Absorbent article and method of making the same
阅读说明：本技术 吸收制品及其制备方法 (Absorbent article and method of making the same ) 是由 J.W.布施 M.D.特伦内波尔 S.J.瓦斯 于 2019-04-11 设计创作，主要内容包括：本文公开了一次性吸收制品及其制备方法。该一次性吸收制品具有顶片、底片以及在该顶片与该底片之间的吸收系统。该吸收系统具有彼此偏置的第一吸收芯和第二吸收芯。粘合剂层至少部分地设置在该第一吸收芯与该第二吸收芯之间。(Disclosed herein are disposable absorbent articles and methods of making the same. The disposable absorbent article has a topsheet, a backsheet, and an absorbent system between the topsheet and the backsheet. The absorbent system has a first absorbent core and a second absorbent core offset from each other. An adhesive layer is at least partially disposed between the first absorbent core and the second absorbent core.)
1. A disposable absorbent article (10) having a longitudinal centerline (80) and a lateral centerline (90), a first end (40) and an opposing second end (48), the disposable absorbent article further comprising:
a liquid-permeable cover sheet (203);
a liquid impervious backsheet (207), said liquid pervious cover sheet and said liquid impervious backsheet forming at least a portion of the outer periphery of said disposable absorbent article;
a first absorbent core (60,760) having a first width (369), wherein the first absorbent core comprises a first outer edge (363) and a first slit edge (361) each oriented generally parallel to the longitudinal centerline, a first leading edge (66) and a first trailing edge (67) joining each of the first outer edge and the first slit edge at opposite ends of the first absorbent core;
a second absorbent core (70,770) having a second width (379), wherein the second width is greater than the first width, wherein the second absorbent core comprises a second outer edge (373) and a second slit edge (371) each oriented substantially parallel to the longitudinal centerline, a second leading edge (76) and a second trailing edge (77) joining each of the second outer edge and the second slit edge at opposite ends of the second absorbent layer, wherein the first leading edge is disposed closer to the first end than the second leading edge, and wherein the second trailing edge is disposed closer to the second end than the first trailing edge;
An adhesive layer disposed at least partially between the first absorbent core and the second absorbent core, at least a portion of the adhesive layer being disposed on the liquid permeable cover sheet or an intermediate layer between the liquid permeable cover sheet and the first absorbent core longitudinally outboard of the first leading edge or the first trailing edge, and wherein the adhesive layer does not extend longitudinally beyond the second leading edge or the second trailing edge.
2. The disposable absorbent article according to claim 1, wherein the first absorbent core comprises a carrier web (800), a support web (870), and a first component zone (930) disposed between the carrier web and the support web, wherein the carrier web is joined to the liquid permeable cover sheet or second topsheet, and wherein the carrier web is folded onto the support web such that the carrier web forms a first outer edge (363).
3. The disposable absorbent article of claim 2, wherein the first component comprises a first proximal edge (935) and the carrier web comprises a first edge (910), and wherein a first offset distance (913) between the first proximal edge and the first edge is between 3mm and 35 mm.
4. The disposable absorbent article according to any one of claims 2 and 3, wherein the second absorbent core comprises a carrier web (800), a support web (870), and a second component zone (940) disposed between the carrier web and the support web, wherein the second set of zone has a second proximal edge (945) and the carrier web has a second edge (920), and wherein a second offset distance between the second proximal edge and the second edge is between 3mm and 35 mm.
5. The disposable absorbent article of claim 4, wherein the first set of component zones and the second set of component zones comprise different basis weight materials.
6. The disposable absorbent article of claim 4, wherein the first set of component zones and the second set of component zones comprise the same basis weight of material.
7. The disposable absorbent article of claim 4, wherein the first absorbent core comprises a first surface (60A) and an opposing second surface (60B), wherein the second surface is at least partially formed by the support web, and wherein the second absorbent core comprises a first surface (70A) and an opposing second surface (70B), wherein the first surface of the second absorbent core is joined to the second surface of the first absorbent core, and wherein the first surface of the second absorbent core is at least partially formed by the support web.
8. The disposable absorbent article of claim 4, wherein the carrier web is folded onto the support web such that the carrier web forms a second outer edge (373).
9. The disposable absorbent article of claim 1, wherein the first absorbent core comprises a carrier web, wherein the carrier web of the first absorbent core is folded onto the support web such that the carrier web forms a first outer edge, wherein the second absorbent core comprises a carrier web, wherein the carrier web of the second absorbent core is folded onto the support web such that the carrier web forms a second outer edge, and wherein the first outer edge and the second outer edge are disposed on opposite sides of the disposable absorbent article.
10. The disposable absorbent article according to any of the preceding claims, wherein the first leading edge is convex and the first trailing edge is concave.
11. The disposable absorbent article according to any of the preceding claims, wherein the second leading edge is concave and the second trailing edge is convex.
12. The disposable absorbent article of any of the preceding claims, wherein the second absorbent core is at least 2mm wider than the first absorbent core.
13. The disposable absorbent article of claim 1, wherein the first absorbent core comprises a carrier web, wherein the carrier web of the first absorbent core is folded onto the support web such that the carrier web forms a first outer edge, wherein the second absorbent core comprises a carrier web, wherein the carrier web of the second absorbent core is folded onto the support web such that the carrier web forms a second outer edge, and wherein the first outer edge and the second outer edge are disposed on the same side of the disposable absorbent article.
14. The disposable absorbent article according to any of the preceding claims, wherein the absorbent article comprises a middle layer between the liquid permeable coversheet and the first absorbent core.
Technical Field
The present invention relates to disposable absorbent articles adapted to absorb and contain body exudates.
Background
Consumers have relied on a variety of disposable absorbent articles to treat or manage body exudates. These consumers may include infants, toddlers, children, adolescents, adults, and the elderly. Thus, it will be apparent that the type of fluid or bodily exudates managed by such articles may also vary to include urine, feces, menses, and other excretions. Typically, in the case of adults, the articles take the form of sanitary napkins, adult incontinence pads and adult incontinence diapers or undergarments. One of the main desires of wearers for these products is to convince them: others will not perceive the occurrence of incontinence as they occur, and even more desirably the wearer will not perceive the occurrence of incontinence.
One way widely utilized by manufacturers to improve the performance and overall discreteness of disposable absorbent articles is to include superabsorbent polymers, which are capable of absorbing increased amounts of liquid and thus forming swollen hydrogel materials. The resulting hydrogel is used to retain fluids, such as discharged body fluids, within the structure.
While disposable absorbent articles having these superabsorbent materials tend to be highly absorbent and less bulky, many users of these products have high Body Mass Indices (BMIs) and many expectations remain for these products. In particular, these users tend to experience excessive bunching of the absorbent article during wear, and thus may increase the chance of leakage occurring.
Accordingly, there is a need for a disposable absorbent article that is intended to provide enhanced leakage protection for consumers with high BMI, while maintaining a level of wearer balance during use. And a need exists for a method that facilitates the manufacture of such disposable absorbent articles.
Disclosure of Invention
Described herein are disposable absorbent articles that can provide improved leakage protection for consumers with multiple BMIs. Additionally, the methods disclosed herein may facilitate the manufacture of such articles.
In some forms, the disposable absorbent article has a longitudinal centerline and a lateral centerline, a first end and an opposing second end. The disposable absorbent article further comprises: a liquid permeable cover sheet; a liquid impervious backsheet, said liquid pervious cover sheet and said liquid impervious backsheet forming at least a portion of the outer periphery of said disposable absorbent article; a first absorbent core having a first width, wherein the first absorbent core comprises a first outer edge and a first slit edge each oriented generally parallel to the longitudinal centerline, a first leading edge and a first trailing edge joining each of the first outer edge and the first slit edge at opposite ends of the first absorbent core; a second absorbent core having a second width, wherein the second width is greater than the first width, wherein the second absorbent core comprises a second outer edge and a second slit edge each oriented generally parallel to the longitudinal centerline, a second leading edge and a second trailing edge joining each of the second outer edge and the second slit edge at opposite ends of the second absorbent layer, wherein the first leading edge is disposed closer to the first end than the second leading edge, and wherein the second trailing edge is disposed closer to the second end than the first trailing edge; and an adhesive layer disposed at least partially between the first absorbent core and the second absorbent core, at least a portion of the adhesive layer being disposed on the liquid permeable cover sheet or an intermediate layer between the liquid permeable cover sheet and the first absorbent core longitudinally outboard of the first leading edge or the first trailing edge, and wherein the adhesive layer does not extend longitudinally beyond the second leading edge or the second trailing edge.
In some forms, the disposable absorbent article has a longitudinal centerline and a lateral centerline, a first end and an opposing second end. The disposable absorbent article further comprises: a liquid permeable cover sheet; a liquid impervious backsheet, said liquid pervious cover sheet and said liquid impervious backsheet forming at least a portion of the outer periphery of said disposable absorbent article; a first absorbent core having a first width, wherein the first absorbent core comprises a first outer edge and a first slit edge each oriented generally parallel to the longitudinal centerline, a first leading edge and a first trailing edge joining each of the first outer edge and the first slit edge at opposite ends of the first absorbent core, wherein the first absorbent core further comprises a first carrier web, a first support web, and a first component zone disposed between the first carrier web and the first support web; a second absorbent core having a second width, wherein the second width is greater than the first width, wherein the second absorbent core comprises a second outer edge and a second slit edge each oriented generally parallel to the longitudinal centerline, a second leading edge and a second trailing edge joining each of the second outer edge and the second slit edge at opposite ends of the second absorbent layer, wherein the first leading edge is disposed closer to the first end than the second leading edge, and wherein the second trailing edge is disposed closer to the second end than the first trailing edge, wherein the second absorbent core further comprises a second carrier web, a second support web, and a second component zone disposed between the second carrier web and the second support web; an adhesive layer disposed at least partially between the first absorbent core and the second absorbent core, at least a portion of the adhesive layer being disposed on the liquid permeable cover sheet or an intermediate layer between the liquid permeable cover sheet and the first absorbent core longitudinally outboard of the first leading edge or the first trailing edge, and wherein the adhesive layer does not extend longitudinally beyond the second leading edge or the second trailing edge; and wherein the first carrier web is folded over the first support web forming a first outer edge, wherein the second carrier web is folded over the second support web forming a second outer edge, and wherein the first outer edge and the second outer edge are disposed on opposite sides of the absorbent article.
Drawings
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the following description which is taken in conjunction with the accompanying drawings in which like reference numerals identify substantially identical elements and in which:
FIG. 1 is a plan view illustrating an exemplary disposable absorbent article according to the present disclosure;
fig. 2 is a cross-sectional view of the incontinence pad of fig. 1, taken along 2-2;
FIG. 3 is a plan view illustrating an exemplary absorbent system according to the present disclosure;
FIG. 4 is an elevation view illustrating an exemplary absorbent system according to the present disclosure;
FIG. 5 is a process diagram illustrating an exemplary method according to the present disclosure;
FIG. 6 is a plan view of an absorbent core web according to the present disclosure;
FIG. 7 is an elevation view illustrating another exemplary absorbent system according to the present disclosure;
FIG. 8 is a process diagram illustrating another exemplary method according to the present disclosure;
fig. 9A is a plan view illustrating a carrier web having a first component and a second component thereon according to the present disclosure;
FIG. 9B is a cross-sectional view of the carrier web shown in FIG. 9A having a first component and a second component;
FIG. 10 is a cross-sectional view of the carrier web of FIG. 9B with additional features of a support web according to the present disclosure;
FIG. 11 is a cross-sectional view of the web of FIG. 10 with the additional features of a first outer edge and a second outer edge;
FIG. 12 is a process diagram illustrating additional processes of the method of FIG. 8 according to the present disclosure; and
fig. 13 is a cross-sectional view showing the web of fig. 11 after being separated into a first absorbent core laminate and a second absorbent core laminate.
Detailed Description
The following explanations of terms may aid in understanding the present disclosure: the disposable absorbent article of the present invention, particularly an incontinence pad or pant, may provide flexibility to allow for an improved and comfortable fit that is less prone to bunching during use. In particular, it is contemplated that the articles of the present invention exhibit increased structural resilience through the proposed configuration and orientation of the layers contained therein. For the purposes of this disclosure, reference will be made to an incontinence pad, a disposable absorbent article or an absorbent article. However, the present invention is applicable to a variety of absorbent articles including, but not limited to, sanitary napkins, pantiliners, catamenial pads, diapers, training pants, adult incontinence pants, and the like.
"elastic," "elastomeric" or "elastomeric" means that a material exhibits elastic properties, and includes any material that is capable of being stretched or elongated to an elongated length greater than 10% of its original length upon application of a force to its relaxed, original length, and will substantially recover to about its original length upon release of the applied force.
As used herein, the term "joined" includes configurations in which an element is directly secured to another element by affixing the element directly to the other element, and configurations in which the element is indirectly secured to the other element by affixing the element to an intermediate member (which in turn is affixed to the other element).
"longitudinal" refers to a direction running substantially perpendicular from a waist edge of an absorbent article to a longitudinally opposing waist edge, or in a bi-folded article from a waist edge to the bottom of the crotch (i.e., the fold line), when the article is in a flat, uncontracted state. Directions within 45 degrees of the longitudinal direction are considered to be "longitudinal". "lateral" refers to a direction running from a longitudinally extending side edge of the article to a laterally opposing longitudinally extending side edge and generally at right angles to the longitudinal direction. Directions within 45 degrees of lateral are considered "lateral".
The term "nonwoven" refers herein to a material made from continuous (long) filaments (fibers) and/or discontinuous (short) filaments (fibers) by processes such as spunbonding, meltblowing, carding, and the like. The nonwoven does not have a woven filament or woven filament pattern.
The term "machine direction" (MD) refers herein to the direction of material flow during processing. Further, the relative placement and movement of materials may also be described as passing through the process from upstream of the process to downstream of the process in the machine direction.
The term "cross direction" (CD) refers herein to a direction that is generally perpendicular to the machine direction.
The disposable absorbent article of the present invention, particularly an incontinence pad or pant, may provide flexibility to allow for an improved and comfortable fit that is less prone to bunching during use. In particular, it is contemplated that the articles of the present invention exhibit increased structural resilience through the proposed configuration and orientation of the layers contained therein. For the purposes of this disclosure, reference will be made to an incontinence pad, a disposable absorbent article or an absorbent article. However, the present disclosure is applicable to a variety of absorbent articles including, but not limited to, sanitary napkins, pantiliners, catamenial pads, diapers, training pants, adult incontinence pants, and the like.
When designing disposable absorbent articles, such as incontinence pads, several factors need to be considered, particularly if improved fit and performance are desired. First, the stiffness of the pad is an important factor. Generally, thinner pads provide less stiffness than bulkier pads. While bulkier pads may have a lower likelihood of collapsing when subjected to typical compression during wear, bulkier pads are less desirable because they may cause the incontinence pad to be noticeable during use. Furthermore, a certain flexibility of the absorbent core makes it easier for the incontinence pad to adjust to the contours of the user's body during use. Second, the absorbency of the pad is critical in determining whether the pad is usable by the consumer. Ideally, the pad is well suited to contain small or large loads of exudates. This containment means not only that any type of load is adequately stored, but that such loads are effectively and quickly wicked from the body-contacting surface of the pad so that the user experiences little to no wetness sensation upon release of the load. Under light load conditions, the wearer should be able to continue wearing the pad for a reasonable period of time after release, as it may not be feasible or desirable to immediately replace the pad.
In the past, the design of incontinence pads has required a slight compromise between these factors. In contrast, absorbent articles designed according to the present invention, including but not limited to incontinence pads, take these factors into account, and the resulting absorbent articles exhibit improved leakage protection, particularly for wearers above the average Body Mass Index (BMI). That is, the incontinence pads of the present disclosure provide good core flexibility, excellent wicking, distribution, and overall absorbency, and in certain embodiments may include barrier cuffs that stand up during use and contact the wearer in place, included as part of the construction to further prevent the possibility of pad leakage.
Fig. 1 shows an absorbent article, or more particularly, an incontinence pad or sanitary napkin 10 (referred to herein primarily as an "incontinence pad") according to the present disclosure, which may include a
The
The
In some forms, the chassis may also include
The
The
Still referring to fig. 3, in some forms, the
The first
Notably, while the slit edges may be formed via cutting from a larger web as disclosed herein, this is not required. The absorbent article manufacturer can receive the first absorbent core and the second absorbent core separately. In such cases, the need to cut the absorbent core web can be avoided. Thus, the term "slit edge" is used herein to distinguish one edge from another edge, rather than requiring one edge to have to be cut from a portion of a larger web.
In addition, the first
Referring now to fig. 4, the first
As shown, in some forms, the first
Methods according to the present disclosure may facilitate such forms of processing. As shown in fig. 5 and 6, the
Referring still now to fig. 5 and 6, in some forms, the
The first
Referring now to fig. 3-5, as shown, the
Referring back to fig. 5, a plurality of discrete first absorbent core layers 560A are provided from the cutting
Similarly, a plurality of discrete second
It is worth noting how the adhesive is applied in the case where the first
Still referring to fig. 4 and 5, the laminate structure 581 comprising the carrier web, the first
In some forms, as previously described, the first
For the version of fig. 7, the first leading
In an alternative form, the first
In some forms, the overlap region or area forming the
Referring back to fig. 4, as previously described, the first
For those forms in which the first absorbent core and/or the second absorbent core comprise a laminate structure, the process according to the present disclosure may facilitate the processing of such forms. As shown in fig. 8, the
Referring now to fig. 8-9B,
As shown, second set of
The
Referring now to fig. 8-11, after forming
In some forms, after the
Folding unit operations are well known in the art of absorbent article manufacturing. However, for those forms in which the
Additionally, in conjunction with, or independent of, the first offset
After the
Referring now to fig. 12, the first
For clarity, a single first
Referring now to fig. 3, 7, and 12, as shown, the
Notably, where convex and concave edges are desired on the ends of the absorbent core, whether a monolayer or laminate, cross-tracking should be noted. The curvature on the concave edge may be skewed if the web enters the cutting device such that the web centerline does not match the cutting device centerline in the machine direction. Such a skewed edge may create a side of the edge with a tail (e.g., a longer end). If the tail produced is too long, a portion of the core may become trapped in the peripheral product seal (curl), thereby resulting in quality defects. To minimize the possibility of such quality defects, the centerline of the web entering the cutting device should be within 1 σ, i.e., plus or minus 2.5mm of the centerline of the cutting device. In the event that the incoming web is outside of this 1 σ value, the web tracking device can be used to correct the tracking of the incoming web so that the desired tolerance is achieved. Web tracking devices are known in the art.
Referring back to fig. 12, the plurality of discrete first
Similarly, a plurality of discrete second
It is noted that in the case where the first
In some forms, the cut and slide or cut and
The laminate
The inventors have also discovered that upstream or downstream of the cut and slide and/or cut and place operations described herein in fig. 5 and 12, the core orientation can be monitored to reduce the likelihood of core orientation errors. For example, a visual sensor may be utilized where it is desired that the first superabsorbent layer and/or the second superabsorbent layer be oriented closer to the wearer. Alternatively, visual sensors may be utilized even where the first and/or second distribution layers are desired to be closer to the wearer. While a vision system may be utilized to orient the absorbent layers of the absorbent articles of the present disclosure, the vision system may be bulky and costly to purchase and operate. In contrast, the cost of a vision sensor may be much lower than a vision system, and space for the vision system may not be required.
The visual sensor can be programmed to recognize the texture of the opposite side of the super absorbent layer. For example, the carrier webs utilized herein can be relatively smooth. In contrast, the component (e.g., AGM) deposited on the carrier web may have a rougher surface. The visual sensor may be programmed to "observe" the difference in roughness of the carrier web and the component deposited thereon. In doing so, the vision sensor may then provide a binary output (e.g., 1 or 0) to a Central Processing Unit (CPU). For a correct orientation, the signal may be 0, and for an incorrect orientation, the signal may be 1. In addition, the CPU may be programmed such that the CPU monitors a moving average of the artifacts, e.g., artifacts 1-101, then 2-102, etc. The moving average may be used to determine if more than a few articles continue to be improperly oriented (e.g., 1). Any suitable visual sensor may be utilized. One specific example includes a visual sensor available from Keyence and sold under the trade name IV-HG500 MA.
Applicants will now provide a more detailed description of the various components of the disposable absorbent articles contemplated herein.
Main top sheet
Referring back to fig. 2, the primary topsheet 203 (also referred to herein as the "topsheet") of the
The absorbent article may comprise any known or otherwise effective primary topsheet, such as one that is compliant, soft feeling, and non-irritating to the wearer's skin. Suitable primary topsheet materials include liquid pervious materials that are oriented toward and contact the body of the wearer, permitting bodily exudates to pass rapidly therethrough, without permitting fluid to pass back through the topsheet to the skin of the wearer. While the primary topsheet allows for rapid transfer of fluid therethrough, it also allows for transfer or migration of the lotion composition to the exterior or interior of the wearer's skin. Suitable topsheets can be made from a variety of materials, such as woven and nonwoven materials; apertured film materials including apertured formed thermoplastic films, apertured plastic films and fiber wound apertured films; a hydroformed thermoplastic film; a porous foam; reticulated foam; a reticulated thermoplastic film; a thermoplastic scrim; or a combination thereof. Some suitable examples of films that can be used as topsheets are described in U.S. Pat. nos. 3,929,135, 4,324,246, 4,342,314, 4,463,045, 5,006,394, 4,609,518, and 4,629,643.
Non-limiting examples of woven and nonwoven materials suitable for use as the topsheet include fibrous materials made from natural fibers, modified natural fibers, synthetic fibers, or combinations thereof. Some suitable examples are described in U.S. Pat. nos. 4,950,264, 4,988,344, 4,988,345, 3,978,185, 7,785,690, 7,838,099, 5,792,404, and 5,665,452.
In some forms, the topsheet can include tufts as described in U.S. Pat. Nos. 8,728,049, 7,553,532, 7,172,801, 8,440,286, 7,648,752, and 7,410,683. The primary topsheet may have a pattern of discrete hair-like fibrils as described in U.S. patent 7,655,176 or 7,402,723. Additional examples of suitable topsheets include those described in U.S. patents 8,614,365, 8,704,036, 6,025,535 and U.S. patent application publication 2016/0129661.
Another suitable primary topsheet or a primary topsheet combined with a secondary topsheet may be formed from a three-dimensional substrate as described in detail in U.S. patent application publication 2017/0258647a 1.
The primary topsheet can have one or more layers as described in U.S. patent application publication nos. 2016/0167334a1, 2016/0166443a1, 2017/0258651a 1. The topsheet may be apertured as disclosed in U.S. patent 5,628,097 to Benson et al, 5/13 in 1997.
Secondary topsheet
As previously mentioned, the disposable absorbent articles of the present disclosure may include additional layers, one of which includes a secondary topsheet. As previously mentioned, the secondary topsheet can be separate and apart from the absorbent system. In addition, a secondary topsheet is disposed beneath the
Some exemplary secondary topsheets are described in U.S. patent application publications 2015/0351976a1 and 2014/0343523a 1; and U.S. patent application serial No. 2018/0098893. A form is contemplated in which the carrier web 800 (shown in fig. 9B-11) includes a secondary topsheet.
Negative film
The
The
Some suitable examples of backsheets are described in U.S. Pat. Nos. 5,885,265, 4,342,314, and 4,463,045. Suitable single layer breathable backsheets for use herein include those described in, for example, GB a 2184389, GB a 2184390, GB a 2184391, U.S. patent 4,591,523, U.S. patent 3989867, U.S. patent No. 3,156,242, WO 97/24097, and U.S. patents 6,623,464, 6,664,439, and 6,436,508.
The backsheet may have two layers: a first layer comprising a breathable formed film layer and a second layer comprising a breathable microporous film layer, as described in U.S. patent 6,462,251. Suitable dual or multi-layer breathable backsheets for use herein include those exemplified in U.S. patent 3,881,489, U.S. patent 4,341,216, U.S. patent 4,713,068, U.S. patent 4,818,600, EP 203821, EP 710471, EP 710472, and EP 793952.
Absorption system
The
As previously mentioned, the
The configuration and construction of the
In some forms of the present disclosure, the
The
Absorbent cores containing relatively large amounts of SAP with various core designs are disclosed in U.S. patent No. 5,599,335, EP 1,447,066, WO 95/11652, U.S. patent publication No. 2008/0312622a1, and WO 2012/052172 to Goldman et al. These can be used to construct the superabsorbent layer.
The addition of the core of the present disclosure is contemplated. In particular, potential additions to current multi-layer laminate absorbent cores are described in U.S. Pat. nos. 4,610,678, 4,673,402, 4,888,231, 4,834,735, 5,234,423, and 5,147,345. These are useful as long as they do not counteract or conflict with the action of the layers of the absorbent core of the present invention described below.
The first and second absorbent core layers and/or laminates of the
In some cases, the first absorbent core layer or laminate and the second absorbent core layer or laminate may have the same longitudinal length, while in other cases, the first absorbent core and the second absorbent core have different longitudinal lengths. In the latter case, the first absorbent core layer or laminate may have a smaller machine direction length than the second absorbent core layer or laminate, or conversely, the first absorbent core layer or laminate may have a larger machine direction length than the second absorbent core layer or laminate.
In some forms, the first and second absorbent core layers or laminates may further include an optional intermediate layer disposed between the respective superabsorbent layers and distribution layers. Generally, the optional intermediate layer may comprise the materials detailed herein with respect to the optional layer of the chassis.
In addition, in some forms, the absorbent article or incontinence pad may comprise, in addition to the first and second absorbent core layers or laminates, an optional additional absorbent core comprising a superabsorbent layer and/or a distribution layer. The optional additional core may take the form of a third, fourth, fifth or even additional layer. The superabsorbent layer and the distribution layer may exhibit the same or different properties as previously detailed with respect to the first and second superabsorbent layers and the distribution layer. Any optional additional cores may be disposed on the body facing surface of the first or second absorbent core or on the garment facing surface of the first or second absorbent core.
As previously noted, in some forms the first absorbent core layer or laminate has a first
Referring to fig. 3 and 7, as previously described, the front end portion of the
In some forms, the first absorbent core or the second absorbent core may include one or more recessed regions extending in the longitudinal or transverse direction. These recessed regions can coincide with a discontinuous pattern of one or more of the superabsorbent layer and the distribution layer, whether it be the first absorbent core, the second absorbent core, or both. These recessed regions may also be formed by embossing of the first absorbent core or the second absorbent core only. These recessed areas may alternatively be formed by cutting, ring rolling, or otherwise providing mechanical deformation through the first and/or second absorbent cores. Each of the ways of forming the indented regions mentioned herein is intended to create an indented region that is capable of providing a preferential bending point for the entire article. For example, a plurality of recessed regions or gaps or embossed channels may be disposed in the machine direction in at least one or both of the first and second absorbent cores of the
Additionally, for those forms in which the first absorbent core and/or the second absorbent core do not comprise a laminate structure, airlaid core materials may be utilized. Any suitable airlaid core may be utilized. Airlaid core materials are available from manufacturers of such materials, or can be prepared in-line via equipment known in the art. In the case of airlaid cores, the need for separate superabsorbent and distribution layers may be reduced.
Super absorbent layer
The first and second
The size of the fluid-absorbent gelling material particles can vary within a wide range. For industrial hygiene reasons, an average particle size of less than about 30 microns is less desirable. Particles having a minimum dimension greater than about 2mm can also create a gritty feel in the absorbent article that is undesirable from a consumer aesthetic standpoint. In addition, the fluid absorption rate may be affected by particle size. Larger particles have a very reduced absorption rate. The fluid absorbent gelling material particles preferably have a particle size (for substantially all particles) of from about 30 microns to about 2 mm. As used herein, "particle size" refers to the weighted average of the smallest dimension of individual particles.
In some forms, the absorbent cores of the present disclosure, or portions thereof, may be substantially free of airfelt and, thus, differ from the intermixed layer, which may comprise airfelt. As used herein, "substantially free of airfelt" means less than 5%, 3%, 1%, or even 0.5% airfelt. In some forms, there may be no measurable airfelt in the superabsorbent layer. As far as the first superabsorbent layer is concerned, it is preferably discontinuously disposed on the first distribution layer. And as previously mentioned, the second superabsorbent layer may be bonded to the first superabsorbent layer or discontinuously disposed on the second distribution layer independently of the first superabsorbent layer. As used herein, "discontinuous" or "in a discontinuous pattern" means that the superabsorbent polymer is applied to the first distribution layer in a pattern that separates the shaped regions. These regions of superabsorbent polymer or regions free of superabsorbent polymer can include, but are not limited to, linear stripes, non-linear stripes, circles, rectangles, triangles, waves, meshes, and combinations thereof. However, like the second superabsorbent layer, the first superabsorbent layer may be disposed in a continuous pattern on its respective distribution layer. As used herein, "continuous pattern" or "continuous" means that the material is deposited and/or secured to the superabsorbent carrier material and/or adjacent distribution layer in an uninterrupted manner such that the superabsorbent polymer has a fairly complete coverage of the distribution layer.
In certain embodiments, the first superabsorbent layer and the second superabsorbent layer can comprise the same superabsorbent polymer. In other embodiments, the first superabsorbent layer and the second superabsorbent layer can comprise superabsorbent polymers that are different from each other. This may be in addition to the different deposition patterns discussed above.
The superabsorbent layer is configured to have a thickness of 0.2mm, 0.3mm, 0.4mm, or 0.5mm to 1mm, 1.2mm, 1.4mm, 1.8mm, or 2 mm. The first superabsorbent layer and the second superabsorbent layer may have the same or different lateral widths when applied to their respective distribution layers. For example, the first and second superabsorbent layers can have a transverse width of 20mm, 25mm, 30mm, 35mm, or 40mm to 50mm, 60mm, 65mm, 70mm, 80mm, or 90 mm. Alternatively, in embodiments in which the lateral widths of the first and second superabsorbent layers are different from each other, the first superabsorbent layer may have a smaller lateral width than the second superabsorbent layer. In particular, the first superabsorbent layer may have a lateral width that is about 95%, 90%, 80%, 70%, or even 60% less than the width of the second superabsorbent layer.
In certain embodiments, one or both of the first and second superabsorbent layers span greater than about 50%, 60%, 70%, 80%, 90%, or even 95% of the transverse width of the superabsorbent carrier layer and/or the respective adjoining first or second distribution layer.
Carrier web/optional layer
Recall that the carrier web can comprise a primary topsheet and/or a secondary topsheet. Also, as with the optional layers that may be included in the chassis, the absorbent system may also include similar optional layers. The following description and attributes of the optional layers also apply to the carrier web. For convenience, the term "web" shall encompass optional layer webs as well as carrier webs. The optional layer and/or carrier web can be a web selected from the group consisting of fibrous structures, air-laid webs, wet-laid webs, high loft nonwovens, needle punched webs, hydroentangled webs, fiber tows, woven webs, knitted webs, flocked webs, spunbond webs, layered spunbond/meltblown webs, carded webs, coform webs of cellulosic fibers and meltblown fibers, coform webs of staple fibers and meltblown fibers, and layered webs that are layered combinations thereof.
These optional layers and/or carrier webs may include materials such as creped cellulose wadding, fluffed cellulose fibers, airfelt, and textile fibers. The material of the web may also be fibers such as, for example, synthetic fibers, thermoplastic particles or fibers, tricomponent fibers, and bicomponent fibers such as, for example, sheath/core fibers having the following polymer combinations: polyethylene/polypropylene, polyethylvinyl acetate/polypropylene, polyethylene/polyester, polypropylene/polyester, copolyester/polyester, and the like. An optional layer can be any combination of the above-listed materials and/or a plurality of the above-listed materials, alone or in combination. The materials of the fibrous web may be hydrophobic or hydrophilic depending on their location within the chassis.
The material of the web may include constituent fibers comprising polymers such as polyethylene, polypropylene, polyester, and blends thereof. The fibers may be spunbond fibers. The fibers may be meltblown fibers. The fibers may comprise cellulose, rayon, cotton, or other natural materials or blends of polymers and natural materials. The fibers may also include superabsorbent materials such as polyacrylates or any combination of suitable materials. The fibers may be monocomponent, bicomponent and/or biconstituent, non-round (e.g., capillary channel fibers), and may have a major cross-sectional dimension (e.g., diameter of round fibers) in the range of 0.1 to 500 microns. The constituent fibers of the nonwoven precursor web can also be a mixture of different fiber types that differ in characteristics such as chemistry (e.g., polyethylene and polypropylene), composition (mono-and bi-), denier (micro-and >20 denier), shape (i.e., capillary and circular), and the like. The constituent fibers may range from about 0.1 denier to about 100 denier.
The web may comprise thermoplastic particles or fibers. The material, particularly the thermoplastic fibers, can be made from a variety of thermoplastic polymers including polyolefins such as polyethylene (e.g., PULPEX) TM) Polypropylene, polyester, copolyester, and copolymers of any of the foregoing.
Depending on the desired characteristics, suitable thermoplastic materials include hydrophobic fibers made hydrophilic, such as surfactant-treated or silica-treated thermoplastic fibers derived from, for example, polyolefins such as polyethylene or polypropylene, polyacrylates, polyamides, polystyrenes, and the like. The surface of the hydrophobic thermoplastic fibers can be treated with a surfactant, such as a nonionic or anionic surfactant, to become hydrophilic, for example, spraying the fibers with a surfactant, dipping the fibers into a surfactant, or including a surfactant as part of the polymer melt in the production of the thermoplastic fibers. Upon melting and resolidification, the surfactant will tend to remain at the surface of the thermoplastic fibers. Suitable surfactants include nonionic surfactants such as Brij76 manufactured by ICI America, Inc. (Wilmington, Del.) and Pegosperse under the trademarkTMVarious surfactants are sold by Glyco Chemical, Inc. In addition to nonionic surfactants, anionic surfactants may also be used. These surfactants may be, for example, from about 0.2 to about 1g/cm 2The amount of thermoplastic fiber is applied to the thermoplastic fiber.
Suitable thermoplastic fibers can be made from a single polymer (monocomponent fibers) or can be made from more than one polymer (e.g., bicomponent fibers). The polymer comprising the sheath often melts at a different (usually lower) temperature than the polymer comprising the core. Thus, these bicomponent fibers provide thermal bonding due to the melting of the sheath polymer while maintaining the desired strength characteristics of the core polymer.
Suitable bicomponent fibers for the webs of the present disclosure may include sheath/core fibers having the following polymer combinations: polyethylene/polypropylene, polyethylvinyl acetate/polypropylene, polyethylene/polyester, polypropylene/polyester, copolyester/polyester, and the like. Particularly suitable bicomponent thermoplastic fibers for use herein are those having a polypropylene or polyester core and a copolyester, polyethylvinyl acetate or polyethylene sheath having a lower melting temperature (e.g., DANAKLON)TM、CELBONDTMOr CHISSOTMBicomponent fibers). These bicomponent fibers may be concentric or eccentric. As used herein, the terms "concentric" and "eccentric" refer to whether the sheath has a uniform or non-uniform thickness across the cross-sectional area of the bicomponent fiber. Eccentric bicomponent fibers are desirable when providing greater compressive strength at lower fiber thickness. Suitable bicomponent fibers for use herein can be uncrimped (i.e., unbent) or crimped (i.e., curved). Bicomponent fibers can be crimped by typical textile methods such as the stuffer box method or the gear crimping method to obtain a predominantly two-dimensional or "flat" crimp.
The length of the bicomponent fibers may vary depending on the particular characteristics desired for the fibers and the web forming process. Typically, in an airlaid web, the thermoplastic fibers are from about 2mm to about 12mm long, such as from about 2.5mm to about 7.5mm long, or from about 3.0mm to about 6.0mm long. The nonwoven fibers may be between 5mm and 75mm long, such as 10mm long, 15mm long, 20mm long, 25mm long, 30mm long, 35mm long, 40mm long, 45mm long, 50mm long, 55mm long, 60mm long, 65mm long, or 70mm long. The properties of these thermoplastic fibers can also be adjusted by varying the diameter (thickness) of the fibers. The diameter of these thermoplastic fibers is generally defined in terms of denier (grams/9000 meters) or dtex (grams/10000 meters). Suitable bicomponent thermoplastic fibers for use in the airlaid machine can have a dtex in the range of from about 1.0 to about 20, such as from about 1.4 to about 10 dtex, or from about 1.7 to about 7 dtex.
The compressive modulus of these thermoplastic materials, particularly the compressive modulus of the thermoplastic fibers, may also be important. The compressive modulus of thermoplastic fibers is affected not only by their length and diameter, but also by the composition and characteristics of the polymer or polymers from which they are made, the shape and configuration of the fibers (e.g., concentric or eccentric, crimped or uncrimped), and the like. The difference in compression modulus of these thermoplastic fibers can be used to modify the properties, particularly the density characteristics, of the corresponding thermally bonded fibrous matrix.
The web may also include synthetic fibers that are not normally used as binder fibers but which modify the mechanical properties of the web. Synthetic fibers include cellulose acetate, polyvinyl fluoride, polyvinylidene 1, 1-dichloride, acrylics (such as orlon), polyvinyl acetate, insoluble polyvinyl alcohol, polyethylene, polypropylene, polyamides (such as nylon), polyesters, bicomponent fibers, tricomponent fibers, mixtures thereof, and the like. These may include, for example, polyester fibers such as polyethylene terephthalate (e.g., DACRON)TMAnd KODELTM) High melting crimped polyester fibers (e.g., KODEL made by Eastman Chemical Co., Ltd.)TM431) Hydrophilic nylon (HYDROFLIL)TM) And so on. Suitable fibers may also hydrophilize hydrophobic fibers, such as surfactant-treated or silica-treated thermoplastic fibers derived from, for example, polyolefins such as polyethylene or polypropylene, polyacrylics, polyamides, polystyrenes, polyurethanes, and the like. In the case of non-binding thermoplastic fibers, their length may vary depending on the particular properties desired for the fibers. Typically, they are about 0.3cm to 7.5cm in length, such as about 0.9cm to about 1.5 cm. Suitable non-binding thermoplastic fibers can have a dtex in the range of from about 1.5 to about 35, such as from about 14 to about 20 dtex.
Distribution layer
The first and second distribution layers may be used to wick body fluids away from the wearer's skin, thereby facilitating sustained wear comfort after release. In some forms, the support web may include a distribution layer. In some forms, the support web may be configured similar to the carrier web described herein. In some forms, the first and second distribution layers of the first and/or second laminates not only face each other, but are also joined in an offset manner to form a portion of the core. The distribution layer includes one or more of cellulose and compensated wood pulp. This may be in the form of an air-laid web. Airlaying can be chemical bonding or thermal bonding. In particular, the airlaid can be a multi-bond airlaid (MBAL). In this case, the distribution layer may also comprise a fibrous thermoplastic binder material that at least partially air-laid bonds to itself and to an adjacent distribution layer, superabsorbent layer or other additional (optional) layer. It should be noted that it is contemplated that the same materials that are suitable for use in the optional layers of the chassis are suitable for use in the distribution layer. The first and second distribution layers each have a basis weight ranging from 80gsm, 80gsm 100gsm, 110gsm, 120gsm, or 130gsm to 140gsm, 150gsm, 160gsm, 180gsm, 200gsm, 220gsm, or 240 gsm. The distribution layer of the first and second laminates each preferably has a basis weight of 135 gsm. The support web 870 (shown in fig. 8, 10, 11, and 13) can comprise the same composition as the distribution layer.
Health-beneficial agent
As previously mentioned, in some forms, the health benefit agent may be deposited on a carrier web as described herein. Some suitable health benefit agents include prebiotics (e.g., fructooligosaccharides), clays (e.g., laponite), activated carbon, organic acids (e.g., lactic acid), xylitol, and/or antioxidants (e.g., vitamin C). In some forms, such combinations of actives may be provided on the carrier web or in other portions of the absorbent article (e.g., topsheet, barrier cuffs, secondary topsheet, distribution layer, or any combination thereof). Health benefit agents are additionally disclosed in detail in U.S. patent 8,552,251.
Barrier hoop
Referring back to fig. 2, the
The
As shown, in some forms, the
Although the
The first
As shown, the
The elastic member comprised of the barrier cuff may be glued at various bond lengths using various glue and glue amounts and arrangements. Glue placement is another variable that should be considered particularly where core flexibility is a design concern. The adhesion of the elastic member to the cover may form an anchor point on the pad.
The cover of the barrier cuff of the present invention may be made of various types of nonwovens having different MD and CD flexibility. The cover member may be bonded to the topsheet of the absorbent article, for example by a slot-coated adhesive strip, a bead of glue, an ultrasonic seal, or other suitable adhesive. In some forms of the invention, the cover may be bonded to the backsheet at the side edges 22 and 24 (see fig. 1) of the pad, for example using a fold or other suitable adhesive such as an adhesive.
The elastic member may comprise any suitable elasticityA material. Some suitable examples include SpandexTMOr other similar polyurethanes, natural or synthetic rubbers, styrene block copolymers, metallocene polyolefins, LycraTMOr any other suitable elastomeric material known in the art. Preferably, the elastic member is easy to process and durable during use of the article, and exhibits excellent elasticity (recovery after strain) even at strains up to 400%.
Additionally, the elastic members of the present disclosure may have any suitable dtex. In other forms, the elastic member may have a dtex of 680 or less. In some forms, the elastic member may have a decitex between 680 and 470, specifically including all values within these ranges and any ranges formed thereby.
The minimum spacing between the
Test method
Linear distance
The linear distance may be measured by any suitable instrument calibrated and capable of measuring to the nearest 0.1 mm.
Basis weight test
Using 9.00cm2A large sample substrate, 1.0cm wide by 9.0cm long. Samples may be cut from consumer products such as absorbent articles. The sample needs to be dry and free of other materials such as glue or dust. The samples were conditioned at 23 degrees celsius (± 2 ℃) and a relative humidity of about 50% (± 5%) for 2 hours to reach equilibrium. The weight of the cut nonwoven substrate was measured on a balance with an accuracy of 0.0001 g. The mass obtained is divided by the area of the sample to give the mass in g/m2Results in units of (gsm). The same procedure was repeated for at least 20 samples from 20 identical consumer products or packaging materials therefor. More than one sample may be obtained from each if the consumer product or the packaging material used for it is sufficiently large. One example of a sample is a portion of a topsheet of an absorbent article. If a local basis weight change test is performed, those same samples and data are used to calculate and report the average basis weight.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Rather, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".
Each document cited herein, including any cross referenced or related patent or patent application and any patent application or patent to which this application claims priority or its benefits, is hereby incorporated by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with any disclosure of the invention or the claims herein or that it alone, or in combination with any one or more of the references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
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