US20140072767A1 - Nonwoven webs with enhanced loft and process for forming such webs - Google Patents

Nonwoven webs with enhanced loft and process for forming such webs Download PDF

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Publication number
US20140072767A1
US20140072767A1 US14/006,534 US201214006534A US2014072767A1 US 20140072767 A1 US20140072767 A1 US 20140072767A1 US 201214006534 A US201214006534 A US 201214006534A US 2014072767 A1 US2014072767 A1 US 2014072767A1
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Prior art keywords
bonding
shape
web
bond
batt
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Inventor
Frantisek Klaska
Jiri Kummer
Zdenek Mecl
Pavlina Kasparkova
Han Xu
Olaf Erik Alexander Isele
Antonius Lambertus Johannes de Beer
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Pegas Nonwovens sro
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Pegas Nonwovens sro
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Assigned to PEGAS NONWOVENS S.R.O. reassignment PEGAS NONWOVENS S.R.O. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUMMER, Jiri, KASPARKOVA, PAVLINA, KLASKA, FRANTISEK, MECL, ZDENEK, ISELE, OLAF ERIK ALEXANDER, XU, HAN, JOHANNES DE BEER, ANTONIUS LAMBERTUS
Publication of US20140072767A1 publication Critical patent/US20140072767A1/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
    • D04H3/10—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 yarns or filaments made mechanically
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/544—Olefin series
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • 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
    • D04H3/08—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
    • 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
    • D04H3/147—Composite yarns or filaments
    • 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
    • B32B2250/02—2 layers
    • 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester 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
    • B32B2262/04—Cellulosic plastic fibres, e.g. rayon
    • 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
    • B32B2262/06—Vegetal fibres
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness

Definitions

  • the present invention relates to a method of producing a nonwoven web material exhibiting improved properties as well as to such a nonwoven material.
  • a nonwoven web material exhibiting improved properties as well as to such a nonwoven material.
  • Such a material may be useful for a number of applications, such as cleaning articles, like wipes or dusters, or in particular for disposable articles, such as disposable absorbent articles.
  • thermally bonded nonwoven webs can be significantly influenced by an appropriate pattern of bonding points or bonding impressions expressed particularly by the shape and the size of the bond impression as well as the total bond area, and their arrangement in the plane such as in a certain pattern.
  • an appropriate pattern of bonding points or bonding impressions expressed particularly by the shape and the size of the bond impression as well as the total bond area, and their arrangement in the plane such as in a certain pattern.
  • One of the ways is to create a web with a so-called 3D-structure, as described for example in documents U.S. Pat. No. 4,333,979 published in 1982 or JP2004113489 published in 2004. In both cases a pair of patterned rollers is used to bond the webs. The achieved thickness and structure of the resulting material are, however, not suitable for all applications.
  • the elongated bonding points together with convex borders of bonding points combine for example document WO2008/129138 published in 2008, where individual bonding points have the shape of oval perimeter.
  • the orientation of longer axe regularly varies MD and CD direction. According to the description it improves the abrasion resistance without compromising softness and drapeability.
  • a particular application area of nonwoven webs is in the area of absorbent articles, such as disposable diapers, training pants, adult incontinence undergarments, feminine hygiene products, breast pads, care mats, bibs, wound dressing products, and the like.
  • Manufacturers of such articles must continually strive to enhance their products in ways that serve to differentiate them from those of their competitors, while at the same time controlling costs so as to enable competitive pricing and the offering to the market of an attractive value-to-price proposition.
  • Perceptions of softness also may be affected by auditory signals, e.g., whether and to what extent the material makes audible rustling, crinkling or other noises when touched or manipulated.
  • perceptions of softness of a material also may be affected by visual signals, i.e., its visual appearance. It is believed that, if a nonwoven material looks relatively soft to a person, it is much more likely that the person will perceive it as having relative tactile softness as well. Visual impressions of softness may be affected by a variety of features and properties, including but not limited to color, opacity, light reflectivity, refractivity or absorption, as well as to the loft, which in turn may be impacted by apparent thickness/caliper, fiber size and density, and macroscopic physical surface features.
  • Complicating efforts to define and enhance softness is the fact that differing individuals will have differing individual physiological and experiential frames of reference and perceptions concerning what material features and properties will cause them to perceive softness to a lesser or greater extent in a material, and relative other materials.
  • nonwovens may have importance for reasons in addition to or other than creating an impression of softness.
  • nonwovens may be used as components of cleaning articles, such as wipes or dusters. Improving loft of such a nonwoven can also improve its efficacy as a cleaning element.
  • a nonwoven may be used to form the loops component of a hook-and-loop fastening system. Improving loft of such a nonwoven can improve its suitability for this purpose.
  • one approach to enhancing perceived softness of a nonwoven web has involved simply increasing the basis weight of the web, otherwise manufactured through a spunlaid/spunbond process that includes formation of a batt of loose spun fibers and then consolidating by calender-bonding in a pattern. All other variables remaining constant, increasing the basis weight of such a web will have the effect of increasing the number of fibers per unit surface area, and correspondingly, increasing apparent thickness, fiber density and/or loft.
  • This approach might be deemed effective if the only objective is increasing depth and/or loft signals affecting perceptions of softness, i.e., simply increasing the basis weight of a spunbond nonwoven is one way to increase its depth or loft.
  • nonwoven web material formed of polymer fibers is the cost of the polymer resin(s) from which the fibers are spun.
  • Higher basis weight nonwovens require more resin to produce, and therefore, cost more per unit.
  • attempting to enhance loft and/or perceived softness by increasing nonwoven basis weight is incompatible with the ever-present objective of controlling or reducing costs.
  • bicomponent polymer fibers may be formed by spinnerets that have two adjacent sections, that express a first polymer from one and a second polymer from the other, to form a fiber having a cross section of the first polymer in one portion and the second polymer in the other (hence the term “bicomponent”).
  • the respective polymers may be selected so as to have differing melting temperatures and/or expansion-contraction rates.
  • the present invention relates to providing a process of forming a web exhibiting improved softness and loft as well as to providing such a nonwoven material.
  • the process for the forming of a bonded web from a batt comprises the steps of
  • FIG. 1A is a perspective view of a disposable diaper shown laid out horizontally in a relaxed condition, wearer-facing surfaces up;
  • FIG. 1B is a plan view of a disposable diaper shown laid out horizontally in a stretched out, flattened state (stretched out against elastic contraction induced by the presence of elastic members), wearer-facing surfaces facing the viewer;
  • FIG. 2A is a cross section of the diaper depicted in FIGS. 1A and 1B , taken through line 2 - 2 in those figures;
  • FIG. 2B is a schematic cross section of a portion of a laminate of a polymeric film and a nonwoven web, taken through a pattern of bond impressions in the nonwoven web;
  • FIG. 3 is a simplified schematic view of a batt moving through the nip between calender rollers to form a calender-bonded nonwoven web;
  • FIG. 4 A is a view of a pattern of bonding surface shapes of bonding protrusions that may be imparted to the surface of a calender roller, to create a corresponding pattern of consolidating bond impressions having bond shapes in a nonwoven web;
  • FIG. 4B is a view of another pattern of bonding surface shapes of bonding protrusions that may be imparted to the surface of a calender roller, to create another corresponding pattern of consolidating bond impressions having bond shapes in a nonwoven web;
  • FIG. 4C is a magnified view of the pattern of bonding surface shapes of bonding protrusions or consolidating bond impressions having bond shapes appearing in FIG. 4B ;
  • FIG. 5A is a view of another pattern of bonding surface shapes of bonding protrusions that may be imparted to the surface of a calender roller, to create another corresponding pattern of consolidating bond impressions having bond shapes in a nonwoven web;
  • FIG. 5B is a magnified view of the pattern of bonding surface shapes of bonding protrusions or consolidating bond impressions having bond shapes appearing in FIG. 5A ;
  • FIG. 5C is a magnified view of the pattern of bonding surface shapes of bonding protrusions or consolidated bond impressions having bonding impressions appearing in FIG. 5A ;
  • FIG. 6B is a magnified view of the pattern of bonding surface shapes of bonding protrusions or consolidating bond impressions having bond shapes appearing in FIG. 6A .
  • Absorbent article refers to devices that absorb and contain body exudates, and, more specifically, refers to devices that are placed against or in proximity to the body of the wearer to absorb and contain the various exudates discharged from the body.
  • Absorbent articles may include diapers, training pants, adult incontinence undergarments and pads, feminine hygiene pads, breast pads, care mats, bibs, wound dressing products, and the like.
  • exudates includes, but is not limited to, urine, blood, vaginal discharges, breast milk, sweat and fecal matter.
  • a “batt” is used herein to refer to fiber materials prior to being consolidated in a final calendering process as described herein.
  • a “batt” comprises individual fibers, which are usually unbonded to each other, although a certain amount of pre-bonding between fibers may be performed and is also included in the meaning, such as may occur during or shortly after the lay-down of fibers in a spunlaying process, or as may be achieved be a pre-calendering. This pre-bonding, however, still permits a substantial number of the fibers to be freely moveable such that they can be repositioned.
  • a “batt” may comprise several strata, such as may result from depositing fibers from several beams in a spunlaying process.
  • Bicomponent refers to fiber having a cross-section comprising two discrete polymer components, two discrete blends of polymer components, or one discrete polymer component and one discrete blend of polymer components. “Bicomponent fiber” is encompassed within the term “multicomponent fiber.” A Bicomponent fiber may have an overall cross section divided into two or more subsections of the differing components of any shape or arrangement, including, for example, coaxial subsections, core-and-sheath subsections, side-by-side subsections, radial subsections, etc.
  • Bond area percentage on a nonwoven web is a ratio of area occupied by bond impressions, to the total surface area of the web, expressed as a percentage, and measured according to the Bond Area Percentage Method set forth herein.
  • Bending roller “Bonding roller,” “calender roller” and “roller” are used interchangeably.
  • a “bond impression” in a nonwoven web is the surface structure created by the impression of a bonding protrusion on a calender roller into a nonwoven web.
  • a bond impression is a location of deformed, intermeshed or entangled, and melted or thermally fused, materials from fibers superimposed and compressed in a z-direction beneath the bonding protrusion, which form a bond.
  • the individual bonds may be connected in the nonwoven structure by loose fibres between them.
  • the shape and size of the bond impression approximately corresponds to the shape and size of the bonding surface of a bonding protrusion on the calender roller.
  • a “column” of bonds on a nonwoven web is a group of nearest neighboring bonds of like shape and rotational orientation that are arranged along the line that extends most predominately in the machine direction.
  • Cross direction refers to the direction along the web material substantially perpendicular to the direction of forward travel of the web material through the manufacturing line in which the web material is manufactured.
  • the cross direction is perpendicular to the direction of movement through the nip, and parallel to the nip.
  • Disposable is used in its ordinary sense to mean an article that is disposed or discarded after a limited number of usage events over varying lengths of time, for example, less than about 20 events, less than about 10 events, less than about 5 events, or less than about 2 events.
  • Diaper refers to an absorbent article generally worn by infants and incontinent persons about the lower torso so as to encircle the waist and legs of the wearer and that is specifically adapted to receive and contain urinary and fecal waste. As used herein, term “diaper” also includes “pant” which is defined below.
  • Fiber and “filament” are used interchangeably.
  • Fiber diameter is expressed in units of p.m.
  • the terms “grams of fiber per 9000 m” (denier or den) or “grams of fiber per 10000 m” (dTex) are used to describe the fineness or coarseness of fibers, which are linked to the diameter (when assumed to be circular) by the density of the employed material(s).
  • Frm means a skin-like or membrane-like layer of material formed of one or more polymers, which does not have a form consisting predominately of a web-like structure of consolidated polymer fibers and/or other fibers.
  • “Length” or a form thereof, with respect to a diaper or training pant refers to a dimension measured along a direction perpendicular to the waist edges and/or parallel to the longitudinal axis.
  • Machine direction refers to the direction along the web material substantially parallel to the direction of forward travel of the web material through the manufacturing line in which the web material is manufactured.
  • machine direction is parallel to the direction of movement through the nip, and perpendicular to the nip.
  • “Monocomponent” refers to fiber formed of a single polymer component or single blend of polymer components, as distinguished from bicomponent or multicomponent fiber.
  • Multicomponent refers to fiber having a cross-section comprising more than one discrete polymer component, more than one discrete blend of polymer components, or at least one discrete polymer component and at least one discrete blend of polymer components.
  • Multicomponent fiber includes, but is not limited to, “bicomponent fiber.”
  • a multicomponent fiber may have an overall cross section divided into subsections of the differing components of any shape or arrangement, including, for example, coaxial subsections, core-and-sheath subsections, side-by-side subsections, radial subsections, islands-in-the-sea, etc.
  • a “nonwoven” is a manufactured sheet or web of directionally or randomly oriented fibers which are first formed into a batt and then consolidated and bonded together by friction, cohesion, adhesion or one or more patterns of bonds and bond impressions created through localized compression and/or application of pressure, heat, ultrasonic, or heating energy, or a combination thereof.
  • the term does not include fabrics which are woven, knitted, or stitch-bonded with yarns or filaments.
  • the fibers may be of natural or man-made origin and may be staple or continuous filaments or be formed in situ.
  • Nonwoven fabrics can be formed by many processes including but not limited to meltblowing, spunbonding, spunmelting, solvent spinning, electrospinning, carding, film fibrillation, melt-film fibrillation, airlaying, dry-laying, wetlaying with staple fibers, and combinations of these processes as known in the art.
  • the basis weight of nonwoven fabrics is usually expressed in grams per square meter (gsm).
  • Opacity is a numeric value relating to the ability of a web material to transmit light therethrough, measured according the Opacity Measurement Method set forth herein.
  • Pant or “training pant”, as used herein, refer to disposable garments having a waist opening and leg openings designed for infant or adult wearers.
  • the term “predominately” means that the component makes up greater than 50% by weight of the material.
  • “predominately” means the feature or attribute has a projection onto a line extending along the direction indicated, greater in length than the projection onto a line perpendicular thereto.
  • the term “predominantly” refers to a condition which imparts a substantial effect on a property or feature.
  • a material comprises “predominantly” a component said to impart a property
  • this component imparts a property that the material otherwise would not exhibit.
  • the quantity and components of these fibers must be sufficient to allow heat fusion of the fibers.
  • a “bonding protrusion” or “protrusion” is a feature of a bonding roller at its radially outermost portion, surrounded by recessed areas. Relative the rotational axis of the bonding roller, a bonding protrusion has a radially outermost bonding surface with a bonding surface shape and a bonding surface shape area, which generally lies along an outer cylindrical surface with a substantially constant radius from the bonding roller rotational axis; however, protrusions having bonding surfaces of discrete and separate shapes are often small enough relative the radius of the bonding roller that the bonding surface may appear flat/planar; and the bonding surface shape area is closely approximated by a planar area of the same shape.
  • a bonding protrusion may have sides that are perpendicular to the bonding surface, although usually the sides have an angled slope, such that the cross section of the base of a bonding protrusion is larger than its bonding surface.
  • a plurality of bonding protrusions may be arranged on a calender roller in a pattern. The plurality of bonding protrusions has a bonding area per unit surface area of the outer cylindrical surface which can be expressed as a percentage, and is the ratio of the combined total of the bonding shape areas of the protrusions within the unit, to the total surface area of the unit.
  • a “row” of bonds on a nonwoven web is group of bonds of like shape and rotational orientation that are arranged along the line that extends most predominately in the cross direction.
  • Tensile Strength refers to the maximum tensile force (Peak Force) a material will sustain before tensile failure, as measured by the Tensile Strength Measurement Method set forth herein.
  • volume mass[kg/m 3 ] basis weight[g/m 2 ]/thickness[mm].
  • “Width” or a form thereof, with respect to a diaper or training pant refers to a dimension measured along a direction parallel to the waist edges and/or perpendicular to the longitudinal axis.
  • Z-direction with respect to a web, means generally orthogonal or perpendicular to the plane approximated by the web along the machine and cross direction dimensions.
  • Nonwovens according to the present invention may be used for the topsheet, backsheet outer layer, loops component in a hook-and-loop fastening system of an absorbent article, or any other portion of a manufactured article such as cleansing wipes and other personal hygiene products, dusters and dusting cloths, household cleaning cloths and wipes, laundry bags, dryer bags and sheets comprising a layer formed of nonwoven web.
  • a particularly preferred application is in the area of disposable absorbent articles, wherein the enhanced properties of the nonwoven materials also enhance the softness attributes.
  • FIG. 1A is a perspective view of a diaper 10 in a relaxed, laid-open position as it might appear opened and lying on a horizontal surface.
  • FIG. 1B is a plan view of a diaper 10 shown in a flat-out, uncontracted state (i.e., without elastic induced contraction), shown with portions of the diaper 10 cut away to show underlying structure. The diaper 10 is depicted in FIG. 1B with its longitudinal axis 36 and its lateral axis 38 . Portions of the diaper 10 that contact a wearer are shown oriented upwards in FIG. 1A , and are shown facing the viewer in FIG. 1B .
  • FIG. 2A is a cross section of the diaper taken at line 2 - 2 in FIG. 1B .
  • the diaper 10 generally may comprise a chassis 12 and an absorbent core 14 disposed in the chassis.
  • the chassis 12 may comprise the main body of the diaper 10 .
  • the chassis 12 may include a topsheet 18 , which may be liquid pervious, and a backsheet 20 , which may be liquid impervious.
  • the absorbent core 14 may be encased between the topsheet 18 and the backsheet 20 .
  • the chassis 12 may also include side panels 22 , elasticized leg cuffs 24 , and an elastic waist feature 26 .
  • the chassis 12 may also comprise a fastening system, which may include at least one fastening member 46 and at least one landing zone 48 .
  • One or more layers of the topsheet and/or backsheet may be formed of a nonwoven web as described below.
  • the leg cuffs 24 and the elastic waist feature 26 may each typically comprise elastic members 28 .
  • One end portion of the diaper 10 may be configured as a first waist region 30 of the diaper 10 .
  • An opposite end portion of the diaper 10 may be configured as a second waist region 32 of the diaper 10 .
  • An intermediate portion of the diaper 10 may be configured as a crotch region 34 , which extends longitudinally between the first and second waist regions 30 and 32 .
  • the second waist region 32 may be attached by the fastening member 46 to the first waist region 30 to form leg opening(s) and an article waist.
  • the fastening system When fastened, the fastening system carries a tensile load around the article waist.
  • the diaper 10 may be provided with a re-closable fastening system or may alternatively be provided in the form of a pant-type diaper.
  • the chassis 12 and absorbent core 14 may form the main structure of the diaper 10 with other features added to form the composite diaper structure. While the topsheet 18 , the backsheet 20 , and the absorbent core 14 may be assembled in a variety of well-known configurations.
  • the backsheet 20 may be joined with the topsheet 18 .
  • the backsheet 20 may serve to prevent the exudates absorbed by the absorbent core 14 and contained within the diaper 10 from soiling other external articles that may contact the diaper 10 , such as bed sheets and clothing.
  • the backsheet 20 may be substantially impervious to liquids (e.g., urine) and may be formed of a laminate of a nonwoven 21 and a thin polymeric film 23 such as a thermoplastic film having a thickness of about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils).
  • Nonwoven 21 may be a nonwoven web as described herein.
  • the backsheet of the present invention may have a water vapor transmission rate (WVTR) of greater than about 2,000 g/24 h/m2, measured according to WSP 70.5 (08) at 37.8° C. and 60% Relative Humidity.
  • WVTR water vapor transmission rate
  • Suitable nonwoven web materials useful in the present invention include, but are not limited to spunbond, meltblown, spunmelt, solvent-spun, electrospun, carded, film fibrillated, melt-film fibrillated, air-laid, dry-laid, wet-laid staple fibers, and other and other nonwoven web materials formed in part or in whole of polymer fibers, as known in the art.
  • a suitable nonwoven web material may also be an SMS material, comprising a spunbonded, a melt-blown and a further spunbonded stratum or layer or any other combination of spunbonded and melt-blown layers, such as a SMMS or SSMMS etc.
  • Examples include one or more layers of fibers with diameters below 1 micron (nanofibers and nanofiber layers); examples of these rise in combinations of SMS, SMNS, SSMNS or SMNMS nonwoven webs (where “N” designates a nanofiber layer).
  • permanently hydrophilic non-wovens, and in particular, nonwovens with durably hydrophilic coatings may be desirable.
  • the suitable nonwoven is air permeable.
  • the suitable nonwoven is water or liquid permeable, but may also be water impermeable by reason of fiber size and density, and hydrophobicity of the fibers. Water or liquid permeability may be enhanced by treatments to render the fibers hydrophilic, as discussed below.
  • the nonwoven web may be formed predominately of polymeric fibers.
  • suitable non-woven fiber materials may include, but are not limited to polymeric materials such as polyolefins, polyesters, polyamide, or specifically polypropylene (PP), polyethylene (PE), poly-lactic acid (PLA), polyethylene terephthalate (PET) and/or blends thereof.
  • Nonwoven fibers may be formed of, or may include as additives or modifiers, components such as aliphatic polyesters, thermoplastic polysaccharides, or other biopolymers (bio-based or renewable polymers).
  • Some polymers used for nonwoven fiber production may be inherently hydrophobic, and for certain applications they may be surface treated or coated with various agents to render them hydrophilic.
  • a surface coating may include a surfactant coating.
  • One such surfactant coating is available from Schill & Silacher GmbH, Böblingen, Germany, under the Tradename Silastol PHP 90.
  • Another way to produce nonwovens with durably hydrophilic coatings is via applying a hydrophilic monomer and a radical polymerization initiator onto the nonwoven, and conducting a polymerization activated via UV light resulting in monomer chemically bound to the surface of the nonwoven as described in co-pending U.S. Patent Publication No. 2005/0159720.
  • hydrophilic nonwovens made predominantly from hydrophobic polymers such as polyolefins is to add hydrophilic additives into the melt prior to extrusion.
  • Nanoparticles typically have a largest dimension of below 750 nm. Nanoparticles with sizes ranging from 2 to 750 nm may be economically produced. An advantage of nanoparticles is that many of them can be easily dispersed in water solution to enable coating application onto the nonwoven, they typically form transparent coatings, and the coatings applied from water solutions are typically sufficiently durable to exposure to water. Nanoparticles can be organic or inorganic, synthetic or natural. Inorganic nanoparticles generally exist as oxides, silicates, and/or carbonates. Typical examples of suitable nanoparticles are layered clay minerals (e.g., LAPONITETM from Southern Clay Products, Inc.
  • a suitable nanoparticle coated non-woven is that disclosed in the co-pending patent application Ser. No. 10/758,066 entitled “Disposable absorbent article comprising a durable hydrophilic core wrap” by Ponomarenko and Schmidt.
  • the nonwoven web surface can be pre-treated with high energy treatment (corona, plasma) prior to application of nanoparticle coatings.
  • High energy pre-treatment typically temporarily increases the surface energy of a low surface energy surface (such as PP) and thus enables better wetting of a nonwoven by the nanoparticle dispersion in water.
  • a nonwoven also may include other types of surface coating.
  • the surface coating may include a fiber surface modifying agent that reduces surface friction and enhances tactile lubricity.
  • Preferred fiber surface modifying agents are described in U.S. Pat. Nos. 6,632,385 and 6,803,103; and U.S. Pat. App. Pub. No. 2006/0057921.
  • nonwovens forming the backsheet may be hydroenhanced or hydroengorged. Hydroenhanced/hydroengorged nonwovens are described in U.S. Pats. Nos. 6,632,385 and 6,803,103, and U.S. Pat. App. Pub. No. 2006/0057921, the disclosures of which are incorporated herein by reference.
  • the absorbent core generally may be disposed between the topsheet 18 and the backsheet 20 . It may include one or more layers, such as a first absorbent layer 60 and a second absorbent layer 62 .
  • the absorbent layers 60 , 62 may include respective substrates 64 , 72 , an absorbent particulate polymer material 66 , 74 disposed on substrates 64 , 72 , and a thermoplastic adhesive material 68 , 76 disposed on and/or within the absorbent particulate polymer material 66 , 74 and at least portions of the substrates 64 , 72 as an adhesive for immobilizing the absorbent particulate polymer material 66 , 74 on the substrates 64 , 65 .
  • the substrate 64 of the first absorbent layer 60 may be referred to as a dusting layer and has a first surface which faces the backsheet 20 and a second surface which faces the absorbent particulate polymer material 66 .
  • the substrate 72 of the second absorbent layer 62 may be referred to as a core cover and has a first surface facing the topsheet 18 and a second surface facing the absorbent particulate polymer material 74 .
  • the first and second substrates 64 and 72 may be adhered to one another with adhesive about the periphery to form an envelope about the absorbent particulate polymer materials 66 and 74 to hold the absorbent particulate polymer material 66 and 74 within the absorbent core 14 .
  • the substrates 64 , 72 may be of one or more nonwoven materials, and may be liquid permeable.
  • the absorbent particulate polymer material 66 , 74 may be deposited on the respective substrates 64 , 72 in clusters 90 of particles to form a grid pattern comprising land areas 94 and junction areas 96 between the land areas 94 .
  • Land areas 94 are areas where the thermoplastic adhesive material does not contact the nonwoven substrate or the auxiliary adhesive directly; junction areas 96 are areas where the thermoplastic adhesive material does contact the nonwoven substrate or the auxiliary adhesive directly.
  • the junction areas 96 in the grid pattern contain little or no absorbent particulate polymer material 66 and 74 .
  • the land areas 94 and junction areas 96 can have a variety of shapes including, but not limited to, circular, oval, square, rectangular, triangular, and the like.
  • First and second layers 60 , 62 may be combined to form the absorbent core 14 .
  • the foregoing description describes features of an absorbent article, any combination of which can be employed to enhance consumer perceptions of softness of the article.
  • a nonwoven web according to the present invention and using it as a component of an absorbent article including, e.g., a topsheet 18 and/or backsheet 20 (see FIGS. 2A , 2 B), according to the following description, provides for enhancement of loft of the component, and has synergistic effects with respect to enhancing perceptions of softness of the article as a whole.
  • nonwoven web may enhance tensile strength of the nonwoven web, and consequently, of the topsheet, backsheet or other component formed of it.
  • preserving or enhancing tensile strength of a nonwoven may be of particular interest in absorbent articles for at least two reasons.
  • the nonwoven web may typically be required to sustain certain minimum tensile forces and undergo sufficiently low changes in dimension so as to be effectively processable in downstream manufacturing operations.
  • the nonwoven web typically may be a substantial contributor to structural integrity of a backsheet laminate in absorbent products such as disposable diapers, in which the backsheet may be required to sustain forces resulting from application/donning on a wearer (e.g., when a caregiver tugs on fastening members to apply a diaper), wearer movements, and weight and bulk contained and sustained by the backsheet when the diaper is loaded with the wearer's exudates.
  • a backsheet 20 may be formed of a laminate of a nonwoven 21 and a thin polymeric film 23 .
  • the nonwoven and film may be bonded in the laminating process by adhesive or any other suitable means.
  • the polymeric film may have a thickness of about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils).
  • the opacity and whiteness of the backsheet laminate may be enhanced by addition of, for example, calcium carbonate (CaCO 3 ) to the film during its formation.
  • Inclusion of fine particles of CaCO 3 cause the formation of micropores about the particles upon stretching, or biaxial stretching in processing of the film, which serve to make the resulting film air- and vapor-permeable (thus, “breathable”, reducing the likelihood of skin overhydration and thereby reducing the likelihood of conditions such as diaper rash).
  • the CaCO 3 particles and the resulting micropores in the film also serve to enhance its opacity.
  • a nonwoven according to the present invention may be formed from one or more resins of polyolefins, polyesters, polyamide including but not limited to polypropylene (PP), polyethylene (PE), and polyethylene terephthalate (PET), poly-lactic acid (PLA), and blends thereof.
  • Resins including polypropylene may be particularly useful because of polypropylene's relatively low cost and surface friction properties of fibers formed from it (i.e., they have a relatively smooth, slippery tactile feel).
  • Resins including polyethylene may also be desirable because of polyethylene's relative softness/pliability and even more smooth/slippery surface friction properties.
  • Nonwoven web fibers may be formed of PP/PE blends such as described in U.S. Pat. No. 5,266,392.
  • Nonwoven fibers may be formed of, or may include as additives or modifiers, components such as aliphatic polyesters, thermoplastic polysaccharides, or other biopolymers.
  • the individual fibers may be monocomponent or multicomponent.
  • the multicomponent fibers may be bicomponent, such as in a core-and-sheath or side-by-side arrangement.
  • the individual components comprise aliphatic polyolefins such as polypropylene or polyethylene, or their copolymers, aliphatic polyesters, thermoplastic polysaccharides or other biopolymers.
  • a batt may be formed from any of these resins by conventional methods, such as carding, meltblowing, spunlaying, airlaying, wet-laying etc.
  • a batt comprises individual fibers, which are usually unbonded to each other, although a certain amount of pre-bonding between fibers may be performed and is also included in the meaning, such as may occur during or shortly after the lay-down of fibers in a spunlaying process, or as may be achieved be a pre-calendering. This pre-bonding, however, still permits a substantial number of the fibers to be freely moveable such that they can be repositioned.
  • a batt may comprise several strata, such as may result from depositing fibers from several beams in a spunlaying process.
  • a preferred execution relates to spunlaying processes, in which the resin(s) are heated and forced under pressure through spinnerets.
  • the spinnerets eject fibers of the polymer(s), which are then directed onto a moving belt; as they strike the moving belt they may be laid down in somewhat random orientations, but often with a machine-direction orientation or bias, to form a spunlaid batt.
  • the batt then may be calender-bonded to form the nonwoven web.
  • Nonwovens formed of any basis weight may be produced. However, as noted in the background, relatively higher basis weight, while having relatively greater apparent caliper and loft, also has relatively greater cost. On the other hand, relatively lower basis weight, while having relatively lower cost, adds to the difficulty of providing a backsheet that has and sustains a dramatic visual 3-dimensional appearance following compression in a package, and has suitable mechanical properties. It is believed that the combination of features described herein strikes a good balance between controlling material costs while providing a dramatic visual 3-dimensional appearance and suitable mechanical properties. It is believed that the features of consolidating bond shapes and patterns described herein may be particularly useful in applications of nonwovens of relatively low basis weights in some applications, in that it is believed that such features provide a way to enhance loft while reducing, or at least without adding, basis weight.
  • a nonwoven having a basis weight from 6.0 to 50 gsm, more preferably from 8.0 to 35 gsm, even more preferably from 9.0 to 25 gsm, and still more preferably from 10 to 20 gsm may be used.
  • a lower basis weight nonwoven may provide strikethrough superior to that of a higher basis weight nonwoven.
  • a lower basis weight nonwoven may be preferable to a higher basis weight one when used, for example, as a component of a zero-strain stretch laminate, because it will be more accommodating of an activation/incremental stretching process.
  • the desired overall visual softness signals of a backsheet laminate may be better achieved when the backsheet laminate is substantially white in color, and has an Opacity of at least 45%, more preferably at least 70%, even more preferably at least 73%, and still more preferably at least 75%, as measured by the Opacity Measurement Method set forth below. Accordingly, it may be desirable to add a white-tinting/opacifying agent also to the polymer(s) forming the polymeric film, and to the polymer(s) supplying the spinnerets used to form the fibers of the nonwoven web.
  • a white-tinting/opacifying agent be added to the polymer resin that is spun to make the nonwoven. Adjusting the opacity of the nonwoven web, through addition of an opacifying agent, may be desirable, such that the nonwoven web has an Opacity of at least 10%, more preferably at least 18%, and still more preferably at least 40%.
  • TiO 2 titanium dioxide
  • TiO 2 is a relatively hard, abrasive material
  • inclusion of TiO 2 in amounts greater than 5.0% by weight may have deleterious effects, including wear and/or clogging of spinnerets; interruption and weakening of the structure of the fibers and/or calender bonds therebetween; undesirably increasing the surface friction properties of the fibers (resulting in a less smooth tactile feel); and unacceptably rapid wear of downstream processing equipment components. It is believed that the increased opacity provided by whitener helps to produce a visually distinctive, soft appearance of the nonwoven. It also may be desired in some applications that a coloring or tinting agent be added to one or more the polymer resin(s) from which the nonwoven fibers will be spun.
  • Opacity can also be enhanced by using fiber having cross-sectional shapes other than round and solid (non-hollow) geometries, namely trilobal or multilobal cross-sections, or hollow configurations or combinations thereof.
  • Those non-circular cross-sectional shapes can also provide advantages in terms of loft and compression resilience.
  • Spunbonding includes the step of calender-bonding the batt of spunlaid fibers, to consolidate them and bond them together to some extent to create the web as a fabric-like structure and enhance mechanical properties e.g., tensile strength, which may be desirable so the material can sufficiently maintain structural integrity and dimensional stability in subsequent manufacturing processes, and in the final product in use.
  • calender-bonding may be accomplished by passing the batt 21 a through the nip between a pair of rotating calender rollers 50 , 51 , thereby compressing and consolidating the fibers to form a nonwoven web 21 .
  • rollers may be heated, so as to promote heating, plastic deformation, intermeshing and/or thermal bonding/fusion between superimposed fibers compressed at the nip.
  • the rollers may form operable components of a bonding mechanism in which they are urged together by a controllable amount of force, so as to exert the desired compressing force/pressure at the nip.
  • an ultrasonic energy source may be included in the bonding mechanism so as to transmit ultrasonic vibration to the fibers, again, to generate heat energy within them and enhance bonding.
  • One or both of the rollers may have their circumferential surfaces machined, etched, engraved or otherwise formed to have thereon a bonding pattern of bonding protrusions and recessed areas, so that bonding pressure exerted on the batt at the nip is concentrated at the bonding surfaces of the bonding protrusions, and is reduced or substantially eliminated at the recessed areas.
  • the bonding surfaces have bonding surface shapes.
  • roller 51 may have a smooth, unpatterned cylindrical surface so as to constitute an anvil roller, and the other roller 50 may be formed with a pattern as described, to constitute a bonding pattern roller; this combination of rollers will impart a pattern on the web reflecting the pattern on the bonding pattern roller.
  • both rollers may be formed with patterns, and in particular examples, differing patterns that work in combination to impress a combination pattern on the web such as described in, for example, U.S. Pat. No. 5,370,764.
  • a repeating pattern of bonding protrusions and recessed areas such as, for example, depicted in FIG. 4 , may be formed onto a bonding roller 50 ( FIG. 3 ).
  • the rod-shaped bonding shapes 100 depicted in FIG. 4 depict raised surfaces of bonding protrusions on a roller, while the areas between them represent recessed areas 101 .
  • the bonding shapes 100 of the bonding protrusions impress like-shaped bond impressions on the web in the calendering process.
  • the bonding protrusions on a roller will have a height, which may be expressed as a difference between the radius of the roller at the outermost (bonding) surfaces of the bonding protrusions, and the radius of the roller at the recessed areas 101 .
  • the height may be adjusted with the objective of minimizing the amount of material that must be removed from the roller surface by machining or etching to create the desired shapes and pattern, while still providing for sufficient clearance between the roller bearing the bonding protrusions and the opposing roller, at the recessed areas 101 , to accommodate passage of the batt through the nip in areas of the batt not to be bonded (i.e., at the recessed areas), without substantially compressing it—because maximum loft/caliper is the objective.
  • a bonding protrusion height between 0.3 mm and 1.0 mm may be desired, or more preferably, a bonding protrusion height between 0.5 mm and 0.8 mm, or even a bonding protrusion height between 0.6 mm and 0.7 mm.
  • the bonding surfaces of the bonding protrusions may have an average area between 0.3 mm 2 and 10 mm 2 .
  • the bonding protrusions typically have sides with an angled slope when viewed in cross section through the height thereof.
  • Nonwoven webs of the type contemplated herein may be calender-bonded at line speed greater than 300 m/min., or 600 m/min., or even 800 m/min., or more, depending upon nonwoven web composition, basis weight, bonding pattern, and equipment and process variables selected. Referring again to FIG. 3 , it will be appreciated that at such speeds, the batt 21 a and the surfaces of rollers 50 , 51 will entrain surrounding air and move it toward the nip 52 , as suggested by the arrows. Surface features of a bonding roller 50 , as described above, will enhance this effect.
  • patterns of bonding protrusions having bonding surface shapes with certain features, reflected in the bonding surfaces and the cross sections of the protrusions along planes substantially parallel with the bonding surfaces, rotational orientations relative the plane approximated by the web surface, and spacing may be employed to channel these air flows in a way that causes them to reposition the fibers during the calender bonding process, such as by teasing or fluffing the fibers, thus providing an enhanced calender-bonded nonwoven web having greater loft/caliper than a similar nonwoven web having other consolidated bond shapes and patterns, all other variables being the same.
  • FIGS. 5A , 5 B and 5 C depict one example of a bonding pattern and bonding shapes that will be reflected in bond shapes of bond impressions in a nonwoven web.
  • Bonding shapes 100 represent the shapes of bonding surfaces of bonding protrusions that may be imparted to a bonding roller by etching, machining or other methods. Such bonding protrusions on a bonding roller will impress bond impressions into a web, of like bond shapes, arranged in a like bonding pattern. Without intending to be bound by theory, it is believed that certain aspects and features of the depicted shapes and pattern may have the beneficial effect described above.
  • the bonding shape 100 has a greatest measurable length L, which is measured by identifying a shape length line 104 intersecting the perimeter of the shape at points of intersection that are the greatest distance apart that may be identified on the perimeter, i.e., the distance between the two farthest-most points on the perimeter.
  • the bonding shape 100 has a greatest measurable width W which is measured by identifying respective shape width lines 105 a , 105 b which are parallel to shape length line 104 and tangent to the shape perimeter at one or more outermost points that are most distant from shape length line 104 on either side of it, as reflected in FIG. 5 b .
  • a bonding shape 100 may have a shape perimeter with a convex portion 102 , lying on one side of the shape length line 104 .
  • FIG. 5B shows also that the convex portion may have a varying radius or radii.
  • the varying radius/radii of the convex portion 102 may render the shape perimeter similar to the profile of the camber of an airfoil in cross section.
  • the cross-sectional profile of an airfoil has a convex portion and is asymmetric about any line or axis that traverses the profile, which can be identified.
  • the convex portion 102 may have a camber height CH measured as the distance between shape length line 104 and the shape width line 105 b that is tangent to the convex portion 102 . It is believed that, for maximum beneficial impact on airflow, it may be desirable that the ratio between camber height CH and greatest measurable length L be 0.30 or less, more preferably 0.25 or less, but greater than zero. It is believed that a bonding protrusion having a cross section along a plane parallel the bonding surface, fitting this description, repeated and arranged in a pattern, has beneficial effects on acceleration and deceleration of air through nonwoven fibers at and about the nip. Again, the bond shapes and sizes impressed on the nonwoven web will reflect and correspond with the bonding shapes and sizes on the roller.
  • the shape perimeter may have a convex portion with or without a varying radius on both sides of shape length line 104 , such that it has the overall contour of an airfoil with symmetrical camber, in cross section.
  • the shape perimeter may have a convex portion on one side of shape length line 104 and a straight portion on or on the other side of shape length line 104 , such that it has the overall contour of an airfoil/aircraft wing with asymmetrical camber, in cross section.
  • the shape perimeter may have a convex portion on one side of shape length line 104 and a concave portion 103 , disposed substantially opposite the concave portion, as reflected in FIG. 5B , such that it has the overall contour of an airfoil/aircraft wing with asymmetrical camber and relatively high-loft, low-speed features, in cross section.
  • the extent of the concavity of concave portion 103 may be quantified by measuring the depth thereof, relative the greatest measurable length.
  • the concavity depth D may be measured by identifying a shape concavity line 106 that is parallel with the shape length line 104 and tangent to the deepest point along the concave portion 103 .
  • the concavity depth D is the distance between the shape width line 105 a facing the concavity and the shape concavity line 106 .
  • the extent of the concavity of concave portion 103 may be expressed as a ratio of concavity depth D to shape length L (hereinafter, “concavity depth ratio”).
  • a bonding shape has a concave portion having a concavity depth ratio between 0.00 and 0.30, more preferably between 0.00 and 0.25, and even more preferably between 0.00 and 0.20. Again, the bond shapes and sizes impressed on the nonwoven web will reflect and correspond with the bonding shapes and sizes on the roller.
  • each of the terms “convex” and “concave” herein includes a portion of a shape perimeter formed of a chain of 5 or more straight line segments lying on one side of a shape length line and connected end-to-end, that is each a chord of a smooth convex or concave curve lying on one side of the shape length line, or portion of a curve lying on one side of the shape length line that does not include an inflection point.
  • calender roller bonding protrusions having bonding shapes with one or more features as described above have aerodynamic effects on air flow in and about the nip, that cause acceleration and deceleration of air in and about the interstices of the nonwoven fibers in a way that repositions the fibers, and may effect teasing or fluffing, adding loft and caliper.
  • the rotational orientations of the protrusions affect the orientations of the bonding protrusions at the nip, and it is believed that this has an impact.
  • Bonding shapes 100 and the bonding protrusions supporting them may be arranged along an individual shape tilt angle relative the machine and cross directions. Without intending to be bound by theory, it is believed that the shape tilt angle should not exceed a certain amount for the bonding protrusion to have maximum beneficial effect on air flow.
  • the shape tilt angle ⁇ T may be expressed as the smaller angle formed by the intersection of an axis along the machine direction 108 and the shape length line 104 . It is believed, that the shape and the shape tilt angle have cooperating effects on the air flow.
  • an asymmetric bonding shape such as the described airfoil-like shape
  • this asymmetric bonding shape is sufficient for effecting the desired changes in air flow.
  • a rotational orientation with a tilt angle of more than zero may enhance the effect.
  • the shape tilt angle ⁇ T provides the desired effects on air flow, such that it then should not be less than 1 degree and should not exceed 40 degrees, more preferably, 30 degrees, and still more preferably, 20 degrees. It is believed that a shape tilt angle within this range effectively provides air flow through the nip, while at the same time, imparts cross-direction vector components to air flows through the nip.
  • a shape tilt angle greater than 40 degrees may create too much of an obstruction to air flow through the nip to have a beneficial effect, and even greater shape tilt angles combined with sufficient density of bonding protrusions may have the effect of creating enough obstruction at the nip to substantially divert airflow from the nip, i.e., toward the sides of the bonding rollers, rather than through the nip.
  • the bond shapes and rotational orientations impressed on the nonwoven web will reflect and correspond with the bonding shapes and rotational orientations on the roller.
  • any process that tends to impart some added cross-direction orientation to the fibers prior to bonding may be useful for increasing cross direction tensile strength, bringing about better balance between machine direction tensile strength and cross-direction tensile strength, and adding loft such as by repositioning of the fibers in the z-direction. It is believed that, for best results, it may be even more desirable that shape tilt angle ⁇ T is between 5 degrees and 15 degrees, more preferably between 8 degrees and 12 degrees, and even more preferably between 9 degrees and 11 degrees, for the most beneficial effects on airflow at the line speeds contemplated herein.
  • the rotational orientation of the bonding pattern impressed on the nonwoven web will reflect and correspond with the rotational orientation of the bonding pattern on the roller.
  • a pattern of bonding protrusions not be excessively obstructive of air flow through the nip, nor that it remove too much energy from the air flow by overly slowing, or halting, and absorbing the energy from, forward (machine-direction) momentum of air flows.
  • a nip line 107 a along the cross direction is identified along a pattern where the bonding shapes occupy the greatest proportion of distance along a cross direction line that can be identified in a pattern.
  • nip line 107 a located as shown represents a cross-direction line along which bonding protrusions presented the greatest amount of obstruction that can be identified in a particular pattern, to air flow through the nip, during the bonding process.
  • a repeating series of shapes can be identified; in this example, the repeating series consists of the four shapes 100 a , 100 b , 100 c and 100 d .
  • Widths w 1 , w 2 , w 3 , and w 4 of the identified shapes 100 a , 100 b , 100 c , 100 d in the repeating series reflect restriction of air flow along the nip line 107 a .
  • Width w P is the width of the entire repeating series, including the distances between the bonding shapes.
  • the proportion of maximum restriction along the nip length for the pattern is reflected by the ratio (w 1 +w 2 +w 3 +w 4 . . . +w n )/w P , referred to herein as the nip airflow restriction ratio (where “w” is the cross-direction width along the nip line 107 a of a bonding shape perimeter, and “n” is the number of bonding shapes along nip line 107 a that make up a repeating series).
  • the nip airflow restriction ratio be 0.40 or less, more preferably 0.30 or less, and even more preferably 0.25 or less.
  • the bond shapes, rotational orientations and density/numerosity per unit surface area of bond impressions on the nonwoven web will reflect and correspond with the bonding shapes, rotational orientations and density/numerosity per unit surface area of bonding protrusions on the roller, and thus, also reflect the airflow restriction ratio.
  • the repeated bonding shape 100 and profile of the associated bonding protrusion is a composite of a pair generally convex/concave sub-shapes joined or superimposed at their respective tips, in reversed orientation, to form an open “S” shape which is rotationally symmetric about this juncture of the component sub-shapes, respectively its middle inflection point.
  • the depicted repeated “S” shape may have several of the features of the bonding shape depicted in FIGS. 5A and 5B , described above, which are believed to be beneficial.
  • bonding shapes 100 within the scope of the present invention have an aspect ratio of greatest measurable length L to greatest measurable width W of at least 2.5, more preferably at least 2.7, and even more preferably at least 2.8.
  • the depicted bonding shape in FIGS. 6A and 6B also has convex portions 102 a , 102 b along its perimeter.
  • One or both of the convex portions 102 a , 102 b may have varying radii, and have camber heights CH A and CH B . It is believed that, for maximum beneficial impact on airflow, it may be desirable that the ratio between camber height CH and the greatest measurable length L also be 0.30 or less, more preferably 0.25 or less, but greater than zero.
  • pattern angle ⁇ P may be expressed as the smaller angle formed by the intersection of a line connecting like points on repeating, similarly oriented shapes in columns 112 , and a machine direction axis.
  • pattern angle ⁇ P it may be desirable that pattern angle ⁇ P be greater than 0 degrees.
  • a pattern angle greater than 0 degrees will ensure that an indefinitely long machine direction strip of web without bonds will not exist.
  • the features described above apply to the shapes of bonding surfaces of bonding protrusions in a pattern on a bonding roller, and it will be understood that these features are impressed by the roller into the nonwoven batt to form bond impressions having bond shapes and bonds thereat, to form the calender-bonded nonwoven web.
  • the bonding shapes are reflected as bond shapes, and are identifiable, and measurable in the web, in laminates that include such nonwoven web as a composite layer, and in composite products made from such nonwoven web and/or such laminates.
  • bonding area of a roller Imagining a pattern of bonding surfaces having shapes reflected in FIGS. 5A and 6A impressed on a surface of a nonwoven web, bonding area and bond area is the area occupied by the bonding shapes on the roller and bond shapes impressed on the surface of the web. In the field of nonwoven web manufacturing, bonding area is often expressed as a percentage, calculated as:
  • Bonding area [(bonding area within a surface area unit)/(total surface area of the surface area unit)]*100%.
  • bonding area should be in the range of 4.0% and 18%, more preferably between 6% and 16%, and even more preferably between about 8% and 14%.
  • the average surface area per bonding shape affects bonding area and bonding protrusion density.
  • the speed of travel of the batt toward the bonding nip is important. It will be appreciated that, if the batt line speed is too slow, air mass entrained by the batt as it approaches the nip will not have sufficient linear momentum to maintain a large enough zone of sufficiently elevated air pressure at the entry side effective to ensure that substantial air mass is urged through the nip, rather than being merely urged around the nip and the rollers along alternate pathways. Accordingly, it is believed that line speed at which the batt is conveyed toward the nip should be equal to or greater than 300 meters/minute, more preferably, equal to or greater than 600 meters/minute, and even more preferably, equal to or greater than 800 meters/minute.
  • the batt was produced from 3 following spunbond beams on REICOFIL 4 technology, using the four different bonding patterns:
  • a patterned calender is used consisting of a pair of heated rollers, where one roller has raised comparative pattern “Standard” ( FIG. 4B ).
  • the temperature of the calender rollers is 170° C./173° C. and the pressure is 95 N/mm.
  • a patterned calender is used consisting of a pair of heated rollers, where one roller has raised comparative pattern “Standard” ( FIG. 4B ).
  • the temperature of the calender rollers is 170° C./173° C. and the pressure is 95 N/mm.
  • a 15 gsm spunmelt type nonwoven batt produced using a continuous online process from polypropylene (HH 450 FB from Borelais) and polylactic acid (Ingeo 6202D from NatureWorks), where first the bicomponent core/sheath type filaments are produced, where the core representing 80% is from polylactic acid and the sheath is from polypropylene.
  • the individual filaments a fibre diameter of 10-20 ⁇ m are collected on a moving belt.
  • the batt was produced on REICOFIL 3 technology from 1 beam.
  • a patterned calender is used, that consist of a pair of heated rollers, where one roller has raised comparative pattern “Standard” ( FIG. 4B ).
  • the temperature of the calender rollers is 140° C./140° C. and the pressure is 75 N/mm.
  • the 15 gsm spunmelt type nonwoven batt produced online in a continuous process from a mixture of polypropylene (Mosten NB425 from Unipetrol) and copolymer (Vistamaxx 6102 from Exxon) in the weight ratio 81:19, where monocomponent polypropylene filaments with a fibre diameter of 15-25 ⁇ m are produced and subsequently collected on a moving belt.
  • the batt was produced on REICOFIL 3 technology from 2 beams.
  • a patterned calender consisting of a pair of heated rollers, where one roller has raised comparative pattern “Standard” ( FIG. 4B ).
  • the temperature of the calender rollers is 145° C./145° C. and the pressure is 75 N/mm.
  • a patterned calender consisting of a pair of heated rollers, where one roller has raised pattern “S-shape” according to the invention ( FIG. 6 ).
  • the temperature of the calender rollers is 165° C./168° C. and the pressure is 75 N/mm.
  • a patterned calender consisting of a pair of heated rollers, where one roller has raised pattern “S-shape” according to the invention ( FIG. 6 ).
  • the temperature of the calender rollers is 165° C./168° C. and the pressure is 75 N/mm.
  • a patterned calender consisting of a pair of heated rollers, where one roller has raised pattern “S-shape” according to the invention ( FIG. 6 ).
  • the temperature of the calender rollers is 168° C./171° C. and the pressure is 75 N/mm.
  • a patterned calender consisting of a pair of heated rollers, where one roller has raised pattern “S-shape” according to the invention ( FIG. 6 ).
  • the temperature of the calender rollers is 168° C./171° C. and the pressure is 75 N/mm.
  • the strengthened nonwoven web is then subsequently impregnated with a hydrophilic surfactant (Silastol PHP 90 from Schill and Seilacher) using a dip roller (kiss-roll) and dried.
  • a hydrophilic surfactant Silastol PHP 90 from Schill and Seilacher
  • the extra weight of the surfactant in dry form is approximately 0.4%.
  • a patterned calender consisting of a pair of heated rollers, where one roller has raised pattern “S-shape” according to the invention ( FIG. 6 ).
  • the temperature of the calender rollers is 168° C./171° C. and the pressure is 75 N/mm.
  • a patterned calender is used consisting of a pair of heated rollers, where one roller has raised pattern “S-shape” according to the invention ( FIG. 5 ).
  • the temperature of the calender rollers is 165° C./168° C. and the pressure is 75 N/mm.
  • a patterned calender consisting of a pair of heated rollers, where one roller has raised pattern “wing-shape” according to the invention ( FIG. 5 ).
  • the temperature of the calender rollers is 168° C./171° C. and the pressure is 75 N/mm.
  • the strengthened nonwoven web is then subsequently impregnated with a hydrophilic surfactant (Silastol PHP 90 from Schill and Seilacher) using a dip roller (kiss-roll) and dried.
  • a hydrophilic surfactant Silastol PHP 90 from Schill and Seilacher
  • the extra weight of the surfactant in dry form is approximately 0.4%.
  • a 25 gsm spunmelt type nonwoven batt produced using a continuous online process from polypropylene (Mosten NB425 from Unipetrol) and polyethylene (Liten LS87 from Unipetrol), where first the bicomponent side/side type filaments are produced, where the one side representing 50% is from polyethylene and the second side is from polypropylene.
  • the individual filaments with a fibre diameter of 15-25 ⁇ m are collected on a moving belt.
  • the batt was produced from two beams REICOFIL 3 technology.
  • a patterned calender is used, that consist of a pair of heated rollers, where one roller has raised pattern “S-shape v2” ( FIG. 7 ).
  • the temperature of the calender rollers is 152° C./142° C. and the pressure is 60 N/mm.
  • the batt was produced from two beams on REICOFIL 3 technology.
  • a patterned calender is used consisting of a pair of heated rollers, where one roller has raised pattern “S-shape v2” according to the invention ( FIG. 7 ).
  • the temperature of the calender rollers is 150° C./145° C. and the pressure is 70 N/mm.
  • the individual filaments a with a fibre diameter of 15-25 ⁇ m are collected on a moving belt.
  • the batt was produced from two beams on REICOFIL 3 technology.
  • a patterned calender is used, that consist of a pair of heated rollers, where one roller has raised pattern “S-shape v2” ( FIG. 7 ).
  • the temperature of the calender rollers is 158° C./155° C. and the pressure is 70 N/mm.
  • the “thickness” of a nonwoven web is measured according to the European standard test EN ISO 9073-2:1995 (conforms to WSP 120.6) with following modification: the overall weight of upper arm of the machine including added weight is 130 g.
  • the “softness” of a nonwoven web may be measured using to the “Handle-O-Meter” test.
  • the test used herein is the INDA IST 90.3-01. The lower the value, the softer is the web.
  • volume mass is the ratio of basis weight and thickness and indicates the bulkiness and fluffiness of the product, which are important qualities of the nonwoven web according to the invention. The lower the value, the bulkier is the web.
  • volume mass[kg/m 3 ] basis weight[g/m 2 ]/thickness[mm].
  • the “hydrophilic properties” of a nonwoven web may be measured using the “Strike Through Time” test.
  • the test used herein is the EDANA standard test WSP 70.3-2005 The lower the value, the more hydrophilic is the web.
  • the “opacity” of a material is the degree to which light is blocked by that material. A higher opacity value indicates a higher degree of light block by the material.
  • Opacity may be measured using a 0° illumination/45° detection, circumferential optical geometry, spectrophotometer with a computer interface such as the HunterLab LabScan XE running Universal Software (available from Hunter Associates Laboratory Inc., Reston, Va.). Instrument calibration and measurements are made using the standard white and black calibration plates provided by the vendor. All testing is performed in a room maintained at about 23 ⁇ 2° C. and about 50 ⁇ 2% relative humidity.
  • the specimen lay the sample flat on a bench, body facing surface downward, and measure the total longitudinal length of the article. Note a site 33% of the total length from the front waist of the article along the longitudinal axis and a second site, 33% of the total length from the back waist of the article. Carefully remove the backsheet laminate, consisting of both the film and nonwoven web, from the garment-facing side of the article.
  • a cryogenic spray such as Cyto-Freeze (obtained from Control Company, Houston, Tex.), may be used to separate the backsheet laminate from the article. Cut a piece 50.8 mm by 50.8 mm centered at each site identified above. Precondition samples at about 23° C. ⁇ 2 C.° and about 50% ⁇ 2% relative humidity for 2 hours prior to testing.
  • Opacity Y value (black backing) /Y value (white backing) ⁇ 100
  • cryogenic spray can once again be employed. Precondition samples at about 23° C. ⁇ 2 C.° and about 50% ⁇ 2% relative humidity for 2 hours prior to testing. In like fashion, analyze the nonwoven web layer following the above procedure. Calculate and report the average opacity and standard deviation for the 10 nonwoven web measurements to the nearest 0.01%.
  • Samples of the subject nonwoven web that are 80 mm by 80 mm are used. Precondition the samples at about 23° C. ⁇ 2 C.° and about 50% ⁇ 2% relative humidity for 2 hours prior to testing. Identify the machine direction of the nonwoven web and draw a fine line on each sample along the machine direction to enable scanned images to be aligned.
  • a black backing is placed over the specimen and the lid to the scanner is closed.
  • FIGS. 5A through 6B are referenced to illustrate the following dimension measurements. These measurement methods are equally applicable to other bond shapes and repeating bond patterns.
  • the bond shape has a perimeter and a greatest measurable length. Identify a shape length line (e.g. line 104 ) which intersects the two farthest-most points along the perimeter. Draw a shape length line through these points. With the measuring tool, measure the length along the line segment between these points to the nearest 0.001 mm. For example, the greatest measurable lengths in FIGS. 5B and 6B are indicated at L, respectively measured along shape length lines 104 .
  • a shape length line e.g. line 104
  • the bond shape has a greatest measurable width measured along a direction perpendicular to the shape length line.
  • the measuring tool measure the greatest measurable width between the shape width lines along a line segment perpendicular to the shape length line to the nearest 0.001 mm.
  • the greatest measurable widths in FIGS. 5B and 6B are indicated at W, respectively measured between lines 105 a and 105 b perpendicular to shape length lines 104 .
  • the convex portion lies a maximum distance from the shape length line, referred to herein as the camber height.
  • the camber heights of the convex portions in FIGS. 5B and 6B are CH, and CH a and CH b , respectively.
  • the concave portion has a maximum distance from the facing shape width line.
  • the concavity depths of the concave portions in FIGS. 5B and 6B are D, and D a and D b , respectively.
  • the bond shape is rotationally oriented relative to the machine direction by shape tilt angle ⁇ T .
  • the angle between lines 108 and 104 in FIG. 5B is the shape tilt angle
  • the bond shapes may form a pattern that is tilted from the machine direction by the angle ⁇ P . Identify a repeating series of bond shapes in a column. Draw a column line that is tangent on one side at the same position on two similar shapes having similar rotational orientations in the column. Draw a line in the machine direction that intersects this column line at an angle, if such a line exists. With the angle measuring tool, measure the smaller angle between the column line and the machine direction line to the nearest 0.1 degree.
  • the bond shapes form a pattern that identifies a maximum airflow restriction by the corresponding bonding roller at the nip. Identify a repeating series of bond shapes lying in a row. Draw a line in the cross direction which intersects these bond shapes at the position relative the machine direction where the shapes occupy the greatest proportion of the distance along the cross direction line. It will be appreciated that it may be necessary to take measurements along several cross direction lines to empirically and/or iteratively identify the one along which the bond shapes occupy the greatest proportion of the distance. With the measuring tool, measure the length from the start of the repeating series to the corresponding location at the end of the repeating series (including distances between bonding shapes) to the nearest 0.001 mm. This is the repeat length in the cross direction.
  • the measuring tool measure each of the lengths of the line segments on the cross direction line that lie over the bond shapes, to the nearest 0.001 mm. Add the lengths of all of these line segments within the repeat length, and divide the total by the repeat length. Report to the nearest 0.001.
  • the repeat length w P is measured along the cross direction line 107 a .
  • the line segments lying over the bond shapes are w 1 through w 4 .
  • the airflow restriction ration is the sum of lengths w 1 through w 4 divided by the repeat length w P .
  • the bond pattern may provide an airflow path that has a machine direction vector component.
  • line 109 in FIGS. 5A and 109 in FIG. 6A are cross-nip airflow lines which intersects the cross direction line 107 to form the cross-nip airflow angle ⁇ A
  • Bond Area % (Sum of areas of bond shapes within repeat pattern)/(total area of repeat pattern) ⁇ 100%

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Outer Garments And Coats (AREA)
US14/006,534 2011-03-25 2012-03-23 Nonwoven webs with enhanced loft and process for forming such webs Abandoned US20140072767A1 (en)

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RU2587790C2 (ru) 2016-06-20
CN103459693A (zh) 2013-12-18
PE20141245A1 (es) 2014-09-29
CZ2011163A3 (cs) 2012-10-03
JP6148662B2 (ja) 2017-06-14
JP2014514465A (ja) 2014-06-19
EP2689058B1 (de) 2016-01-13
EP2689058A1 (de) 2014-01-29
ZA201309347B (en) 2014-07-30
WO2012130414A1 (en) 2012-10-04
RU2013147027A (ru) 2015-04-27
AR085540A1 (es) 2013-10-09
KR20140029417A (ko) 2014-03-10
MX2013011007A (es) 2014-03-27

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