CA2132970C - Stitchbonded absorbent articles - Google Patents
Stitchbonded absorbent articles Download PDFInfo
- Publication number
- CA2132970C CA2132970C CA002132970A CA2132970A CA2132970C CA 2132970 C CA2132970 C CA 2132970C CA 002132970 A CA002132970 A CA 002132970A CA 2132970 A CA2132970 A CA 2132970A CA 2132970 C CA2132970 C CA 2132970C
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- Prior art keywords
- nonwoven
- layer
- fibers
- yarn
- fiber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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- 230000002745 absorbent Effects 0.000 title claims abstract description 61
- 239000002250 absorbent Substances 0.000 title claims abstract description 61
- 239000000835 fiber Substances 0.000 claims abstract description 91
- 229920000297 Rayon Polymers 0.000 claims abstract description 28
- 239000000853 adhesive Substances 0.000 claims abstract description 23
- 230000001070 adhesive effect Effects 0.000 claims abstract description 23
- 239000000463 material Substances 0.000 claims abstract description 22
- 239000000203 mixture Substances 0.000 claims abstract description 15
- 229920000742 Cotton Polymers 0.000 claims abstract description 14
- 239000011230 binding agent Substances 0.000 claims abstract description 14
- 229920000098 polyolefin Polymers 0.000 claims abstract description 10
- 229920002994 synthetic fiber Polymers 0.000 claims abstract description 8
- 239000012209 synthetic fiber Substances 0.000 claims abstract description 8
- 238000002844 melting Methods 0.000 claims description 18
- 230000008018 melting Effects 0.000 claims description 18
- -1 polyethylene Polymers 0.000 claims description 11
- 239000004743 Polypropylene Substances 0.000 claims description 8
- 229920000728 polyester Polymers 0.000 claims description 7
- 239000002964 rayon Substances 0.000 claims description 7
- 239000004698 Polyethylene Substances 0.000 claims description 6
- 229920001155 polypropylene Polymers 0.000 claims description 5
- 239000004952 Polyamide Substances 0.000 claims description 4
- 229920002647 polyamide Polymers 0.000 claims description 4
- 229920000573 polyethylene Polymers 0.000 claims description 4
- 229920001577 copolymer Polymers 0.000 claims description 3
- 229920002239 polyacrylonitrile Polymers 0.000 claims description 2
- 102000004169 proteins and genes Human genes 0.000 claims description 2
- 108090000623 proteins and genes Proteins 0.000 claims description 2
- 229920000642 polymer Polymers 0.000 claims 2
- 229920002301 cellulose acetate Polymers 0.000 claims 1
- NBVXSUQYWXRMNV-UHFFFAOYSA-N fluoromethane Chemical compound FC NBVXSUQYWXRMNV-UHFFFAOYSA-N 0.000 claims 1
- 238000005406 washing Methods 0.000 abstract description 14
- 230000001747 exhibiting effect Effects 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 51
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 25
- 238000012360 testing method Methods 0.000 description 16
- 239000004744 fabric Substances 0.000 description 15
- 238000000034 method Methods 0.000 description 15
- 238000010998 test method Methods 0.000 description 7
- 238000010276 construction Methods 0.000 description 6
- 229920001131 Pulp (paper) Polymers 0.000 description 5
- 230000007423 decrease Effects 0.000 description 5
- 238000010521 absorption reaction Methods 0.000 description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 229920001169 thermoplastic Polymers 0.000 description 4
- 239000004416 thermosoftening plastic Substances 0.000 description 4
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 3
- 239000008367 deionised water Substances 0.000 description 3
- 229910021641 deionized water Inorganic materials 0.000 description 3
- 239000003599 detergent Substances 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- 229920002678 cellulose Polymers 0.000 description 2
- 239000001913 cellulose Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 230000000717 retained effect Effects 0.000 description 2
- 239000004749 staple nonwoven Substances 0.000 description 2
- 238000009864 tensile test Methods 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- 238000005303 weighing Methods 0.000 description 2
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- 241000288673 Chiroptera Species 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 206010041235 Snoring Diseases 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000003292 diminished effect Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000005357 flat glass Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- 238000002074 melt spinning Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000008399 tap water Substances 0.000 description 1
- 235000020679 tap water Nutrition 0.000 description 1
- 235000013616 tea Nutrition 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/45—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by forming intermeshing loops or stitches from some of the fibres
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
- A61B17/32—Surgical cutting instruments
- A61B17/3203—Fluid jet cutting instruments
-
- 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
- A61F9/00—Methods or devices for treatment of the eyes; Devices for putting-in contact lenses; Devices to correct squinting; Apparatus to guide the blind; Protective devices for the eyes, carried on the body or in the hand
- A61F9/007—Methods or devices for eye surgery
- A61F9/00736—Instruments for removal of intra-ocular material or intra-ocular injection, e.g. cataract instruments
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
- D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
- D04B21/165—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/52—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by applying or inserting filamentary binding elements
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2401/00—Physical properties
- D10B2401/04—Heat-responsive characteristics
- D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24033—Structurally defined web or sheet [e.g., overall dimension, etc.] including stitching and discrete fastener[s], coating or bond
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/253—Cellulosic [e.g., wood, paper, cork, rayon, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3707—Woven fabric including a nonwoven fabric layer other than paper
- Y10T442/3724—Needled
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/40—Knit fabric [i.e., knit strand or strip material]
- Y10T442/494—Including a nonwoven fabric layer other than paper
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/666—Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
- Y10T442/667—Needled
Abstract
A stitchbonded absorbent article exhibiting good hand, repeated washing durability, and absorbency. The article includes (a) at least a first layer of material comprising a first nonwoven batt consisting essentially of cellulosic pulp fibers bonded together by an adhesive binder, the first layer having a basis weight of at least 95 gsm per ply; and preferably (b) a second layer comprising materials selected from the group consisting of i) a second nonwoven batt consisting essentially of cellulosic pulp fibers bonded together by an adhesive binder, wherein the second nonwoven batt consisting essentially of nonwoven cellulosic pulp fiber being the same or different than the first batt, and ii) a woven, nonwoven, or knitted layer of materials selected from the group consisting of viscose rayon, cotton, non-polyolefin synthetic fibers, and mixtures thereof, wherein the first and second layers are mechanically held together by stitches of yarn, at a stitch density ranging from 15 to 35 st/10 cm, and stitch gauge ranging from to 40, using a stitching yarn comprising at least two compositionally different fibers having different heat stability being at least partially melt-bonded together at points of mutual contact, the yarn being melt-bonded at least partially to outer surfaces of the article.
Description
WO 93!22485 ~ ~ ~ ' l ~ P~TlUS93/0~550 STIT~CHBO1~1DED ABSORBENT ARTICLES
This invention pertains to stitchbonded, durable, absorbent articles made using a stitching yarn having fibers of differing heat stabilities, and to methods of producing such articles.
Parella, J.C., "Iolonwoven Technology and Wipers", paper presented at IPtDA~TEC 1989, presents a perceptive account of the nonwoven industry.
Specifically, Parella describes and compares the four primary techniques that commercial manufacturers have focused on for producing wipes. In order of commercialization they are:
dry staple (carded, air laid, saturation or spray bonded webs made from textile fibers);
air~lay (fabric made by air laying and bonding cellulosic or synthetic pulp fibers);
melt blown (webs formed by in-line melt spinning of very fine fibers); and spunlace (fabrics produced by hydraulic entangling of fibers).
Parella compares these primarily using the "alphabet" of consumer driven requirements for wipes:
"A" for absorbency; "B" for bulk density; "C" for consistency; "D" for durability;
and "P°° for price.
Dry staple nonwoven wipes were acceptable in terms of A and D, but P
was ~ premium over T00% cellulosic paper wipes; Wipes made using the air-lay process generally met consumer needs for A; 8, C, and P but fell short on improving D ~ver already, available dry staple nonwoven wipes. Despite this, product acceptance rwas almost immediate in industrial and consumer sectors.
B5 Fabrics made fxorn melt blown fibers exhibited outstanding oil absorbency, and aqueous absorbency was acceptable. Adsorption or entrapment is the methad of absorbency empl~yed rather than absorption int~ the fiber or cellulose as in the use of the dry staple or air lying techniques. ~, C; D, and P were adequate but not dramatically different from prior wipes. Spunlaced fabrics were said to be "the m~st complete nonwoven wiper seen to date" in terms ~f A, B, C, and D, and P
was "within the range of acceptance given the performance characteristics."
~~~.a~~~ ~~.;
W~ 93/2245 Pt.'TIUS931~355() Whitehead et al. (U.S. Pat. No. 3,881,490), at column 4, line 63, through column 5, Line 68) gives a respectable rendition of the air-lay technique of fabricating nonwoven wipes. However, Anderson et al. (L1.S. Pat. No.
4,100,324) describes one apparent disadrrantage of air lay wood pulp fiber webs, that they exhibit reduced absorbent capacity and rate (as compared to mechanically entangled webs of wood and synthetic pulp fibers) due to the adhesive used to contain the wood pulp fibers.
Stitchbonding, as a method of bonding two fabrics together to form a durable, absorbent wipe, has apparently not received the amount of attention of the wipes industry as hive the above mentioned techdiques. Schwartz, in U.S. Pat.
No. 3;717,150, describes an absorbent stretchable diaper comprising a Layer of h~rdrophilic material, at least one layer of hydrophobic material, stitched together with substantially non-shrinkable yarn:
Two Czechoslovakian patents, 162277 (issued November 15, 1976) and 193700 (published 3~nuary: 31, 1979), relate to stitchbonded materials. The '277 patent is drawn toward a nanwoven fabric, suitable for use as a wipe, comprising base loose fibers of natural ar chemical fibers having on at least one side thereof, attached a layer of lintless, bonded nonwnven fabric made by the wet laid process.
The '700 Czechoslovakian patent describes a stitchbonded article, the stitching yarn containing at least two yarns of differing heat stability. The finished article as it appears from the technical back side is illustrated in a schematic perspective view in FIG: lA; showing ,the article 10 comprised of the cotton/viscose batt 12plain stitch 14 of polyamide yarn, and chain stitch 16 of polypropylene yarn. FIG. 1B is a schematic representation o~ the stitching pattern used, and also how the Lapping bars or guides'are threaded: No criticality is given to the stitch density; stitch gauge (as defined herein), or fibrous web composition as they relate to rate and absolute amount of water absorbency or durability of these wipes.
Otf (U.S: Pat: N~o. 4,675,226), desca~bes a stitchbonded composite wiper having a middle layer of 'cellulose natur~ll fibers and outer layers of either continuous filament thermoplastic fibers, meltblown thermoplastic mierofibers or 4N0 )3/22485 ~ ~ ~ ~~ r ~~,- PCTlU~93/03550 rayon fibers. The layers are laminated into a composite by chain stitchbonding using stitching yarn of either polyester, cotton, rayon, nylon or a blend.
The manner of producing stitchbonded materials is performed by stitchbonding machines, such as that known under the trade designation S "Maliwatt", as described in U.S. Pat. Nos. 2,890,79; 3,030,786; and 3,279,221.
Equivalent machines, such as that known under the trade designation "Arachne", can be used for Iareparing the stitchbonded materials which are precursors to the articles of the present invention.
A series of patents by Zafiroglu describes nonwaven fabrics which are mufti-needle stiteheei with an elastic yarn (U.S. Pat. Nos. 4,704,321;
This invention pertains to stitchbonded, durable, absorbent articles made using a stitching yarn having fibers of differing heat stabilities, and to methods of producing such articles.
Parella, J.C., "Iolonwoven Technology and Wipers", paper presented at IPtDA~TEC 1989, presents a perceptive account of the nonwoven industry.
Specifically, Parella describes and compares the four primary techniques that commercial manufacturers have focused on for producing wipes. In order of commercialization they are:
dry staple (carded, air laid, saturation or spray bonded webs made from textile fibers);
air~lay (fabric made by air laying and bonding cellulosic or synthetic pulp fibers);
melt blown (webs formed by in-line melt spinning of very fine fibers); and spunlace (fabrics produced by hydraulic entangling of fibers).
Parella compares these primarily using the "alphabet" of consumer driven requirements for wipes:
"A" for absorbency; "B" for bulk density; "C" for consistency; "D" for durability;
and "P°° for price.
Dry staple nonwoven wipes were acceptable in terms of A and D, but P
was ~ premium over T00% cellulosic paper wipes; Wipes made using the air-lay process generally met consumer needs for A; 8, C, and P but fell short on improving D ~ver already, available dry staple nonwoven wipes. Despite this, product acceptance rwas almost immediate in industrial and consumer sectors.
B5 Fabrics made fxorn melt blown fibers exhibited outstanding oil absorbency, and aqueous absorbency was acceptable. Adsorption or entrapment is the methad of absorbency empl~yed rather than absorption int~ the fiber or cellulose as in the use of the dry staple or air lying techniques. ~, C; D, and P were adequate but not dramatically different from prior wipes. Spunlaced fabrics were said to be "the m~st complete nonwoven wiper seen to date" in terms ~f A, B, C, and D, and P
was "within the range of acceptance given the performance characteristics."
~~~.a~~~ ~~.;
W~ 93/2245 Pt.'TIUS931~355() Whitehead et al. (U.S. Pat. No. 3,881,490), at column 4, line 63, through column 5, Line 68) gives a respectable rendition of the air-lay technique of fabricating nonwoven wipes. However, Anderson et al. (L1.S. Pat. No.
4,100,324) describes one apparent disadrrantage of air lay wood pulp fiber webs, that they exhibit reduced absorbent capacity and rate (as compared to mechanically entangled webs of wood and synthetic pulp fibers) due to the adhesive used to contain the wood pulp fibers.
Stitchbonding, as a method of bonding two fabrics together to form a durable, absorbent wipe, has apparently not received the amount of attention of the wipes industry as hive the above mentioned techdiques. Schwartz, in U.S. Pat.
No. 3;717,150, describes an absorbent stretchable diaper comprising a Layer of h~rdrophilic material, at least one layer of hydrophobic material, stitched together with substantially non-shrinkable yarn:
Two Czechoslovakian patents, 162277 (issued November 15, 1976) and 193700 (published 3~nuary: 31, 1979), relate to stitchbonded materials. The '277 patent is drawn toward a nanwoven fabric, suitable for use as a wipe, comprising base loose fibers of natural ar chemical fibers having on at least one side thereof, attached a layer of lintless, bonded nonwnven fabric made by the wet laid process.
The '700 Czechoslovakian patent describes a stitchbonded article, the stitching yarn containing at least two yarns of differing heat stability. The finished article as it appears from the technical back side is illustrated in a schematic perspective view in FIG: lA; showing ,the article 10 comprised of the cotton/viscose batt 12plain stitch 14 of polyamide yarn, and chain stitch 16 of polypropylene yarn. FIG. 1B is a schematic representation o~ the stitching pattern used, and also how the Lapping bars or guides'are threaded: No criticality is given to the stitch density; stitch gauge (as defined herein), or fibrous web composition as they relate to rate and absolute amount of water absorbency or durability of these wipes.
Otf (U.S: Pat: N~o. 4,675,226), desca~bes a stitchbonded composite wiper having a middle layer of 'cellulose natur~ll fibers and outer layers of either continuous filament thermoplastic fibers, meltblown thermoplastic mierofibers or 4N0 )3/22485 ~ ~ ~ ~~ r ~~,- PCTlU~93/03550 rayon fibers. The layers are laminated into a composite by chain stitchbonding using stitching yarn of either polyester, cotton, rayon, nylon or a blend.
The manner of producing stitchbonded materials is performed by stitchbonding machines, such as that known under the trade designation S "Maliwatt", as described in U.S. Pat. Nos. 2,890,79; 3,030,786; and 3,279,221.
Equivalent machines, such as that known under the trade designation "Arachne", can be used for Iareparing the stitchbonded materials which are precursors to the articles of the present invention.
A series of patents by Zafiroglu describes nonwaven fabrics which are mufti-needle stiteheei with an elastic yarn (U.S. Pat. Nos. 4,704,321;
4,773,238;
4,876,128; and 5,041;255).
In accordance with the present invention, a stitchbonded absorbent article is presented characterized by a nonwoven batt consisting essentially of cellulosic pulp fibers bonded together by an' adhesive binder: The bonding of the fibers may be by thermoplastic powder bondfng; thermoplastic fibers, or by spray bonding.
Preferred is spray bonded baits; easing acrylic Iatex-based adhesive binders. The batt has a basis weight of at least about 95 g/mz (gsm) per ply:
The batt is stitchbanded, using a plain or tricot stitch, with a stitching yarn compzising two c~mposi6ona11~ different fibers having different heat stability:
In the final form of the absorbent articles of the invention the two fibers are at least partially melt-bonded together: after titching, az~d are also melt-bonded to at least a portion of the external surfaces of the articles after stitching.
In one class of preferred embodiments; a second layer is stitchbonded to the first hyer: The second layer is selected from the group consisting of 2$ i) a Second nonwoven bate consisting essentially of cellulosic pulp fibers banded together by an adhesive binder, wherein the second batt may be the same or 'different from: the first butt; and ii) a woven, norivvoven, or knitted layer of materials selected from the group consisting of viscose rayon; cotton, non-polyolefin synthetic fibers, and rhixtures thereof:
~~~'cf~/~2~g~~ PCT/US93/o3550 The first and second (or more) layers are mechanically held together by stitches of yarn, preferably a plain or tricot stitch. A stitch density (number of stitches in the machine direction per 10 em) ranging from about 15 to about 35 st/ lOcm, and stitch gauge (number of stitch Wales per 10 cm) ranging from about I0 to about 40, have been found to afford the articles with surprisingly good water absorbency properties (rate and absolute) and durability when used in conjunction with the adhesive bonded cellulosic pulp fiber batts.
It was unexpected that the increase in durability of the articles of the invention could be obtained by stitchbonding with only a slight decrease in water absorbency properties compared with a non-stitchbonded article of otherwise similar construction. The "hand°' properties, flexibility, and drapability are also not substantially decreased ~ver non-stitchbonde~i articles of similar construction, and an essentially disposable ikem is rendered into a mufti-use item, reducing waste disposal problems. Tlae attractiveness of articles of the invention can be modified 1S by changing the colors of the stitching yarns and/or khe Layers used to make the articles.
A stitching yarn comprising at least two compositionally different fibers, and thus of different heat stability, is used. The two fibers are milt-bonded to each other al~ng at least a portion of their co~taet area, and at Least aportion of the yarn is in turn melt-bonded to the outer surfaces of the articles. As used hezein "cellulosic pulp fibers" means cellulosic fibers, such as wood pulp fibers, having a length ranging from about 3 to about S mm, and diameter ranging from ab~ut 15 to about 40 micr~meters (denier ranging from about 1 to about S
dtex).
Thus, these fibers are distinguished from staple or textile fibers (which generally are between ab~ut 2 and 3 cm) and continuous filaments. "Consisting essentially of nonwoven cellulosic pulp fibers" means that the bats contains zero or a de minimis amount of fibers which do not meet the definition of "pulp fgbers".
one particuhrly preferred class of articles ~f' the invention are those wherein the second Layer comprises a second batt of nonwoven cellulosic pulp fibers bbndcd together by an adhesive binder.
WO 93/224f3j r~ ~,'~~ L~ r~ ~ PC1'/US93/03550 ~5-Also preferred absorbent articles within the invention are those wherein the second layer comprises viscose rayon fibers. Particularly preferred articles of this class are those wherein the article includes a third layer similar to the second Payer, the second and third layers forming a sandwich around the first Layer.
Manufacturing stitchbonded absorbent articles of the invention comprises as a first step forming a stitchbonded material having a stitch density ranging from about 15 to about 35 st/lOcm, and stitch gauge ranging from about 14 to about 40, using a yarn comprising first and second compositionally different fibers having different heat stability. 'Thereafter the stitchbonded material is heated for a time and at a temperature sufficiirnt to partially melt the lower melting temperature fibers but insufficient to melt the higher melting temperature fiber, thereby melt-bonding at least a portion of the farst and second fibers together and melt-bonding at least a portion of the first I~wer melting fiber to the outer surfaces of the article.
FIG. lA is a perspective schematic view of the article of Czech patent 193700 Example 1, showing the plain/chain combination stitch;
FIG. 1B is a schematic representation of the stitch structure of the article illustrated inn FIG. lA; and FIGs. 2-5 sh~w perspE;ctive schematic views of absorbent articles within the invention.
As previously noted; in all absorbent artidle embodiments in accordance with the invention, the first (or only) Iayer of material comprises a first batt of nonwoven c~llulosic pulp fibers bonded together by an adhesive binder, the first bate having a basis weight of at least about 95 grams/m2 (gsm) per ply.
It should thus be noxed that all absorbent articles of the invention are water absorbent and very durable, and yet are inexpensive to produce. Particularly, if the absorbent articles of the invention are made from 100 % cellulosic pulp fibers, the articles ~f the invention are Low in cost cp~pared with articles based on synthetic wood pulp: fibers Articles which include a second or third layers of 100% ~riscose rayon ox cotton ark similarly relatively inexpensive to produce, thus reducing cost to the ultiuate user:
..
i.l s. : ' : ,' " ,A) ~.j WC> 93!22485 Pt'T/US93/03550 The adhesive binder of the first and, if used, second butts of cellulosic pulp fiber may comprise any of the commonly used adhesive binders known in the art.
Typically and preferably the adhesive binder comprises a copolymer of ethylene and vinyl acetate, wherein the vinyl acetate is present at about 10 to about weight percent of the copolymer. Cellulosic wood pulp butts having this adhesive and found useful in the invention include those known under the trade designation "Airtex°', from James River Corporation, especially product numbers 395 and 399.
The 399 version is more absorbent but less strong than the 395 version.
Although the composition of these butts is proprietary, it is believed the adhesive generally comprises from about 2 to about 20 weight percent of the adhesive bonded eellulosie pulp fiber butts.
The second layer, or more layers if preferred depending on the end use, comprises materials selected from the group consisting of i) a second butt of nonwoven cellulosic pulp fibers bonded together by an adhesive, the second butt being the same or different than the first butt, and ii) a woven; nonwoven, or knitteai layer of materials selected from the group consisting ~f viscose rayon, cotton, non-polyolefin synthetic fibers, and mixtures thereof.
' 20 If the second layer is viscose rayon, this layer is preferably nonwoven, more preferably sgunlaced nonwoven: Suitable spunlaced 100% viscose rayon layers are available from various commercial sources. lane spunlaced 100%
viscose rayon layer found useful for the purposes of this invention is that sold under the trade designation "Brand 6411 Apertured", from Scott Paper Company.
The first and econd layers are st~tchbonded using a stitch density (stitches per 10 cm in machine direction) ranging from about 15 to about 35 st/ lOcm, more preferably ranging from about 20 to about 30 st/lOcm.
The stitch gauge (number of vertical dines of stitches (wiles) per 10 cm in cross direction) preferably ranges from about 10 to about 40, more preferably from about 13 to about 28 gauge, snore preferably about 20 gauge.
W~ 93/22485 ~ ~ '~ ? ~ ~ .~~ PC'1'/US93/03550 t,~ cy ". .
Stitching densities and gauges outside of these ranges, especially when used with embodiments having no second viscose rayon layer, have been found inadequate in meeting the acceptable durability, absorbency, and consistency that users have come to demand. For example, stitchbonded articles having stitch S density greater than about 35 st/10 cm were found to have unacceptable water absorbency rate and total water absorbency values. 5titchbonded articles of the invention having stitch density less than about 1~ stllOcm were found to lack acceptable durability. To be aGCeptable and thus within this invention, stitchbonded article durability (measured as peak load in a tensile test) should be greater than or equal to about 4.5 kg for one and two layer articles, and greater than or equal to 9 kg for three layer articles, as measured according to American Society of Testing Materials (ASTM) D-1682-64 (reapproved 19?5). This test is described in the Examples. Acceptable water absorbency is determined by a "drip" test, wherein the article is soaked in water, allowed to drip for 60 seconds, thin oven dried, after which the dried and 60 second drip weights are compared.
The results are given as a pdrcentage of the oven dried weight. To be acceptable, the stitchbonded arkicles of the invention hould exhibit a 60 second drip value of at least about 400 %. This test is also described in the Examples. Articlea of the irnvention having stitch gauge of above about 40 exhibit decreased water absorbency due to higher degree of compression of the absorbent cellulosic pulp fpber layer(s). Thus, stitching gauges higher than about 40 are not advantageous for stitching prebonded cellulosic pulp based nonwcwen layers due to excessive perforation by the stitching needles; resulting in diminished original tensile strength and integrity of the absorbent cellulosic pulp ~ayer(s).
As mentioned previously, a critical aspect of the invention is the use of a yarn comprising at least two compositi~nally different types of fibers having different heat stability r~rhich can be at least partially melt-bonded together. The y~ s alsa capable of melt-bonding to at least a portion of the article outer surfaces.
Pr~ferrably, the yarn comprises a farst fiber having a melting temperature below that c~f the cellulosic pulp fibe>: but no greater than about 175°C, and a WO )3!22485 PCT/iJS93103~50 second fiber having a melting temperature of at least about 200°C, more preferably at least about 240°C.
The portion of the yarn having a melting temperature below that of the cellulosic gulp fiber but no greater than about 175°C may be polyolefins selected from the group consisting of branched polyethylene, linear polyethylene, polypropylene, and mixtures thereof. Particularly preferred is polypropylene, which has a melting temperature range of about 160-170°C. The denier of these fibers should be such as to allow sufficient bonding between the higher melting temperature fibers of the yarn and the cellulosic or viscose rayon layer outer surface. ~therwise, the denier of these fibers is not critical, and may range from about 40 to about 200 denier, more preferably from about 70 to about 10(?
denier.
Fiber deniers lower than about 40 are difficult to melt-bond simply because of there is Iess mass of the fiber.
The second fiber having a melting temperature of at least about 200°C
may 1S be chosen from polyester (polyethylene terephthalate melts at about 248°C), alpha-cellulose (cotton) and rayon (decomposes after long exposure to temperatures of about 225°C), protein, acetate, ~dorocarbon, polyacrylonitrile, polyamide (the variaus nylons melt at about 220°C), and mixtures thereof.
Particularly preferred as the second fiber is polyethylene terephthalate (PET) polyester. These fibers have the advantage of drawing water toward the absorbent layer in the case where viscose rayon is used as second and third cover layers. The in~ereonnected network of the PET sdtehes through the layers of the articles of the invention increases the strength of the articles, and provides the durability demanded by users for repeated washing.
The denier of the second fibers is also not critical, and may range from about 10 to about 400 denier, more preferably from about 120 to about 180 denier.
Fibers having 1~wer denier than about ?O are presently not preferred as they may be'too v~reak in tensile strength; however; .should fibers having denier less than ?0 become available which pxovide the requisite strength to the articles of the invention, these may also be used. ' Fiber deniers above about 400 are more expensive and generally not retluired f~r increasing the durability of the articles .7. .
7 .:
. :i'...
I
a 5 .!
..
y ~I
n:1 u~, .i~,i .. m.1 n r." 1 .i..r ...L-n.. . , .m.
b !, 1'C.'l . .. , I' S''~.. . v .w", , . n .. ~ . . :1.'f:.,... . ..... ,..... . , i..~. ,. . ..3,.'I..n....., o . ..
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W(? 93122485 ~ ~ a~ taj E,~ .~ ~~. P~'/1JS93/03550 J
of the invention beyond the point where the user would normally dispose of the article. Larger denier fibers are also more expensive.
~ne preferred absorbent article embodiment 20 of the invention is illustrated in perspective in FIG. 2. In this embodiment, a first layer 22 of a butt of adhesive bonded cellulosic pulp fibers (such as those sold under the trade designations "Airtex 395" and "Airtex 399") is stitchbonded to a second layer of a butt of adhesive bonded nonwoven cellulosic pulp fibers (such as those known under the trade designations "Airtex 395" and "Airtex 399"). The '°technical backside" of article 20 is shown on top, showing the preferred "plain" stitch pattern of stitching yarn 26 used in the articles of the invention. A "tricot"
stitch may also be used. Holes 2g are shown slightly exaggerated in size to emphasize the point where individual needles have penetrated the layers. Alternatively, either one of or both layers 22 and 24 may be a nonwoven mixture of rayon/non-polyolefin synthetic fibers, or, more preferably, 100% cellulosic fibers.
Higher than about 30 weight percent non-golyolefin synthetic f bars are not preferred due the decrease ~n water absorbency of the articles of the invention. Suitable non-pcalyolefin synthetic fibers include polyester, acrylic, polyamide, and the like.
Another preferred embodiment 30 of the absorbent article of the invention is illustrated in FIG: 3, also as a perspective schematic. In this embodiment, the first layer 32 is the same as the first Iayer 22 of embodiment 20 shown in FIG. 2;
however, the second layer 34 iin this embodiment is constructed from woven, nonwoven; or knitted viscose rayon fibers. Dyer 34 is preferably spunlaced viscose rayon fibers. Alternatively; layer 34 could be cotton or a mixture of eotton and viscose rayon fibers:
FIG. 4 illustrates another embodiment 40, similar to the embodiment illustrated in FIG. 3.; except that embodiment 40 includes three layers stitchbonded together. Layer 44 comprises an adhesive bonded cellulosic pulp fiber butt or combinnti~h rayon/polyolefin bast as above described in reference to FIG. 2, while layers 42 comprise woven, zz~nwo~en, or knitted viscose rayon, preferably spunlaced viscose rayon. Stitching yarn 26 and holes 28 in FIGs. 3 and 4 are the same as in the embodiments illustrated in FIGs. 2 and 3.
W~ 93/2248 PCT/US93/035~0 ~~~'~j~~ ~~,' to FIG. 5 illustrates embodiment S0, again in a perspective schematic view, a single layer of cellulosic pulp fibers and binder 22 stitchbonded through using a plain stitch of two component yarn 26, as described in reference to the previous embodiments.
The method of manufacturing stitchbonded absorbent articles of the invention comprises first forming a stitchbonded fabric having a stitch density ranging from about 15 to about 35 st/ l Ocm, and stitch gauge ranging from about to about 40 walesl l0 cm, using a plain or tricot stitch. Stitchbonding machines known under the trade designations °°1'vlaliwatt°°
and °°Arachne°° are adequate for 10 these purposes.
A yarn as above described comprising first and second fibers of different heat stability; preferably 80 denier p~olypropyl~ne and 150 denier polyester, is used. Thereafter, the stitchbonded material is passed through a heated space for a time and at a temperature sufficient to melt the fabers having lower melting temperature but insufficient to melt the fibers having higher melting temperatures.
This causes melt-bonding of at least a portion of the lower melting fibers to the higher melting f bars end melt-bonding of at least a portion of the low melting fibers to the outer surfaces of the cellulosic pulp and viscose rayon layers, depending on the layers used: The stitchbonded, melt-bonded article is then ~20 cooled and is ready tv~ be ctat into individual absorbent articles of the invention.
One method of heating the stitchbonded article to cause melt bonding to occur is by contacting the stitchb~nded fabric to a series of perforated or screen drums which are designed to have heated gas passed thez~ethrough (air of relative humidity below about 7~ % being the preferred gas). The stitchbonded fabric is typically and preferably passed ~n the top side of ~ne drum and the bottom side of the next succeeding drum in l~nown fashion. Heated air or other gas is drawn through the stitchbonded fabric and the 'perforations or screen of the drums by reducing the pressuro on the inside of the drums in a rpanner which maintains the loft of the layer but is just, sufficient to keep the layer in contact with the drum.
For this method; the time su~fici~nt to cause the melt bonding to occur varies with the temperature of the-heated air. Typically; if ~e temperature ranges from about Wt~ 93/22485 ~ ~ ~ ~ ~ ~,~ ~ PCT/US93/03550 200 to about 210°C, the time ranges from about 15 to about 25 seconds.
It is important to keep the time required at a minimum as the nonwoven cellulosic pulp materials may begin to oxidize slightly (tum mildly yellow) if time at temperature is too long. ' Other methods of heating the stitchbonded fabric, may be used, such as passing the stitchbonded fabric through an open, heated passage having air circulation without drums, as for example in a tenter frame dryer. Tenter frame dryers are well known in the art.
The articles of the invention will novv be described W th reference to the following examples and test methods, wherein all percentages and parts are by weight unless otherwise specified.
Test Methods Test Method I:
Total Absorp~on iWith T9~rip I5 Scope: The purpose of the this' test v~ias to measure the amount of water that stitchbonded absorbent arti~ies of the invention could absorb (as a percentage of tlhe article's dry weight, lVd) and how much water was retained under a gravity load:
~Iu~F~ment:
1. A large container (baker} that was capable holding the test samples and an excess of deionized water.
2:, D~ionized (D.g.) water'.
3. Analytical balant;e accurate to +O.Ol g~.
4: A flat glass plate (black glass is preferable} with a 10.2 cm X 20.4 cm rectangular section (test area) marked off. There was adequate clearance of the test area from the edge of the glass plate (greater than ?.6 cm).
~~ A negative clearance nip roller with rubber rolls of durometer 25T/27B
~~ng and a negative clearance of 0.35 cm:
6. Stopwatch. accurate to '~0.5 sec, 7. A controlled environment of I8-24°C and 45-~S percent relative huanidity ~)-dV(3 93!224$5 PCT/US93/0355(>
:) y :> ~ ., r M~C~~J t.~
In addition, a weighing tray large enough to hold the example absorbent articles, a flat perforated steel screen large enough to fully support the samples, tweezers, and an oven to dry the wet example absorbent articles were used.
Eacample size:
15.2 em X 20.3 cm stitchbonded absorbent articles of the invention and control Examples that have been preconditioned (see below).
Preconditioning of Example Absorbent Articles:
1. Absorbent articles were immersed in 1S-25°C tap water and allowed the to soak for at least 1 minute. The articles were then squeezed to remove entrapped air bubbles, and subsequently wrung using the nip roller to remove excess water. This procedure was repeated far a total of 8 times for each absorbent article tested.
2. The articles from step 1 were immersed individually in 15-25°C
deionized water; and allowed the to soak for at least 1 minute. The articles were 1S ' then squeezed to remove entrapped air bubbles, and subsequently wrung using the nip roller to remove excess water. This 'procedure was repeated fox a total of times for each absorbent article tested:
Procedure for Absorption With Drip:
1. The preconditioned example absorbent articles were immersed in deioniaed water using the large container; squeezing to remove air, for at least 5 minutes or until they appeared to be totally saturated.
2. ~'he immersed example absorbent articles were removed from the large container by grabbing at one corner with the tweezers. The example absorbent articles were allowed to drip froz~ii the opposite corner for 60 sacs, and the time allotted for the drip recorded:
3: The example absorbent articles were placed onto the balance and the weight recorded as M1 to the nearest 0.01 gm.
4. Each example absorbent article was wrung using the nip xoller by first running the artacle through the roller and then folding it into quarters and wringing the article again.
WO 93/22x85 c~ ~ :j ; r- ~> PCT/L~S93103550 ~~.v~,~a ~~~
4,876,128; and 5,041;255).
In accordance with the present invention, a stitchbonded absorbent article is presented characterized by a nonwoven batt consisting essentially of cellulosic pulp fibers bonded together by an' adhesive binder: The bonding of the fibers may be by thermoplastic powder bondfng; thermoplastic fibers, or by spray bonding.
Preferred is spray bonded baits; easing acrylic Iatex-based adhesive binders. The batt has a basis weight of at least about 95 g/mz (gsm) per ply:
The batt is stitchbanded, using a plain or tricot stitch, with a stitching yarn compzising two c~mposi6ona11~ different fibers having different heat stability:
In the final form of the absorbent articles of the invention the two fibers are at least partially melt-bonded together: after titching, az~d are also melt-bonded to at least a portion of the external surfaces of the articles after stitching.
In one class of preferred embodiments; a second layer is stitchbonded to the first hyer: The second layer is selected from the group consisting of 2$ i) a Second nonwoven bate consisting essentially of cellulosic pulp fibers banded together by an adhesive binder, wherein the second batt may be the same or 'different from: the first butt; and ii) a woven, norivvoven, or knitted layer of materials selected from the group consisting of viscose rayon; cotton, non-polyolefin synthetic fibers, and rhixtures thereof:
~~~'cf~/~2~g~~ PCT/US93/o3550 The first and second (or more) layers are mechanically held together by stitches of yarn, preferably a plain or tricot stitch. A stitch density (number of stitches in the machine direction per 10 em) ranging from about 15 to about 35 st/ lOcm, and stitch gauge (number of stitch Wales per 10 cm) ranging from about I0 to about 40, have been found to afford the articles with surprisingly good water absorbency properties (rate and absolute) and durability when used in conjunction with the adhesive bonded cellulosic pulp fiber batts.
It was unexpected that the increase in durability of the articles of the invention could be obtained by stitchbonding with only a slight decrease in water absorbency properties compared with a non-stitchbonded article of otherwise similar construction. The "hand°' properties, flexibility, and drapability are also not substantially decreased ~ver non-stitchbonde~i articles of similar construction, and an essentially disposable ikem is rendered into a mufti-use item, reducing waste disposal problems. Tlae attractiveness of articles of the invention can be modified 1S by changing the colors of the stitching yarns and/or khe Layers used to make the articles.
A stitching yarn comprising at least two compositionally different fibers, and thus of different heat stability, is used. The two fibers are milt-bonded to each other al~ng at least a portion of their co~taet area, and at Least aportion of the yarn is in turn melt-bonded to the outer surfaces of the articles. As used hezein "cellulosic pulp fibers" means cellulosic fibers, such as wood pulp fibers, having a length ranging from about 3 to about S mm, and diameter ranging from ab~ut 15 to about 40 micr~meters (denier ranging from about 1 to about S
dtex).
Thus, these fibers are distinguished from staple or textile fibers (which generally are between ab~ut 2 and 3 cm) and continuous filaments. "Consisting essentially of nonwoven cellulosic pulp fibers" means that the bats contains zero or a de minimis amount of fibers which do not meet the definition of "pulp fgbers".
one particuhrly preferred class of articles ~f' the invention are those wherein the second Layer comprises a second batt of nonwoven cellulosic pulp fibers bbndcd together by an adhesive binder.
WO 93/224f3j r~ ~,'~~ L~ r~ ~ PC1'/US93/03550 ~5-Also preferred absorbent articles within the invention are those wherein the second layer comprises viscose rayon fibers. Particularly preferred articles of this class are those wherein the article includes a third layer similar to the second Payer, the second and third layers forming a sandwich around the first Layer.
Manufacturing stitchbonded absorbent articles of the invention comprises as a first step forming a stitchbonded material having a stitch density ranging from about 15 to about 35 st/lOcm, and stitch gauge ranging from about 14 to about 40, using a yarn comprising first and second compositionally different fibers having different heat stability. 'Thereafter the stitchbonded material is heated for a time and at a temperature sufficiirnt to partially melt the lower melting temperature fibers but insufficient to melt the higher melting temperature fiber, thereby melt-bonding at least a portion of the farst and second fibers together and melt-bonding at least a portion of the first I~wer melting fiber to the outer surfaces of the article.
FIG. lA is a perspective schematic view of the article of Czech patent 193700 Example 1, showing the plain/chain combination stitch;
FIG. 1B is a schematic representation of the stitch structure of the article illustrated inn FIG. lA; and FIGs. 2-5 sh~w perspE;ctive schematic views of absorbent articles within the invention.
As previously noted; in all absorbent artidle embodiments in accordance with the invention, the first (or only) Iayer of material comprises a first batt of nonwoven c~llulosic pulp fibers bonded together by an adhesive binder, the first bate having a basis weight of at least about 95 grams/m2 (gsm) per ply.
It should thus be noxed that all absorbent articles of the invention are water absorbent and very durable, and yet are inexpensive to produce. Particularly, if the absorbent articles of the invention are made from 100 % cellulosic pulp fibers, the articles ~f the invention are Low in cost cp~pared with articles based on synthetic wood pulp: fibers Articles which include a second or third layers of 100% ~riscose rayon ox cotton ark similarly relatively inexpensive to produce, thus reducing cost to the ultiuate user:
..
i.l s. : ' : ,' " ,A) ~.j WC> 93!22485 Pt'T/US93/03550 The adhesive binder of the first and, if used, second butts of cellulosic pulp fiber may comprise any of the commonly used adhesive binders known in the art.
Typically and preferably the adhesive binder comprises a copolymer of ethylene and vinyl acetate, wherein the vinyl acetate is present at about 10 to about weight percent of the copolymer. Cellulosic wood pulp butts having this adhesive and found useful in the invention include those known under the trade designation "Airtex°', from James River Corporation, especially product numbers 395 and 399.
The 399 version is more absorbent but less strong than the 395 version.
Although the composition of these butts is proprietary, it is believed the adhesive generally comprises from about 2 to about 20 weight percent of the adhesive bonded eellulosie pulp fiber butts.
The second layer, or more layers if preferred depending on the end use, comprises materials selected from the group consisting of i) a second butt of nonwoven cellulosic pulp fibers bonded together by an adhesive, the second butt being the same or different than the first butt, and ii) a woven; nonwoven, or knitteai layer of materials selected from the group consisting ~f viscose rayon, cotton, non-polyolefin synthetic fibers, and mixtures thereof.
' 20 If the second layer is viscose rayon, this layer is preferably nonwoven, more preferably sgunlaced nonwoven: Suitable spunlaced 100% viscose rayon layers are available from various commercial sources. lane spunlaced 100%
viscose rayon layer found useful for the purposes of this invention is that sold under the trade designation "Brand 6411 Apertured", from Scott Paper Company.
The first and econd layers are st~tchbonded using a stitch density (stitches per 10 cm in machine direction) ranging from about 15 to about 35 st/ lOcm, more preferably ranging from about 20 to about 30 st/lOcm.
The stitch gauge (number of vertical dines of stitches (wiles) per 10 cm in cross direction) preferably ranges from about 10 to about 40, more preferably from about 13 to about 28 gauge, snore preferably about 20 gauge.
W~ 93/22485 ~ ~ '~ ? ~ ~ .~~ PC'1'/US93/03550 t,~ cy ". .
Stitching densities and gauges outside of these ranges, especially when used with embodiments having no second viscose rayon layer, have been found inadequate in meeting the acceptable durability, absorbency, and consistency that users have come to demand. For example, stitchbonded articles having stitch S density greater than about 35 st/10 cm were found to have unacceptable water absorbency rate and total water absorbency values. 5titchbonded articles of the invention having stitch density less than about 1~ stllOcm were found to lack acceptable durability. To be aGCeptable and thus within this invention, stitchbonded article durability (measured as peak load in a tensile test) should be greater than or equal to about 4.5 kg for one and two layer articles, and greater than or equal to 9 kg for three layer articles, as measured according to American Society of Testing Materials (ASTM) D-1682-64 (reapproved 19?5). This test is described in the Examples. Acceptable water absorbency is determined by a "drip" test, wherein the article is soaked in water, allowed to drip for 60 seconds, thin oven dried, after which the dried and 60 second drip weights are compared.
The results are given as a pdrcentage of the oven dried weight. To be acceptable, the stitchbonded arkicles of the invention hould exhibit a 60 second drip value of at least about 400 %. This test is also described in the Examples. Articlea of the irnvention having stitch gauge of above about 40 exhibit decreased water absorbency due to higher degree of compression of the absorbent cellulosic pulp fpber layer(s). Thus, stitching gauges higher than about 40 are not advantageous for stitching prebonded cellulosic pulp based nonwcwen layers due to excessive perforation by the stitching needles; resulting in diminished original tensile strength and integrity of the absorbent cellulosic pulp ~ayer(s).
As mentioned previously, a critical aspect of the invention is the use of a yarn comprising at least two compositi~nally different types of fibers having different heat stability r~rhich can be at least partially melt-bonded together. The y~ s alsa capable of melt-bonding to at least a portion of the article outer surfaces.
Pr~ferrably, the yarn comprises a farst fiber having a melting temperature below that c~f the cellulosic pulp fibe>: but no greater than about 175°C, and a WO )3!22485 PCT/iJS93103~50 second fiber having a melting temperature of at least about 200°C, more preferably at least about 240°C.
The portion of the yarn having a melting temperature below that of the cellulosic gulp fiber but no greater than about 175°C may be polyolefins selected from the group consisting of branched polyethylene, linear polyethylene, polypropylene, and mixtures thereof. Particularly preferred is polypropylene, which has a melting temperature range of about 160-170°C. The denier of these fibers should be such as to allow sufficient bonding between the higher melting temperature fibers of the yarn and the cellulosic or viscose rayon layer outer surface. ~therwise, the denier of these fibers is not critical, and may range from about 40 to about 200 denier, more preferably from about 70 to about 10(?
denier.
Fiber deniers lower than about 40 are difficult to melt-bond simply because of there is Iess mass of the fiber.
The second fiber having a melting temperature of at least about 200°C
may 1S be chosen from polyester (polyethylene terephthalate melts at about 248°C), alpha-cellulose (cotton) and rayon (decomposes after long exposure to temperatures of about 225°C), protein, acetate, ~dorocarbon, polyacrylonitrile, polyamide (the variaus nylons melt at about 220°C), and mixtures thereof.
Particularly preferred as the second fiber is polyethylene terephthalate (PET) polyester. These fibers have the advantage of drawing water toward the absorbent layer in the case where viscose rayon is used as second and third cover layers. The in~ereonnected network of the PET sdtehes through the layers of the articles of the invention increases the strength of the articles, and provides the durability demanded by users for repeated washing.
The denier of the second fibers is also not critical, and may range from about 10 to about 400 denier, more preferably from about 120 to about 180 denier.
Fibers having 1~wer denier than about ?O are presently not preferred as they may be'too v~reak in tensile strength; however; .should fibers having denier less than ?0 become available which pxovide the requisite strength to the articles of the invention, these may also be used. ' Fiber deniers above about 400 are more expensive and generally not retluired f~r increasing the durability of the articles .7. .
7 .:
. :i'...
I
a 5 .!
..
y ~I
n:1 u~, .i~,i .. m.1 n r." 1 .i..r ...L-n.. . , .m.
b !, 1'C.'l . .. , I' S''~.. . v .w", , . n .. ~ . . :1.'f:.,... . ..... ,..... . , i..~. ,. . ..3,.'I..n....., o . ..
,...,.., . .....
W(? 93122485 ~ ~ a~ taj E,~ .~ ~~. P~'/1JS93/03550 J
of the invention beyond the point where the user would normally dispose of the article. Larger denier fibers are also more expensive.
~ne preferred absorbent article embodiment 20 of the invention is illustrated in perspective in FIG. 2. In this embodiment, a first layer 22 of a butt of adhesive bonded cellulosic pulp fibers (such as those sold under the trade designations "Airtex 395" and "Airtex 399") is stitchbonded to a second layer of a butt of adhesive bonded nonwoven cellulosic pulp fibers (such as those known under the trade designations "Airtex 395" and "Airtex 399"). The '°technical backside" of article 20 is shown on top, showing the preferred "plain" stitch pattern of stitching yarn 26 used in the articles of the invention. A "tricot"
stitch may also be used. Holes 2g are shown slightly exaggerated in size to emphasize the point where individual needles have penetrated the layers. Alternatively, either one of or both layers 22 and 24 may be a nonwoven mixture of rayon/non-polyolefin synthetic fibers, or, more preferably, 100% cellulosic fibers.
Higher than about 30 weight percent non-golyolefin synthetic f bars are not preferred due the decrease ~n water absorbency of the articles of the invention. Suitable non-pcalyolefin synthetic fibers include polyester, acrylic, polyamide, and the like.
Another preferred embodiment 30 of the absorbent article of the invention is illustrated in FIG: 3, also as a perspective schematic. In this embodiment, the first layer 32 is the same as the first Iayer 22 of embodiment 20 shown in FIG. 2;
however, the second layer 34 iin this embodiment is constructed from woven, nonwoven; or knitted viscose rayon fibers. Dyer 34 is preferably spunlaced viscose rayon fibers. Alternatively; layer 34 could be cotton or a mixture of eotton and viscose rayon fibers:
FIG. 4 illustrates another embodiment 40, similar to the embodiment illustrated in FIG. 3.; except that embodiment 40 includes three layers stitchbonded together. Layer 44 comprises an adhesive bonded cellulosic pulp fiber butt or combinnti~h rayon/polyolefin bast as above described in reference to FIG. 2, while layers 42 comprise woven, zz~nwo~en, or knitted viscose rayon, preferably spunlaced viscose rayon. Stitching yarn 26 and holes 28 in FIGs. 3 and 4 are the same as in the embodiments illustrated in FIGs. 2 and 3.
W~ 93/2248 PCT/US93/035~0 ~~~'~j~~ ~~,' to FIG. 5 illustrates embodiment S0, again in a perspective schematic view, a single layer of cellulosic pulp fibers and binder 22 stitchbonded through using a plain stitch of two component yarn 26, as described in reference to the previous embodiments.
The method of manufacturing stitchbonded absorbent articles of the invention comprises first forming a stitchbonded fabric having a stitch density ranging from about 15 to about 35 st/ l Ocm, and stitch gauge ranging from about to about 40 walesl l0 cm, using a plain or tricot stitch. Stitchbonding machines known under the trade designations °°1'vlaliwatt°°
and °°Arachne°° are adequate for 10 these purposes.
A yarn as above described comprising first and second fibers of different heat stability; preferably 80 denier p~olypropyl~ne and 150 denier polyester, is used. Thereafter, the stitchbonded material is passed through a heated space for a time and at a temperature sufficient to melt the fabers having lower melting temperature but insufficient to melt the fibers having higher melting temperatures.
This causes melt-bonding of at least a portion of the lower melting fibers to the higher melting f bars end melt-bonding of at least a portion of the low melting fibers to the outer surfaces of the cellulosic pulp and viscose rayon layers, depending on the layers used: The stitchbonded, melt-bonded article is then ~20 cooled and is ready tv~ be ctat into individual absorbent articles of the invention.
One method of heating the stitchbonded article to cause melt bonding to occur is by contacting the stitchb~nded fabric to a series of perforated or screen drums which are designed to have heated gas passed thez~ethrough (air of relative humidity below about 7~ % being the preferred gas). The stitchbonded fabric is typically and preferably passed ~n the top side of ~ne drum and the bottom side of the next succeeding drum in l~nown fashion. Heated air or other gas is drawn through the stitchbonded fabric and the 'perforations or screen of the drums by reducing the pressuro on the inside of the drums in a rpanner which maintains the loft of the layer but is just, sufficient to keep the layer in contact with the drum.
For this method; the time su~fici~nt to cause the melt bonding to occur varies with the temperature of the-heated air. Typically; if ~e temperature ranges from about Wt~ 93/22485 ~ ~ ~ ~ ~ ~,~ ~ PCT/US93/03550 200 to about 210°C, the time ranges from about 15 to about 25 seconds.
It is important to keep the time required at a minimum as the nonwoven cellulosic pulp materials may begin to oxidize slightly (tum mildly yellow) if time at temperature is too long. ' Other methods of heating the stitchbonded fabric, may be used, such as passing the stitchbonded fabric through an open, heated passage having air circulation without drums, as for example in a tenter frame dryer. Tenter frame dryers are well known in the art.
The articles of the invention will novv be described W th reference to the following examples and test methods, wherein all percentages and parts are by weight unless otherwise specified.
Test Methods Test Method I:
Total Absorp~on iWith T9~rip I5 Scope: The purpose of the this' test v~ias to measure the amount of water that stitchbonded absorbent arti~ies of the invention could absorb (as a percentage of tlhe article's dry weight, lVd) and how much water was retained under a gravity load:
~Iu~F~ment:
1. A large container (baker} that was capable holding the test samples and an excess of deionized water.
2:, D~ionized (D.g.) water'.
3. Analytical balant;e accurate to +O.Ol g~.
4: A flat glass plate (black glass is preferable} with a 10.2 cm X 20.4 cm rectangular section (test area) marked off. There was adequate clearance of the test area from the edge of the glass plate (greater than ?.6 cm).
~~ A negative clearance nip roller with rubber rolls of durometer 25T/27B
~~ng and a negative clearance of 0.35 cm:
6. Stopwatch. accurate to '~0.5 sec, 7. A controlled environment of I8-24°C and 45-~S percent relative huanidity ~)-dV(3 93!224$5 PCT/US93/0355(>
:) y :> ~ ., r M~C~~J t.~
In addition, a weighing tray large enough to hold the example absorbent articles, a flat perforated steel screen large enough to fully support the samples, tweezers, and an oven to dry the wet example absorbent articles were used.
Eacample size:
15.2 em X 20.3 cm stitchbonded absorbent articles of the invention and control Examples that have been preconditioned (see below).
Preconditioning of Example Absorbent Articles:
1. Absorbent articles were immersed in 1S-25°C tap water and allowed the to soak for at least 1 minute. The articles were then squeezed to remove entrapped air bubbles, and subsequently wrung using the nip roller to remove excess water. This procedure was repeated far a total of 8 times for each absorbent article tested.
2. The articles from step 1 were immersed individually in 15-25°C
deionized water; and allowed the to soak for at least 1 minute. The articles were 1S ' then squeezed to remove entrapped air bubbles, and subsequently wrung using the nip roller to remove excess water. This 'procedure was repeated fox a total of times for each absorbent article tested:
Procedure for Absorption With Drip:
1. The preconditioned example absorbent articles were immersed in deioniaed water using the large container; squeezing to remove air, for at least 5 minutes or until they appeared to be totally saturated.
2. ~'he immersed example absorbent articles were removed from the large container by grabbing at one corner with the tweezers. The example absorbent articles were allowed to drip froz~ii the opposite corner for 60 sacs, and the time allotted for the drip recorded:
3: The example absorbent articles were placed onto the balance and the weight recorded as M1 to the nearest 0.01 gm.
4. Each example absorbent article was wrung using the nip xoller by first running the artacle through the roller and then folding it into quarters and wringing the article again.
WO 93/22x85 c~ ~ :j ; r- ~> PCT/L~S93103550 ~~.v~,~a ~~~
5. Each example absorbent article was reimmersed in the deionized water for at least 30 seconds.
6. Steps 2-5 were repeated for a total of 3 times per sample, recording each result.
7. The test was repeated for two example absorbent articles of like construction.
After the completion of the above, the dry weight of each of the example absorbent articles was determined. Examples were dried in an oven with an air atmosphere at temperatures that would not degrade the samples (about 4 hrs at 50°C): At least two weighings at different times with less than a 1 %
by weight difference determined that the example absorbent articles were dry. The dried examph absorbent articles were weighed and the weights recorded as M.
Calculations:
Water absorption with drip after 60 seconds for each test =
L(M1 - 1~)~Ml(100) The water absorption with drip was the average of the 9 tests (3 samples of each exaz~ple absorbent article tested 3' times.) Test Method IIWashini; Machine "A_puarent" I?~rability Scope: To determine the "apparent" durability of stitchbonded absorbent articles of the invention to the agitation experienced in commercially available washing machines:
~u'pment:
1. Washing Machine: a commercially available top load washing machine (known under the trade designation "Lady Kenmore Heavy Duty Plus") from Sears, Roebuck & Co 2. Thermometer: 100n~ maximum with 1 °C graduations.
3: Detergent: a commercially available detergent (known under the trade ' designation ..Tide") from Proctor & Gamble Company:
4. 14. plain (100% eotton) towels, each 76:2 cm x 91.4 cm, with a weight of about 1: g2 ' kg each : (dry) WO 93/22485 P(.'T/U~93/03550 ~~~~~r'~~i~
,. t. ~ :~ a ~ - 14 -S. '°Go/na go" samples with varying levels of wear (durability indication.) Exaanple Size:
15.24 cm X 20.3 cm.
Test Conditions:
1. The washing machine was set to the following washing cycle options:
- Cotton Sturdy / 35 minutes total washing cycle - Hat Wash / 'Temperature of water 6015°C
- Warm Rinse procedure:
1. The 14 plain towels and 10 example absorbent articles of the invention were put into the washing machine.
2. 90 gms of detergent were put into the washing machine.
3. ''The washing machine was set at the washing machine cycle options as specified above and started.
5; ~e water temperature was checked tc~ be sure it was 6015°C.
6. At the ena of' the wash cycle the example absorbent articles of the invention were evaluated and compared with unwashed examples noting any variations such as:
color tinting dimensional changes wearing (i:e. Searing, delamination, abrasions) - general appearance The wished examples were graded from 1 (= BAD) to 5(= EXCELLENT) according to the scale described below. Since this was subjective and sample dependent, a grading board (board with samples of various grades) was used to minimize operator variability.
7. ~'he example absorbent articles were then rewashed.
WO 93122485 ~ '~ j F~ ~~ ~'~ ;~ t'C1'lUS93/03550 8. detains of the wipes after a particular wash can be done (typically 2 samples are retained after every other wash.) Typical Grading Scale:
1. BAD - Example absorbent article has fallen apart into pieces or has S become severely tom at the edges.
2. PC)~I~ - Example absorbent article was falling apart and losing its shape and color. In addition the article was moderately torn at the edges.
3. EAIIt - Article lost some shape and color and had begun to fray at the edges.
IO 4. GOLD - Article had almost no discernible loss in shape and color and almost no wear at the edges.
5. EXCELLE1~ZT - Article exhibited no obvious change in color, shape and physical appearance.
On an acceptable/not acceptable scale a minimum Grade of 3 is required 15 for acceptance.
'H' t~~ethud ~l(: Tex~gilg Streng~
A modified grab (tensile) tesf was ge~formed in general accordance with AS'TIvL D l6&2-6~. In this test, only a part of the width of the specimen is gripped in the clamps. Lateral slits are made are made in the specimen to sever all yarns 20 bordering the portion whose strength is to be tested, reducing to a practical minimum the "fabric assistance°' inherent in the grab method. (Section 20 of the standard.) Specimen size used was IOO mm X 200 mrr~. A constant-rate-of tra~rerse tensile testing rryachine known under the trade designation °'Sintech") was used; using a machine peed of 305 +/- 10 mm per minute. The peak load before Z5 break, in Kg; wr~s recorded' as the tensile strength of the specimen.
Exarra~les In the follo~ring Examples; all parts and perczntages are by weight unless othenavise specified. In Tables I-~ the following definitions apply:
'°395" and "399" refer to the ethylene/vinyl acetate adhesive bonded eellulosic pulp 30 fiber butts k~~wn under the trade desigh~tion "Airtex", from 3ames Igiver Corporation;
WC> ~~3/~2485 Pt'1'/US93/tD3550 ~~ .q ,~~ c? t~ ~ r') (~
~.1.~~;~.. ~ U
"AM" = absorbent material;
"GA" = stitch gauge (needles per 10 cm, cross direction);
"SD" = stitch density (stitches per 10 cm, machine direction);
"'~'T" = stitching yarn type;
"PE" = polyester;
. "PP" = polypropylene;
"C°' _ cotton;
"ST" = stitch type;
"PS" _ plain stitch;
"TS" . = tricot stitch;
"CS" - chain stitch;
..WC.. = wash cycles;
"MD°' _ machine direction;
'°therm" -- thermobond~d material available form Weyerhaeuser Company, Tacoma, Washington; described in U.S: Pat. I~To. 4,$$2,213;
and I, II, and III refer to the Test Ivrethods described above.
Eleven E~camples within the invention and four controls were made for evaluation. The composition and construction of Examples l~l l and Controls A-D
are presented in Table 1.
W~ 93122435 ~ ~ ~ ~,~ t! ~ t~ P~.T/US93/03550 Table 1 Exam~le Constue~ctians Example Construction Example AM A GA YT Sh ST
M
S 395 2 40 pEIPP 30 TS
After the completion of the above, the dry weight of each of the example absorbent articles was determined. Examples were dried in an oven with an air atmosphere at temperatures that would not degrade the samples (about 4 hrs at 50°C): At least two weighings at different times with less than a 1 %
by weight difference determined that the example absorbent articles were dry. The dried examph absorbent articles were weighed and the weights recorded as M.
Calculations:
Water absorption with drip after 60 seconds for each test =
L(M1 - 1~)~Ml(100) The water absorption with drip was the average of the 9 tests (3 samples of each exaz~ple absorbent article tested 3' times.) Test Method IIWashini; Machine "A_puarent" I?~rability Scope: To determine the "apparent" durability of stitchbonded absorbent articles of the invention to the agitation experienced in commercially available washing machines:
~u'pment:
1. Washing Machine: a commercially available top load washing machine (known under the trade designation "Lady Kenmore Heavy Duty Plus") from Sears, Roebuck & Co 2. Thermometer: 100n~ maximum with 1 °C graduations.
3: Detergent: a commercially available detergent (known under the trade ' designation ..Tide") from Proctor & Gamble Company:
4. 14. plain (100% eotton) towels, each 76:2 cm x 91.4 cm, with a weight of about 1: g2 ' kg each : (dry) WO 93/22485 P(.'T/U~93/03550 ~~~~~r'~~i~
,. t. ~ :~ a ~ - 14 -S. '°Go/na go" samples with varying levels of wear (durability indication.) Exaanple Size:
15.24 cm X 20.3 cm.
Test Conditions:
1. The washing machine was set to the following washing cycle options:
- Cotton Sturdy / 35 minutes total washing cycle - Hat Wash / 'Temperature of water 6015°C
- Warm Rinse procedure:
1. The 14 plain towels and 10 example absorbent articles of the invention were put into the washing machine.
2. 90 gms of detergent were put into the washing machine.
3. ''The washing machine was set at the washing machine cycle options as specified above and started.
5; ~e water temperature was checked tc~ be sure it was 6015°C.
6. At the ena of' the wash cycle the example absorbent articles of the invention were evaluated and compared with unwashed examples noting any variations such as:
color tinting dimensional changes wearing (i:e. Searing, delamination, abrasions) - general appearance The wished examples were graded from 1 (= BAD) to 5(= EXCELLENT) according to the scale described below. Since this was subjective and sample dependent, a grading board (board with samples of various grades) was used to minimize operator variability.
7. ~'he example absorbent articles were then rewashed.
WO 93122485 ~ '~ j F~ ~~ ~'~ ;~ t'C1'lUS93/03550 8. detains of the wipes after a particular wash can be done (typically 2 samples are retained after every other wash.) Typical Grading Scale:
1. BAD - Example absorbent article has fallen apart into pieces or has S become severely tom at the edges.
2. PC)~I~ - Example absorbent article was falling apart and losing its shape and color. In addition the article was moderately torn at the edges.
3. EAIIt - Article lost some shape and color and had begun to fray at the edges.
IO 4. GOLD - Article had almost no discernible loss in shape and color and almost no wear at the edges.
5. EXCELLE1~ZT - Article exhibited no obvious change in color, shape and physical appearance.
On an acceptable/not acceptable scale a minimum Grade of 3 is required 15 for acceptance.
'H' t~~ethud ~l(: Tex~gilg Streng~
A modified grab (tensile) tesf was ge~formed in general accordance with AS'TIvL D l6&2-6~. In this test, only a part of the width of the specimen is gripped in the clamps. Lateral slits are made are made in the specimen to sever all yarns 20 bordering the portion whose strength is to be tested, reducing to a practical minimum the "fabric assistance°' inherent in the grab method. (Section 20 of the standard.) Specimen size used was IOO mm X 200 mrr~. A constant-rate-of tra~rerse tensile testing rryachine known under the trade designation °'Sintech") was used; using a machine peed of 305 +/- 10 mm per minute. The peak load before Z5 break, in Kg; wr~s recorded' as the tensile strength of the specimen.
Exarra~les In the follo~ring Examples; all parts and perczntages are by weight unless othenavise specified. In Tables I-~ the following definitions apply:
'°395" and "399" refer to the ethylene/vinyl acetate adhesive bonded eellulosic pulp 30 fiber butts k~~wn under the trade desigh~tion "Airtex", from 3ames Igiver Corporation;
WC> ~~3/~2485 Pt'1'/US93/tD3550 ~~ .q ,~~ c? t~ ~ r') (~
~.1.~~;~.. ~ U
"AM" = absorbent material;
"GA" = stitch gauge (needles per 10 cm, cross direction);
"SD" = stitch density (stitches per 10 cm, machine direction);
"'~'T" = stitching yarn type;
"PE" = polyester;
. "PP" = polypropylene;
"C°' _ cotton;
"ST" = stitch type;
"PS" _ plain stitch;
"TS" . = tricot stitch;
"CS" - chain stitch;
..WC.. = wash cycles;
"MD°' _ machine direction;
'°therm" -- thermobond~d material available form Weyerhaeuser Company, Tacoma, Washington; described in U.S: Pat. I~To. 4,$$2,213;
and I, II, and III refer to the Test Ivrethods described above.
Eleven E~camples within the invention and four controls were made for evaluation. The composition and construction of Examples l~l l and Controls A-D
are presented in Table 1.
W~ 93122435 ~ ~ ~ ~,~ t! ~ t~ P~.T/US93/03550 Table 1 Exam~le Constue~ctians Example Construction Example AM A GA YT Sh ST
M
S 395 2 40 pEIPP 30 TS
10 395. 2 13.3 PE/PP 30 PS
11 * 399 1 13.3 PlE/PP 30 PS
Control A* 399 1 -- ..____ ___ ___ Control B 399 2 -- _____ ___ ___ Control ~ 395 2 - _____ ___ ___ Coralroll3 therm 1 - _____ ___ ___ * Example ll had construction illustrated in FIG.
4, with Layers 42 being 100%
viscose rayon,layer being celiulo~i~
pulp f ber bait (trade designation 'Airtex 399"~. Control .P~ had similar constn~ction but was riot stitchbonded.
Table 2 preser~xs durability, data. or for haw "apparent" stitchbonded articles of the invention appeared after washing (Controls were not subject to washing machine tests as they would disi~ntegrat~).
w~ '931224~j PCI'/lJS93/03550 ~, J G,t Table 2 V'~ashin~ Machine "Apparent" Durability Example Test Method II, number of l7VCs 5 5 5 ~ ~ 4 4 3 3 3 2 4 4 4 ~4 4 3 3 3 3 7 5 5 5 S 5 5 4 4. 4 3 ~1 g 2 _ _ _ _ _ _ _ _ Table 3 presents results of test methods I and III for Examples 1-11 and Control Examples ~-D.
~. r~ .~ C : b if 'fable 3 'dVater Absorbency_and Tensile Strength Test Method Example - '-I (Water Abs III
(Tensile Strength) with drip) MD, after WCs, (Kg)*
? 19 1 --540' 8.01 ?.22 6.6? 6.?2 2 4?? 9.?2 11.0 10.2 ___ 3 522 ___ ___ ___ ___ 4 600 g,81 ___ ___ ___ w 5 _ 656 9.85 9. L? ___g.26___ 56? 10.g 8.54 ___ ___ I0 ? 486 17.4 _-_ 16.6 ___ 8 420 I4.5 16.8 ___ _._ 440 18.0 _.._ 5.22 ..__ 598 4 ~ 4. 86 ___ ..__ 08 35.6 ___ ___ ___ Control A _ 7.95 ___ ___ ___ Control B 1;14 ___ ___ Control C 83? 2:21 _._ 3.I9 ___ Control D 669 ?s0 3.15 3.32 * Measured in accordance with ASTM
(1975) Analysis of Test Results From the data of Tables l-3 it may be seen that although Examples ?-9 weie'the most nurable in both the "apparent"
.and tensile durability teas; they were not as absorbent'as some of the other Examples.
Examples I and 1 I appeared to provide the best balance of absorbency and strength'.
~ comparison can be made between the stitched and unstitched versions of articles of the invention to determine the percent .increase in detr~bility and the r..) ... ~. t m i.'I
~a ,..r..,~
4 , h ,.
,.'.' :,v ~.
,sr... .,. r., "...,. . . ... ... .,-.r. , ~. .,. . . .,. , .,.. . . "7R'.~.st . .., .. .. . , -i~VO 93!224$5 PCT/US93/03550 percent decrease in absorbency after stitchbonding. Comparison of the average tensile sta~ength of all stitchbonded Examples having 2 layers of the cellulosic pulp fiber ~batt known under the trade designation "Airtex" 395, with an unstitched version (Control C) shows an average of 570 percent increase in tensile strength, but only a 20 percent decrease in absorbency. The same comparison can be made with the article of Control D, a thermobonded article. An average increase of percent in tensile strength, with only a 4.5 percent loss of absorbency was seen.
It was highly u~rexpected that such large increases in tensile strength could be achieved with such small decreases in absorbency.
Various modifications and alterations of this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not to be unduly limited to the illustrative embodiments set forth herein. .
Control A* 399 1 -- ..____ ___ ___ Control B 399 2 -- _____ ___ ___ Control ~ 395 2 - _____ ___ ___ Coralroll3 therm 1 - _____ ___ ___ * Example ll had construction illustrated in FIG.
4, with Layers 42 being 100%
viscose rayon,layer being celiulo~i~
pulp f ber bait (trade designation 'Airtex 399"~. Control .P~ had similar constn~ction but was riot stitchbonded.
Table 2 preser~xs durability, data. or for haw "apparent" stitchbonded articles of the invention appeared after washing (Controls were not subject to washing machine tests as they would disi~ntegrat~).
w~ '931224~j PCI'/lJS93/03550 ~, J G,t Table 2 V'~ashin~ Machine "Apparent" Durability Example Test Method II, number of l7VCs 5 5 5 ~ ~ 4 4 3 3 3 2 4 4 4 ~4 4 3 3 3 3 7 5 5 5 S 5 5 4 4. 4 3 ~1 g 2 _ _ _ _ _ _ _ _ Table 3 presents results of test methods I and III for Examples 1-11 and Control Examples ~-D.
~. r~ .~ C : b if 'fable 3 'dVater Absorbency_and Tensile Strength Test Method Example - '-I (Water Abs III
(Tensile Strength) with drip) MD, after WCs, (Kg)*
? 19 1 --540' 8.01 ?.22 6.6? 6.?2 2 4?? 9.?2 11.0 10.2 ___ 3 522 ___ ___ ___ ___ 4 600 g,81 ___ ___ ___ w 5 _ 656 9.85 9. L? ___g.26___ 56? 10.g 8.54 ___ ___ I0 ? 486 17.4 _-_ 16.6 ___ 8 420 I4.5 16.8 ___ _._ 440 18.0 _.._ 5.22 ..__ 598 4 ~ 4. 86 ___ ..__ 08 35.6 ___ ___ ___ Control A _ 7.95 ___ ___ ___ Control B 1;14 ___ ___ Control C 83? 2:21 _._ 3.I9 ___ Control D 669 ?s0 3.15 3.32 * Measured in accordance with ASTM
(1975) Analysis of Test Results From the data of Tables l-3 it may be seen that although Examples ?-9 weie'the most nurable in both the "apparent"
.and tensile durability teas; they were not as absorbent'as some of the other Examples.
Examples I and 1 I appeared to provide the best balance of absorbency and strength'.
~ comparison can be made between the stitched and unstitched versions of articles of the invention to determine the percent .increase in detr~bility and the r..) ... ~. t m i.'I
~a ,..r..,~
4 , h ,.
,.'.' :,v ~.
,sr... .,. r., "...,. . . ... ... .,-.r. , ~. .,. . . .,. , .,.. . . "7R'.~.st . .., .. .. . , -i~VO 93!224$5 PCT/US93/03550 percent decrease in absorbency after stitchbonding. Comparison of the average tensile sta~ength of all stitchbonded Examples having 2 layers of the cellulosic pulp fiber ~batt known under the trade designation "Airtex" 395, with an unstitched version (Control C) shows an average of 570 percent increase in tensile strength, but only a 20 percent decrease in absorbency. The same comparison can be made with the article of Control D, a thermobonded article. An average increase of percent in tensile strength, with only a 4.5 percent loss of absorbency was seen.
It was highly u~rexpected that such large increases in tensile strength could be achieved with such small decreases in absorbency.
Various modifications and alterations of this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention, and it should be understood that this invention is not to be unduly limited to the illustrative embodiments set forth herein. .
Claims (10)
1. A stitchbonded absorbent article characterized by a nonwoven batt consisting essentially of cellulosic pulp fibers bonded together by an adhesive binder, the batt having a basis weight of at least about 95 gsm per ply, the article stitchbonded by stitches of yarn, at a stitch density ranging from about 15 to about 35 st/10cm, and stitch gauge ranging from about 10 to about 40, using a stitching yarn comprising at least two compositionally different fibers having different heat stability being at least partially melt-bonded together at points of mutual contact, the yarn being melt-bonded at least partially to external surfaces of the article.
2. The absorbent article of claim 1, the nonwoven batt being a first layer, the article further characterized by a second layer selected from the group consisting of i) a second nonwoven batt consisting essentially of cellulosic pulp fibers bonded together by an adhesive binder, wherein the second nonwoven batt consists essentially of nonwoven cellulosic pulp fiber, and ii) a material selected from the group consisting of viscose rayon, cotton, non-polyolefin synthetic fibers, and mixtures thereof, wherein the first and second layers are mechanically held together by said stitches of yarn.
3. The absorbent article of claim 2, further characterized by the second layer being a second nonwoven batt consisting essentially of cellulosic pulp fibers bonded together by an adhesive binder, the second nonwoven batt.
consisting essentially of nonwoven cellulosic pulp fiber.
consisting essentially of nonwoven cellulosic pulp fiber.
4. The absorbent article of claim 2 further characterized by the second layer comprising material selected from the group consisting of viscose rayon, cotton, non-polyolefin synthetic fiber, and mixtures thereof.
5. The absorbent article of claim 1 further characterized by the stitch density ranging from 20 to 30 st/10cm.
6. The absorbent article of claim 1 further characterized by the yarn comprising a first fiber having a melting temperature below 175°C, and a second fiber having a melting temperature of at least 200°C.
7. The absorbent article of claim 2 further characterized by the yarn comprising a first fiber having a melting temperature below 175°C, and a second fiber having a melting temperature of at least 200°C.
8. The absorbent article of claim 4 further characterized by a third layer of material selected from the group consisting of viscose rayon, cotton, non-polyolefin synthetic fibers, and mixtures thereof.
9. The absorbent article of claim 6 further characterized by the first fiber consisting essentially of polyolefin polymers selected from the group consisting of branched polyethylene, linear polyethylene, polypropylene, mixtures thereof, and copolymers thereof.
10. The absorbent article of claim 6 further characterized by the second fiber consisting essentially of polymers selected from the group consisting of polyester, cotton, protein, rayon, cellulose acetate, fluorocarbon, polyacrylonitrile, polyamide, and mixtures thereof.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US07/879,876 US5308673A (en) | 1992-05-07 | 1992-05-07 | Stitchbonded absorbent articles and method of making same |
US07/879876 | 1992-05-07 | ||
PCT/US1993/003550 WO1993022485A1 (en) | 1992-05-07 | 1993-04-14 | Stitchbonded absorbent articles |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2132970A1 CA2132970A1 (en) | 1993-11-11 |
CA2132970C true CA2132970C (en) | 2005-01-04 |
Family
ID=25375065
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002132970A Expired - Fee Related CA2132970C (en) | 1992-05-07 | 1993-04-14 | Stitchbonded absorbent articles |
Country Status (12)
Country | Link |
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US (3) | US5308673A (en) |
EP (1) | EP0639235B1 (en) |
JP (1) | JP3459420B2 (en) |
KR (1) | KR100275619B1 (en) |
BR (1) | BR9306324A (en) |
CA (1) | CA2132970C (en) |
CZ (1) | CZ286043B6 (en) |
DE (1) | DE69304322T2 (en) |
ES (1) | ES2093428T3 (en) |
GR (1) | GR3021183T3 (en) |
MX (1) | MX9302550A (en) |
WO (1) | WO1993022485A1 (en) |
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-
1992
- 1992-05-07 US US07/879,876 patent/US5308673A/en not_active Expired - Lifetime
-
1993
- 1993-04-14 ES ES93912256T patent/ES2093428T3/en not_active Expired - Lifetime
- 1993-04-14 BR BR9306324A patent/BR9306324A/en not_active IP Right Cessation
- 1993-04-14 CA CA002132970A patent/CA2132970C/en not_active Expired - Fee Related
- 1993-04-14 WO PCT/US1993/003550 patent/WO1993022485A1/en active IP Right Grant
- 1993-04-14 CZ CZ942726A patent/CZ286043B6/en not_active IP Right Cessation
- 1993-04-14 JP JP51929793A patent/JP3459420B2/en not_active Expired - Fee Related
- 1993-04-14 DE DE69304322T patent/DE69304322T2/en not_active Expired - Fee Related
- 1993-04-14 KR KR1019940703967A patent/KR100275619B1/en not_active IP Right Cessation
- 1993-04-14 EP EP93912256A patent/EP0639235B1/en not_active Expired - Lifetime
- 1993-04-30 MX MX9302550A patent/MX9302550A/en not_active IP Right Cessation
-
1994
- 1994-03-02 US US08/204,667 patent/US5368668A/en not_active Expired - Lifetime
-
1995
- 1995-05-10 US US08/438,906 patent/US5674226A/en not_active Expired - Lifetime
-
1996
- 1996-09-27 GR GR960402535T patent/GR3021183T3/en unknown
Also Published As
Publication number | Publication date |
---|---|
DE69304322D1 (en) | 1996-10-02 |
CA2132970A1 (en) | 1993-11-11 |
BR9306324A (en) | 1998-01-13 |
KR100275619B1 (en) | 2000-12-15 |
EP0639235A1 (en) | 1995-02-22 |
DE69304322T2 (en) | 1997-04-17 |
JPH07506505A (en) | 1995-07-20 |
US5308673A (en) | 1994-05-03 |
CZ272694A3 (en) | 1995-06-14 |
WO1993022485A1 (en) | 1993-11-11 |
US5674226A (en) | 1997-10-07 |
EP0639235B1 (en) | 1996-08-28 |
JP3459420B2 (en) | 2003-10-20 |
ES2093428T3 (en) | 1996-12-16 |
CZ286043B6 (en) | 1999-12-15 |
KR950701400A (en) | 1995-03-23 |
GR3021183T3 (en) | 1996-12-31 |
US5368668A (en) | 1994-11-29 |
MX9302550A (en) | 1994-07-29 |
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Legal Events
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EEER | Examination request | ||
MKLA | Lapsed |