WO1995017301A2 - Liquid permeable, quilted film laminates - Google Patents

Liquid permeable, quilted film laminates Download PDF

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Publication number
WO1995017301A2
WO1995017301A2 PCT/US1994/014403 US9414403W WO9517301A2 WO 1995017301 A2 WO1995017301 A2 WO 1995017301A2 US 9414403 W US9414403 W US 9414403W WO 9517301 A2 WO9517301 A2 WO 9517301A2
Authority
WO
WIPO (PCT)
Prior art keywords
film
film layer
layer
composite
quilted
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1994/014403
Other languages
English (en)
French (fr)
Other versions
WO1995017301A3 (en
Inventor
Gregory Alan Zelazoski
William Anthony Georger
Cheryl Anne Perkins
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Corp
Original Assignee
Kimberly Clark Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Corp filed Critical Kimberly Clark Corp
Priority to AU18664/95A priority Critical patent/AU1866495A/en
Publication of WO1995017301A2 publication Critical patent/WO1995017301A2/en
Publication of WO1995017301A3 publication Critical patent/WO1995017301A3/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers of the pads
    • A61F13/511—Topsheet, i.e. the permeable cover or layer facing the skin
    • A61F13/512—Topsheet, i.e. the permeable cover or layer facing the skin characterised by its apertures, e.g. perforations
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching
    • B32B2038/0028—Stretching, elongating
    • 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
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • 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
    • B32B2437/00—Clothing
    • 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 or 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
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y10T156/1064—Partial cutting [e.g., grooving or incising]
    • 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.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • 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.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24298—Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
    • Y10T428/24314—Slit or elongated
    • 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.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • 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.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component
    • 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.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24446—Wrinkled, creased, crinkled or creped
    • 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.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24826—Spot bonds connect components
    • 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
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]

Definitions

  • Figure 1 is a perspective view of a liquid permeable, quilted film laminate according to the present invention.
  • Figure 2 is a perspective view of a liquid permeable, quilted film laminate according to the present invention.
  • Figure 2 is a cross-sectional side view of a liquid permeable, quilted film laminate according to the present invention.
  • Figures 5 through 9 are examples of slit patterns which can be used for the film layer of the liquid permeable, quilted film laminate according to the present invention.
  • the present invention is directed to a quilted film laminate.
  • the laminate is designed to be liquid permeable thereby making it suitable for a wide variety of uses including, but not limited to, a liner material for personal care products including feminine pads or sanitary napkins, diapers, training pants, incontinence garments, bandages and the like.
  • the laminate could be used in the construction of meat and poultry pads, wipers and absorbents in general. Other applications would include fluid management materials for health care applications such as absorbents for use around the incise portion of surgical drapes. If made oleophilic, the laminate of the present invention could also be used in the construction of oil absorption materials.
  • the foregoing list of uses should be considered as illustrative only as other uses are also contemplated to be within the scope of the present invention.
  • the film layer 12 can be made from a number of polymers including homopolymers, copolymers and blends of polyolefins, acetate polymers, polyesters and the like.
  • the particular polymer selection can be influenced by the desire for particular attributes including strength, softness and opacity.
  • film thicknesses will typically range between about 0.4 and about 2.0 mils with 0.75 to 1 mils being more desirable. It should be noted, however, that larger or smaller film thicknesses are also contemplated to be within the scope of the present invention depending upon the end use.
  • opacifying agents may be added to the film.
  • the film layer 12 may be desirable to impart other properties or characteristics to the film layer 12.
  • other additives can be incorporated into the film layer 12 to impart such properties or characteristics.
  • the film layer 12 is provided with a plurality of slits 18.
  • the slits 18 are distinguishable from apertures in that when making the slits 18 in the film 12, little or no material is removed when cutting through the film layer.
  • a slit film unlike an apertured film, provides limited visibility through the slits when the film is flat.
  • the slits 13 are provided m pairs wnicn are generally parallel to one another. By “generally parallel” it is meant that the intersection of the axes of the slits forms an interior angle which is less than or equal to 45°.
  • the pairs of slits 18 are provided in staggered rows with the axes of all these slits and pairs of slits being generally parallel to one another due to their alignment in the same general direction.
  • the pairs of slits 18 are provided in a herringbone design.
  • FIG. 5 there is shown a plurality of slits 18 which have an alternating perpendicular pattern. In such a configuration there are a plurality of pairs of slits 18a, 18b and 18a', 18b' which are generally parallel to one another yet separated by intervening slits.
  • a particularly well-suited spunbonded nonwoven web for the substrate layer 14 is made from side-by-side polyethylene/polypropylene spunbond bicomponent fibers.
  • the process for forming such fibers and resultant webs includes using a pair of extruders for separately supplying both the polyethylene and the polypropylene to a bicomponent spinneret.
  • Spinnerets for producing bicomponent fibers are well known in the art and thus are not described in detail herein.
  • the spinneret includes a housing containing a spin pack which includes a plurality of plates having a pattern of openings arranged to create flow paths for directing the high melting and low melting polymers to each fiber-forming opening in the spinneret.
  • the drawn and crimped fibers are deposited onto a continuous forming surface in a random manner, generally assisted by a vacuum device placed underneath the forming surface.
  • the purpose of the vacuum is to eliminate the undesirable scattering of the fibers and to guide the fibers onto the forming surface to form a uniform unbonded web of bicomponent fibers.
  • the resultant web can be lightly compressed by a compression roller before the web is subjected to a bonding process.
  • a through-air bonder is used to bond the bicomponent spunbonded web.
  • Such through-air bonders are well known in the art and therefore need not be described in detail.
  • a flow of heated air is applied through the web to heat the web to a temperature above the melting point of the lower melting point component of the bicomponent fibers but below the melting point of the higher melting point component.
  • the lower melting polymer portion of the web fibers are melted and the melted portions of the fibers adhere to adjacent fibers at the cross-over points while the high melting polymer portions of the fibers tend to maintain the physical and dimensional integrity of the web.
  • Fiber sizes for the fibers making up the fibrous nonwoven webs can be relatively uniform or can be a mixture of various sizes of fibers.
  • fiber diameters in the range of about 5 to about 150 microns can be used. It is possible, however, to utilize fiber sizes ranging from submicron to several hundred microns depending upon the particular end use application.
  • basis weight The nature of the end use will also bear upon the basis weight. of the nonwoven, however, here again the basis weight must be sufficiently great to allow expansion and retraction of the nonwoven substrate layer if gathering or puckering is not being caused solely by the use of a heat-shrinkable material.
  • basis weights oetween about 0.3 and 2.2 ounces per square yard (osy) (about 14 and about 75 grams per square meter (gsm) will work for personal care product applications.
  • a third method of imparting gathers or puckers to the composite 10 involves stretching one of the layers and bonding it to the other layer with the other layer being made from a heat shrinkable material. Once the two layers are bonded, the tension in the stretched layer can be relaxed and heat can be applied to the composite thereby providing two means within the same composite for creating gathers or puckers. If desired, the direction of orientation of the heat shrinkable material can be parallel with or skewed from the direction of stretching in the other layer to provide gathering or puckering in one or more directions.
  • a fifth way to impart gathers or puckers to the material of the present invention would be to use elastic threads sandwiched between and bonded to the film layer 12 and substrate layer 14.
  • the elastic threads would be stretched or elongated prior to their adhesion or bonding between and to the two layers. Once the bonding had been completed, the elastic threads would retract thereby gathering and puckering the composite material 10 of the present invention.
  • the degree of gathering or puckering of the composite 10 is due at least in part, to the degree of retraction of the composite.
  • the composite will have a first or original length which is greater than the second or extended length and a third or retracted length which will be less than the second length.
  • Factors affecting the retraction will include the degree or percent to which a material can be heat shrunk and/or the extent to which a particular layer can be extended and whether or not all or a portion of the extension forces can be regained upon release of the tension in the stretched layer.
  • Figure 10 depicts a process for forming a quilted film/fibrous nonwoven laminate using ultrasonic bonding techniques while Figure 11 utilizes heat and pressure.
  • a supply of nonwoven material 40 being unwound from a supply roll 42.
  • Unwound from a similar supply roll 44 is a supply of slit film 46 which has previously been slit.
  • the nonwoven or substrate layer 40 passes through a pair of controlled S-wrapped rollers 48 driven or braked at a speed V, so that the substrate layer is stretched in the machine direction.
  • the film layer 46 is sent through a series of spreader rolls 50 whose function is to maintain uniform width with minimal wrinkles.
  • the spreader rolls are traveling at a speed V 2 which is greater than V 1 .
  • the nonwoven layer 40 and the film layer 46 are brought into contact with one another between a pattern roll 52 and an ultrasonic horn 54 where the two layers are bonded to one another.
  • the speed of the nonwoven layer and the speed of the film layer are the same, V 2 .
  • the nonwoven layer is bonded to the film layer while the nonwoven substrate in a stretched condition with the degree of stretch being a function of the speed differential between V 1 and V 2 .
  • the composite 56 is allowed to retract thereby gathering and puckering the composite prior to its accumulation on take up roll 58.
  • Air permeability was measured using the Frazier porosity test. Air permeability is the rate of air flow through a material under a pressure differential between two fabric surfaces. Samples were tested on a Frazier Air Permeability Tester available from Frazier Precision Instrument Company of Gaithersburg, Maryland. The procedures used conformed to the specifications of Method 5450, Federal Test Methods Standard 191A except that the specimen size was 8 inches ⁇ 8 inches (20.3 ⁇ 20.3 cm) rather than 7 inches ⁇ 7 inches (17.8 ⁇ 17.8 cm). The larger size made it possible to ensure that all sides of the specimen extended well beyond the retaining ring and facilitated clamping of the specimen securely and evenly across the orifice. In the procedure, air was drawn through the specimen and a calibrated orifice using a suction fan.
  • the rate of air flow through the fabric was adjusted to obtain a pressure differential of 0.51 inches (13 mm) of water between the two surfaces.
  • the amount of air flowing through the specimen was determined from the drop in pressure across a calibrated orifice as indicated by a vertical oil manometer. This reading was converted to an air flow rate using a conversion table provided by the manufacturer of the instrument. The results were expressed in cubic feet of air per square foot of specimen per minute or in cubic centimeters per square centimeter per second. The higher the number, the more permeable or porous the material.
  • a trapezoid tear test was conducted. This test was a measure of the tearing strength of a material or materials when a constantly increasing load was applied parallel to the length of the specimen. The test can be conducted on a constant rate of extension tester such as an Instron, model TM available from Instron Corporation of Canton, Massachusetts or a Thwing-Albert, Model INTELLECT II tester available from Thwing-Albert Instrument Company of Philadelphia, Pennsylvania.
  • extension tester such as an Instron, model TM available from Instron Corporation of Canton, Massachusetts or a Thwing-Albert, Model INTELLECT II tester available from Thwing-Albert Instrument Company of Philadelphia, Pennsylvania.
  • the surface smoothness of a material is another important feature of a material if the material is to be used as a body contacting layer as is the case with the present material when used as a liner for a sanitary napkin.
  • the surface smoothness of the materials described herein was tested by measuring the coefficient of friction of the surface when contacted with a sensor plate drawn across the surface of the material. Values between materials were then compared to establish a relative scale for purposes of evaluation. Higher coefficients of friction corresponded to rougher surfaces.
  • a fluid run-off test was performed to measure the ability of a material to absorb a liquid.
  • a 3 inch by 7 inch sample of the material was placed at a 30° incline and 5cc of synthetic menstrual fluid was then applied to the surface over a 3 second period.
  • the amount of fluid which was not absorbed and therefore ran off the end of the sample was measured in grams. The lower the gram reading and thus the run-off, the higher was the degree of absorption of the material.
  • the adhesion level between the film layer and the substrate layer is also important.
  • an adhesion test was performed. For each sample, the cohesion force of a 1 inch square sample was measured using a Chatillon Digital Force Gauge Model DFI 50 from John Chatillon and Sons, Inc., of Greensboro, North Carolina. The device has a pneumatically operated base plate measuring 2 inches by 4 inches and a one inch square top plate vnicn was connected to a digital force gauge. Double-faced adhesive tape was applied to both the base plate and the top plate and a 2 inch by 4 inch sample of material was positioned cn top of the 2 inch by 4 inch base plate.
  • the spacing between slits in a pair was 0.035 inches (0.9 mm) and the spacing between each pair of slits lying along the same horizontal line or row was 0.145 inches (3.7 mm).
  • the pairs of slits were spaced 0.015 inches (0.4 mm) apart.
  • the film can be slit in line or ahead of time and then unrolled into the converting process.
  • the film had a slit density of 19 inches of slits per square inch (7.48 cm/cm 2 ) of film.
  • the substrate layer in Example I was a fibrous bicomponent spunbond web made in the manner described above. Fiber sizes ranged between 3 and 5 denier (21.9 and 28.2 microns) and the fibers due to the use of the spunbond process were essentially continuous in length. By “continuous” it is meant that the ratio of fiber length to width approached infinity.
  • the bicomponent fibers were a side-by-side construction using polyethylene and polypropylene.
  • the polyethylene was Grade 6811 from Dow Chemical, U.S.A. of Midland, Michigan and the polypropylene was Grade 3445 from Exxon Chemical Company of Darien, Connecticut. Basis weights ranged between 1 and 1.5 ounces per square yard (osy) (34-51 gsm) and the webs were through air bonded.
  • the nonwoven substrate layer was treated with Y12488 surfactant from Union Carbide of Tarrytown, New York. This is a non-ionic surfactant wetting packaging which references U.S. Patent No. 5,057,361.
  • the surfactant was added in spray form and the treated nonwoven web had an add on of 0.4 percent surfactant based upon the total dry weight of the nonwoven web.
  • the nonwoven layer Prior to bonding the two layers together, the nonwoven layer was stretched between 5 and 20 percent due to the speed differential of the rolls. See the process description above. As an example, a material that was originally 100 inches (254 cm) in length and which was then stretched to 120 incnes (305 cm) would be stretched 20 percent.
  • the film and substrate layers were point bonded to one another using conventional ultrasonic equipment from Branson Sonic Power Corp of Danbury, Connecticut using a model #501 series bonder.
  • the relative energy was 65 and the line speed at the point of bonding was 12 feet per minute (3.7 meters per minute).
  • Total bond area per unit area of material was eight percent with approximately 28 bond points per square inch (4.34 points/cm 2 ).
  • the gap setting between the horn and anvil was 0.010 inches (0.3 mm).
  • the nonwoven substrate layer was allowed to relax thereby causing the composite to gather or pucker which in turn caused a plurality of the slits to vertically open up and form paths for greater transmission of liquids through the composite.
  • the composite was then hand sprayed on the exposed film surface with the same surfactant used on the nonwoven layer at an add on level of 0.4 percent on a dry weight basis, based upon the total weight of the film.
  • the compositions of the samples are listed in Table I below.
  • One method of measuring the openness and thus the fluid handling properties of the composite 10 is by measuring the intake time for a given quantity of fluid.
  • the samples were tested for fluid intake time (8 cc), rewet (10 cc) and fluid run off (5 cc) using "Z-Date", a synthetic menstrual fluid containing, on a weight percent basis, approximately 82.5% water, 15.8% polyvinyl pyrrolidone and 1.7% salts, coloring agents and surfactants. It has a viscosity of 17 centipoise and a surface tension of 53.5 dynes per centimeter.
  • Table III As shown by the data in Table III below, intake rates for "Z-DATE" synthetic menstrual fluid were on the average less than 10 seconds. Once the synthetic menses had been absorbed, the rewet was less than 0.5 grams.
  • Caliper or bulk is a measure of the thickness of a material. While again depending upon the particular end use application, for personal care applications calipers of at least about 0.035 inches (0.15 mm) are desirable so as to prevent rewet of the film layer 12 by already absorbed exudate contained within the absorbent core of the personal care structure.
  • Example 2 four sample materials according to the present invention were prepared and compared against two controls.
  • the first control was a KOTEX ® Maxi Pad sanitary napkin manufactured by the assignee of record.
  • the napkin had a polypropylene spunbond nonwoven cover.
  • the second control was an ALWAYS ® sanitary napkin manufactured by the Procter and Gamble Company of Cincinnati, Ohio.
  • the ALWAYS ® sanitary napkin had an apertured film cover.
  • the film and substrate layers were bonded to one another using heat and pressure via a pair of patterned and anvil bond rolls.
  • the patterned roll was heated to 140°F (60°C) and the anvil roll was heated to 160°F (71oC).
  • the bond pressure at the nip was 20 pounds per square inch (6.8 kg/cm 2 ) and the two layers were bonded to one another at a rate of 10 feet per minute (3 m/min) using a point bond pattern with an overall bond area of 8%.
  • the exposed sides of the nonwoven and film layers were hand sprayed with a surfactant solution of Gemtex SM-33 surfactant from Finetex, Inc. of Elmwood Park, New Jersey at an add-on of 0.6% based on the weight of the composite.
  • Example 2 three samples according to the present invention were prepared all of which used the same substrate layer.
  • the substrate layer was made in the same fashion as Examples 1 and 2 using 5 denier polyethylene/polypropylene side-by-side bicomponent fibers.
  • the substrate layer had a basis weight of 1.5 ounces per square yard (51 gsm) and was treated with 0.4% of the same surfactant used in Example 1.
  • Example 4 the film and substrate layers used were the same as in Example 2. The difference between Example 4 and Example 2 was in the slit pattern used to slit the film layer.
  • Example 4 a herringbone design similar to that shown in Figure 2 was used. The herringbone design yielded an average slit length per square inch of 16.3 in/in 2 (6.4 cm/cm 2 ).
  • 10 grams per square meter of a 34-5541 hot-melt adhesive from the National Starch Company of Cincinnati, Ohio was applied in continuous spray pattern across the width of the nonwoven layer. Prior to bonding the two layers together, the film layer was stretched in the machine direction and the percent stretch was calculated to be 5%.
  • Example IV After forming the sample, it was hand-sprayed with 0.6%, based upon the dry weight of the composite, with Gemtex SM-33 surfactant on the exposed sides of the film and substrate layers. Fluid handling properties including bulk, intake and rewet rates were measured and are given below in Table VI below. Relative to the two controls, the sample in Example IV had a much better intake rate and far less rewet. In addition, there was no run-off of synthetic menses with the herringbone slit design. Lastly, it should be noted that the same good fluid handling properties were achieved using an adhesively laminated composite instead of a thermally laminated composite.

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  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Vascular Medicine (AREA)
  • Epidemiology (AREA)
  • Biomedical Technology (AREA)
  • Heart & Thoracic Surgery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Nonwoven Fabrics (AREA)
PCT/US1994/014403 1993-12-17 1994-12-16 Liquid permeable, quilted film laminates Ceased WO1995017301A2 (en)

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US08/169,479 1993-12-17

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FR (1) FR2713982B1 (cg-RX-API-DMAC7.html)
GB (1) GB2284786B (cg-RX-API-DMAC7.html)
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WO1995017301A3 (en) 1995-07-13
GB9425481D0 (en) 1995-02-15
GB2284786B (en) 1997-06-18
FR2713982B1 (fr) 1996-05-03
PH31526A (en) 1998-11-03
AU1866495A (en) 1995-07-10
TW275576B (cg-RX-API-DMAC7.html) 1996-05-11
GB2284786A (en) 1995-06-21
TR28306A (tr) 1996-04-17
CA2136675C (en) 2005-02-15
US5536555A (en) 1996-07-16
CA2136675A1 (en) 1995-06-18
ZA9410025B (en) 1995-08-22

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