CA2175991C - Fibrous and apertured, three-dimensional, macroscopically expanded plastic web - Google Patents
Fibrous and apertured, three-dimensional, macroscopically expanded plastic web Download PDFInfo
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- CA2175991C CA2175991C CA002175991A CA2175991A CA2175991C CA 2175991 C CA2175991 C CA 2175991C CA 002175991 A CA002175991 A CA 002175991A CA 2175991 A CA2175991 A CA 2175991A CA 2175991 C CA2175991 C CA 2175991C
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- Prior art keywords
- web
- fibers
- dimensional
- forming
- capillaries
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- 0 **1CCCC1 Chemical compound **1CCCC1 0.000 description 1
Classifications
-
- 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
- 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
-
- 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
- A61F13/15707—Mechanical treatment, e.g. notching, twisting, compressing, shaping
- A61F13/15731—Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
Abstract
A fluid pervious web suitable for use as a topsheet on an absorbent article is disclosed. The topsheet includes a fibrous and apertured, three-dimensional, macroscopically expanded. plastic web. The fibrous and apertured, three-dimensional, macroscopically expanded, plastic web permits bodily fluids to penetrate while providing an improved, less plastic-like feel and visual aesthetics.
Description
WO 95/13773 _ PC1'/US94/1309'%
FIBROUS AND APERT'LJRFD, THItEE-DIIviENSIONAL, MACROSCOPICALLY EXPANDED PLASTIC WEB
The preset invention relates to absorbent articles such as sanitary napkins, psntilinera, disposal dispen, incontinent articles, and the like, and more particxrlarly, the present invention relates to absorbent articles having a fibrous and apa~turcd, three-dimensional, macroscopically expanded, Plastic topsheet.
BACKGROUND OF TEE >NV>CNTION
All mariner and variety of absorbent articles configured for the absorption of bodily 9uids are, of course, well known. Currant types of absorbent articles include sanitary napiona, pantiiir~rs, disposable diapers, sad incorninent articles.
Macmscopicsslly expanded, thra.~dimensional, apertured, films have been used as topskasets on such absorbent articles. As used herein, the term "macroacopics>yy expanded', when used to describe thrre~dimeasional, plastic webs, nbbons and films, refixs to webs, ribbons and films, which have been caused to confirm to the sur6cx of a thrao-dima~sionat forming structure so that both au6oa thereof exku'bit the throe-dimensional pattern of the forming the pstta~n being readily viable to the nakcad eye when the parpeadiatlar distance between the viewer's eye and the plane of the web is aboyt I2 iac~s.
One macroscopically expanded, three-dimensional, apatirred plastic web which is partiaslariy weU suited to tranafening fluid deposited on one thereof to its opposite s~ufice and thanRer isolating the trantfared $uid firom the ararda akon is disclosed in commonly assigned U.S. Pat. No. 3, 929,135 issued to Thornp:On on Dec. 30, 1975 _ _ 3 5 Thonrpaon describes a macroscopically ocpanded, thr~nensional, topslxei cornprited of liquid impemeable material, but provided with a pattern of tapc~ed cspil>uies, the capilLria have a base opening in the plane of the topskreet corrtacring the wearer's body and an apex opening remote from the base ?. 5 _ WO 9S/13773 ~ ~ 7 5 9 9 1 p~'rt1S94/13097 opening of the topsheet, the spat opening being in intimate contact with the absorbent pad utilized in the disposable absorbent article. The Thompson topderet allows for the free transfer of fluid from the weata's body into the absorbart dm~t of the device while inhibiting the reverse flow of these fluids.
This s rdstively much dryer s~uface in contact with the user than had previously been obtainable.
Another rnuxoacopically acpanded, threbdimars;onal, apa~A~red Plastic web wdl suited for use as a topabett on absorbent articles such as san;tary napkins is disc~aed in commonly assigned U.S. Pat. No. 4,342,314 issued to Radd et al. on Aug. 3, 1982_ _ _ - _ The macroscopically expanded, throe.dimarsiona! plastic web disclosed in tkre Radd d aL patern exhibits a fiber l~ca appararae and tactile impreadon which has been favorably rxdved by ~~nmmers when used as a wnrrr cornuting aufl~.
While macroscopicany expanded, throe.dimnuional, ap~urad plastic carobs have adrieved vvidesprad connndraal success when employed as topaheas on absorbent articles, some users are very to place a topsheet which they rad~y pacxive as plsstic in contact with their skin.
Accordingly, it is therefore an object of an aspect of the present invention to provide a top:heu for an absorbent article having fluid hand>>ng charada~istics comparable to those found in macros~pi~r expanded, throo-dimensionat, apert<ued Plastic topsheets and an improved :ofta, less plastio-like feel.
The presort imrartion relates to absorbent articles such as diapers, inco~ artida, :a~tary aspbna, and the lie. More partiarlar>y, this ion rolstes to absorbent articles having a ~osita 5bnous and macroscopically expanded, throe-dimensional. apa~aund Plastic film topsheet.
The ros8imt, tbree~dms~aional, macroscopically exQanded, fluid pervious plastic web has s fast and a second :<u&ce located in plarKS ranote from one another. A phua>ay of capillaries attend from the first s<u6a to the second ~r&cx of the plastic web. The capillaries aro defined by a plurality of aidewall portions intesoonnaxed to one another itrtamediste the 5rat and second ~rr~Ca and terminates in the second s<rrfux. A plurality of Sbas are warred to the fast s<u&ce of the fluid pervious plastic web. The fibers extend into the cap8laries of the fluid pervious plastic web and aro secured to tlu sidewalk portions.
WO 95113773 21 7 5 9 9 1 p~'n1S94113097 2a In accordance with one embodiment of the invention, a fluid pervious web comprises:
(a) s resilient, three-dimensional, macroscopically expanded, fluid pervious Plastic web having first acrd second strrfaca located in planes remote from one another, said web having a plurality of cspiluries extending 6rom said fltat surfiux to said second auface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfacas; said sidewaV portions terminating in said second surlact; and (b) a plurality of fibers secured to said 8nt strrlnce of said fluid pwious Plastic web, said Sbas ~din,~ into the capillaries of said Said payiow plastic wab and being ~sewr~ed to said sidearall tn accordance with the further embodiment, an absorbent article comprises:
(a) a guid pa~rioua web comprising:
(i) a r~li~t, three-dima~ional, n~oaoop~y ocpaadad, ~ w~ g~ and second aurflroa located in plans ranote from one another, said web having s phrrality of apillatia extatding from said first strr6ot to said second stu~oa, said capillaries bang defined by s phuality of sidewall portions interconnected to one another intermediate said 5rst and second surfaces, said sidewall portions terminating in said second surface; and (ii) a plurality of fibers secured to said first surface of said fluid pervious pla~ic web, said Bbers attending into the capillaries of said fluid pervious plastic web and being secured to said sidewaU portions;
(b) a fluid impervious backsheet joined to said topslmet; and (c) an absorbent core positioned betwan said topshoet and said The praau imrenbon also provides a process fot forming a fibrous and app ;oral, macroscopically expanded, Plastic web. A
~"r .
wo m3n3 ,2 ~ 7 5 9 9 ~ PCTNS94/13097 polyma~ic >tilm is extruded onto a forming aaucturo. The foaming swcture exhbit: a n~uxoacopic, threo-dimaraional, cross-section defined by a multiplicity ~ macroxopic apertures which plan the opposod of the fon~g stnrcdrte in grid conu~cstion with one another. A pof libaa are deposited on the film whUe the 51m is s<rpported by the forming strucxure to inrm a composite web. A pnamu~ic preanrre differential ~ applied to the composite web of 5Ln and fibers to cause the co~npoaite web to be urged into substantial cosd'arrdace w'tth the macroscopic, threo-dimensional, cross-action of the forming ro forming s three-d men~ional, mat~oxopicavy expanded, web having s phQatity of apiUaries exuding fiarn the Brat to said second surface. Tlre cspiUaria aro defined by s phuabty of sidearaU portions imaeormeaed to one motba imannediate the fiat and second sur6oa and which terminate in the second . The ~annatic prawro causes the fibers to be pulled aga>Ht the fast aur~oe of the formed'web and into the capillaries of the formed web. The Sbers aro to the fiat and the Wll portio<u of acid formed web forming a fibrous and apero~red, flares-dirna~iona>, macrosoopicaUY expsnded web.
In accordance with the further embodiment, a process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web comprises the steps of:
(~) a pdyma~ic film onto s fornt~g ~nrcatre~ said forming sttucwn a macnosoopic, tltr~ea~du~ionat, cxoas.
s~On defined by s nwltipliatyr of macroxa~ apatura which plaon the opposed ~a of said forming stn~au~e in grid oommuacatioa with one another;
(b) a phmabty of fibers on said 86n to fam s o~posta web; sad (c) app~y~ a pneumatic lure to ctoa~ts web to cue said oompo~te web to be urged into trtial cooEotmanoe with the 3o mo~ ~~"s°~°° of said forming ro Forming s three-dim~iotul. rtucroxoPK'~lY handed.
formed wab having fiat and second s~r8roes, said Formed web a P~ih ~ capi~ from said &at stufaca to said aa~otid said aria being de8~d by ~ P1~Y
of sidewaU portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface, said pneumatic pressure causing said fiber to be pulled against said first surface of said formed web and into said - capillaries of said formed web, said fiber being secured to said first surface and said sidewall portions of said formed web forming said fibrous and apertured, three-dimensional, macroscopically expanded web.
y'f~ r WO 95/13773 21 7 5 9 9 1 . PCTNS94/13097 3a In accordance with the further embodiment, a process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web comprises the steps of (a) s polymeric film onto s forn>uag :at~turo, s>ud forming rro exlu'biting a macroxopie, three.din~ion~l, crcs~-roctioo defined by a mWtipbcaey of mscnoaeopic apertures which place the opposod srrrfua of said forming stnrcarro in Huid comatunication with one anotlrar;
(b) spplying s ~un~stic pressure to said film to coax said Slm to be urged into wbstar~ial ~nforntanoe with tire macroxopic, throo-I o ~of said forming f~,g a t!>nee.dima»aional, macros~pi~ll~r ~panded, fonried web lu~ri~
Br>t std second s~rr>~ said formed web having a phrratity of apinaies mctending 8rom said &st ~n~B~oe to said second ~ ~ ~P~« defined by a phrrality of sidcwaU
portions interconnected to one another intarrrediate said first and second sur6ces and taminstina in said second (c) meitblowing a plurality of fibers onto said three-dimensional, macroscopically expanded, formed web, forming a fibrous and apertured, three-dimensional, macroscopically expanded web, In accordance with the further embodiment, a process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web comprises the steps of:
(a) mdtblowing a plurality of fibers onto a forming drum;
(b) excluding a polymeric film onto said phtr,lity of fiber to form a ~~~ web;
(c) plaang said composite web oa s forning said fornring stnrcdtro aciubiting a nracroxo~ three-dimensional, cross-section defined by s nmlaplicity of macroscopic spertues whidr 3o p~ the opposed stufi~ ~of said fo<rning swcture in 9u;d connnunicstion with one anotlser; and (d) aPP~ a PPto said composite ~ web to cause said composite web to be urged into substaada! conformance with the rna~xoscopic, thcee~dima~sional, cross-section of said fonn~ structure forming a three-dimensional, macroscopicallyr expanded, formed web hsving first and second sur6ca, said formed web hsving s plurs>it~r of capi»uies acta>~g from said fiat arnfa<x to said second strrfiuxr, said cstpiUarid being defined by s p~alit)r of sidaaralt portions intaconnecteo to one another intermediate said first and second and terminating in said second ~rr6~.
w0 95/13773 ~ ~ ~ ~ 9 9 1 PCTNS94/13097 3b $$~,p~'~IP'!'ION O!~ THIr 1~RAW~ICc Whik the sp~cation concludes with claims particularly p~,g ~
~ ~~8 ~ Pon, n is bdi~ed that the pr~c invention will be betty understood from the following description in conjunction with the acxompanying drawings in which:
Fig. 1 is a simpli5ed perspective view of an absorbent article of the Prat inv~ott;
Fig. 2 a a crou.aectiona! view taker, along soon line 2-2 of Fig 1;
F'rg. 3 is s crosr:mcxional view taken along secdor, line 3-3 of Fig. 1;
F'~. 4 is an enlarged, partially ate, pave ;ion of a P~ art plastic web of the type generally enclosed in only ~g~ U.S.
Pat. No. 4,342,314;
Fig. 5 is an enlarged, psrtisUy ae~aerrt~, per; of a pnfemed embodiment of the fibrous and apatured, plastic web of the ptaerit ;
Fig. 6 is an a~laarged, cross-aactional vicar of s 5ber-like dement of the f~ous and aperdrred, plastic web of the press invamon taken along section line 6-6 of Fig. 5;
Fig. 7 is a aimpli8ed schematic repreamtation of a proves: for making the fi~ ~ plc web of the pteserri invention;
WO 95/I3773 21 7 5 9 9 ~ P~'~1594/1309-Fig. 8 is a greatly enlarged fragmentary view of the forming structure utilized to support the fibrous and apertured, plastic web in accordance with the process illustrated in Fig. 7;
Fig. 9 is a simplified schematic reprexntstion of an alternative process for making the fibrous and apat<ued, plastic web of the present invention; and Fig. 10 is s simplified schematic reprexntation of an alternative process for making the fibrous and spertured, plastic web of the prexnt invention.
DETAILED DESCRIPTION OF TSE PRESENT INVENTION
The term "absorbent article", as used herein, refers to articles which absorb and contain body aaidatGS. More specifically, the term refers to articles which are placed against or in proxin>ity to the body of the wearer to absorb and comain the various exudates discharged from the body. The term "absorbent article" is irr<ended to include diapers; incontinent articles, sanitary napkins, par>tilinas, and other article uxd to absorb body exudates. The term "disposable ' is used herein to describe absorbent articles which are not intended to be laundered or otherwix restored or reused as an absorbent article, i.e., they are intended to be discard after a single ux, and, preferably to be recycled, composted or otherwix disposed of in an environmentally compatible manner.
The term 'diaper" refers to a ga:tne~ generally worn by infants and incontinent persons which is worn shout the lows torso of the wearer. Suitable diapers that can be provided with the topsheet described herein are disclosed in U.S. Pat. No. Re. 26,152, issuod to Duncan, a al. on Jan. 31, 1967; U.S. Pat.
No. 3,860,003 issued to Buell on Jan. 14, 1975; U.S. Pst. No. 4,610,678 issued to Wastnar~, d al. on Sept. 9, 1986, U.S. Pat. No. 4,673,402 issued to Weisman, ei al. on June 16, 1987; U.S. Pat. No. 4,695,278 issued to I,awson on Sept.
22, 1987; U. S. Pal. No. 4,704,115 issued to Buell on Nov. 3, 1987; U.S. Pat. No.
4,834,735 cawed to Alemany et al. on May 30, 1989; U. S. Pat. No. 4,888,231 rued to Angstadt on Dec. 19, 1989; and U. S. Pat. No. 4, 909,803 issued to Aziz, d s<. on March 20, 1990 The term "incontinent article" refers to pads, undergarments (pads held in place by s wsp~on system of some type, such as a belt, or the Iike), insects for absorbent articles, cspacityr boosters for absorbent articles, briefs, bed pads, and the like, regardless of whether they are worn by adults or other incontinent persons. Suitable incontinent articles that can be provided with the topsheet ddrn'bed herein are discloxd in U.S. Pat. No. 4,253,461 issued to Strickland, et al. on March 3, 1981; U.S. Pat. Nos. 4,597,760 and 4,597,761 issued to Buell;
W095/i3773 21 7 5 9 9 1 P~~S9s~i309;
the above-mentioned U.S. Pat No. 4,704,115; U.S. Pat. No. 4,909,802 issued to Ahr, et al.; and U.S. Pat. No. 4,964,860 issued to Gipson, et al. on Oct. 23, 1990' The term 'sanitary napkin' rekrs to an article which is worn by females 5 adjacent to the pudenda! region that is intended to absorb and contain various exudates which are discharged from the body (e.g., blood, menses and urine).
Suitable sanitary napkins that can be provided with the topsheet described herein are disclosed in U.S. Pat. No. 4,285,343, issued to McNair on Aug. 25, 1981;
U.S Pat. Nos. 4,589, 876 and 4,687,478 issued to Van Tilburg on May 20, 1986 and Aug. 18, 1987 respectively, U.S Pat. Nos. 4,917,697 and 5,007,906 issued to Osborn, et al. on April 17, 1990 and April 16, 1991, respectively, and U.S.
Pat. Nos. 4,950,264 and 5,009,653 issued to Osborn on Aug. 21, 1990 and April 23, 1991, rapxdvely.
The term "pantiliner" refers to absorbent articles that are less bulky than sanitary napkins which are generally worn by women betvvaen their menstrual periods. Suitable pantiliners that can be provided with the topshxt descn'bed herein are disclosed in U.S. Pal. No. 4,738,676 issued to Osborn on April 19, 1988.
Fig. 1 shows a simpli5ed absorbent article 10 that could represent a diaper prior to its being placed on a wearer. It should be understood, however, that the present invention is not limited to the particular type or configuration of absorbent article shown in the drawings. As shown in Figs. 2 and 3, such an absorbent article 10 basically comprises a topsheet 12, a backsheet 14, and an absorbent core 16.
The absorbent article 10 has two sirrfiuxs, a body-contacting sruface (or "body sur6oe') l0a and a s<rrfaa lOb. The body auface l0a is iatarded to be worn adjsceru to the body of the weans. The garment surface lOb of the absorbent article 10 (shown in Fig. 2) is on the opposite side and is intended to be placed sdjacatt to the wearer's undergarm«tts or clothing when the absorbent article 10 is worn.
The absorbent article 10 has two centerlines, a longitudinal centerline I
and a transverse centerline t. The term "longitudinal", as used hervein, refers to a line, axis or direction in the plane of the absorbent article 10 that is generally aligned with (e.g., approximately parallel to) a vertical plane which bisects a standing wearer into leR and right body halves when the absorbent article 10 is worn. The terms 'transverse" or "lateral" as used herein, are interchangeable, and refer to a line, axis or direction which lies within the plane of the absorbent article 10 that is general perpendicular to the longitudinal direction. Fig. 1 ::V,a:
:,:;.
WO 95/13773 21 7 5 9 9 ~ - PCT/US94/13097 shows that the absorbent article 10 has two spaced apart longitudinal edges 18 and two spaced apart transverse or end edges (or "ends") 20, which together form the periphery 22 of the absorbent article 10.
The topaheet 12 is compliant, soft-feeling and non-irritating to the wearer's skin. Further, topsheet 12 is liquid permeable, permitting liquids to readily penetrate through its thicW as. The topsheet 12 has a body-facing side or face 12a and a garment-facing side or face 12b, two longitudinal or side edges 12c and two end edges 12d. (A similar numbering system will be used for the other components of the diaper 10. That is, the side of the component facing the wearer's body will be designated by the number of the component and a reference letter "a", the side facing the wearer's undergarments by the number of the component and the letter "b", sad the side and end edges by the number of the component and the reference letters "c" and "d" respectively.) Fig. 4 is as enlarged, partially segmented, perspective illustration of a prior art macroscopically expanded, three-dimensional, fiber-like, apertured, plastic film 26 which has been found highly suitable for use as a topsheet in disposal absorbent articles. Prior art plastic 51m 26 is generally in accordance with the teachings of commonly assigned U.S. Pal. No. 4,342,314 issued to Itadel, et al. on Aug. 3, 1982. _ .
The plastic film 26 exhrbits a multiplicity of apertures, e.g., apertures 31, which are formed by a multiplicity of intersecting fiber-like elements, e.g., elements 32, 33, 34, 35 and 36 interconnected to one another in the first surface 40 of the web. Each fiber-like element comprises a base portion, e.g., base portion 41 lob in plane 42. Each base portion has a sidewall portion, e.g., sidewall portions 43, attached to each edge thereof. The sidewall portions extend garaally is the direction of a second surface 45 of the web. The intersecting aidewall portions of the fiber-like elements are interconnected to one another intermediate the 5rst arrd second of the web, and terminate substantially cona>rrmtly with one another in the plane 46 of the second surface to form spernua 39 in the second surface 45 of the web. The capillaries 49 formed by the intcconmaxed sidewall portions allows for free transfer of fluid from the 5rst aruiace of the web directly to the second surface of the web without lateral transmission of the fluid between the adjacent capillaries.
The apattued plastic film 26 is manufrom a liquid impervious, preferably thermoplastic mataisl. The thermoplastic material for use in the manufacture of the apertured plastic film 26 is selected from a group generally consisting of polyethylene, polypropylene, polyvinyl chloride, starch base resins, ~:
WO 95/13773 217 5 9 91 P~~s9a/1309?
FIBROUS AND APERT'LJRFD, THItEE-DIIviENSIONAL, MACROSCOPICALLY EXPANDED PLASTIC WEB
The preset invention relates to absorbent articles such as sanitary napkins, psntilinera, disposal dispen, incontinent articles, and the like, and more particxrlarly, the present invention relates to absorbent articles having a fibrous and apa~turcd, three-dimensional, macroscopically expanded, Plastic topsheet.
BACKGROUND OF TEE >NV>CNTION
All mariner and variety of absorbent articles configured for the absorption of bodily 9uids are, of course, well known. Currant types of absorbent articles include sanitary napiona, pantiiir~rs, disposable diapers, sad incorninent articles.
Macmscopicsslly expanded, thra.~dimensional, apertured, films have been used as topskasets on such absorbent articles. As used herein, the term "macroacopics>yy expanded', when used to describe thrre~dimeasional, plastic webs, nbbons and films, refixs to webs, ribbons and films, which have been caused to confirm to the sur6cx of a thrao-dima~sionat forming structure so that both au6oa thereof exku'bit the throe-dimensional pattern of the forming the pstta~n being readily viable to the nakcad eye when the parpeadiatlar distance between the viewer's eye and the plane of the web is aboyt I2 iac~s.
One macroscopically expanded, three-dimensional, apatirred plastic web which is partiaslariy weU suited to tranafening fluid deposited on one thereof to its opposite s~ufice and thanRer isolating the trantfared $uid firom the ararda akon is disclosed in commonly assigned U.S. Pat. No. 3, 929,135 issued to Thornp:On on Dec. 30, 1975 _ _ 3 5 Thonrpaon describes a macroscopically ocpanded, thr~nensional, topslxei cornprited of liquid impemeable material, but provided with a pattern of tapc~ed cspil>uies, the capilLria have a base opening in the plane of the topskreet corrtacring the wearer's body and an apex opening remote from the base ?. 5 _ WO 9S/13773 ~ ~ 7 5 9 9 1 p~'rt1S94/13097 opening of the topsheet, the spat opening being in intimate contact with the absorbent pad utilized in the disposable absorbent article. The Thompson topderet allows for the free transfer of fluid from the weata's body into the absorbart dm~t of the device while inhibiting the reverse flow of these fluids.
This s rdstively much dryer s~uface in contact with the user than had previously been obtainable.
Another rnuxoacopically acpanded, threbdimars;onal, apa~A~red Plastic web wdl suited for use as a topabett on absorbent articles such as san;tary napkins is disc~aed in commonly assigned U.S. Pat. No. 4,342,314 issued to Radd et al. on Aug. 3, 1982_ _ _ - _ The macroscopically expanded, throe.dimarsiona! plastic web disclosed in tkre Radd d aL patern exhibits a fiber l~ca appararae and tactile impreadon which has been favorably rxdved by ~~nmmers when used as a wnrrr cornuting aufl~.
While macroscopicany expanded, throe.dimnuional, ap~urad plastic carobs have adrieved vvidesprad connndraal success when employed as topaheas on absorbent articles, some users are very to place a topsheet which they rad~y pacxive as plsstic in contact with their skin.
Accordingly, it is therefore an object of an aspect of the present invention to provide a top:heu for an absorbent article having fluid hand>>ng charada~istics comparable to those found in macros~pi~r expanded, throo-dimensionat, apert<ued Plastic topsheets and an improved :ofta, less plastio-like feel.
The presort imrartion relates to absorbent articles such as diapers, inco~ artida, :a~tary aspbna, and the lie. More partiarlar>y, this ion rolstes to absorbent articles having a ~osita 5bnous and macroscopically expanded, throe-dimensional. apa~aund Plastic film topsheet.
The ros8imt, tbree~dms~aional, macroscopically exQanded, fluid pervious plastic web has s fast and a second :<u&ce located in plarKS ranote from one another. A phua>ay of capillaries attend from the first s<u6a to the second ~r&cx of the plastic web. The capillaries aro defined by a plurality of aidewall portions intesoonnaxed to one another itrtamediste the 5rat and second ~rr~Ca and terminates in the second s<rrfux. A plurality of Sbas are warred to the fast s<u&ce of the fluid pervious plastic web. The fibers extend into the cap8laries of the fluid pervious plastic web and aro secured to tlu sidewalk portions.
WO 95113773 21 7 5 9 9 1 p~'n1S94113097 2a In accordance with one embodiment of the invention, a fluid pervious web comprises:
(a) s resilient, three-dimensional, macroscopically expanded, fluid pervious Plastic web having first acrd second strrfaca located in planes remote from one another, said web having a plurality of cspiluries extending 6rom said fltat surfiux to said second auface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfacas; said sidewaV portions terminating in said second surlact; and (b) a plurality of fibers secured to said 8nt strrlnce of said fluid pwious Plastic web, said Sbas ~din,~ into the capillaries of said Said payiow plastic wab and being ~sewr~ed to said sidearall tn accordance with the further embodiment, an absorbent article comprises:
(a) a guid pa~rioua web comprising:
(i) a r~li~t, three-dima~ional, n~oaoop~y ocpaadad, ~ w~ g~ and second aurflroa located in plans ranote from one another, said web having s phrrality of apillatia extatding from said first strr6ot to said second stu~oa, said capillaries bang defined by s phuality of sidewall portions interconnected to one another intermediate said 5rst and second surfaces, said sidewall portions terminating in said second surface; and (ii) a plurality of fibers secured to said first surface of said fluid pervious pla~ic web, said Bbers attending into the capillaries of said fluid pervious plastic web and being secured to said sidewaU portions;
(b) a fluid impervious backsheet joined to said topslmet; and (c) an absorbent core positioned betwan said topshoet and said The praau imrenbon also provides a process fot forming a fibrous and app ;oral, macroscopically expanded, Plastic web. A
~"r .
wo m3n3 ,2 ~ 7 5 9 9 ~ PCTNS94/13097 polyma~ic >tilm is extruded onto a forming aaucturo. The foaming swcture exhbit: a n~uxoacopic, threo-dimaraional, cross-section defined by a multiplicity ~ macroxopic apertures which plan the opposod of the fon~g stnrcdrte in grid conu~cstion with one another. A pof libaa are deposited on the film whUe the 51m is s<rpported by the forming strucxure to inrm a composite web. A pnamu~ic preanrre differential ~ applied to the composite web of 5Ln and fibers to cause the co~npoaite web to be urged into substantial cosd'arrdace w'tth the macroscopic, threo-dimensional, cross-action of the forming ro forming s three-d men~ional, mat~oxopicavy expanded, web having s phQatity of apiUaries exuding fiarn the Brat to said second surface. Tlre cspiUaria aro defined by s phuabty of sidearaU portions imaeormeaed to one motba imannediate the fiat and second sur6oa and which terminate in the second . The ~annatic prawro causes the fibers to be pulled aga>Ht the fast aur~oe of the formed'web and into the capillaries of the formed web. The Sbers aro to the fiat and the Wll portio<u of acid formed web forming a fibrous and apero~red, flares-dirna~iona>, macrosoopicaUY expsnded web.
In accordance with the further embodiment, a process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web comprises the steps of:
(~) a pdyma~ic film onto s fornt~g ~nrcatre~ said forming sttucwn a macnosoopic, tltr~ea~du~ionat, cxoas.
s~On defined by s nwltipliatyr of macroxa~ apatura which plaon the opposed ~a of said forming stn~au~e in grid oommuacatioa with one another;
(b) a phmabty of fibers on said 86n to fam s o~posta web; sad (c) app~y~ a pneumatic lure to ctoa~ts web to cue said oompo~te web to be urged into trtial cooEotmanoe with the 3o mo~ ~~"s°~°° of said forming ro Forming s three-dim~iotul. rtucroxoPK'~lY handed.
formed wab having fiat and second s~r8roes, said Formed web a P~ih ~ capi~ from said &at stufaca to said aa~otid said aria being de8~d by ~ P1~Y
of sidewaU portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface, said pneumatic pressure causing said fiber to be pulled against said first surface of said formed web and into said - capillaries of said formed web, said fiber being secured to said first surface and said sidewall portions of said formed web forming said fibrous and apertured, three-dimensional, macroscopically expanded web.
y'f~ r WO 95/13773 21 7 5 9 9 1 . PCTNS94/13097 3a In accordance with the further embodiment, a process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web comprises the steps of (a) s polymeric film onto s forn>uag :at~turo, s>ud forming rro exlu'biting a macroxopie, three.din~ion~l, crcs~-roctioo defined by a mWtipbcaey of mscnoaeopic apertures which place the opposod srrrfua of said forming stnrcarro in Huid comatunication with one anotlrar;
(b) spplying s ~un~stic pressure to said film to coax said Slm to be urged into wbstar~ial ~nforntanoe with tire macroxopic, throo-I o ~of said forming f~,g a t!>nee.dima»aional, macros~pi~ll~r ~panded, fonried web lu~ri~
Br>t std second s~rr>~ said formed web having a phrratity of apinaies mctending 8rom said &st ~n~B~oe to said second ~ ~ ~P~« defined by a phrrality of sidcwaU
portions interconnected to one another intarrrediate said first and second sur6ces and taminstina in said second (c) meitblowing a plurality of fibers onto said three-dimensional, macroscopically expanded, formed web, forming a fibrous and apertured, three-dimensional, macroscopically expanded web, In accordance with the further embodiment, a process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web comprises the steps of:
(a) mdtblowing a plurality of fibers onto a forming drum;
(b) excluding a polymeric film onto said phtr,lity of fiber to form a ~~~ web;
(c) plaang said composite web oa s forning said fornring stnrcdtro aciubiting a nracroxo~ three-dimensional, cross-section defined by s nmlaplicity of macroscopic spertues whidr 3o p~ the opposed stufi~ ~of said fo<rning swcture in 9u;d connnunicstion with one anotlser; and (d) aPP~ a PPto said composite ~ web to cause said composite web to be urged into substaada! conformance with the rna~xoscopic, thcee~dima~sional, cross-section of said fonn~ structure forming a three-dimensional, macroscopicallyr expanded, formed web hsving first and second sur6ca, said formed web hsving s plurs>it~r of capi»uies acta>~g from said fiat arnfa<x to said second strrfiuxr, said cstpiUarid being defined by s p~alit)r of sidaaralt portions intaconnecteo to one another intermediate said first and second and terminating in said second ~rr6~.
w0 95/13773 ~ ~ ~ ~ 9 9 1 PCTNS94/13097 3b $$~,p~'~IP'!'ION O!~ THIr 1~RAW~ICc Whik the sp~cation concludes with claims particularly p~,g ~
~ ~~8 ~ Pon, n is bdi~ed that the pr~c invention will be betty understood from the following description in conjunction with the acxompanying drawings in which:
Fig. 1 is a simpli5ed perspective view of an absorbent article of the Prat inv~ott;
Fig. 2 a a crou.aectiona! view taker, along soon line 2-2 of Fig 1;
F'rg. 3 is s crosr:mcxional view taken along secdor, line 3-3 of Fig. 1;
F'~. 4 is an enlarged, partially ate, pave ;ion of a P~ art plastic web of the type generally enclosed in only ~g~ U.S.
Pat. No. 4,342,314;
Fig. 5 is an enlarged, psrtisUy ae~aerrt~, per; of a pnfemed embodiment of the fibrous and apatured, plastic web of the ptaerit ;
Fig. 6 is an a~laarged, cross-aactional vicar of s 5ber-like dement of the f~ous and aperdrred, plastic web of the press invamon taken along section line 6-6 of Fig. 5;
Fig. 7 is a aimpli8ed schematic repreamtation of a proves: for making the fi~ ~ plc web of the pteserri invention;
WO 95/I3773 21 7 5 9 9 ~ P~'~1594/1309-Fig. 8 is a greatly enlarged fragmentary view of the forming structure utilized to support the fibrous and apertured, plastic web in accordance with the process illustrated in Fig. 7;
Fig. 9 is a simplified schematic reprexntstion of an alternative process for making the fibrous and apat<ued, plastic web of the present invention; and Fig. 10 is s simplified schematic reprexntation of an alternative process for making the fibrous and spertured, plastic web of the prexnt invention.
DETAILED DESCRIPTION OF TSE PRESENT INVENTION
The term "absorbent article", as used herein, refers to articles which absorb and contain body aaidatGS. More specifically, the term refers to articles which are placed against or in proxin>ity to the body of the wearer to absorb and comain the various exudates discharged from the body. The term "absorbent article" is irr<ended to include diapers; incontinent articles, sanitary napkins, par>tilinas, and other article uxd to absorb body exudates. The term "disposable ' is used herein to describe absorbent articles which are not intended to be laundered or otherwix restored or reused as an absorbent article, i.e., they are intended to be discard after a single ux, and, preferably to be recycled, composted or otherwix disposed of in an environmentally compatible manner.
The term 'diaper" refers to a ga:tne~ generally worn by infants and incontinent persons which is worn shout the lows torso of the wearer. Suitable diapers that can be provided with the topsheet described herein are disclosed in U.S. Pat. No. Re. 26,152, issuod to Duncan, a al. on Jan. 31, 1967; U.S. Pat.
No. 3,860,003 issued to Buell on Jan. 14, 1975; U.S. Pst. No. 4,610,678 issued to Wastnar~, d al. on Sept. 9, 1986, U.S. Pat. No. 4,673,402 issued to Weisman, ei al. on June 16, 1987; U.S. Pat. No. 4,695,278 issued to I,awson on Sept.
22, 1987; U. S. Pal. No. 4,704,115 issued to Buell on Nov. 3, 1987; U.S. Pat. No.
4,834,735 cawed to Alemany et al. on May 30, 1989; U. S. Pat. No. 4,888,231 rued to Angstadt on Dec. 19, 1989; and U. S. Pat. No. 4, 909,803 issued to Aziz, d s<. on March 20, 1990 The term "incontinent article" refers to pads, undergarments (pads held in place by s wsp~on system of some type, such as a belt, or the Iike), insects for absorbent articles, cspacityr boosters for absorbent articles, briefs, bed pads, and the like, regardless of whether they are worn by adults or other incontinent persons. Suitable incontinent articles that can be provided with the topsheet ddrn'bed herein are discloxd in U.S. Pat. No. 4,253,461 issued to Strickland, et al. on March 3, 1981; U.S. Pat. Nos. 4,597,760 and 4,597,761 issued to Buell;
W095/i3773 21 7 5 9 9 1 P~~S9s~i309;
the above-mentioned U.S. Pat No. 4,704,115; U.S. Pat. No. 4,909,802 issued to Ahr, et al.; and U.S. Pat. No. 4,964,860 issued to Gipson, et al. on Oct. 23, 1990' The term 'sanitary napkin' rekrs to an article which is worn by females 5 adjacent to the pudenda! region that is intended to absorb and contain various exudates which are discharged from the body (e.g., blood, menses and urine).
Suitable sanitary napkins that can be provided with the topsheet described herein are disclosed in U.S. Pat. No. 4,285,343, issued to McNair on Aug. 25, 1981;
U.S Pat. Nos. 4,589, 876 and 4,687,478 issued to Van Tilburg on May 20, 1986 and Aug. 18, 1987 respectively, U.S Pat. Nos. 4,917,697 and 5,007,906 issued to Osborn, et al. on April 17, 1990 and April 16, 1991, respectively, and U.S.
Pat. Nos. 4,950,264 and 5,009,653 issued to Osborn on Aug. 21, 1990 and April 23, 1991, rapxdvely.
The term "pantiliner" refers to absorbent articles that are less bulky than sanitary napkins which are generally worn by women betvvaen their menstrual periods. Suitable pantiliners that can be provided with the topshxt descn'bed herein are disclosed in U.S. Pal. No. 4,738,676 issued to Osborn on April 19, 1988.
Fig. 1 shows a simpli5ed absorbent article 10 that could represent a diaper prior to its being placed on a wearer. It should be understood, however, that the present invention is not limited to the particular type or configuration of absorbent article shown in the drawings. As shown in Figs. 2 and 3, such an absorbent article 10 basically comprises a topsheet 12, a backsheet 14, and an absorbent core 16.
The absorbent article 10 has two sirrfiuxs, a body-contacting sruface (or "body sur6oe') l0a and a s<rrfaa lOb. The body auface l0a is iatarded to be worn adjsceru to the body of the weans. The garment surface lOb of the absorbent article 10 (shown in Fig. 2) is on the opposite side and is intended to be placed sdjacatt to the wearer's undergarm«tts or clothing when the absorbent article 10 is worn.
The absorbent article 10 has two centerlines, a longitudinal centerline I
and a transverse centerline t. The term "longitudinal", as used hervein, refers to a line, axis or direction in the plane of the absorbent article 10 that is generally aligned with (e.g., approximately parallel to) a vertical plane which bisects a standing wearer into leR and right body halves when the absorbent article 10 is worn. The terms 'transverse" or "lateral" as used herein, are interchangeable, and refer to a line, axis or direction which lies within the plane of the absorbent article 10 that is general perpendicular to the longitudinal direction. Fig. 1 ::V,a:
:,:;.
WO 95/13773 21 7 5 9 9 ~ - PCT/US94/13097 shows that the absorbent article 10 has two spaced apart longitudinal edges 18 and two spaced apart transverse or end edges (or "ends") 20, which together form the periphery 22 of the absorbent article 10.
The topaheet 12 is compliant, soft-feeling and non-irritating to the wearer's skin. Further, topsheet 12 is liquid permeable, permitting liquids to readily penetrate through its thicW as. The topsheet 12 has a body-facing side or face 12a and a garment-facing side or face 12b, two longitudinal or side edges 12c and two end edges 12d. (A similar numbering system will be used for the other components of the diaper 10. That is, the side of the component facing the wearer's body will be designated by the number of the component and a reference letter "a", the side facing the wearer's undergarments by the number of the component and the letter "b", sad the side and end edges by the number of the component and the reference letters "c" and "d" respectively.) Fig. 4 is as enlarged, partially segmented, perspective illustration of a prior art macroscopically expanded, three-dimensional, fiber-like, apertured, plastic film 26 which has been found highly suitable for use as a topsheet in disposal absorbent articles. Prior art plastic 51m 26 is generally in accordance with the teachings of commonly assigned U.S. Pal. No. 4,342,314 issued to Itadel, et al. on Aug. 3, 1982. _ .
The plastic film 26 exhrbits a multiplicity of apertures, e.g., apertures 31, which are formed by a multiplicity of intersecting fiber-like elements, e.g., elements 32, 33, 34, 35 and 36 interconnected to one another in the first surface 40 of the web. Each fiber-like element comprises a base portion, e.g., base portion 41 lob in plane 42. Each base portion has a sidewall portion, e.g., sidewall portions 43, attached to each edge thereof. The sidewall portions extend garaally is the direction of a second surface 45 of the web. The intersecting aidewall portions of the fiber-like elements are interconnected to one another intermediate the 5rst arrd second of the web, and terminate substantially cona>rrmtly with one another in the plane 46 of the second surface to form spernua 39 in the second surface 45 of the web. The capillaries 49 formed by the intcconmaxed sidewall portions allows for free transfer of fluid from the 5rst aruiace of the web directly to the second surface of the web without lateral transmission of the fluid between the adjacent capillaries.
The apattued plastic film 26 is manufrom a liquid impervious, preferably thermoplastic mataisl. The thermoplastic material for use in the manufacture of the apertured plastic film 26 is selected from a group generally consisting of polyethylene, polypropylene, polyvinyl chloride, starch base resins, ~:
WO 95/13773 217 5 9 91 P~~s9a/1309?
polyvinyl alcohol, poiyurethanes, poiycaproiactone cellulose esters and blends thereof.
Examples of other macroscopically expanded, three-dimensional, apaaued, plastic webs are disclosed in U.S. Pat. No. 3,939,135 issued to Thompson on Dec. 30, 1975; U.S. Pat. No. 4,324,426, issued to Mullane, et al.
on April 13, 1982; and U.S. Pat. No. 4,463,045, issued to Ahr, et al on Juiy 31, 1984 .
Fig. 5 is an enlarged, partially segmented, petspe~ve illustration of a particularly preferred embodiment of a fibrous and apertured, plastic web 112.
F'brous and apertured plastic web 112 is particularly well suited for use as a topsheet,.e.g., topsheet 12 illustrated in Fig. 1, on an absorbent article, such as a diaper or sanitary napkin. Web 112 comprises a plurality of fibers 124 secured to a macroscopically expanded, three-dimensional, =-°rtured, plastic web 126.
Apat<und plastic web 126 is generally in accordance with the teachings of commonly assigned U.S. Pat. No. 4,342,314 issued to Radel et al. lttferring now to Fig. 6, the fibers 124 are saxtred to the aperritred plastic web 126 along the first s<ufacx 140 and extend substantially into the capillaries 149 where a substantial portion of the fibers 124 are secured to the sidewall portions 143 of the apertured plastic film 126. Despite the presence of fibers 124 the appearance of web 112, is generally similar to that of prior art web 26 illustrated in Fig. 4, that is, the pentagonal shape of capillaries 49 of web 26 is similar to the pentagonal shape of capillaries 149 of web 112.
By seauing the fibers 124 to both the first surface 140 and the sidewall portions 143 of the spattued plastic web 126, a substantial portion of the fibers 124 do not span the capillaries 149, where the fibers would possibly hinder the trsasfa of bodt'ly fluids finm the first 140 to the second surface 145 of the web. By leaving the capillaries substantially open and free of fibers, the fibrous and aperttwed, composite web 112 is able to handle heavy or viscous fluids such as runny bowel movement, when the composite web is employed as a topsheet on a disposable diaper. Some fibers 124 may span across the capillaries 149, but they will not aubsnrrtiaUy hinder the transmission of bodily fluids from the first su:fice 140 to the second s<uface 145 of the web.
Due to the saxrrement of the fibers 124 to the first sur6ce 140 and the sidevvall portions 143 of the apanucd plastic web 126, the composite vveb 112 has an open arcs approaching that of apaarred plastic web 126. Therefore, fluid deposited on the first surface 140 is transmitted from the first or wearer cotttacting s<uface to the second or pad contacting sruface 145 of the composite web 112.
2175i991.~ 8 The addition of the fibers 124 to the first or wearer contacting surface of the apertured plastic web 126 provides a textured surface which when utilized as a topsheet on an absorbent article is in contact with the wearer's skin. The tactile perception of the web 112 is similar to that of a fibrous nonwoven web.
The addition of the fibers to the wearer contacting surface of the apertured plastic film 126 reduces the plastic feel associated with such films which some users resist placing in contact with their skin.
The addition of the fibers 124 to the wearer contacting surface of the apertured plastic film 126 also provides the web 112 with a visual distinction from the plastic web 126. That is, the fibers provide a roughness or an irregularity such that light incident upon the visible surface of the web 15 substantially diffused into a multiplicity of directions rather than being speculary J
reflected, thereby providing a non-glossy visible surface which reduces the wearer's perception that the web is comprised of plastic.
In one preferred embodiment, the fibers 124 may be in the form of a nonwoven fabric or web. The nonwoven fabric may be manufactured from a wide range of material such as natural fibers (e.g., wood, or cotton fiber), synthetic fibers (e.g., polyester, polypropylene) or a combination thereof.
The nonwoven fabric is preferably made from fibers selected from a group consisting of polypropylene, polyester, polyethylene polyvinyl alcohol, starch base resins, polyurethanes, cellulose and cellulose esters.
There are a number of manufacturing techniques which may be utilized to manufacture the nonwoven fabric. For example, nonwoven fabric may be resin-bonded, needle punched, spunbonded, carded, the latter including, thermally bonded, air-thru bonded, and spunlaced fabrics. A preferred nonwoven fabric is a thernially bonded polypropylene fabric.
The nonwoven fabric preferably has a relatively low basis weight ranging fi~om about l.Og/sq.m. to about 22 g/sq.m. For one embodiment, the nonwoven fabric has a basis weight range of from about 15 to about 17 grams per square yard (about 18 to about 20 g/sq.m.) and a caliper of from about 3 to about 5 mils (about 0.76 to about 0.12 mm.) when measured under a load of about 200 pascals. Such a nonwoven fabric is firrther characterized by a maacimum wet or dry tensile strength of less than about 600 grams per centimeter in the longitudinal or machine direction and less than about 150 grams per centimeter in the cross machine direction.
In another preferred embodiment, the nonwoven fi~bric has a lighter weight of from about 8 g/sq.m. to about 10 g/sq.m. Such lighter nonwoven fabrics are highly preferred. They are preferred because they can be used (with a .fin...... .___.v_...._.. .._. _ ..._.._..
.. WO x/13773 21 7 5 ~ 9 ' PCT/US94/1309' lightweight film) to form a composite fibrous and apertured, plastic web 112 that is su$cientiy thin and lightweight that it behaves as a single sheet of material.
This provides the advantages of being more flexible and requiring the use of smaller amouttu of raw materials.
In another preferred embodiment, the fibers 124 may be meltblown onto the plastic web 126. Preferably, the meltblown fibers 124 are deposited on the plastic web in a tsttge of basis weighu up to about 22 g/sq.m. and most preferably in a range of basis weighu from about 2.0 g/sq.m. to about 5.0 g/sq.m. The meltblown fibers may be selected firm a wide range of materials selected from the group consisting of polypropylene, polyester, polyethylene polyvinyl alcohol, starch base resins, polyurethanes, cellulose and cellulose esters. A detailed description of this particular mtthod of securing the fibers 124 to the plastic web 126 is described in greater detail below.
A suitable process of preparing the fibrous and aperntred, plastic web 112 of the presets imrendon is shown in Fig. 7. In the embodiment shown in Fig. 7, a web of mohen resin Z00 is extruded from a convernional extruder 201 onto the s<u6cx of a forming drum 205 about which s forming structure 210 rotates. A web of nonwoven fi~bric 202 is fed fi-om a supply roll 203 over nip roll 204 onto the web of mohen resin 200 located on forming structure 210.
The web of nonwoven fisbric 202 adheres to the semi-mohen resin forming a composite web 206. The forming drum 205 preferably includes an internally locatod vacuum chamber 220 which is preferably stationary relative to the moving forming structure 210. As the composite web 206 of semi-molten resin 200 and nomvoven fitbric 202 passes across vacuum chamber 220 a pneumatic pressure is applied to the composite web to cause the composite web to be urged into substantial conformance with the forming structure 210.
The macroscopic cross-section of forming strucatre 210 is visible in the greatly enlarged 5~sgmeatary paspxtive illustration of Fig. 8. Methods of con~avcring a suitable three-dimensional tubular forming member similar to that ~lustiated in Fig. 8 are disclosed in commonly assigned U.S. Pat. No.
4,508,256 issued to Itadd et ~. on Apr. 2, 1985 and in commonly assigned U.S. Pat. No.
4,509,908 issued to MuUatte, 3r. on Apr. 9, 1985, As the composite web 206 of semi-mohen resin 200 and nonwoven fitbric 202 conforms with the macroscopic cross-section of forming structure 210 a fibrous and threo-dimensional, macroscopically expanded, apertured web is similar to web 112 illustrated in Fig. 5. The web has a first surfitc,~
and a second s~uface located in planes remote from one another. The formed . , .:
WO 95/13773 ~ PCT/US94/1309' web includes a plurality of capillaries which extend from the first surface to the second surface. The capillaries are defined by a plurality of sidewall portions interconnected to one another intermediate the first and second surfaces and which terminate in the second surface of the web.
5 The pras<ue of vacuum chamber 220 causes the nonwoven fabric to be pulled against the first siufirce of the plastic web and down into the capillaries of the plastic web. The pressure applied by the vacuum chamber 220 also helps to bond or secure the nonwoven fitbrie to the base portions and the sidewall portions of the first aufi<cx of the plastic web.
10 The composite web 208 is preferably treated with an effective amount of surfitce active agent or surfactant. The surfactant provides the nonwoven fitbric's sruface with greater polararizebility than it would have without the surfactant being added. I-figher surface polarity yields, higher wet ability.
Suitable s~ufactants include a product known commercially ATNER645 manufactured by ICIS Specialty Ch. The nonwoven fitbric may be treated with a surfactant prior to or during the time it is manufi<ctiued. For example, it may be trated after it is umvound firom feedroll 203. The wrfiictant may be applied by any know technique, such as spraying, padding, or by the use of transferals.
The surfactant can sjternabveiy (or additionally) be incorporated into the nonwoven fitbric such as between or within the fibers of the nonwoven fitbric.
Preferably, the nomvoven is treated with a surfactant prior to the time it is supplied in the present process.
After the nonwoven firbric and apertured plastic film have been have been formed into composite web 208, composite web 208 is removed from forming drum 210 by way of nip roll 225. The composite web 208 may be fed to a rewind station for temporary storage or may be utilized without further procx~8 as a tops>uet in an absorbent article.
Another suitable process for preparing the topsheet 112 is shown in Fig.
9. In the embodiment shown in 1 ig. 9, a web of mohen resin 300 is extruded fin:<i a conventional extruder 301 onto the surface of a fotining drum 305 about which a foaming structure 310 rotates. A stream of meltbiown fibers 302 is blown from die 303 onto the web of molten resin 300 which is supported by forming structure 310. The forming drum 305 preferably includes an internally located vacuum chamber 320 which is preferably stuionary relative to the moving forming structure 310. As the molten resin 300 and the meltblown fibers 302 pass across vacuum chamber 320 a pneumatic pressure is applied to the mohen resin and the meltblown fibers to cause the resin along with the fibers to * = Trade-mark WO 95/13773 ~ PCTJUS94/13097 be urged into substantial conformance with the foaming structure 310. The forming strocture 310 is similar to forming structure 110 illustrated in Fig.
7.
In the embodiment of Fig. 9, a non-water soluble adhesive 342 may be added from applicator 340 onto molten resin 300 prior to the addition of meltblown fibers 302. The adhesive 342 helps ensure the attachment of meltblown fibers 302 to molten resin 300.
To create a topsheet similar to that illustrated in Fig. 5, where the nonwoven layer does not span across or block the capillaries of the apertured plastic film, the nonwoven or fibrous matter must be able to conform with the general shape of the macroscopically expanded, three-dimensional forming structure. To permit the nonwoven or fibrous matter to conform with the shape of the foaming structure it must not be so dense or tightly bonded such that the individual fibers are not permitted to be pulled down into the capillaries of the apertured plastic film' where they are secured with the sidewall portions of the apertured plastic web.
In another embodiment, the stream of meltblown fibers may be applied to a molten resin after the resin has been formed into a macroscopically expanded, three-dimensional, apertured plastic web, similar to that illustrated in Fig.
4.
This embodiment is illustrated in Fig. 9, when die 350 is positioned downstream of the vacuum forming operation. The fibers must be blown from a die with such a force that they are able to extend in the capillaries of the macroscopically expanded, three-dimensional, apertured, plastic web. By varying the velocity of the meltblown fibers, the effective momentum and it turn the depth of penetration of the meltblown fibers into the capillaries of the plastic web can be varied. The fibers must be heated to such a temperature or the apertured, plastic web must be heated such that the meltblown fibers will adhere to the apertured, plastic web.
Another process for preparing the fibrous and apertured, plastic web of the present immtion is shown in Fig. 10. A stream of meltblown fibers 402 is blown from die 403 onto the surface of drum 423. A web of molten resin 400 is extruded from a conventional extruder 401 onto meltblown fibers 402 to create a composite web 424. Composite web 424 is fed over nip roll 409 onto the surface of a foaming drum 405 about which a forming structure 410 rotates such that the molten resin side of composite web 424 is in contact with forming structure 410. As the composite web 424 passes across internally located vacuum chamber 420 a pneumatic pressure is applied to composite web 424 to cause the composite web to be urged into substantial conformance with forming WO 95Ii3773 PCT/US94/13097 structure 410. After forming, web 408 is removed from forming drum 405 by way of nip roll 425.
In the process illustrated in Fig. 10, a set of calendaring rolls 430 may be added to help ensure that the composite web remains in tact. In the embodiment illustrated in Fig. 10, the calendaring rolls 430 are added prior to the composite web reaching the forming drum 405. Calendaring rolls may also be added after the formed web 408 is removed from forming drum 405.
The absorbent core 16 is positioned between the topsheet 12 and the backsheet 14. The absorbent core 16 may be any absorbent means which is capable of absorbing or retaining liquids (e.g., menses and/or urine). As shown in Figs. 1-3, the absorbent core 16 has a body surface, a garment surface, side edges and end edges. The absorbent core 16 may be manufactured in a wide variety of sizes and shapes (e.g., rectangular, ~.~?l, hourglass, dog bone, asymmetric, etc.) and from a wide variety of squid-absorbent materials commonly used in absorbent articles such as comminuted wood pulp which is generally referred to as airfelt. Examples of other suitable materials include creped cellulose wadding, cross-linked cellulose fibers, absorbent foams, absorbent sponges, synthetic staple fibers, polymeric fibers, hydrogel-forming polymer gelling agents, peat moss, combinations of the foregoing, or any equivalent material or combinations of materials. The configuration and construction of the absorbent core may also be varied (e.g., the absorbent core may have varying caliber zones (e.g., profiled so as to be thicker in the center) hydrophilic gradients, super absorbent gradients, or lower density and lower average basis weight acquisition zones); or may comprise one or more layers or structures. The total absorbent capacity of the absorbent core should, however, be compatible with the desired loading and the intended use of the absorbent article. Further, the size and absorbent capacity of the absorbent core may be varied to accommodate different uses such as incontinence pads, pantiliners, regular sanitary napkins, or overnight sanitary napkins.
Suitable cross-linked cellulose fibers are described in U.S. Pat. No.
4,888,093, issued to Cook, et al. on Dec. 19, 1989;
U.S. Pat. No. 4,822,543, issued to Dean, et al. on April 18, 1989; U.S. Pat.
No. 4,889,595, issued to Schoggen, et al. on Dec. 26, 1989; U.S. Pat. No. 4,889,596, issued to Schoggen, et al. on Dec. 26, 1989; U.S. Pat. No. 4,898,642 issued to Moore, et al. on Feb. 6, 1990; U.S. Pat. No. 4,935,022, issued to Lash, et al. on June 19, 1990.
The characteristics of the absorbent core 16 for particular types of absorbent articles are described in greater detail in the patents and documents _ I ._..~ _ I
_ _ Ocher suitable absorbent core arrangements are described in U.S. Pat. Nos. 4,988,344 and 4,988,345, and European Patent Application Publication No. 0 198 683, published Oct. 22, 1986 in the name of Duetth et al. _ 'The absorbent article could also include any additional layers or other components such as are described in the patenu incorporated by reference. For example, the absorbent article 10 may comprise an acquisition byer or patch of cross-linked ceUuiose fibers positioned between the topsheet 12 and the absorbent core 16.
The backsheet 14 and the topsheet 12 are positioned adjacent to the surfacx and the body saufacx, respectively, of the absorbent core 16 and are preferably joined thereto and to each other by attachment means (not shown) such as those well known in the art. For example, the backsheet 14 and/or the topsheet 12 may be secured to the absorbent core 16 by a uniform continuous layer of adhauve, a patterned layer of adhesive, or an array of separate lines, spirals, spots of adhesive, or meltblown adhesives. Adhesive which have been found to be dory are manufacarre by HB Fuller Company of St. Paul, Mrnnaota under the designation HL-1258. The attachment means will preferably comprise an open pattern network of filaments of adhesives as is disclosed in U.S. Pat. No. 4,573,986 issued to Muietola et al. on March 4, 1986, An exemplary attachment means of an open patrtern network of filaments comprises several Iines of adhesive filaments swirled into a spiral pattern such as illustrated by the apparatus and method shown in U.S. Pat. No. 3,911,173 issued to Sprague, Jr. on October 7, 19?5; U.S. Pat. No. 4,785,996 issued to Zieka et al. on November 22, 1978;
and U.S. Pat. No. 4,842,666 issued to Werenicz on June 27, 1989.
_ Aharrstively, the attachment mearu may comprise heat bonds, pressure bonds, ultrasonic bonds, dynamic n>echanical bonds, or any other suitable stt$chment means or combinations of these attachment means as arc known in the art.
The backsheet 14 is impervious to liquids and is preferably manui~ctiu~ed from a thin plastic film, although other $exible liquid impervious materials may also be used. The backsheet 14 prevents liquid contained in absorbent core 16 from wrtting articles which contact the absorbent article 10. Polyethylene films having a thicknaa of from about 0.001 to about 0.002 inches (0.0025 to 0.0051 cm.) have been used for the backsheet 14 with satisfactory results. As used 1 .,~.
t " " 14 herein, the term flexible refers to materials which are compliant and which will readily conform to the general shape and contours of the human body.
The backsheet 14 is superimposed on the garment-facing side 16b of absorbent core 16 and preferably extends beyond the edges thereof. The topsheet 12 is superimposed over the body-facing side 16a of the absorbent core 16, and may also extend beyond the edges of the core 16. The absorbent core 16 is, therefore, positioned between the topsheet 12 and the backsheet 14. The topsheet 12 and backsheet 14 are joined to each other such as around their peripheries. The topsheet 12 and backsheet 14 can be joined in any suitable manner such as by the use of adhesives, crimping, heat-sealing, or ultrasonic bonding.
While a number of particularly preferred embodiments in the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications can be made without the departing from the spirit and scope of the invention, and it is intended to the appended claims all such modifications that are in the scope of this invention.
._
Examples of other macroscopically expanded, three-dimensional, apaaued, plastic webs are disclosed in U.S. Pat. No. 3,939,135 issued to Thompson on Dec. 30, 1975; U.S. Pat. No. 4,324,426, issued to Mullane, et al.
on April 13, 1982; and U.S. Pat. No. 4,463,045, issued to Ahr, et al on Juiy 31, 1984 .
Fig. 5 is an enlarged, partially segmented, petspe~ve illustration of a particularly preferred embodiment of a fibrous and apertured, plastic web 112.
F'brous and apertured plastic web 112 is particularly well suited for use as a topsheet,.e.g., topsheet 12 illustrated in Fig. 1, on an absorbent article, such as a diaper or sanitary napkin. Web 112 comprises a plurality of fibers 124 secured to a macroscopically expanded, three-dimensional, =-°rtured, plastic web 126.
Apat<und plastic web 126 is generally in accordance with the teachings of commonly assigned U.S. Pat. No. 4,342,314 issued to Radel et al. lttferring now to Fig. 6, the fibers 124 are saxtred to the aperritred plastic web 126 along the first s<ufacx 140 and extend substantially into the capillaries 149 where a substantial portion of the fibers 124 are secured to the sidewall portions 143 of the apertured plastic film 126. Despite the presence of fibers 124 the appearance of web 112, is generally similar to that of prior art web 26 illustrated in Fig. 4, that is, the pentagonal shape of capillaries 49 of web 26 is similar to the pentagonal shape of capillaries 149 of web 112.
By seauing the fibers 124 to both the first surface 140 and the sidewall portions 143 of the spattued plastic web 126, a substantial portion of the fibers 124 do not span the capillaries 149, where the fibers would possibly hinder the trsasfa of bodt'ly fluids finm the first 140 to the second surface 145 of the web. By leaving the capillaries substantially open and free of fibers, the fibrous and aperttwed, composite web 112 is able to handle heavy or viscous fluids such as runny bowel movement, when the composite web is employed as a topsheet on a disposable diaper. Some fibers 124 may span across the capillaries 149, but they will not aubsnrrtiaUy hinder the transmission of bodily fluids from the first su:fice 140 to the second s<uface 145 of the web.
Due to the saxrrement of the fibers 124 to the first sur6ce 140 and the sidevvall portions 143 of the apanucd plastic web 126, the composite vveb 112 has an open arcs approaching that of apaarred plastic web 126. Therefore, fluid deposited on the first surface 140 is transmitted from the first or wearer cotttacting s<uface to the second or pad contacting sruface 145 of the composite web 112.
2175i991.~ 8 The addition of the fibers 124 to the first or wearer contacting surface of the apertured plastic web 126 provides a textured surface which when utilized as a topsheet on an absorbent article is in contact with the wearer's skin. The tactile perception of the web 112 is similar to that of a fibrous nonwoven web.
The addition of the fibers to the wearer contacting surface of the apertured plastic film 126 reduces the plastic feel associated with such films which some users resist placing in contact with their skin.
The addition of the fibers 124 to the wearer contacting surface of the apertured plastic film 126 also provides the web 112 with a visual distinction from the plastic web 126. That is, the fibers provide a roughness or an irregularity such that light incident upon the visible surface of the web 15 substantially diffused into a multiplicity of directions rather than being speculary J
reflected, thereby providing a non-glossy visible surface which reduces the wearer's perception that the web is comprised of plastic.
In one preferred embodiment, the fibers 124 may be in the form of a nonwoven fabric or web. The nonwoven fabric may be manufactured from a wide range of material such as natural fibers (e.g., wood, or cotton fiber), synthetic fibers (e.g., polyester, polypropylene) or a combination thereof.
The nonwoven fabric is preferably made from fibers selected from a group consisting of polypropylene, polyester, polyethylene polyvinyl alcohol, starch base resins, polyurethanes, cellulose and cellulose esters.
There are a number of manufacturing techniques which may be utilized to manufacture the nonwoven fabric. For example, nonwoven fabric may be resin-bonded, needle punched, spunbonded, carded, the latter including, thermally bonded, air-thru bonded, and spunlaced fabrics. A preferred nonwoven fabric is a thernially bonded polypropylene fabric.
The nonwoven fabric preferably has a relatively low basis weight ranging fi~om about l.Og/sq.m. to about 22 g/sq.m. For one embodiment, the nonwoven fabric has a basis weight range of from about 15 to about 17 grams per square yard (about 18 to about 20 g/sq.m.) and a caliper of from about 3 to about 5 mils (about 0.76 to about 0.12 mm.) when measured under a load of about 200 pascals. Such a nonwoven fabric is firrther characterized by a maacimum wet or dry tensile strength of less than about 600 grams per centimeter in the longitudinal or machine direction and less than about 150 grams per centimeter in the cross machine direction.
In another preferred embodiment, the nonwoven fi~bric has a lighter weight of from about 8 g/sq.m. to about 10 g/sq.m. Such lighter nonwoven fabrics are highly preferred. They are preferred because they can be used (with a .fin...... .___.v_...._.. .._. _ ..._.._..
.. WO x/13773 21 7 5 ~ 9 ' PCT/US94/1309' lightweight film) to form a composite fibrous and apertured, plastic web 112 that is su$cientiy thin and lightweight that it behaves as a single sheet of material.
This provides the advantages of being more flexible and requiring the use of smaller amouttu of raw materials.
In another preferred embodiment, the fibers 124 may be meltblown onto the plastic web 126. Preferably, the meltblown fibers 124 are deposited on the plastic web in a tsttge of basis weighu up to about 22 g/sq.m. and most preferably in a range of basis weighu from about 2.0 g/sq.m. to about 5.0 g/sq.m. The meltblown fibers may be selected firm a wide range of materials selected from the group consisting of polypropylene, polyester, polyethylene polyvinyl alcohol, starch base resins, polyurethanes, cellulose and cellulose esters. A detailed description of this particular mtthod of securing the fibers 124 to the plastic web 126 is described in greater detail below.
A suitable process of preparing the fibrous and aperntred, plastic web 112 of the presets imrendon is shown in Fig. 7. In the embodiment shown in Fig. 7, a web of mohen resin Z00 is extruded from a convernional extruder 201 onto the s<u6cx of a forming drum 205 about which s forming structure 210 rotates. A web of nonwoven fi~bric 202 is fed fi-om a supply roll 203 over nip roll 204 onto the web of mohen resin 200 located on forming structure 210.
The web of nonwoven fisbric 202 adheres to the semi-mohen resin forming a composite web 206. The forming drum 205 preferably includes an internally locatod vacuum chamber 220 which is preferably stationary relative to the moving forming structure 210. As the composite web 206 of semi-molten resin 200 and nomvoven fitbric 202 passes across vacuum chamber 220 a pneumatic pressure is applied to the composite web to cause the composite web to be urged into substantial conformance with the forming structure 210.
The macroscopic cross-section of forming strucatre 210 is visible in the greatly enlarged 5~sgmeatary paspxtive illustration of Fig. 8. Methods of con~avcring a suitable three-dimensional tubular forming member similar to that ~lustiated in Fig. 8 are disclosed in commonly assigned U.S. Pat. No.
4,508,256 issued to Itadd et ~. on Apr. 2, 1985 and in commonly assigned U.S. Pat. No.
4,509,908 issued to MuUatte, 3r. on Apr. 9, 1985, As the composite web 206 of semi-mohen resin 200 and nonwoven fitbric 202 conforms with the macroscopic cross-section of forming structure 210 a fibrous and threo-dimensional, macroscopically expanded, apertured web is similar to web 112 illustrated in Fig. 5. The web has a first surfitc,~
and a second s~uface located in planes remote from one another. The formed . , .:
WO 95/13773 ~ PCT/US94/1309' web includes a plurality of capillaries which extend from the first surface to the second surface. The capillaries are defined by a plurality of sidewall portions interconnected to one another intermediate the first and second surfaces and which terminate in the second surface of the web.
5 The pras<ue of vacuum chamber 220 causes the nonwoven fabric to be pulled against the first siufirce of the plastic web and down into the capillaries of the plastic web. The pressure applied by the vacuum chamber 220 also helps to bond or secure the nonwoven fitbrie to the base portions and the sidewall portions of the first aufi<cx of the plastic web.
10 The composite web 208 is preferably treated with an effective amount of surfitce active agent or surfactant. The surfactant provides the nonwoven fitbric's sruface with greater polararizebility than it would have without the surfactant being added. I-figher surface polarity yields, higher wet ability.
Suitable s~ufactants include a product known commercially ATNER645 manufactured by ICIS Specialty Ch. The nonwoven fitbric may be treated with a surfactant prior to or during the time it is manufi<ctiued. For example, it may be trated after it is umvound firom feedroll 203. The wrfiictant may be applied by any know technique, such as spraying, padding, or by the use of transferals.
The surfactant can sjternabveiy (or additionally) be incorporated into the nonwoven fitbric such as between or within the fibers of the nonwoven fitbric.
Preferably, the nomvoven is treated with a surfactant prior to the time it is supplied in the present process.
After the nonwoven firbric and apertured plastic film have been have been formed into composite web 208, composite web 208 is removed from forming drum 210 by way of nip roll 225. The composite web 208 may be fed to a rewind station for temporary storage or may be utilized without further procx~8 as a tops>uet in an absorbent article.
Another suitable process for preparing the topsheet 112 is shown in Fig.
9. In the embodiment shown in 1 ig. 9, a web of mohen resin 300 is extruded fin:<i a conventional extruder 301 onto the surface of a fotining drum 305 about which a foaming structure 310 rotates. A stream of meltbiown fibers 302 is blown from die 303 onto the web of molten resin 300 which is supported by forming structure 310. The forming drum 305 preferably includes an internally located vacuum chamber 320 which is preferably stuionary relative to the moving forming structure 310. As the molten resin 300 and the meltblown fibers 302 pass across vacuum chamber 320 a pneumatic pressure is applied to the mohen resin and the meltblown fibers to cause the resin along with the fibers to * = Trade-mark WO 95/13773 ~ PCTJUS94/13097 be urged into substantial conformance with the foaming structure 310. The forming strocture 310 is similar to forming structure 110 illustrated in Fig.
7.
In the embodiment of Fig. 9, a non-water soluble adhesive 342 may be added from applicator 340 onto molten resin 300 prior to the addition of meltblown fibers 302. The adhesive 342 helps ensure the attachment of meltblown fibers 302 to molten resin 300.
To create a topsheet similar to that illustrated in Fig. 5, where the nonwoven layer does not span across or block the capillaries of the apertured plastic film, the nonwoven or fibrous matter must be able to conform with the general shape of the macroscopically expanded, three-dimensional forming structure. To permit the nonwoven or fibrous matter to conform with the shape of the foaming structure it must not be so dense or tightly bonded such that the individual fibers are not permitted to be pulled down into the capillaries of the apertured plastic film' where they are secured with the sidewall portions of the apertured plastic web.
In another embodiment, the stream of meltblown fibers may be applied to a molten resin after the resin has been formed into a macroscopically expanded, three-dimensional, apertured plastic web, similar to that illustrated in Fig.
4.
This embodiment is illustrated in Fig. 9, when die 350 is positioned downstream of the vacuum forming operation. The fibers must be blown from a die with such a force that they are able to extend in the capillaries of the macroscopically expanded, three-dimensional, apertured, plastic web. By varying the velocity of the meltblown fibers, the effective momentum and it turn the depth of penetration of the meltblown fibers into the capillaries of the plastic web can be varied. The fibers must be heated to such a temperature or the apertured, plastic web must be heated such that the meltblown fibers will adhere to the apertured, plastic web.
Another process for preparing the fibrous and apertured, plastic web of the present immtion is shown in Fig. 10. A stream of meltblown fibers 402 is blown from die 403 onto the surface of drum 423. A web of molten resin 400 is extruded from a conventional extruder 401 onto meltblown fibers 402 to create a composite web 424. Composite web 424 is fed over nip roll 409 onto the surface of a foaming drum 405 about which a forming structure 410 rotates such that the molten resin side of composite web 424 is in contact with forming structure 410. As the composite web 424 passes across internally located vacuum chamber 420 a pneumatic pressure is applied to composite web 424 to cause the composite web to be urged into substantial conformance with forming WO 95Ii3773 PCT/US94/13097 structure 410. After forming, web 408 is removed from forming drum 405 by way of nip roll 425.
In the process illustrated in Fig. 10, a set of calendaring rolls 430 may be added to help ensure that the composite web remains in tact. In the embodiment illustrated in Fig. 10, the calendaring rolls 430 are added prior to the composite web reaching the forming drum 405. Calendaring rolls may also be added after the formed web 408 is removed from forming drum 405.
The absorbent core 16 is positioned between the topsheet 12 and the backsheet 14. The absorbent core 16 may be any absorbent means which is capable of absorbing or retaining liquids (e.g., menses and/or urine). As shown in Figs. 1-3, the absorbent core 16 has a body surface, a garment surface, side edges and end edges. The absorbent core 16 may be manufactured in a wide variety of sizes and shapes (e.g., rectangular, ~.~?l, hourglass, dog bone, asymmetric, etc.) and from a wide variety of squid-absorbent materials commonly used in absorbent articles such as comminuted wood pulp which is generally referred to as airfelt. Examples of other suitable materials include creped cellulose wadding, cross-linked cellulose fibers, absorbent foams, absorbent sponges, synthetic staple fibers, polymeric fibers, hydrogel-forming polymer gelling agents, peat moss, combinations of the foregoing, or any equivalent material or combinations of materials. The configuration and construction of the absorbent core may also be varied (e.g., the absorbent core may have varying caliber zones (e.g., profiled so as to be thicker in the center) hydrophilic gradients, super absorbent gradients, or lower density and lower average basis weight acquisition zones); or may comprise one or more layers or structures. The total absorbent capacity of the absorbent core should, however, be compatible with the desired loading and the intended use of the absorbent article. Further, the size and absorbent capacity of the absorbent core may be varied to accommodate different uses such as incontinence pads, pantiliners, regular sanitary napkins, or overnight sanitary napkins.
Suitable cross-linked cellulose fibers are described in U.S. Pat. No.
4,888,093, issued to Cook, et al. on Dec. 19, 1989;
U.S. Pat. No. 4,822,543, issued to Dean, et al. on April 18, 1989; U.S. Pat.
No. 4,889,595, issued to Schoggen, et al. on Dec. 26, 1989; U.S. Pat. No. 4,889,596, issued to Schoggen, et al. on Dec. 26, 1989; U.S. Pat. No. 4,898,642 issued to Moore, et al. on Feb. 6, 1990; U.S. Pat. No. 4,935,022, issued to Lash, et al. on June 19, 1990.
The characteristics of the absorbent core 16 for particular types of absorbent articles are described in greater detail in the patents and documents _ I ._..~ _ I
_ _ Ocher suitable absorbent core arrangements are described in U.S. Pat. Nos. 4,988,344 and 4,988,345, and European Patent Application Publication No. 0 198 683, published Oct. 22, 1986 in the name of Duetth et al. _ 'The absorbent article could also include any additional layers or other components such as are described in the patenu incorporated by reference. For example, the absorbent article 10 may comprise an acquisition byer or patch of cross-linked ceUuiose fibers positioned between the topsheet 12 and the absorbent core 16.
The backsheet 14 and the topsheet 12 are positioned adjacent to the surfacx and the body saufacx, respectively, of the absorbent core 16 and are preferably joined thereto and to each other by attachment means (not shown) such as those well known in the art. For example, the backsheet 14 and/or the topsheet 12 may be secured to the absorbent core 16 by a uniform continuous layer of adhauve, a patterned layer of adhesive, or an array of separate lines, spirals, spots of adhesive, or meltblown adhesives. Adhesive which have been found to be dory are manufacarre by HB Fuller Company of St. Paul, Mrnnaota under the designation HL-1258. The attachment means will preferably comprise an open pattern network of filaments of adhesives as is disclosed in U.S. Pat. No. 4,573,986 issued to Muietola et al. on March 4, 1986, An exemplary attachment means of an open patrtern network of filaments comprises several Iines of adhesive filaments swirled into a spiral pattern such as illustrated by the apparatus and method shown in U.S. Pat. No. 3,911,173 issued to Sprague, Jr. on October 7, 19?5; U.S. Pat. No. 4,785,996 issued to Zieka et al. on November 22, 1978;
and U.S. Pat. No. 4,842,666 issued to Werenicz on June 27, 1989.
_ Aharrstively, the attachment mearu may comprise heat bonds, pressure bonds, ultrasonic bonds, dynamic n>echanical bonds, or any other suitable stt$chment means or combinations of these attachment means as arc known in the art.
The backsheet 14 is impervious to liquids and is preferably manui~ctiu~ed from a thin plastic film, although other $exible liquid impervious materials may also be used. The backsheet 14 prevents liquid contained in absorbent core 16 from wrtting articles which contact the absorbent article 10. Polyethylene films having a thicknaa of from about 0.001 to about 0.002 inches (0.0025 to 0.0051 cm.) have been used for the backsheet 14 with satisfactory results. As used 1 .,~.
t " " 14 herein, the term flexible refers to materials which are compliant and which will readily conform to the general shape and contours of the human body.
The backsheet 14 is superimposed on the garment-facing side 16b of absorbent core 16 and preferably extends beyond the edges thereof. The topsheet 12 is superimposed over the body-facing side 16a of the absorbent core 16, and may also extend beyond the edges of the core 16. The absorbent core 16 is, therefore, positioned between the topsheet 12 and the backsheet 14. The topsheet 12 and backsheet 14 are joined to each other such as around their peripheries. The topsheet 12 and backsheet 14 can be joined in any suitable manner such as by the use of adhesives, crimping, heat-sealing, or ultrasonic bonding.
While a number of particularly preferred embodiments in the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications can be made without the departing from the spirit and scope of the invention, and it is intended to the appended claims all such modifications that are in the scope of this invention.
._
Claims (18)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A fluid pervious web comprising:
(a) a resilient, three-dimensional, macroscopically expanded, fluid pervious plastic web having first and second surfaces located in planes remote from one another, said web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces, said sidewall portions terminating in said second surface;
and (b) a plurality of fibers secured to said first surface of said fluid pervious plastic web, said fibers extending into the capillaries of said fluid pervious plastic web and being secured to said sidewall portions.
(a) a resilient, three-dimensional, macroscopically expanded, fluid pervious plastic web having first and second surfaces located in planes remote from one another, said web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces, said sidewall portions terminating in said second surface;
and (b) a plurality of fibers secured to said first surface of said fluid pervious plastic web, said fibers extending into the capillaries of said fluid pervious plastic web and being secured to said sidewall portions.
2. The fluid pervious web of claim 1, wherein said fibers are in a nonwoven fabric.
3. The fluid pervious web of claim 1, wherein said fibers are meltblown fibers.
4. The fluid pervious web of claim 1, wherein said plastic web is comprised of a material selected from the a group consisting of polyethylene, polypropylene, polyvinylchloride, starch base resins, polyvinylalcohol, polyurethanes, polycaprolactone and cellulose esters.
5. The fluid pervious web of claim 1, wherein said web is a topsheet on an absorbent article.
6. An absorbent article comprising:
(a) a fluid pervious web comprising:
(i) a resilient, three-dimensional, macroscopically expanded, fluid pervious plastic web having first and second surfaces located in planes remote from one another, said web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces, said sidewall portions terminating in said second surface; and (ii) a plurality of fibers secured to said first surface of said fluid pervious plastic web, said fibers extending into the capillaries of said fluid pervious plastic web and being secured to said sidewall portions;
(b) a fluid impervious backsheet joined to said topsheet; and (c) an absorbent core positioned between said topsheet and said backsheet.
(a) a fluid pervious web comprising:
(i) a resilient, three-dimensional, macroscopically expanded, fluid pervious plastic web having first and second surfaces located in planes remote from one another, said web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces, said sidewall portions terminating in said second surface; and (ii) a plurality of fibers secured to said first surface of said fluid pervious plastic web, said fibers extending into the capillaries of said fluid pervious plastic web and being secured to said sidewall portions;
(b) a fluid impervious backsheet joined to said topsheet; and (c) an absorbent core positioned between said topsheet and said backsheet.
7. The absorbent article of Claim 6, wherein said fibers are in a nonwoven fabric.
8. The absorbent article of Claim 6, wherein said fibers are meltblown fibers.
9. The absorbent article of claim 6, wherein said absorbent article is a disposable diaper.
10. The absorbent article of claim 6, wherein said absorbent article is a sanitary napkin.
11. A process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web, said process comprising the steps of:
(a) extruding a polymeric film onto a forming structure, said forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic apertures which place the opposed surfaces of said forming structure in fluid communication with one another;
(b) depositing a plurality of fibers on said film to form a composite web;
and (c) applying a pneumatic pressure to composite web to cause said composite web to be urged into substantial conformance with the macroscopic, three-dimensional, cross-section of said forming structure forming a three-dimensional, macroscopically expanded, formed web having first and second surfaces, said formed web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface, said pneumatic pressure causing said fibers to be pulled against said first surface of said formed web and into said capillaries of said formed web, said fibers being secured to said first surface and said sidewall portions of said formed web forming said fibrous and apertured, three-dimensional, macroscopically expanded web.
(a) extruding a polymeric film onto a forming structure, said forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic apertures which place the opposed surfaces of said forming structure in fluid communication with one another;
(b) depositing a plurality of fibers on said film to form a composite web;
and (c) applying a pneumatic pressure to composite web to cause said composite web to be urged into substantial conformance with the macroscopic, three-dimensional, cross-section of said forming structure forming a three-dimensional, macroscopically expanded, formed web having first and second surfaces, said formed web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface, said pneumatic pressure causing said fibers to be pulled against said first surface of said formed web and into said capillaries of said formed web, said fibers being secured to said first surface and said sidewall portions of said formed web forming said fibrous and apertured, three-dimensional, macroscopically expanded web.
12. The process of Claim 11, wherein said fibers are meltblown fibers.
13. The process of Claim 11, wherein said fibers are in a nonwoven web.
14. The process of Claim 11, wherein said fibers are secured to said film with glue.
15. The process of Claim 11, wherein said composite web is compressed between a pair of calendar rolls.
16. A process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web, said process comprising the steps of:
(a) extruding a polymeric film onto a forming structure, said forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic apertures which place the opposed surfaces of said forming structure in fluid communication with one another;
(b) applying a pneumatic pressure to said film to cause said film to be urged into substantial conformance with the macroscopic, three-dimensional, cross-section of said forming structure forming a three-dimensional, macroscopically expanded, formed web having first and second surfaces, said formed web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface;
(c) meltblowing a plurality of fibers onto said three-dimensional, macroscopically expanded, formed web, forming a fibrous and apertured, three-dimensional, macroscopically expanded web.
(a) extruding a polymeric film onto a forming structure, said forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic apertures which place the opposed surfaces of said forming structure in fluid communication with one another;
(b) applying a pneumatic pressure to said film to cause said film to be urged into substantial conformance with the macroscopic, three-dimensional, cross-section of said forming structure forming a three-dimensional, macroscopically expanded, formed web having first and second surfaces, said formed web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface;
(c) meltblowing a plurality of fibers onto said three-dimensional, macroscopically expanded, formed web, forming a fibrous and apertured, three-dimensional, macroscopically expanded web.
17. The process of Claim 16, wherein said meltblown fibers are blown and secured to said first surface and said sidewall portions of said formed web.
18. A process for forming a fibrous and apertured, three-dimensional, macroscopically expanded web, said process comprising the steps of:
(a) meltblowing a plurality of fibers onto a forming drum;
(b) extruding a polymeric film onto said plurality of fiber to form a composite web;
(c) placing said composite web on a forming structure, said forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic apertures which place the opposed surfaces of said forming structure in fluid communication with one another; and (d) applying a pneumatic pressure to said composite web to cause said composite web to be urged into substantial conformance with the macroscopic, three-dimensional, cross-section of said forming structure forming a three-dimensional, macroscopically expanded, formed web having first and second surfaces, said formed web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface.
(a) meltblowing a plurality of fibers onto a forming drum;
(b) extruding a polymeric film onto said plurality of fiber to form a composite web;
(c) placing said composite web on a forming structure, said forming structure exhibiting a macroscopic, three-dimensional, cross-section defined by a multiplicity of macroscopic apertures which place the opposed surfaces of said forming structure in fluid communication with one another; and (d) applying a pneumatic pressure to said composite web to cause said composite web to be urged into substantial conformance with the macroscopic, three-dimensional, cross-section of said forming structure forming a three-dimensional, macroscopically expanded, formed web having first and second surfaces, said formed web having a plurality of capillaries extending from said first surface to said second surface, said capillaries being defined by a plurality of sidewall portions interconnected to one another intermediate said first and second surfaces and terminating in said second surface.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US15466093A | 1993-11-18 | 1993-11-18 | |
| US08/154,660 | 1993-11-18 | ||
| PCT/US1994/013097 WO1995013773A1 (en) | 1993-11-18 | 1994-11-14 | Fibrous and apertured, three-dimensional, macroscopically expanded plastic web |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2175991A1 CA2175991A1 (en) | 1995-05-26 |
| CA2175991C true CA2175991C (en) | 2000-09-05 |
Family
ID=22552226
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002175991A Expired - Lifetime CA2175991C (en) | 1993-11-18 | 1994-11-14 | Fibrous and apertured, three-dimensional, macroscopically expanded plastic web |
Country Status (9)
| Country | Link |
|---|---|
| US (1) | USH1827H (en) |
| EP (1) | EP0729330B8 (en) |
| JP (1) | JPH09505222A (en) |
| KR (1) | KR960705524A (en) |
| AT (1) | ATE332682T1 (en) |
| AU (1) | AU1096295A (en) |
| CA (1) | CA2175991C (en) |
| DE (1) | DE69434791T2 (en) |
| WO (1) | WO1995013773A1 (en) |
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| JP3464587B2 (en) * | 1997-02-28 | 2003-11-10 | ユニ・チャーム株式会社 | Body fluid absorbent articles |
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| WO1998042289A1 (en) | 1997-03-21 | 1998-10-01 | Kimberly-Clark Worldwide, Inc. | Dual-zoned absorbent webs |
| US6497688B2 (en) * | 1999-07-19 | 2002-12-24 | Mcneil-Ppc, Inc. | Absorbent article comprising flocked fibers |
| US6692811B1 (en) | 1999-07-19 | 2004-02-17 | Mcneil-Ppc, Inc. | Substrates comprising flocked fibers of superabsorbent polymer |
| US6562170B2 (en) | 2001-02-07 | 2003-05-13 | Tredegar Film Products Corporation | Method of producing film having a cloth-like look and feel |
| CN102065681A (en) * | 2008-04-25 | 2011-05-18 | 阿克伦大学 | Nanofiber enhanced functional film manufacturing method using melt film casting |
| US9861533B2 (en) | 2013-05-08 | 2018-01-09 | The Procter & Gamble Company | Apertured nonwoven materials and methods for forming the same |
| EP3215089B1 (en) | 2014-11-06 | 2018-08-22 | The Procter and Gamble Company | Methods for making patterned apertured webs |
| EP3215085B1 (en) | 2014-11-06 | 2019-10-09 | The Procter and Gamble Company | Crimped fiber spunbond nonwoven webs / laminates |
| CN107106380A (en) | 2014-11-06 | 2017-08-29 | 宝洁公司 | Absorbent article with color effect |
| EP4056158B1 (en) | 2017-02-16 | 2024-03-06 | The Procter & Gamble Company | Absorbent articles with substrates having repeating patterns of apertures comprising a plurality of repeat units |
| EP3958809A1 (en) | 2019-04-24 | 2022-03-02 | The Procter & Gamble Company | Highly extensible nonwoven webs and absorbent articles having such webs |
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-
1994
- 1994-11-14 DE DE69434791T patent/DE69434791T2/en not_active Expired - Lifetime
- 1994-11-14 CA CA002175991A patent/CA2175991C/en not_active Expired - Lifetime
- 1994-11-14 AT AT95901890T patent/ATE332682T1/en not_active IP Right Cessation
- 1994-11-14 KR KR1019960702626A patent/KR960705524A/en not_active Application Discontinuation
- 1994-11-14 JP JP7514543A patent/JPH09505222A/en not_active Ceased
- 1994-11-14 EP EP95901890A patent/EP0729330B8/en not_active Expired - Lifetime
- 1994-11-14 WO PCT/US1994/013097 patent/WO1995013773A1/en active IP Right Grant
- 1994-11-14 AU AU10962/95A patent/AU1096295A/en not_active Abandoned
-
1997
- 1997-06-10 US US08/872,569 patent/USH1827H/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| WO1995013773A1 (en) | 1995-05-26 |
| DE69434791T2 (en) | 2007-07-12 |
| DE69434791D1 (en) | 2006-08-24 |
| USH1827H (en) | 2000-01-04 |
| CA2175991A1 (en) | 1995-05-26 |
| EP0729330B8 (en) | 2006-10-18 |
| EP0729330B1 (en) | 2006-07-12 |
| JPH09505222A (en) | 1997-05-27 |
| EP0729330A1 (en) | 1996-09-04 |
| AU1096295A (en) | 1995-06-06 |
| KR960705524A (en) | 1996-11-08 |
| ATE332682T1 (en) | 2006-08-15 |
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Legal Events
| Date | Code | Title | Description |
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| EEER | Examination request | ||
| MKEX | Expiry |
Effective date: 20141114 |