CA2640722A1 - Extensible absorbent composites - Google Patents

Extensible absorbent composites Download PDF

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Publication number
CA2640722A1
CA2640722A1 CA 2640722 CA2640722A CA2640722A1 CA 2640722 A1 CA2640722 A1 CA 2640722A1 CA 2640722 CA2640722 CA 2640722 CA 2640722 A CA2640722 A CA 2640722A CA 2640722 A1 CA2640722 A1 CA 2640722A1
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CA
Canada
Prior art keywords
extensible
layer
sheet material
fibers
composite sheet
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.)
Granted
Application number
CA 2640722
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French (fr)
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CA2640722C (en
Inventor
Samuel C. Baer
Jared A. Austin
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fitesa Simpsonville Inc
Original Assignee
Fiberweb Simpsonville, Inc.
Samuel C. Baer
Jared A. Austin
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Application filed by Fiberweb Simpsonville, Inc., Samuel C. Baer, Jared A. Austin filed Critical Fiberweb Simpsonville, Inc.
Publication of CA2640722A1 publication Critical patent/CA2640722A1/en
Application granted granted Critical
Publication of CA2640722C publication Critical patent/CA2640722C/en
Expired - Fee Related legal-status Critical Current
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Classifications

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    • 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
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Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

Absorbent sheet materials are produced from a coformed blend of absorbent fibers and extensible meltblown polymer fibers. Laminates of these extensible coforms are prepared with layers of extensible polymeric fibers or filaments.
The absorbent sheet materials are incrementally stretched to improve softness and drape.

Claims (36)

1. An extensible composite sheet material (10, 10', 10") comprising a first layer (12) formed of a coformed blend of absorbent fibers and extensible meltblown fibers and a second layer (14) of extensible thermoplastic fibers, in which the extensible meltblown fibers of the first layer and the extensible thermoplastic fibers of the second layer have been permanently elongated by-the application of tensile stress..
2. The extensible composite sheet material of claim 1, wherein the second layer (14) of extensible thermoplastic fibers comprises a nonwoven web.
3. The extensible composite sheet material of claim 2, wherein the nonwoven web is a spunbond web comprised of continuous filaments.
4. The extensible composite sheet material of claim 2, wherein the nonwoven web is a carded web of staple fibers.
5. The extensible composite sheet material of claim 2, wherein the nonwoven web is a meltblown web of meltblown fibers.
6. The composite sheet material of claim 1, wherein the meltblown fibers of the first layer are comprised of polyethylene.
7. The composite sheet material of claim 1, wherein the meltblown fibers of the first layer are comprised of blends of polypropylene homopolymer and polypropylene copolymer.
8. The extensible composite sheet material of any of claims 1 to 7, wherein the extensible thermoplastic fibers of the second layer (14) are prepared from a propylene polymer or copolymer.
9. The extensible composite sheet material of any one of claims 1 to 7, wherein extensible thermoplastic fibers of the second layer (14) comprise polyethylene continuous filaments.
10. The extensible composite sheet material of any one of claims 1 to 7, wherein the extensible thermoplastic fibers of the second layer (14) comprise a blend of at least two polymers which are immiscible with one another and at least one additional polymer which is miscible or partially miscible with said immiscible polymers.
11. The extensible composite sheet material of claim 10, wherein said blend of immiscible polymers comprises a propylene polymer and polyethylene.
12. The extensible composite sheet material of any one of claims 1 to 7, wherein the extensible thermoplastic fibers of the second layer (14) comprise multicomponent filaments.
13. The extensible composite sheet material of any one of claims 1 to 7, wherein the extensible thermoplastic fibers of the second layer (14) comprise sheath-core bicomponent filaments including a polyethylene sheath component and a polypropylene core component.
14. The extensible composite sheet material of any one of claims 1 to 13, wherein functional particulate have been incorporated into the blend of absorbent fibers and meltblown fibers.
15. The extensible composite sheet material (10") of any one of claims 1 to 14, in which an additional layer (14) of continuous extensible filaments is in intimate surface-to-surface contact with an opposite side of said coform layer (12) and bonded thereto so that the additional layer of continuous extensible filaments defines an opposite exterior surface of the composite sheet material (10").
16. The extensible composite sheet material (10') of any one of claims 1 to 14, in which an additional layer (12) formed of a coformed blend of absorbent fibers and extensible meltblown fibers is in intimate surface-to-surface contact with an opposite side of said layer (14) of extensible thermoplastic fibers so that the additional layer defines an opposite exterior surface of the composite sheet material (10').
17. The extensible composite sheet material of any one of claims 1 to 16, which has been stretched by ring-rolling to permanently elongate the extensible fibers.
18. The extensible composite sheet material of any one of claims 1 to 16, which has been stretched by deep embossing to permanently elongate the extensible fibers.
19. A method of producing an extensible composite sheet material (10, 10', 10") comprising forming an extensible coform layer (12) containing absorbent fibers and extensible meltblown fibers, applying to one surface of the coform layer (12) a layer (14) of extensible thermoplastic fibers, bonding the coform layer (12) in intimate surface-to-surface contact to the layer (14) of extensible thermoplastic fibers so that the coform layer defines an absorbent exterior surface (16) of the composite sheet material (10, 10', 10"), and stretching the composite sheet material to deform and permanently elongate the fibers.
20. The method of claim 19, comprising the further step of forming an additional extensible coform layer containing absorbent fibers and extensible meltblown fibers and bonding the additional coform layer in intimate surface-to-surface contact with an opposite side of said layer of extensible thermoplastic fibers so that the additional coform layer defines an opposite exterior surface of the composite sheet material (10').
21. The method of claim 19, comprising the further step of forming an additional layer of extensible thermoplastic fibers and bonding the additional layer in intimate surface-to-surface contact with an opposite side of said coform layer (12) so that the additional layer defines an opposite exterior surface of the composite sheet material (10").
22. The method of any one of claims 19 to 21, wherein the step of applying to one surface of the coform layer (12) a layer (14) of extensible thermoplastic fibers comprises forming a nonwoven web of said extensible thermoplastic fibers and applying the nonwoven web to said one surface of the coform layer (12).
23. The method of any one of claims 19 to 22, wherein the step of stretching comprises incrementally stretching the composite sheet material.
24. The method of claim 23 wherein the incremental stretching comprises ring-rolling.
25. The method of claim 23 wherein the incremental stretching comprises deep embossing.
26. The method of any one of claims 19 to 25, wherein the step of forming an extensible coform layer (12) comprises moving a collection surface (114) past a first coform station (110) and directing fiberized absorbent fibers into the path of freshly extruded extensible polymeric thermoplastic fibers exiting a, meltblowing die and depositing the absorbent fibers and extensible thermoplastic fibers onto the moving collection surface (114) to form said coform layer, and wherein the step of applying to one surface of the coform layer a nonwoven layer of extensible fibers comprises directing the thus-formed coform layer past a spunbond station (120) and depositing a layer of freshly extruded continuous extensible filaments onto the coform layer.
27. The method of claim 26 comprising the further step of directing the moving collection surface (114) with the first coform layer and the layer of continuous extensible filaments from the spunbond station (120) and past a second coform station (130) and forming a second coform layer on the layer of continuous extensible filaments by directing fiberized absorbent fibers into the path of freshly extruded extensible polymeric thermoplastic fibers exiting a meltblowing die, and wherein said bonding step comprises bonding the first and second coform layers and the layer of continuous extensible filaments together to form a composite sheet material.
28. The method of any one of claims 19 to 25, including the step of moving a collection surface (114) past a first spunbond station and depositing a web of freshly extruded continuous extensible filaments onto the collection surface, and wherein the step of applying to one surface of the coform layer a nonwoven layer of extensible fibers comprises directing the moving collection surface with the web of continuous extensible filaments thereon underneath a coform station and directing fiberized absorbent fibers into the path of freshly extruded extensible polymeric thermoplastic fibers exiting a meltblowing die and depositing the absorbent fibers and extensible thermoplastic fibers onto the web of continuous extensible filaments moving on the collection surface to form said coform layer.
29. The method of claim 28, including the further step of directing the moving collection surface with the web of continuous filaments and the thus-formed coform layer thereon under a second spunbond station and depositing a second web of continuous extensible filaments onto the coform layer.
30. An extensible composite sheet material (10, 10', 10") comprising a first layer (12) formed of a coformed blend of absorbent fibers and extensible meltblown fibers and a second layer (14) comprising an extensible spunbond nonwoven web of continuous filaments, the continuous filaments comprising a blend of at least two polymers which are immiscible with one another and at least one additional polymer which is miscible or partially miscible with said immiscible polymers.
31. The extensible composite sheet material of claim 30 wherein the blend of immiscible polymers comprises a propylene polymer and polyethylene.
32. An extensible composite sheet material (10, 10', 10") comprising a first layer (12) formed of a coformed blend of absorbent fibers and extensible meltblown fibers and a second layer (14) comprising an extensible spunbond nonwoven web of continuous filaments, the continuous filaments comprising sheath-core bicomponent filaments including a polyethylene sheath component and a polypropylene core component.
33. The extensible composite sheet material of any one of claims 30 to 32, wherein the sheet material is capable of being elongated 150%
beyond its original length without breaking.
34. The extensible composite sheet material (10") of any one of claims 30 to 33, in which an additional layer (14) of continuous extensible filaments is in intimate surface-to-surface contact with an opposite side of said coform layer (12) and bonded thereto so that the additional layer of continuous extensible filaments defines an opposite exterior surface of the composite sheet material (10").
35. The extensible composite sheet material (10') of any one of claims 30 to 33, in which an additional layer (12) formed of a coformed blend of absorbent fibers and extensible meltblown fibers is in intimate surface-to-surface contact with an opposite side of said layer (14) of extensible thermoplastic fibers so that the additional layer defines an opposite exterior surface of the composite sheet material (10').
36
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JP5179384B2 (en) 2013-04-10
WO2007098449A1 (en) 2007-08-30
US20070197117A1 (en) 2007-08-23
EP1991729A1 (en) 2008-11-19
CN101395315B (en) 2012-07-18
CN101395315A (en) 2009-03-25
EP1991729B1 (en) 2012-07-25
MX2008010742A (en) 2008-09-01
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CA2640722C (en) 2011-12-06
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US8685870B2 (en) 2014-04-01
JP2009527660A (en) 2009-07-30

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