esters, preferably glycerol tristearate does not adversely effect the spinablity of the fibers on a spunmelt line (at a concentration of up to 10%) and the addition of an additive is simple and elegant, not demanding extra steps in the production process as opposed to e.g. a coating procedure.
  • Table 1 summarizes the surface energy of some common polymers.
  • the fibers can be made of thermoplastic polymers, including polymer compositions, mixtures and blends.
  • suitable thermoplastic polymers for the use herein include polyolefins, preferably polypropylene or polyethylene or polyethyl-ene-polypropylene copolymers; polyesters, polyamides; polyhydroxyalkanoates, and mixtures thereof.
  • Other suitable thermoplastic polymers include i.a. biodegradable polymers such as PHAs, PLAs or starch compositions.
  • the fibres may also be multicomponent fibres, including bicomponent fibres; a bi-component fibre may be in a side-by-side, sheath-core, segmented pie, ribbon, or islands-in-the-sea configuration.
  • the sheath may be continuous or non-continuous around the core.
  • the sheath may comprise polypropylene.
  • polypropylene and polypropylene compositions are preferred, including homopolymers of propylene, copolymers of propylene, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof; polypropylene homopolymers, and copolymers of propylene with ethylene and/or butane may be suitably used, and polypropylene.
  • the polymers to be mixed with the additive are polymers that are not or hardly elastic.
  • the barrier sheet may comprise one or more nonwoven webs or layers made of fibers that do not comprise said additive.
  • Such nonwoven webs and layers may be made of the thermoplastic polymers described above, and with the processes described above.
  • the fibres of one or more of the webs or layers herein may be nanofibers, with a diameter of less than 1000 nanometers.
  • a layer or web may consist exclusively of nanofibers, or it may be mixed with fibers of a larger diameter.
  • the spunbond web or layer herein may for example have spunbond fibers with a number average fiber diameter of, for example, from 6 to 22 microns, or from 10 to 18 microns, or from 10 microns or 11 microns to 15 microns or to 14 microns.
  • the meltblown web or layer herein may for example have meltblown fibers that have a number average fiber diameter from 1 to 5 microns, or 1 to 4 microns, or preferably from 1 to 3 microns.
  • One preferred polymer material is polypropylene linked with the help of a metallocene catalyst.
  • metallocene-polypropylene polymers offer a much greater level of control than conservative polypropylene materials that are connected with the help of a Ziegler-Natta catalyst, because the metallocene molecules offer better control towards how the monomers are linked, so that a proper choice of catalysts can produce isotactic, syndiotactic or atactic polypropylene, or even a combination of these.
  • polypropylene materials with a much narrower molecular weight distribution than traditional Ziegler-Natta catalysts, which can further improve properties, especially in that the narrower molecular weight distribution allows a higher draw ratio, thus allowing thinner fibers to be spun.
  • the high barrier nonwoven is manufactured by spunbound/meltblown layering.
  • the use of the above mentioned polypropylene material is particularly useful for the production of nonwovens employing this technique because, as already mentioned, it allows thinner fibers to be spun.
  • the additive has a lubricating effect in the extruder, which has a positive effect on processing conditions and stability.
  • the highest effect of adding glycerol tristearate has been achieved in an SMMMS spunmelt, because the allowance for thinner spunbound fibers works in synergy with a second effect, being that three of these thin meltblown fibers are contained in an SMMMS spunmelt (MMM), as opposed to two meltblown beams (MM) as in an SMMS or SSMMS spunmelt.
  • meltblown beams allow each of them to run at a lower throughput to obtain the same coverage (grams per m 2 ).
  • Thinner and more meltblown fibers result in a lower pore size of the nonwoven and a higher surface area of the fibers.
  • a low pore size makes it more difficult for a liquid to penetrate the material and, as the additive blooms to the surface and is active with the surface, a high surface area of the fibers increases the effect of the melt additive.
  • Nonwovens according to the present invention comprise at least one spunbound (S) or meltblown (M) polymer layer that is made of fibers comprising both said polymer material and said melt additive.
  • S spunbound
  • M meltblown
  • these fibers are obtainable from a mixture of the polymer material and the melt additive in their molten form.
  • the nonwoven comprises at least one spunbound (S) or meltblown (M) polymer layer that is made of fibers comprising 90% w/w to 99.9% w/w of said polymer material and 0.1% w/w to 10% w/w of said melt additive, preferably 90% w/w to 99.5% w/w of said polymer material and 0.5% w/w to 10% w/w of said melt additive.
  • S spunbound
  • M meltblown
  • the additive can be present throughout their length and diameter (e.g. from the center to the surface). However, in one embodiment, the additive is present in a higher concentration at the surface than in the centre of the fibers.
  • the nonwoven web or barrier sheet or barrier component, comprising said fibers is heated by a heat source or radiated, or compressed, for example by nip rollers, during or after web formation, (e.g. in order to obtain this concentration gradient). This can be done across the whole width of the nonwoven barrier sheet or in specific lanes, zones or regions (herein referred to as regions).
  • zoned compression rollers with varying diameters and nip gaps or pressures, or with heat zones in form of hot, profiled nip rollers, or infra-red heat sources, or other lanes or alternating regions of radiating energy.
  • These deliberate activation steps can be employed during the nonwoven web production, or during the nonwoven barrier sheet production, or during storage or packaged transportation thereof, or during further processing thereof into a barrier component, or during final production of the absorbent article.
  • the invention relates to absorbent articles with barrier components comprising a nonwoven barrier sheet, comprising a nonwoven web or layer of fibers, obtainable of a mixture of said thermoplastic polymers and said additive, whereby the fibers in one region of said layer or web have a higher concentration of additive on the surface of said fibers than in another region, said region being typically at least 1 mm 2 ; said concentration difference being for example at least 10%, or at least 20% or at least 30%.
  • the present invention comprises, in one embodiment, nonwoven barrier sheets and/or barrier components that may have a pore size of less than 60 ⁇ m, preferably less than 50 ⁇ m, even more preferably less than 45 ⁇ m, but at least 1 ⁇ m, preferably at least 2 ⁇ m.
  • the nonwoven barrier sheet and/or barrier component has a narrow pore size distribution.
  • the nonwoven barrier sheet and/or barrier component may have pores of a mean flow pore size within the range of from 1 to 30 ⁇ m, and preferably from 5 to 20 ⁇ m.
  • a representative spunmelt nonwoven fabric made of standard polypropylene with an area weight of about 22 g/m 2 can for example have have a low surface tension liquid strike through (32 mJ/m 2 ) of around 16 seconds (SMMS) or 26 seconds (SMMMS).
  • the nonwoven barrier sheet and/or barrier component according to the present invention has in one embodiment a surface tension strike through value, as determined by the method described herein for a liquid of 32 mN/m surface tension, which has been increased by at least about 25% preferably by about 50%, even more preferably by more than about 100%, and yeteven more preferably by more than about 200%.
  • the surface tension strike-through value may be limited optionally to less than 200 seconds, or less than 150 seconds or less than 100 seconds.
  • a nonwoven barrier sheet or barrier component is considered to have the above low surface tension strike through values if it has this value at any part of the material, excluding areas comprising elastic material or edges being attached to other materials.
  • the resulting high barrier polymer nonwoven shows an improved low surface tension liquid strike through, or in other words an increased barrier towards low surface tension liquids.
  • the solution presented in the method above is convenient in terms of fabrication in comparison to silicone coating, as an additional coating step, additional equipment, or extra cleaning can be avoided.
  • the additive does not contain fluorine, thus allowing to obtain the necessary reductions in surface energy to contain, for example, runny bowl movement without the use of questionable chemistry.
  • the additives of the present invention can become more drapeable and smooth due to the addition of the melt-additive described above, which in turn can lead to an improvement in perceived softness (this has been tested objectively using the Handle-O-Meter test method). Furthermore, the additive can have a lubricating effect in the extruder, which can have a positive effect on processing conditions and stability.
  • the barrier component may be used as an integral part to absorbent articles, and in one specific embodiment to absorbent hygiene articles.
  • the absorbent hygiene article herein is preferably a panty liner or a sanitary napkin or pad, a baby diaper, a feminine hygiene product, an adult incontinence product, a wipe, a bandage or wound dressing, a medical isolation gown, surgical gown, surgical drape or cover, a surgical scrub suit or cap.
  • the barrier component additionally comprises an ink composition, typically applied in a pattern, and/or in the form of figure(s) and/or letter(s), for example by printing.
  • the ink composition may be an aqueous composition. This can be applied to barrier nonwovens sheet or barrier component despite the presence of fibers on the surface and despite the barrier nature and typically (e.g. hydrophobic) nature of these barrier components and nonwoven barrier sheets herein.
  • the barrier component may comprise a skin care composition, also referred to in the art as lotion or lotion composition.
  • a portion of, or an entire surface of the barrier component may comprise on its surface (e.g. may be coated with) a skin care composition.
  • Preferred may be that said barrier component comprises said skin care composition (or lotion) at least on the elasticated portions, described above, if present.
  • the basis weight herein can be measured consistent with ASTM D 756, ISO 536 and EDANA ERT-40.3-90. It is defined as mass per unit area, in g/m 2 (also referred to gsm), and measured on the component or sheet as a whole, if possible with this method, or a sample thereof; the total sample surface area may be any size suitable for the test method, but preferably a sample of 100 cm 2 ( ⁇ 0.5%) is used.
  • the sample is conditioned at 23° Celsius ( ⁇ 2° C.) and at a relative humidity of 50% for 2 hours to reach equilibrium, prior to weight determination.
  • the number average fiber diameters herein are determined by using a Scanning Electron Microscope (SEM) and its image analysis software. A magnification is chosen such that the fibers are suitably enlarged for measurements, e.g. between 1000 and 10,000. At least 100 fibers are measured, and the number average fiber diameter is calculated with the software and used herein.
  • SEM Scanning Electron Microscope
  • the maximum pore size and mean flow pore size as used herein can be measured with a PMI Porometer in accordance with ASTM E1294-89 and F316-89 methods (capillary Constant as per ASTM method is 1; wetting fluid is Galwick, with Surface Tension of 15.9 mN/m; the surface tension of this fluid can be determined as set out herein below).
  • a PMI Capillary Flow Porometry model CFP-1200-AEX, may suitably be used.
  • a wrinkle free, clean circular sample is obtained from the barrier component (which is free in the sample area of elastic material or film material, as described herein) or nonwoven barrier sheet (depending on which value needs to be tested in accord with the invention), having a diameter of 1.0 cm (conditioned for 2 hours at 20° C., 50% relative humidity).
  • the sample is immersed the in petri dish filled with the Galwick 15.9 mN/m wetting fluid such that the fluid completely covers the sample, for 30 seconds. Then the sample is turned, using tweezers, and reimmersed in the same dish and fluid, for a further 30 seconds. This ensures complete saturation of the pores with the wetting fluid.
  • the saturated sample is directly placed onto the O-ring of the lower sample adaptor, without allowing the wetting fluid to drain, ensuring that that the O-ring is completely covered by the sample, but without covering the gauze during placement of the sample.
  • the Porometer is further prepared as per its manual and the measurement is started according to manual.
  • the apparatus' software will analyse the measurements and report the maximum pore size as used herein. It will also calculate the mean flow pore size.
  • the Handle-O-Meter Stiffness was measured according to the standard test method WSP 90.3.0 (05).
  • Alcohol Repllency was measured by INDA IST 80.8.
  • INDA IST 80.8 is a standard test method for measuring the resistance of nonwoven fabrics to penetration by aqueous isopropanol solutions. The alcohol repellency was reported in ratings based upon alcohol concentrations. The highest number of test solutions that did not penetrate the tested fabric within five minutes was recorded.
  • the low surface tension strike through value referred to herein may be obtained by the Edana method WSP70.3 (05), except that a low surface tension liquid (see below) is used and a sample of 1 inch ⁇ 1 inch (25 mm ⁇ 25 mm) may be used.
  • the sample should be free of elastic material or of edges that are connected to other materials.
  • the low surface tension liquid is a liquid with a surface tension of 32 mN/m prepared as follows:
  • Triton-X-100 is added to 500 ml distilled water (already in flask) and then 5000 ml distilled water is added. The solution is mixed for 30 minutes and then the surface tension is measured, which should be 32 mN/m.
  • the surface tension may be determined by method: ASTM D1331-56 (“Standard test method for surface and interfacial tension of solution of surface active agents”) using a Kruss K12 tensiometer.)
  • FIG. 1 is a graphical representation of the alcohol repellency of comparative example 1 and examples 1 through 5.
  • FIGS. 2 and 3 are graphical representations of the liquid strike through (32 mJ/m 2 ) in seconds for comparative example 1 and examples 1 through 5.
  • the LST is shown depending on the percentual values for active ingredient in the respective examples.
  • FIG. 2 also indicates the percentual increase in LST as compared to comparative example 1.
  • FIG. 4 is a graphical representation of the handle-o-meter stiffness [g] of comparative example 1 and examples 1 through 5.
  • FIGS. 5 and 6 are graphical representations of the liquid strike through (32 mJ/m 2 ) in seconds for comparative example 2 and examples 6 through 8.
  • the LST is shown depending on the percentual values for active ingredient in the respective examples.
  • FIG. 5 also indicates the percentual increase in LST as compared to comparative example 2.
  • FIGS. 7 and 8 are graphical representations of the liquid strike through (32 mJ/m 2 ) in seconds for comparative example 3 and examples 9 through 12.
  • the LST is shown depending on the percentual values for active ingredient in the respective examples.
  • FIG. 7 also indicates the percentual increase in LST as compared to comparative example 3.
  • FIGS. 9 and 10 are graphical representations of the liquid strike through (32 mJ/m 2 ) in seconds for comparative example 4 and examples 13 through 16.
  • the LST is shown depending on the percentual values for active ingredient in the respective examples.
  • FIG. 9 also indicates the percentual increase in LST as compared to comparative example 4.
  • FIGS. 11 and 12 are graphical representations of the liquid strike through (32 mJ/m 2 ) in seconds for comparative example 5 and examples 17 and 18.
  • the LST is shown depending on the percentual values for active ingredient in the respective examples.
  • FIG. 11 also indicates the percentual increase in LST as compared to comparative example 5.
  • Comparative Examples 1 to 5 aim to illustrate the state of the art in comparison to Examples 1 to 19, which aim to illustrate the properties of the nonwoven that can be achieved by using the method disclosed in the present invention.
  • An SMMS multilayer nonwoven was produced from Ziegler-Natta polypropylene in a continuous production on a 4.5 m wide Reifenhe,uml aee user Reicofil 3 SMMS line.
  • Each layer of S-layers had a weight of 9.5 g/m 2 and each of the M layers had a weight of 1.5 g/m 2 , resulting in a thermally bonded SMMS layered nonwoven product having a total weight per area of 22 g/m 2 .
  • a layered fabric was produced following the process described in Comparative Example 1, where the polymer forming Layer 4 contained 0.8% w/w of glycerol tristearate as an additive component, hereinafter referred to as “active ingredient”, resulting in an average weight percentage of 0.3% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 1, where the polymer forming each of the Layers 1 and 4 contained 0.8% w/w of active ingredient, resulting in an average weight percentage of 0.7% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 1, where the polymer forming each of the Layers 1 and 4 contained 1.6% w/w of active ingredient, resulting in an average weight percentage of 1.4% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 1, where the polymer forming each of the layers 1 and 4 contained 2.4% w/w of active ingredient, resulting in an average weight percentage of 2.1% w/w of active ingredient in the total fabric.
  • a layered fabric was produced according to Example 1, where the polymer forming each of the Layers 1, 2 and 4 contained 2.4% w/w of active ingredient, resulting in an average weight percentage of 2.2% w/w of active ingredient in the total fabric.
  • An SMMMS multilayer nonwoven was produced from metallocene-polypropylene in a continuous production on a 4.5 m wide Reifen Reifenberger Reicofil 4 SMMMS line.
  • Each layer of S-layers had a weight of 9.5 g/m 2 and each of the M layers had a weight of 1.0 g/m 2 , resulting in a thermally bonded SMMMS layered nonwoven product having a total weight per area of 22 g/m 2 .
  • a layered fabric was produced following the process described in Comparative Example 2, where the polymers forming Layers 2, 3 and 4 contained 2.3% w/w of active ingredient, resulting in an average weight percentage of 0.3% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 6, where the polymers forming each of the Layers 2, 3 and 4 contained 2.3% w/w and the one forming Layer 5 contained 2.0% w/w of active ingredent of active ingredient, resulting in an average weight percentage of 1.2% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 6, where the polymers forming each of the Layers 2, 3 and 4 contained 2.3% w/w, and the one forming Layer 5 contained 3.0% w/w of active ingredient, resulting in an average weight percentage of 1.6% w/w of active ingredient in the total fabric.
  • An SMMS multilayer nonwoven was produced from Ziegler-Natta polypropylene in a continuous production on a 4.5 m wide Reifen Reifenberger Reicofil 3 SMMS line. Each lay-up of S-layers had a weight of 6.9 g/m 2 and each of the M layers had a weight of 0.6 g/m 2 , resulting in a thermally bonded SMMS layered nonwoven product having a total weight per area of 15 g/m 2 .
  • a layered fabric was produced as described in Comparative Example 3, where the polymers forming each of the Layers 2 and 3 contained 7.6% w/w and the one forming Layer 4 contained 2.3% w/w of active ingredent, resulting in an average weight percentage of 1.7% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 9, where the polymers forming each of the Layers 2, and 3 contained 2.5% w/w and the one forming Layer 4 contained 3.4% w/w of active ingredent, resulting in an average weight percentage of 1.8% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 9, where the polymers forming Layer 1 contained 6.0% and the one forming Layers 2, and 3 contained 7.6% w/w and the one forming Layer 4 contained 6.0% w/w of active ingredent, resulting in an average weight percentage of 6.1% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 9, where the polymers forming Layer 4 contained 4.1% of active ingredent, resulting in an average weight percentage of 1.9% w/w of active ingredient in the total fabric.
  • An SMMMS multilayer nonwoven was produced from Ziegler-Natta polypropylene in a continuous production on a 4.5 m wide Reifen Reifenberger Reicofil 4 SMMMS line. Each lay-up of S-layers had a weight of 6.3 g/m 2 and each of the M layers had a weight of 0.8 g/m 2 , resulting in a thermally bonded SMMMS layered nonwoven product having a total weight per area of 15 g/m 2 .
  • a layered fabric was produced as described in Comparative Example 4, where the polymers forming each of the Layers 2, 3 and 4 contained 1.2% w/w and the one forming Layer 5 contained 1.9% w/w of active ingredent, resulting in an average weight percentage of 1.0% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 13, where the polymers forming each of the Layers 2, 3 and 4 contained 2.4% w/w and the one forming Layer 5 contained 1.9% w/w of active ingredent, resulting in an average weight percentage of 1.2% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 13, where the polymers forming each of the Layers 2, 3 and 4 contained 2.4% w/w and the one forming Layer 5 contained 3.0% w/w of active ingredent, resulting in an average weight percentage of 1.6% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 13, where the polymers forming each of the Layers 2, 3 and 4 contained 2.4% w/w and the one forming Layer 5 contained 3.8% w/w of active ingredent, resulting in an average weight percentage of 2.0% w/w of active ingredient in the total fabric.
  • the Strike Through test was carried out according to the methods introduced in the section “Test Methods” to assess the Strike Through (32 mJ/m 2 ) Properties.
  • the corresponding results for Comparative Example 4 as well as Examples 13 to 16 are summarized in Table 12 and FIGS. 9 and 10 .
  • An SMMMS multilayer nonwoven was produced from metallocene-polypropylene in a continuous production on a 4.5 m wide Reifen Reifenberger Reicofil 4 SMMMS line.
  • Each layer of S-layers had a weight of 6.5 g/m 2 and each of the M layers had a weight of 1.3 g/m 2 , resulting in a thermally bonded SMMMS layered nonwoven product having a total weight per area of 17 g/m 2 .
  • a layered fabric was produced as described in Comparative Example 5, where the polymers forming each of the Layers 2, 3 and 4 contained 2.9% w/w and the one forming Layer 5 contained 3.5% w/w of active ingredent of active ingredient, resulting in an average weight percentage of 2.0% w/w of active ingredient in the total fabric.
  • a layered fabric was produced as described in Example 17, where the polymers forming each of the Layers 2, 3 and 4 contained 3.9% w/w, and the one forming Layer 5 contained 4.8% w/w of active ingredient, resulting in an average weight percentage of 2.7% w/w of active ingredient in the total fabric.
  • the Strike Through test was carried out according to the methods introduced in the section “Test Methods” to assess the Strike Through (32 mJ/m 2 ) Properties.
  • the corresponding results for Comparative Example 5 as well as Examples 17 to 18 are summarized in Table 14 and FIGS. 11 to 12 .
  • the nonwoven fabrics according to the present invention show a percentual increase in LST of more than 25%, in most cases more than 50%, in some cases more than 100% and in some cases even more than 200% as compared to fabrics without the additive component according to claim 1 , for both SMMS and SMMMS layered fabrics with differend area weights.
  • a nonwoven fabric according to the present invention can have twice or even three times the LST as compared to fabrics without the additive component according to claim 1 .
US13/380,095 2009-06-25 2010-04-23 High barrier nonwoven Abandoned US20120100772A1 (en)

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US9205006B2 (en) 2013-03-15 2015-12-08 The Procter & Gamble Company Absorbent articles with nonwoven substrates having fibrils
US9328440B2 (en) 2011-05-20 2016-05-03 The Procter & Gamble Company Fibers of polymer-wax compositions
WO2017136614A1 (fr) 2016-02-05 2017-08-10 The Procter & Gamble Company Procédés d'application de compositions sur des toiles
US20170258955A1 (en) * 2016-03-09 2017-09-14 The Procter & Gamble Company Absorbent article with activatable material
WO2018049108A1 (fr) 2016-09-09 2018-03-15 The Procter & Gamble Company Systèmes et procédés d'application de compositions sur des bandes continues et bandes continues en résultant
WO2020028735A1 (fr) 2018-08-03 2020-02-06 The Procter & Gamble Company Bandes avec des compositions sur celles-ci
WO2020028734A1 (fr) 2018-08-03 2020-02-06 The Procter & Gamble Company Bandes avec des compositions appliquées sur celles-ci
CN111850830A (zh) * 2019-10-16 2020-10-30 宁波炜业科技有限公司 一种耐酒精洗涤不退色印花水刺无纺织布
US11090407B2 (en) 2017-03-09 2021-08-17 The Procter & Gamble Company Thermoplastic polymeric materials with heat activatable compositions
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US11839531B2 (en) 2014-09-10 2023-12-12 The Procter And Gamble Company Nonwoven webs with hydrophobic and hydrophilic layers
US11110013B2 (en) 2014-09-10 2021-09-07 The Procter & Gamble Company Nonwoven webs with hydrophobic and hydrophilic layers
WO2017136614A1 (fr) 2016-02-05 2017-08-10 The Procter & Gamble Company Procédés d'application de compositions sur des toiles
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US20170258955A1 (en) * 2016-03-09 2017-09-14 The Procter & Gamble Company Absorbent article with activatable material
WO2018049108A1 (fr) 2016-09-09 2018-03-15 The Procter & Gamble Company Systèmes et procédés d'application de compositions sur des bandes continues et bandes continues en résultant
US11090407B2 (en) 2017-03-09 2021-08-17 The Procter & Gamble Company Thermoplastic polymeric materials with heat activatable compositions
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