WO2001074281A1 - Materiaux presentant des fibres et des plis en sens z et leur procede de production - Google Patents

Materiaux presentant des fibres et des plis en sens z et leur procede de production Download PDF

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Publication number
WO2001074281A1
WO2001074281A1 PCT/US2000/029754 US0029754W WO0174281A1 WO 2001074281 A1 WO2001074281 A1 WO 2001074281A1 US 0029754 W US0029754 W US 0029754W WO 0174281 A1 WO0174281 A1 WO 0174281A1
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WO
WIPO (PCT)
Prior art keywords
moving surface
ridges
configuration
fibers
web
Prior art date
Application number
PCT/US2000/029754
Other languages
English (en)
Inventor
Edward Jason White
Kurtis Lee Brown
John Herbert Conrad
Robert James Gerndt
Jose Enrique Maldonado
Original Assignee
Kimberly-Clark Worldwide, Inc.
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
Priority claimed from US09/538,744 external-priority patent/US6867156B1/en
Application filed by Kimberly-Clark Worldwide, Inc. filed Critical Kimberly-Clark Worldwide, Inc.
Priority to MXPA02009622A priority Critical patent/MXPA02009622A/es
Priority to AU2001212423A priority patent/AU2001212423A1/en
Publication of WO2001074281A1 publication Critical patent/WO2001074281A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • 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
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F13/15617—Making absorbent pads from fibres or pulverulent material with or without treatment of the fibres
    • A61F13/15634—Making fibrous pads between sheets or webs
    • 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
    • A61F13/53—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 absorbing medium
    • A61F13/534—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 absorbing medium having an inhomogeneous composition through the thickness of the pad
    • A61F13/537—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 absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer
    • A61F13/53708—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 absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer the layer having a promotional function on liquid propagation in at least one direction
    • A61F13/53713—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 absorbing medium having an inhomogeneous composition through the thickness of the pad characterised by a layer facilitating or inhibiting flow in one direction or plane, e.g. a wicking layer the layer having a promotional function on liquid propagation in at least one direction the layer having a promotional function on liquid propagation in the vertical direction
    • 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
    • A61F13/53—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 absorbing medium
    • A61F13/538—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 absorbing medium characterised by specific fibre orientation or weave
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • 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
    • A61F13/15577—Apparatus or processes for manufacturing
    • A61F2013/15821—Apparatus or processes for manufacturing characterized by the apparatus for manufacturing
    • A61F2013/15934—Apparatus or processes for manufacturing characterized by the apparatus for manufacturing for making non-woven
    • A61F2013/15959—Apparatus or processes for manufacturing characterized by the apparatus for manufacturing for making non-woven by spunbond technique
    • 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
    • A61F13/53—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 absorbing medium
    • A61F2013/530131—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 absorbing medium being made in fibre but being not pulp
    • A61F2013/530226—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 absorbing medium being made in fibre but being not pulp with polymeric fibres
    • 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
    • A61F13/53—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 absorbing medium
    • A61F13/538—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 absorbing medium characterised by specific fibre orientation or weave
    • A61F2013/5386—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 absorbing medium characterised by specific fibre orientation or weave by the fibre orientation in the z plane or vertical direction

Definitions

  • This invention relates to a method for producing materials, including films and nonwovens, having z-direction folds or ridges on at least one surface of the material.
  • This invention further relates to a lofty, nonwoven material produced from continuous fibers in which the lofty character of the nonwoven material is the result of the fibers comprising the web having a z-direction orientation, whereby a plurality of ridges or folds are formed on at least one surface of the nonwoven web.
  • These materials may be particularly suitable for use in a broad range of applications including fluid management (surge), air and liquid filtration, acoustic and thermal insulation, packing material, absorbents, and cleaning materials.
  • these materials may be suitable for use as surge, spacer layers, filtration materials and absorbent layers in personal care absorbent products including disposable diapers, incontinence garments, and feminine care products such as sanitary pads and napkins, and in face masks, surgical gowns, sterile wraps and surgical drapes.
  • Absorbent personal care articles such as sanitary pads and napkins, disposable diapers, incontinent-care pads and the like are widely used, and much effort has been made to improve their effectiveness and functionality.
  • These articles generally include a liquid absorbent material backed by a liquid-impervious barrier sheet.
  • the absorbent material has a facing of a material which masks at least the body- facing surface of the product.
  • the purpose of this cover material is to help structurally contain the absorbent material and to protect the wearer from continuous direct contact with moisture from previously wetted absorbent material.
  • the cover material is typically of relatively low basis weight nonwoven fabric.
  • the surge management material is made from a relatively high basis weight, low density, that is, thick, nonwoven web material.
  • nonwoven webs the fibers comprising the web are generally oriented in the x-y plane of the web and the resulting nonwoven web material is relatively thin, that is lacking in loft or significant thickness.
  • Loft or thickness in a nonwoven web suitable for use in personal care absorbent articles promotes comfort (softness) to the user, surge management and fluid distribution to adj acent layers.
  • the present invention does not first form a web of material and pleat it. Rather, fibers are looped on themselves without being first being formed into a material web. These fiber level loops, running from a first major surface of the web to a second major surface, are aggregated in the cross machine direction to form ridged structures herein sometimes called “waves” or “folds” to distinguish them from “pleats” which refer to structures in preformed web or mesh material that has been folded on itself.
  • a “wavelength” may generally be considered the transit of a loop between its successive trough points on one major surface of the web.
  • a method for producing a material having z-direction folds comprising conveying a substantially unformed and flat base material of substantially continuous fibers, and added materials if desired, on a first moving surface into a nip formed by the first moving surface and a second moving surface, the second moving surface traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction folds on at least one surface of the material.
  • the method of this invention conveys a material by means of a moving surface into a confined space (the nip) and removes it from the confined space by means of a second moving surface, whereby the rate of removal of the material from the confined space is slower than the rate of material input to the confined surface, resulting in formation of a nonwoven material having z-direction components.
  • the z-direction components produce ridges or ripples on both the major, or x-y surfaces of the material.
  • the extent of the ridges, and thus the character of the resulting material formed may be easily affected by a number of operatmg parameters including, but not limited to, the type of material being processed, geometry of the confined space, the means for transferring the material in the confined space from the first moving surface to the second moving surface, presence or lack of a binding agent such as an adhesive, and the relative speeds of the first and second moving surfaces.
  • the size of the confined space (nip) and the relative speeds of the moving surfaces are related with respect to the formation of a web having a desired density of folds. For example, for very low differential speeds between the two moving surfaces, the size of the nip will be very small. As the differential speeds increase, the size of the nip will also increase.
  • a material of this invention as produced with the method of this invention, comprises a nonwoven web with a plurality of substantially continuous fibers having a z-direction orientation and forming a plurality of folds or ridges on the major surfaces of the nonwoven web.
  • a lofty nonwoven web made with fibers looped on themselves, is made in a first configuration. This first configuration of the lofty web is made with regularly shaped ridges extending from the plane of the web in the z-direction, and occurring with regular pattern or periodicity in the machine (x-axis) or cross machine (y-axis) directions with the ridges lightly fixed in the first configuration.
  • the first configuration of the ridges is broken and reset to a second predetermined configuration such as by controlled stretching.
  • the ridges are then fixed in the second configuration, resulting in a new shape and periodicity of the ridges.
  • the second configuration thus has no adhered leading or trailing edges of the ridge waveform.
  • the second configuration is generally one which is unattainable through the process used to make the first configuration.
  • the material is particularly useful for filtration media or other fabric structures where a known ridge shape and periodicity is desired. This embodiment may also be utilized for control of the periodicity and pleat shape of a previously pleated web.
  • the present invention seeks to create, and utilize the advantages of, a lofty nonwoven web of continuous fibers having z-direction fibers but without discemable ridge structure which would lead to fluid channelization and other inherent characteristics of the ridge structure which may be undesirable for certain applications. Accordingly, among the objects of this embodiment is to provide a lofty nonwoven web material comprising substantially continuous fibers as opposed to staple fibers traditionally used in the manufacture of such nonwoven materials and to provide for producing nonwoven materials having z-direction portions with an undifferentiated mass of loops or pleats to create a web of material with no discemable ridge structure and no defined fluid channels.
  • a precursor material having differential basis weight is formed using a three dimensional forming surface, which may be a wire or a formed membrane. Bands of higher and lower basis weight are thus formed, preferably running in the cross direction and alternating in the machine direction for the precursor web.
  • the precursor material is then pleated, or folded, with the folds generally occurring along the borders between the higher and lower basis weight bands.
  • the resultant lofty web material may then have major surfaces in x-y planes of a first basis weight material and interstitial material between the major surfaces in the z-direction composed of a second and different basis weight material.
  • only one major surface may be higher basis weight material or, pleats of alternating high basis weight and low basis weight pleats may be produced in a single sheet.
  • the material is particularly useful for fabric structures where a known ridge shape and periodicity is desired.
  • Fig. 1 is a schematic diagram of the method of this invention for producing materials having z-direction components
  • Fig. 2 is a diagram of a-side view of a nonwoven web having z-direction components in the form of ridges or ripples formed in accordance with the method of this invention
  • Figs. 3 A and 3B are diagrammatic representations of a conventional nonwoven web and a high loft nonwoven web in accordance with this invention, respectively;
  • Fig. 4 is a schematic diagram of the method of this invention for producing materials having z-direction components for the second, or final, lofty web configuration
  • Fig. 5 is a photograph of a side view of a second nonwoven web according to the present invention having z-direction components without regular or discemable ridges as formed from side by side polymer, crimped fiber, base material;
  • Figs. 6 and 7 are schematic diagrams of a three dimensional forming surface for producing precursor materials having differential basis weight distributed in bands in the cross direction;
  • Fig. 8 is a diagram of a side view of one embodiment of the resultant lofty nonwoven web having z-direction components
  • Fig. 9 is a diagram of a side view of a second embodiment of the resultant lofty nonwoven web having z-direction components
  • Fig. 10 is a diagram of a side view of a third embodiment of the resultant lofty nonwoven web having z-direction components composed of intermixed higher and lower basis weight materials
  • Fig. 11 is a diagram of a side view of a third embodiment of the resultant lofty nonwoven web having z-direction components composed of alternating areas of higher and lower basis weight materials.
  • nonwoven web or “nonwoven material” means a web having a structure of individual fibers, filaments or threads which are interlaid, but not in a regular or identifiable manner such as those in a knitted fabric or films that have been fibrillated.
  • Nonwoven webs or materials have been formed from many processes such as, for example, meltblowing processes, spunbonding processes, and bonded carded web processes.
  • the basis weight of nonwoven webs or materials is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm), and the fiber diameters usable are usually expressed in microns. (Note that to convert from osy to gsm, multiply osy by 33.91.)
  • z-direction refers to fibers disposed outside of the plane of orientation of a web.
  • Fig. 3 A is a diagram showing a nonwoven web without z- direction fibers. That is, all of the fibers are generally oriented in the direction indicated by arrow 27.
  • Fig. 3B is a diagram showing a nonwoven web having z-direction fibers in accordance with this invention. That is, in addition to fibers oriented in the direction of arrow 28, fibers are also oriented in the direction of arrows 29 and 30.
  • formed z-direction fibers refers to fibers that become oriented in the z- direction during forming of the nonwoven web as distinguished from fibers having a z- direction component resulting from post-forming processing of the nonwoven web, such as in the case of mechanically crimped or creped nonwoven webs.
  • spuribond fibers refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinneret as taught, for example, by U.S. Patent 4,340,563 to Appel et al. and U.S. Patent 3,802,817 to Matsuki et al.
  • meltblown fibers refers to fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity gas streams (for example, airstreams) which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter.
  • gas streams for example, airstreams
  • microfibers refers to small diameter fibers having an average diameter not greater than about 75 microns, for example, having an average diameter of from about 0.5 microns to about 50 microns, or more particularly, having an average diameter of from about 2 microns to about 40 microns.
  • polymer generally includes, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” also includes all possible geometric configurations of the material. These configurations include, but are not limited to, isotactic, syndiotactic, atactic and random symmetries.
  • the term "personal care absorbent article” means disposable diapers, framing pants, absorbent underpants, adult incontinence products, feminine hygiene products and the like.
  • the term “homofilament” refers to a fiber formed from only one polymer. This is not meant to exclude fibers formed from one polymer to which small amounts of additives have been added for coloration, anti-static properties, lubrication, hydrophilicity, etc.
  • bicomponent fibers refers to fibers which have been formed from at least two polymers extruded from separate extruders but spun together to form one fiber. Bicomponent fibers are also sometimes referred to as conjugate fibers or multicomponent fibers. Bicomponent fibers are taught by U.S. Patent 5,382,400 to Pike et al.
  • the term "biconstituent fibers” refers to fibers which have been formed from at least two polymers extruded from the same extruder as a blend.
  • the term “blend” is defined below. Biconstituent fibers are sometimes also referred to as multiconstituent fibers. Fibers of this general type are discussed in, for example, U.S. Patent 5,108,827 to Gessner.
  • the term “blend” means a mixture of two or more polymers.
  • substantially continuous fibers refers to fibers, including without limitation, spunbond and meltblown fibers, which are not cut from their original length prior to being formed into a nonwoven web or fabric.
  • Substantially continuous fibers may have average lengths ranging from greater than about 15 centimeters to more than one meter, and up to the length of the web or fabric being formed.
  • the definition of "substantially continuous fibers" includes fibers which are not cut prior to being formed into a nonwoven web or fabric, but which are later cut when the nonwoven web or fabric is cut, and fibers which are substantially linear or crimped.
  • staple fibers means fibers which are natural or cut from a manufactured filament prior to forming into a web, and which have an average length ranging from about 0.1-15 centimeters, more commonly about 0.2-7 centimeters.
  • the term "through-air bonding” or "TAB” means the process of bonding a nonwoven, for example, a bicomponent fiber web in which air which is sufficiently hot to melt one of the polymers of which the fibers of the web are made is forced through the web.
  • the term “coform” means a process in which at least one meltblown diehead is arranged near a chute through which other materials are added to the base material or the web while it is forming. Such other materials may be pulp, superabsorbent particles, cellulose or staple fibers, for example. Coform processes are shown in commonly assigned U.S. Patent 4,818,464 to Lau. Fig.
  • FIG. 1 is a schematic diagram showing the method of this invention for producing materials including, but not limited to, films, nonwoven materials and woven materials having z-direction components in the form of ridges or peaks on at least one face.
  • the ridges or peaks formed in accordance with the method of this invention may be regularly spaced or irregular in spacing and shape.
  • a base material 21 of lightly, or nonfrinctionally, bonded fibers is transported or conveyed on a first moving surface 11 into the confined space defined by nip 13 formed by first moving surface 11 and second moving surface 12.
  • Nonfunctionally bonded is a bonding sufficient only to hold the fibers in place for processing according to the method herein, but so light as to not hold the fibers together were they to be manipulated manually. Such bonding may be incidental or eliminated altogether if desirable.
  • a coform unit 44 for adding additional materials to the y base material is attached near the outlet of the fiber distribution unit 16.
  • First moving surface 11 is moving in the direction of arrow 18 at a given speed.
  • Base material 21 is held down on first moving surface 11 by a hold down vacuum 14.
  • base material is transferred to second moving surface 12 moving in the direction indicated by arrow 19 via positive air pressure from a blow up box 15a underneath first moving surface 11 and a transfer vacuum 20 beneath the second moving surface.
  • first moving surface 11 The transfer of the material in nip 13 from first moving surface 11 to second moving surface 12 is accomplished by the application of a transfer vacuum beneath second moving surface 12 generated by high vacuum slot 15b and a transfer vacuum represented by reference numeral 20.
  • Second moving surface is moving at a speed slower than the speed of first moving surface 11.
  • First and second moving surfaces are normally foraminous or perforate, wire mesh belts, known in the art as "wires".
  • the speed of first moving surface 11 is in the range of about 1.25 to about 7 times faster than the speed of second moving surface 12.
  • nip 13 The confining nature of nip 13 is such that, as the base material 21 of fibers enters nip 13 and is taken away at a slower speed by second moving surface 12, base material
  • the material exiting from nip 13 comprises at least one surface, and normally both surfaces, having ridges or peaks as indicated by reference numeral 22.
  • the method of this invention is particularly suitable for producing preponderantly open, or low density, nonwoven webs of continuous fibers having z-direction components.
  • the material produced in accordance with a preferred embodiment of this invention is a nonwoven web comprising a plurality of substantially continuous fibers having a z-direction orientation and forming the ridges or peaks 22.
  • the substantially continuous fibers are preferably selected from the group consisting of homofilament fibers, bicomponent fibers, biconstituent fibers and combinations thereof.
  • the substantially continuous fibers are preferably formed with polymers selected from the group consisting of polyolefins, polyamides, polyesters, polycarbonates, polystyrenes, thermoplastic elastomers, fluoropolymers, vinyl polymers, and blends and copolymers thereof.
  • Suitable polyolefins include, but are not limited to, polyethylene, polypropylene, polybutylene, and the like; suitable polyamides include, but are not limited to, nylon 6, nylon 6/6, nylon 10, nylon 12 and the like; and suitable polyesters include, but are not limited to, polyethylene terephthalate, polybutylene terephthalate and the like.
  • Particularly suitable polymers for use in the present invention are polyolefins including polyethylene, for example, linear low density polyethylene, low density polyethylene, medium density polyethylene, high density polyethylene and blends thereof; polypropylene; polybutylene and copolymers as well as blends thereof.
  • the suitable fiber forming polymers may have thermoplastic elastomers blended therein.
  • staple fibers may be employed in the nonwoven web as a binder.
  • the nonwoven web is bonded, either by application of an adhesive from adhesive system 25 or by thermal bonding such as by through-air bonding, a calender, or the like, or by means of a hot air knife (LEAK) 24.
  • a hot air knife is used to bond the individual polymer fibers together at various locations so that the web has increased strength and structural integrity for subsequent treatments such as passage through a through-air bonding (TAB) unit.
  • a conventional hot air knife includes a mandrel with a slot that blows a jet of hot air onto the nonwoven web surface. Such hot air knives are taught, for example, by U.S. Patent 5,707,468 to Arnold et al.
  • abase material 21 of substantially continuous fibers is fed onto first moving surface 11 from a Fiber Distribution Unit 16 as at reference numeral 16.
  • certain base material 21 fibers may be formed directly on first moving surface 11 or unwound from prewound spools or the like.
  • Base materials suitable for use in the material and method of this invention are preferably selected from the group consisting of spunbond, meltblown, spunbond- meltblown-spunbond laminates, coform, spunbond-film-spunbond laminates, bicomponent spunbond, bicomponent meltblown, biconstituent spunbond, biconstituent meltblown, pulp, superabsorbent, and combinations thereof.
  • the characteristics of the material produced in accordance with the method of this invention may be varied by varying such method elements as nip geometry, including the vertical distance between first moving surface 11 and second moving surface 12 as well as the extent of overlap between first moving surface 11 and second moving surface 12, vacuum strength and location, bonding mechanism, and speeds of the material entering and leaving nip 13.
  • the type of fiber will also have an affect on the morphology of the web made, hi addition, although the present invention generally produces a self-supporting lofty web, the end product may include a support structure or a second material 23 , as shown being introduced into nip 13 from the unwind designated by reference numeral 17.
  • Fig.2 is a diagram showing a side view of a z-direction component nonwoven web 40 produced in accordance with the method of this invention comprising folds 41 formed by substantially continuous fibers.
  • the substantially continuous fibers are bicomponent fibers.
  • Particularly suitable polymers for forming the structural component of suitable bicomponent fibers include polypropylene and copolymers of polypropylene and ethylene, and particularly suitable polymers for the adhesive component of the bicomponent fibers includes polyethylene, more particularly linear low density polyethylene, and high density polyethylene.
  • the adhesive component may contain additives for enhancing the crimpability and/or lowering the bonding temperature of the fibers, and enhancing the abrasion resistance, strength and softness of the resulting webs.
  • the nonwoven web of the material of this invention has a basis weight in the range of about 0.25 osy to about 50 osy.
  • the nonwoven web comprises an absorbent, for example, superabsorbent particles.
  • a support structure is attached to at least one face of the nonwoven web so as to provide strength thereto.
  • the resulting laminate structure provides support for the high loft structure, strength for winding, converting, etc., and a boundary layer to either enhance or retard fluid flow into the lofty absorbent structure.
  • the support structure may include spunbond webs of various types including liners, perforated, micro- fiber, creped, etc., spunbond-meltblown-spunbond (SMS), meltblown, and/or films.
  • nonwoven web of this invention Potential applications for the nonwoven web of this invention include personal care absorbent articles such as diapers, training pants, incontinence garments, feminine care products including sanitary pads and napkins, all surge materials, loop for hook and loop, air filtration, liquid filtration, body scrub pads, oil sorb, industrial and baby wipes, insulation material, packaging material, and translucent or shading material for lamp shades or the like.
  • personal care absorbent articles such as diapers, training pants, incontinence garments, feminine care products including sanitary pads and napkins, all surge materials, loop for hook and loop, air filtration, liquid filtration, body scrub pads, oil sorb, industrial and baby wipes, insulation material, packaging material, and translucent or shading material for lamp shades or the like.
  • the method of this invention greatly increases the surface area available for filtration.
  • the method of this invention may be suitable for pleating fabrics.
  • a composite material could be produced by ridging or ruffling a high loft surge/pulp/superabsorbent material laminate and placing it in between an outer cover and a liner, which would produce a laminate with all of the components of a diaper in a single step, which could be wound up and cut and placed later on converting machines.
  • Figure 4 illustrates the method of the present invention in process, whereby a nonwoven web made according to the present invention in a first configuration, illustrated on the left hand side of the figure at reference number 59, is subjected to a controlled force F in the direction of the arrow 61 thereby breaking any inter-ridge 50 or intra-ridge 43 bonding of the first configuration as indicated by the "x" marks, e.g. 63 on the right hand side of the figure.
  • an adhesive may be applied by an adhesive system 67 to set the web in the second configuration.
  • the adhesive may be in the form of liquid or additional fibers or the like and may be supplemented with the application of heat, for example by a hot air knife 69.
  • the web may be set in its second configuration through the use of heat alone by a hot air knife 69, through-air bonding, or the like.
  • the characteristics of the material produced in accordance with the method of this invention may be varied by varying such method elements as nip geometry, including the vertical distance between first moving surface 11 and second moving surface 12 as well as the extent of overlap between first moving surface 11 and second moving surface 12, vacuum strength and location, bonding mechanism, and speeds of the material entering and leaving nip 13.
  • the type of fiber will also have an affect on the morphology of the web made.
  • the end product may include a support structure or a second material 23, as shown being introduced into nip 13 from the unwind designated by reference numeral 17.
  • Fig. 5 is a photograph of a side view of a nonwoven web produced in accordance with the method of the present invention, starting with a base material of substantially continuous individual fibers of the bicomponent side-by-side crimped type showing random intermingling of the fibers to the point of losing any regular shape and periodicity to the ridge structure of the web. No channels are evident within the web structure which would allow the easy passage of fluids in any direction through the web.
  • a bonded carded web precursor material has also be found to work well for this embodiment of the invention.
  • FIGs. 6 and 7 are schematic diagrams showing the method of this invention for producing precursor materials having differential basis weight and differential surface topography.
  • a three dimensional forming surface 71 has thin raised lines 73 in the cross machine direction (y axis).
  • the surface 71 may be a foraminous wire with raised wires in the cross direction interconnected with as few linking points 75 in the machine direction (x axis) as possible for stability of the forming surface.
  • the surface 71 may be a formed membrane without cross links between the cross direction lines. The membrane is laminated or sewed to the circulating belts of forming machines in place of the more typical wire.
  • the desired fiber type is then deposited on the forming surface and fixed as by heat or adhesive, or both, to lock in the formed structure into the precursor material.
  • the precursor material produced is in essence a negative of the forming surface 12 and exhibits areas of higher basis weight and bulk and areas of lower basis weight and bulk.
  • the precursor material is denominated as differential basis weight material. While differential basis weight material has been made in the past it is not believed that the small scale of basis weight differential and surface topography of the present teaching have been utilized.
  • the resultant lofty nonwoven web 77 shows the differential basis weight precursor material changing directions within a fold 79 at the junction 81 of the higher basis weight 83 and lower basis weight 85 material to impart the z-direction orientation to the resultant web 77.
  • both first and second major surfaces 87 and 89, respectively, of the x-y plane are composed of the higher basis weight material 83 with an interstitial material of lower basis weight material 85 lying in the z-direction.
  • FIG. 9 is a diagram of a side view of an alternative embodiment of the resultant lofty nonwoven web wherein the precursor and processing variables as discussed above have been adjusted to provide that only the first major surface 87 is composed of the higher basis weight material 83, with the interstitial material and second major surface 89 being composed of lower basis weight material 85.
  • the resultant web has definite channels, collectively 91 , extending in the cross machine direction.
  • Fig. 10 is a diagram of a side view of an alternative embodiment of the resultant lofty nonwoven web wherein the precursor and processing variables have been adjusted to provide that the z-direction components are composed of both higher basis weight 83 and lower basis weight 85 material.
  • Fig. 11 is a diagram of a side view of an alternative embodiment of the resultant lofty nonwoven web wherein the precursor and processing variables have been adjusted to provide that the z-direction components are composed of alternating folds of higher basis weight 83 and lower basis weight 85 material.
  • nonwoven web of this embodiment includes personal care absorbent articles such as diapers, training pants, incontinence garments, feminine care products including sanitary pads and napkins, all surge materials, loop for hook and loop, air filtration, liquid filtration, body scrub pads, oil sorb, industrial and baby wipes, insulation material, packaging material, and translucent or shading material for lamp shades or the like.
  • personal care absorbent articles such as diapers, training pants, incontinence garments, feminine care products including sanitary pads and napkins, all surge materials, loop for hook and loop, air filtration, liquid filtration, body scrub pads, oil sorb, industrial and baby wipes, insulation material, packaging material, and translucent or shading material for lamp shades or the like.
  • the method of this invention greatly increases the surface area available for filtration.

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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)
  • Manufacturing & Machinery (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

La présente invention concerne un procédé de production d"un matériau présentant des crêtes ou des plis en sens Z, dans lequel une couche de fibres continues est transportée sur une première surface mobile, dans un espacement formé par ladite première surface mobile et une seconde surface mobile, qui se déplace à une vitesse inférieure à celle de la première surface mobile, ce qui résulte en la formation de plusieurs boucles en sens Z dans les fibres, conférant du gonflant au matériau, et d"un motif ondulé, qui produit des crêtes sur les deux surfaces principales du voile non-tissé résultant. Ce procédé permet un réglage aisé en temps réel des paramètres de production, afin de produire une variété de matériaux. Ce procédé permet également de produire des non-tissés gonflants à une vitesse commercialement viable.
PCT/US2000/029754 2000-03-30 2000-10-27 Materiaux presentant des fibres et des plis en sens z et leur procede de production WO2001074281A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
MXPA02009622A MXPA02009622A (es) 2000-03-30 2000-10-27 Materiales que tienen fibras y dobleces en la direccion-z y metodo para producir los mismos.
AU2001212423A AU2001212423A1 (en) 2000-03-30 2000-10-27 Materials having z-direction fibers and folds and method for producing same

Applications Claiming Priority (10)

Application Number Priority Date Filing Date Title
US09/538,744 US6867156B1 (en) 1999-04-30 2000-03-30 Materials having z-direction fibers and folds and method for producing same
US09/538,744 2000-03-30
PCT/US2000/010758 WO2000066057A1 (fr) 1999-04-30 2000-04-21 Tissus comportant des fibres et des plis disposes dans le sens z, et procede de production desdits tissus
USPCT/US00/10758 2000-04-21
US19992500P 2000-04-26 2000-04-26
US19992200P 2000-04-26 2000-04-26
US55915500A 2000-04-26 2000-04-26
US60/199,925 2000-04-26
US60/199,922 2000-04-26
US09/559,155 2000-04-26

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WO2003056089A1 (fr) * 2001-12-21 2003-07-10 Kimberly-Clark Worldwide, Inc. Bandes non tissees a faible densite et fort gonflement en filaments crepes et leurs procedes d'obtention
US7258758B2 (en) 2001-12-21 2007-08-21 Kimberly-Clark Worldwide, Inc. Strong high loft low density nonwoven webs and laminates thereof
US10045888B2 (en) 2014-09-12 2018-08-14 The Procter & Gamble Company Nonwoven material having discrete three-dimensional deformations with wide base openings
US10064766B2 (en) 2014-09-12 2018-09-04 The Procter & Gamble Company Nonwoven material having discrete three-dimensional deformations that are configured to collapse in a controlled manner
US10076898B2 (en) 2014-09-12 2018-09-18 The Procter & Gamble Company Apparatus having forming members with surface texture for making nonwoven material having discrete three-dimensional deformations with wide base openings
US10226385B2 (en) 2014-09-12 2019-03-12 The Procter & Gamble Company Process for making an absorbent article comprising a topsheet/acquisition layer laminate
US10610423B2 (en) 2016-03-08 2020-04-07 The Procter & Gamble Company Absorbent article comprising a topsheet/acquisition web laminate
WO2020107422A1 (fr) * 2018-11-30 2020-06-04 The Procter & Gamble Company Procédés de création de bandes non tissées présentant souplesse et gonflant
US11686026B2 (en) 2018-11-30 2023-06-27 The Procter & Gamble Company Methods for producing through-fluid bonded nonwoven webs
US11696856B2 (en) 2017-03-09 2023-07-11 The Procter & Gamble Comoany Three-dimensional materials having apertures and voids

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US4111733A (en) * 1975-07-23 1978-09-05 S.P.R.L. Limatex Method and apparatus for continuous manufacture of undulating or corrugated material
EP0137644A2 (fr) * 1983-08-15 1985-04-17 Personal Products Company Structure fibreuse ondulée
US5021050A (en) * 1989-12-11 1991-06-04 Weyerhaeuser Company Absorbent panel structure
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DE19937066A1 (de) * 1998-08-05 2000-02-24 Ykk Corp Verfahren zur Herstellung nichtgewebten Schlaufenmaterials für Klettverschlüsse

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Publication number Priority date Publication date Assignee Title
WO2003056089A1 (fr) * 2001-12-21 2003-07-10 Kimberly-Clark Worldwide, Inc. Bandes non tissees a faible densite et fort gonflement en filaments crepes et leurs procedes d'obtention
JP2005514528A (ja) * 2001-12-21 2005-05-19 キンバリー クラーク ワールドワイド インコーポレイテッド クリンプを施したフィラメントの高ロフト低密度不織ウェブ及びその製造方法
US7258758B2 (en) 2001-12-21 2007-08-21 Kimberly-Clark Worldwide, Inc. Strong high loft low density nonwoven webs and laminates thereof
US7291239B2 (en) 2001-12-21 2007-11-06 Kimberly-Clark Worldwide, Inc. High loft low density nonwoven webs of crimped filaments and methods of making same
CN100445452C (zh) * 2001-12-21 2008-12-24 金伯利-克拉克环球有限公司 卷曲长丝的高膨松低密度非织造纤维网及其制造方法
KR100947397B1 (ko) 2001-12-21 2010-03-12 킴벌리-클라크 월드와이드, 인크. 하이 로프트 저밀도 크림핑된 필라멘트 부직 웹 및 그제조방법
JP4881544B2 (ja) * 2001-12-21 2012-02-22 キンバリー クラーク ワールドワイド インコーポレイテッド クリンプを施したフィラメントの高ロフト低密度不織ウェブ及びその製造方法
US10076898B2 (en) 2014-09-12 2018-09-18 The Procter & Gamble Company Apparatus having forming members with surface texture for making nonwoven material having discrete three-dimensional deformations with wide base openings
US10500826B2 (en) 2014-09-12 2019-12-10 The Procter & Gamble Company Method of making nonwoven material having discrete three-dimensional deformations with wide base openings
US10064766B2 (en) 2014-09-12 2018-09-04 The Procter & Gamble Company Nonwoven material having discrete three-dimensional deformations that are configured to collapse in a controlled manner
US10045888B2 (en) 2014-09-12 2018-08-14 The Procter & Gamble Company Nonwoven material having discrete three-dimensional deformations with wide base openings
US10105268B2 (en) 2014-09-12 2018-10-23 The Procter & Gamble Company Nonwoven material having discrete three-dimensional deformations with differential opacity regions
US10182949B2 (en) 2014-09-12 2019-01-22 The Procter & Gamble Company Nonwoven material having discrete three-dimensional deformations with wide base openings that are base bonded to additional layer
US10226385B2 (en) 2014-09-12 2019-03-12 The Procter & Gamble Company Process for making an absorbent article comprising a topsheet/acquisition layer laminate
US10045889B2 (en) 2014-09-12 2018-08-14 The Procter & Gamble Company Nonwoven material having discrete three-dimensional deformations with wide base openings and specific fiber concentrations
US11154428B2 (en) 2014-09-12 2021-10-26 The Procter & Gamble Company Absorbent articles with indicia and/or color
US10993845B2 (en) 2014-09-12 2021-05-04 The Procter & Gamble Company Process for making an absorbent article comprising a topsheet/acquisition layer laminate
US10687987B2 (en) 2014-09-12 2020-06-23 The Procter & Gamble Company Process for making an absorbent article comprising a topsheet/acquisition layer laminate
US10610423B2 (en) 2016-03-08 2020-04-07 The Procter & Gamble Company Absorbent article comprising a topsheet/acquisition web laminate
US11696856B2 (en) 2017-03-09 2023-07-11 The Procter & Gamble Comoany Three-dimensional materials having apertures and voids
WO2020107422A1 (fr) * 2018-11-30 2020-06-04 The Procter & Gamble Company Procédés de création de bandes non tissées présentant souplesse et gonflant
US11686026B2 (en) 2018-11-30 2023-06-27 The Procter & Gamble Company Methods for producing through-fluid bonded nonwoven webs
US11767622B2 (en) 2018-11-30 2023-09-26 The Procter & Gamble Company Methods of creating soft and lofty nonwoven webs

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