阅读说明：本技术 成型非织造布 (Shaped nonwoven fabric ) 是由 A.阿什拉夫 K.A.阿罗拉 P.T.韦斯曼 N.R.怀特利 于 2018-06-27 设计创作，主要内容包括：本发明公开了一种非织造织物。非织造织物可包括第一表面和第二表面以及在第一表面或第二表面中的一者上的三维特征结构的在视觉上可辨别的图案。三维特征结构中的每一个可限定包括第一区域和第二区域的微区。第一区域和第二区域的强度特性的值可具有差异。非织造布还具有多个孔,其中该孔的至少一部分邻接所述微区的第一区域和第二区域中的至少一者。(The invention discloses a non-woven fabric. The nonwoven fabric may include a first surface and a second surface and a visually discernable pattern of three-dimensional features on one of the first surface or the second surface. Each of the three-dimensional features may define a micro-region including a first region and a second region. The values of the intensity characteristic of the first region and the second region may have a difference. The nonwoven also has a plurality of apertures, wherein at least a portion of the apertures adjoin at least one of the first and second regions of the micro-regions.)

1. A nonwoven fabric comprising a first surface and a second surface and a visually discernable pattern of three-dimensional features on one of the first surface or the second surface, each of the three-dimensional features defining a micro-region comprising a first region and a second region, the first region and the second region having a difference in value of an intensity characteristic, wherein the intensity characteristic is one or more of:

a. the thickness of the film is measured by the thickness,

b. the basis weight of the fiber,

c. bulk density; and is

Wherein a plurality of the micro-regions of the nonwoven fabric further comprise apertures, and wherein at least a portion of the apertures adjoin at least one of the first region and the second region.

2. The nonwoven fabric of claim 1, wherein the pattern of three-dimensional features is a non-regular pattern, a repeating pattern, or a combination thereof.

3. The nonwoven fabric of any one of the preceding claims, wherein the first surface has a TS7 value of 3dB V2 rms to 14dB V2 rms and the second surface has a TS7 value that is different from the TS7 value of the first surface.

4. The nonwoven fabric of any one of the preceding claims, wherein the second surface has a TS7 value that is lower than the first surface TS7 value.

5. The nonwoven fabric of any one of the preceding claims, wherein the second surface has a TS7 value of 2dB V2 rms to 12dB V2 rms and the first surface has a TS7 value that is different from the TS7 value of the first surface.

6. The nonwoven fabric of any one of the preceding claims, wherein the first surface has a TS7 value that is higher than the second surface TS7 value.

7. The nonwoven fabric of any one of the preceding claims, wherein the ratio of the TS7 value on the first surface to the TS7 value on the second surface is greater than 1.

8. The nonwoven fabric of any of the preceding claims, wherein the strength characteristic is caliper and the difference in caliper between the first region and the second region is greater than 25 microns.

9. The nonwoven fabric of any of the preceding claims, wherein the intensive property is basis weight and the difference in basis weight between the first and second regions is greater than 5 gsm.

10. The nonwoven fabric of any of the preceding claims, wherein the strength characteristic is bulk density and the difference in bulk density between the first region and the second region is greater than 0.042 g/cc.

11. The nonwoven fabric of any of the preceding claims, wherein the strength characteristics include thickness, basis weight, and bulk density; wherein the difference in thickness between the first and second regions is greater than 25 microns, wherein the difference in basis weight between the first and second regions is greater than 5gsm, and wherein the difference in bulk density between the first and second regions is greater than 0.042 g/cc.

12. The nonwoven fabric of any of the preceding claims, wherein loose fibers extend into the apertures.

13. The nonwoven fabric of any of the preceding claims, wherein the loose fibers extending into the apertures originate from at least one of the adjoining first or second regions.

14. An absorbent article comprising the nonwoven fabric of any of the preceding claims.

15. The nonwoven fabric of any of the preceding claims, wherein the nonwoven fabric is in a spunbond configuration.

Technical Field

The present invention relates to a shaped three-dimensional nonwoven fabric and articles made from the shaped three-dimensional nonwoven fabric.

Background

Nonwoven fabrics are useful in a wide variety of applications, including absorbent personal care products, garments, medical applications, and cleaning applications. Nonwoven personal care products include baby care articles such as diapers, child care articles such as training pants, feminine care articles such as sanitary napkins, and adult care articles such as incontinence products, pads, and pants. Non-woven garments include protective workwear and medical garments such as surgical gowns. Other nonwoven medical applications include nonwoven wound dressings and surgical dressings. Nonwoven cleaning applications include towels and wipes. Other uses for nonwoven fabrics are well known. The foregoing list is not to be considered exhaustive.

Various characteristics of nonwoven fabrics determine the suitability of nonwoven fabrics for different applications. Nonwoven fabrics can be processed to have different combinations of properties to meet different requirements. The variable properties of the nonwoven fabric include liquid handling properties such as wettability, distribution, and absorbency, strength properties such as tensile and tear strength, softness properties, durability properties such as abrasion resistance, and aesthetic properties. The physical shape of the nonwoven fabric also affects the functional and aesthetic properties of the nonwoven fabric. The nonwoven fabric is initially prepared as a sheet that may have a substantially planar featureless surface when placed on a flat surface, or may have a series of surface features such as apertures or protrusions, or both. Nonwoven fabrics with apertures or protrusions are often referred to as three-dimensional forming nonwoven fabrics. The present disclosure relates to three-dimensional shaped nonwoven fabrics.

Despite advances in the nonwoven fabric art, there remains a need for improved nonwoven fabrics having three-dimensional surface features.

In addition, there remains a need for processes and apparatus for making improved nonwoven fabrics having three-dimensional surface features.

In addition, there remains a need for articles, including absorbent articles, that utilize improved nonwoven fabrics having three-dimensional surface features.

In addition, there remains a need for absorbent articles that utilize nonwoven fabrics having three-dimensional surface features and that can be packaged in compressed form while minimizing the loss of three-dimensional surface features upon opening from a package.

In addition, there remains a need for absorbent articles that utilize soft spunbond nonwoven fabrics having three-dimensional surface features with reduced fuzz characteristics when in use.

In addition, there remains a need for improved nonwoven fabrics having three-dimensional surface features and physical integrity that combine Softness as measured by a Tissue Softness Analyzer (Tissue Softness Analyzer) sold by Emtec electronics gmbh.

In addition, there remains a need for improved nonwoven fabrics having three-dimensional surface features with micro-regions and physical integrity in combination with apertures, wherein at least a portion of the apertures adjoin at least one of the first and second regions of the micro-regions.

In addition, there remains a need for absorbent article packages that include a soft nonwoven material with a reduced in-bag stack height as compared to conventional absorbent article packages, thus facilitating the caregiver's handling and storage, and allowing the manufacturer to enjoy low distribution costs without sacrificing the aesthetic clarity, absorbency, or softness of the currently manufactured absorbent articles.

Disclosure of Invention

A nonwoven fabric is disclosed. The nonwoven fabric may include a first surface and a second surface and a visually discernable pattern of three-dimensional features on one of the first surface or the second surface. Each of the three-dimensional features may define a micro-region including a first region and a second region. The values of the intensive property of the first and second regions may have a difference, wherein the intensive property is one or more of thickness, basis weight, or bulk density. The nonwoven also has a plurality of apertures, wherein at least a portion of the apertures adjoin at least one of the first and second regions of the micro-regions.

Drawings

Fig. 1 is a photograph of an example of the present disclosure.

Fig. 2 is a photograph of an example of the present disclosure.

Fig. 3 is a photograph of an example of the present disclosure.

Fig. 4 is a cross-section of a portion of the fabric of the present disclosure as shown in fig. 1.

Fig. 5A is a schematic diagram showing a cross-section of a filament made with a primary component a and a secondary component B in a side-by-side arrangement.

Fig. 5B is a schematic diagram showing a cross-section of a filament made with primary component a and secondary component B in an eccentric sheath/core arrangement.

Fig. 5C is a schematic diagram showing a cross-section of a filament made with primary component a and secondary component B in a concentric sheath/core arrangement.

Fig. 6 is a perspective view of a trilobal bicomponent fiber.

Fig. 7 is a schematic view of an apparatus for making the fabric of the present disclosure.

Fig. 8 is a detail of a portion of an apparatus for bonding a portion of a fabric of the present disclosure.

Fig. 9 is additional detail of a portion of an apparatus for bonding a portion of a fabric of the present disclosure.

Fig. 10 is a detail of a portion of an apparatus for optionally additionally bonding a portion of a fabric of the present disclosure.

Fig. 11 is a photograph of an example of the present disclosure.

FIG. 12 is a photograph of a portion of a forming belt useful in the present disclosure.

FIG. 13 is a cross-sectional view of a portion of the forming belt of FIG. 12.

FIG. 14 is an image of a portion of a mask used to prepare the forming belt shown in FIG. 12.

FIG. 15 is an image of a portion of a mask used to prepare the forming belt shown in FIG. 16.

FIG. 16 is a photograph of a portion of a forming belt useful in the present disclosure.

FIG. 17 is an image of a portion of a mask used to prepare the forming belt shown in FIG. 18.

FIG. 18 is a photograph of a portion of a forming belt useful in the present disclosure.

FIG. 19 is a photograph of a portion of a forming belt useful in the present disclosure.

FIG. 20 is an image of a mask used to prepare the forming belt shown in FIG. 19.

FIG. 21 is a photograph of a fabric of the present disclosure prepared on the forming belt shown in FIG. 19.

FIG. 22 is a schematic perspective view of a forming belt of the present disclosure.

Fig. 23 is a plan view of a nonwoven substrate including a nonwoven fabric of the present disclosure.

Fig. 24 is a plan view of a nonwoven substrate including a nonwoven fabric of the present disclosure.

Fig. 25A is a plan view of a fabric of the present disclosure with portions removed in order to measure local basis weight.

Fig. 25B is a plan view of a fabric of the present disclosure with portions removed in order to measure local basis weight.

Figure 26 is a graphical representation of the cross-directional variation in basis weight of the fabrics of the present disclosure.

Fig. 27 is a schematic view of a package of the present disclosure.

Fig. 28 is a plan view of an absorbent article of the present disclosure.

FIG. 29 is a plan view of an absorbent article of the present disclosure

Fig. 30 is a cross-sectional view of section 29-29 of fig. 28.

Fig. 31 is a plan view of an absorbent article of the present disclosure.

Fig. 32 is a cross-sectional view of section 32-32 of fig. 31.

Fig. 33 is a plan view of an absorbent article of the present disclosure.

FIG. 34 is a cross-sectional view of section 34-34 of FIG. 33.

FIG. 35 is a cross-sectional view of section 35-35 of FIG. 33.

Fig. 36 is a photograph of an example of the present disclosure.

Fig. 37 is a photograph of an example of the present disclosure.

Fig. 38 is a photograph of an example of the present disclosure.

Fig. 39 is a photograph of a cross-section of the example shown in fig. 38.

Fig. 40 is a micro CT perspective image of an example of the present disclosure.

Fig. 41 is a micro CT perspective image of an example of the present disclosure.

Fig. 42 is a micro-CT image of the cross-section of the example shown in fig. 40 and 41.

Fig. 43 is a plan view image of the micro CT shown in fig. 40 and 41.

Fig. 44 is a graphical depiction of various benefits of the disclosed invention.

Fig. 45 is a photo view image of a portion of an example of the present disclosure.

FIG. 46 is a photo view image of a portion of an example of the disclosed invention.

FIG. 47 is a photo view image of a portion of an example of the disclosed invention.

Fig. 48 is a photo view image of a portion of an example of the disclosed invention.

Fig. 49 is a photograph of a cross-section of the example shown in fig. 47 and 48.

FIG. 50 is a photo view image of a portion of an example of the disclosed invention.

FIG. 51 is a photo view image of a portion of an example of the disclosed invention.

Fig. 52 is a photo view image of a portion of an example of the disclosed invention.

Fig. 53 is a photo view image of a portion of an example of the disclosed invention.

Fig. 54 is a plan view image of the micro CT after undergoing additional processing for the example shown in fig. 40 and 41.

FIG. 55 is a graphical depiction of the various benefits of the disclosed invention shown in FIG. 54.

Fig. 56 is a schematic view of an apparatus for making a fabric of the present disclosure.

Fig. 57 is a plan view photograph of an apertured formed nonwoven fabric of the present disclosure.

Fig. 58 is a photograph of a cross-sectional view of an apertured formed nonwoven fabric of the present disclosure.

Fig. 59 is a plan view photograph of an apertured formed nonwoven fabric of the present disclosure.

Fig. 60 is a plan view of a formed nonwoven of the present disclosure.

Fig. 61 illustrates a tensioning apparatus for forming apertures in a formed nonwoven of the present disclosure.

Detailed Description

The present disclosure provides a formed nonwoven fabric and/or an apertured formed nonwoven fabric formed directly on a forming belt with continuous spunbond filaments in a single forming process. The fabrics of the present disclosure may be described as webs and exhibit shapes that correspond to the shapes of the forming belts. The fabrics of the present disclosure prepared on the forming belt of the present disclosure in the process of the present disclosure may be particularly beneficial for use in personal care articles, garments, medical products, and cleaning products. The formed nonwoven and/or apertured formed nonwoven may be fluid permeable such that it is used as a topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of a diaper, or a topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of a sanitary napkin, a topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of an adult incontinence pad or pant, or a pad for a floor cleaning implement.

In some embodiments herein, the beneficial features of the nonwoven fabric will be described in the context of the total area of the nonwoven fabric. The total area may be an area determined by dimensions suitable for certain applications for which the various features of the present invention provide beneficial characteristics. For example, the total area of the fabric may be the total area of a fabric having dimensions such that it is suitable for use as a topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layer of a diaper, orA topsheet, a backsheet nonwoven, an acquisition layer, a distribution layer, or other component layer of a sanitary napkin, a topsheet, a backsheet nonwoven, an acquisition layer, a distribution layer, or other component layer of an adult incontinence pad or pant, or a pad of a floor cleaning implement. Thus, the total area may be based on a width dimension in a range of 3cm wide to 50cm wide and a length dimension in a range of 10cm long to 100cm long, resulting in a 30cm wide to 50cm long dimension²To 500cm²The total area of (a). The foregoing ranges include every integer size between the stated range boundaries as explicitly stated. By way of example, 176cm defined by a width of 11cm and a length of 16cm²Is disclosed in the above range. As will be understood from the description herein, the total area of the formed nonwoven fabric may be an area that is less than the area of the web of nonwoven material, which is a portion of the web when the formed nonwoven fabric is commercially produced. That is, in a given web of commercially produced nonwoven material, there may be a plurality of the formed nonwoven fabrics of the present invention, each of which has a total area that is less than the area of the web on which it is produced.

Photographs of representative examples of the formed nonwoven fabric 10 are shown in fig. 1-3. The forming nonwoven fabric 10 may be a spunbond nonwoven substrate having a first surface 12 and a second surface 14. In fig. 1-3, the second surface 14 faces the viewer and is opposite the first surface 12, which is not visible in fig. 1-3 but is shown in fig. 4. The term "surface" is used broadly to refer to both sides of a web for descriptive purposes and is not intended to infer any necessary flatness or smoothness. While the forming nonwoven fabric 10 is soft and flexible, it will be described in its flat-out state, i.e., in the context of one or more X-Y planes parallel to the flat-out state and corresponding to the cross-machine direction CD plane and machine direction MD plane, respectively, in web making technology, as shown in fig. 1-3. The length L in the MD and the width W in the CD determine the total area a of the nonwoven fabric 10. As shown in fig. 4, which is a cross-section of a portion of the nonwoven fabric 10 shown in fig. 1, for purposes of description, the three-dimensional features of the formed nonwoven fabric are depicted as extending outwardly from the X-Y plane of the first surface 16 in the Z-direction (see fig. 4). In one embodiment, the maximum dimension of the three-dimensional feature in the Z-direction may define the maximum distance between the plane of the first surface 16 and the X-Y plane of the second surface 18, which may be measured as the average thickness AC of the nonwoven fabric 10. The average thickness may be determined via an optical non-contact device, or it may be determined by an instrument involving spaced flat plates that measure the thickness of a nonwoven placed between them at a predetermined pressure. It is not necessary that all three-dimensional features have the same Z-direction maximum dimension, but a plurality of three-dimensional features may have substantially the same Z-direction maximum dimension as determined by the fiber deposition process and the characteristics of the forming belt described below.

The exemplary fabrics shown in fig. 1-4 (as well as the other fabrics disclosed herein) are fluid permeable. In one embodiment, the entire fabric may be considered fluid permeable. In one embodiment, a region or zone (described below) may be fluid permeable. As used herein, "fluid-permeable" with respect to a fabric means that the fabric has at least one zone that allows liquid to pass through in the event that a consumer product is used. For example, if the fabric is used as a topsheet on a disposable diaper, the fabric may have at least one zone that has some fluid permeability, allowing urine, thin BM, menses, or any other bodily exudates to pass through the underlying absorbent core. As used herein, "fluid-permeable" with respect to a region means that the region exhibits a porous structure that allows liquid to pass through. In a form more fully disclosed below, greater fluid permeability may be achieved by providing apertures in the formed nonwoven fabric to provide the formed nonwoven fabric 8.

As shown in fig. 1-4, the nonwoven fabric 10 may have a regular repeating pattern of a plurality of discrete, identifiably distinct three-dimensional features, including first and second three- dimensional features 20, 22, and third three-dimensional features 24, as shown in fig. 2 and 3. For example, in fig. 1, the heart-shaped first three-dimensional feature 20 is identifiably different from the smaller generally triangular second three-dimensional feature 22. The identifiable differences may be visual, such as identifiably different sizes and/or shapes.

The three-dimensional features of the nonwoven fabric 10 may be formed by depositing fibers directly onto a forming belt having a pattern corresponding to the three-dimensional features, such as by carding, air-laying, spinning from solution, or melt spinning. In one sense, the nonwoven fabric 10 is molded onto a forming belt that determines the shape of the three-dimensional features of the fabric 10. Importantly, however, as described herein, the apparatus and method of the present invention produces a nonwoven fabric 10 such that the fabric is imparted with beneficial properties for use in personal care articles, garments, medical products, and cleaning products in addition to assuming the shape of the forming belt due to the properties of the forming belt and the properties of the apparatus used to form the fabric. In particular, due to the nature of the forming belt and other equipment elements, as described below, the three-dimensional features of the nonwoven fabric 10 have strength characteristics that may differ between first and second regions within a micro-region (described more fully below) or may vary from feature to feature as follows: provides beneficial properties to nonwoven fabric 10 when used in personal care articles, garments, medical products, and cleaning products. For example, the first three-dimensional feature 20 may have a basis weight or density that is different than the basis weight or density of the second three-dimensional feature 22, and both may have a basis weight or density that is different than the basis weight or density of the third three-dimensional feature 24, thereby providing beneficial aesthetic and functional properties related to fluid acquisition, distribution and/or absorption in a diaper or sanitary napkin.

It is believed that the differences in strength characteristics between the various three-dimensional features of the nonwoven fabric 10 are due to fiber distribution and compaction resulting from the apparatus and method described below. Fiber distribution occurs during the fiber deposition process, rather than during post-production processes such as hydroentangling or embossing, for example. Since the fibers are free to move during the process, such as a melt spinning process, it is believed that the fibers will be more stably and permanently formed in the nonwoven fabric 10 with movement determined by the nature of the features and the air permeability of the forming belt, as well as other processing parameters.

As can be seen in fig. 1-3, and as can be appreciated from the description herein, the different three-dimensional features can be defined by visually discernable (relative to the interior of the three-dimensional feature) regions, which can be in the form of closed figures (such as the heart-shaped shapes in fig. 1 and 3, and the diamond-shaped shapes of fig. 2 and 3). The closed figure may be a curvilinear closed figure, such as the heart-shaped shapes in fig. 1 and 3. The visually discernable regions in the contours can be regions of the nonwoven fabric 10 that are most closely adjacent to the first surface 12 in the Z-direction, such as regions 21 shown in fig. 4, and wherein they can lie at least partially in or on the first plane 16 when in a flattened state. For example, as shown in fig. 1, first three-dimensional feature 20 is heart-shaped and, as shown in one exemplary first three-dimensional feature 20A, is defined by a curvilinear closed heart-shaped element. A curved line element may be understood as a linear element having a tangential vector V (in the case where a closed shape is present) at any point along its length, such that the tangential vector V has both MD and CD components that change value over more than 50% of the linear element length of the closed figure. Of course, the graphic need not be completely 100% closed, but the linear elements may have breaks that do not deviate from the overall impression of a closed graphic. As discussed below in the context of the forming belt, the curved closed cardioid elements, visually discernable in profile, are formed by corresponding closed cardioid raised elements on the forming belt to produce a closed cardioid pattern on the fabric 10. In one repeating pattern, the individual shapes (in the case of the first three-dimensional feature in fig. 1, heart-shaped shapes) can result in an aesthetically pleasing soft pillow-like feature over the total area OA of the second surface 14 of the fabric 10. In one embodiment, where the nonwoven 10 is used as a topsheet for a diaper or sanitary napkin, the second surface 14 of the nonwoven 10 can face the body to deliver superior aesthetic and performance benefits related to softness, compression resistance, and fluid absorption.

In particular, in the regular repeating pattern of closed three-dimensional features shown in fig. 1-3, it is believed, without being bound by theory, that the dimensions of the various features, the average basis weight of the entire web 10 over its total area, and other processing parameters described below (which define different strength characteristics) contribute to beneficially improving compression recovery. It is believed that the plurality of relatively closely spaced, relatively small and relatively pillow-like three-dimensional features act as springs to resist compression and recover once the compressive force is removed. Compression recovery is important in, for example, personal care articles such as diapers, sanitary napkins, or adult incontinence pads, topsheets of diapers or pants, backsheet nonwovens, acquisition layers, distribution layers, or other component layers, as such articles are typically packaged and folded in a compressed state. Manufacturers of personal care products wish to maintain a large portion, if not all, of the as-made thickness for aesthetic and performance purposes. The three-dimensionality of the resulting features provides significant aesthetic benefits due to the soft appearance and feel and pleasing stiff and smooth appearance, well-defined shapes, including very small shapes such as the careful shape shown in fig. 2. The three-dimensional features also provide softness, improved absorbency, less leakage, and an overall improved use experience during use. However, during folding, packaging, shipping, and storage of the personal care article, the necessary compression may result in a permanent loss of thickness of the topsheet, backsheet nonwoven, acquisition layer, distribution layer, or other component layers of the absorbent article, thereby degrading the functional benefits of the article as it is manufactured. We have surprisingly found that the nonwoven fabrics of the present disclosure retain their as-made three-dimensional features to a significant extent, even after undergoing compression packaging and dispensing in a compressed packaged state.

Table 1 below shows the compression recovery data for two embodiments of the present disclosure. Example 1 corresponds to the nonwoven fabric 10 shown in fig. 1 and was prepared on a forming belt as described with reference to fig. 12 and 14. Example 2 corresponds to the nonwoven fabric 10 shown in fig. 2 and was prepared on a forming belt as described with reference to fig. 15 and 16. As can be seen from the data, the fabric 10 of the present invention shows significant benefits in compression recovery when measured by the "compression aging test". In one form, absorbent article packages having the compression recovery features of the present disclosure can have a reduced in-bag stack height, yet deliver the aesthetic, absorbent, and softness benefits of an existing diaper; or as if it had never been compression packaged. The present invention provides packages having a reduced in-bag stack height that allow a caregiver to easily grasp and store the packages while also providing a reduced distribution cost to the manufacturer while still maintaining the ready-made aesthetic clarity, absorbency, or softness properties of the absorbent article.