Cover material with improved fluid handling properties

• US 20030124927A1
• Filed: 12/18/2001
• Published: 07/03/2003
• Est. Priority Date: 12/18/2001
• Status: Active Grant

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Petryk, Teresa, Waldroup, Donald E., Braverman, Jaime
• Granted Patent: US 6,740,792 B2
• Time in Patent Office: Days
• US Class Current: 442/50
• CPC Class Codes: A61F 13/51104 the top sheet having a three-dimensional cross-section, e.g. corrugations, embossments, recesses or projections
• CPC Class Codes: A61F 13/51121 characterised by the material
• CPC Class Codes: A61F 13/5116 being formed of multiple layers A61F13/5123 takes precedence
• CPC Class Codes: A61F 13/51311 the permeability gradient being in the vertical direction
• CPC Class Codes: A61F 2013/51152 having specific distance between the fibres
• CPC Class Codes: A61F 2013/51178 with the combination of nonwoven webs
• CPC Class Codes: A61F 2013/51338 having improved touch or feeling, e.g. smooth film
• CPC Class Codes: A61F 2013/51355 for improving fluid flow
• CPC Class Codes: D04H 13/00 Other non-woven fabrics
• CPC Class Codes: D04H 3/16 with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 442/184 Nonwoven scrim
• CPC Class Codes: Y10T 442/608 Including strand or fiber material which is of specific structural definition

Abstract

A material having a multi-denier base material layer including a plurality of fine denier fibers, the fine denier fibers of less than about 10 dpf, and a plurality of large denier filaments intermixed with the fine denier fibers which form channels in a longitudinal direction of the material, the large denier filaments of greater than about 10 dpf. A method of producing a multi-denier cover material is also disclosed.

Claims

1. A cover material comprising:

a base material layer including a plurality of fine denier fibers, having a fiber denier of less than about 10 dpf; and

a plurality of large denier filaments bonded to the base material layer, having a filament denier greater than about 10 dpf and forming a plurality of channels in the cover material.

2. The cover material of claim 1 wherein the fine denier fibers have a fiber denier of about 2 dpf to about 8 dpf.

3. The cover material of claim 1 wherein the fine denier fibers have a fiber denier of about 3 dpf to about 5 dpf.

4. The cover material of claim 1 wherein the cover material is treated with a surfactant.

5. The cover material of claim 4 wherein the surfactant is applied to a medial section along a longitudinal centerline of the cover material.

6. The cover material of claim 4 wherein the surfactant comprises a skin wellness treatment.

7. The cover material of claim 1 wherein the large denier filaments have a filament denier of about 10 dpf to about 100 dpf.

8. The cover material of claim 1 wherein the large denier filaments have a filament denier of about 15 dpf to about 40 dpf.

9. The cover material of claim 1 wherein the large denier filaments are colored.

10. The cover material of claim 1 wherein the large denier filaments each comprise a pigment.

11. The cover material of claim 1 wherein the large denier filaments are spaced between about 1 mm and about 15 mm.

12. The cover material of claim 1 wherein the large denier filaments are spaced between about 3 mm to about 8 mm.

13. The cover material of claim 1 wherein the base material layer comprises a spunbond web.

14. The cover material of claim 13 wherein the spunbond web is apertured.

15. The cover material of claim 1 wherein the fine denier fibers and the large denier filaments are bonded together by one of through-air bonding, ultrasonic bonding, adhesive bonding and combinations thereof.

16. The cover material of claim 1 wherein the channels are formed in a longitudinal direction of the cover material.

17. The cover material of claim 1 wherein the fine denier fibers and the large denier filaments comprise a polypropylene polymer.

18. The cover material of claim 1 wherein the fine denier fibers and the large denier filaments each comprises a polymer selected from the group consisting of polypropylene, polyethylene (high and low density), ethylene copolymers with C₃-C₂₀ α

-olefins, propylene copolymers with ethylene or C₄-C₂₀ α

-olefins, butene copolymers with ethylene, propylene, or C₅-C₂₀ α

-olefins, polyvinyl chloride, polyesters, polyamides, polyfluorocarbons, polyurethane, polystyrene, polyvinyl alcohol, caprolactams, and cellulosic and acrylic resins.

19. The cover material of claim 18 wherein the fine denier fibers and the large denier filaments comprise the same polymer.

20. The cover material of claim 1 wherein the large denier filaments comprise an elastomeric material or an extensible material.

21. The cover material of claim 1 wherein the fine denier fibers comprise bicomponent fibers.

22. The cover material of claim 1 wherein the large denier filaments comprise bicomponent filaments.

23. A personal care product comprising the cover material of claim 1.

24. A diaper comprising the cover material of claim 1.

25. An adult incontinence product comprising the cover material of claim 1.

26. A feminine hygiene product comprising the cover material of claim 1.

27. A cover material comprising:

a first nonwoven layer comprising a plurality of fine denier fibers, the fine denier fibers having a denier less than about 10 dpf; and

a plurality of large denier filaments forming a plurality of channels, the large denier filaments having a denier greater than about 10 dpf.

28. The cover material of claim 27 wherein the large denier filaments have a filament denier of about 10 dpf to about 100 dpf.

29. The cover material of claim 27 wherein the large denier filaments have a filament denier of about 15 dpf to about 40 dpf.

30. The cover material of claim 27 wherein the fine denier fibers have a fiber denier of about 2 dpf to about 8 dpf.

31. The cover material of claim 27 wherein the fine denier fibers have a fiber denier of about 3 dpf to about 5 dpf.

32. The cover material of claim 27 wherein the fine denier fibers are thermally bonded to the large denier filaments.

33. The cover material of claim 27 wherein the cover material is treated with a surfactant.

34. The cover material of claim 33 wherein the cover material is selectively treated with the surfactant.

35. The cover material of claim 33 wherein the surfactant comprises a skin wellness treatment.

36. The cover material of claim 27 further comprising a second nonwoven layer.

37. The cover material of claim 36 wherein the second nonwoven layer has a wettability different than a wettability of the first nonwoven material.

38. The cover material of claim 36 wherein the second nonwoven layer has a permeability different than a permeability of the first nonwoven material.

39. The cover material of claim 36 wherein the second nonwoven layer has a pore size different than a pore size of the first nonwoven material.

40. The cover material of claim 36 wherein the second nonwoven layer has a void volume different than a void volume of the first nonwoven material.

41. The cover material of claim 36 wherein the cover material is apertured.

42. The cover material of claim 36 wherein the first nonwoven layer and the second nonwoven layer is coapertured.

43. The cover material of claim 27 wherein the plurality of large denier filaments form a plurality of streams disposed in a longitudinal direction of the first nonwoven layer.

44. The cover material of claim 27 wherein the large denier filaments are intermixed with the fine denier fibers.

45. A method for producing a multi-denier nonwoven material comprising the steps of:

producing a base material layer comprising a plurality of fine denier fibers of less than about 10 dpf;

combining a plurality of large denier filaments with the fine denier fibers to form a plurality of channels, the large denier filaments of at least about 10 dpf; and

bonding the large denier filaments to the fine denier fibers.

46. The method of claim 45 wherein the fine denier fibers and the large denier fibers are bonded together by one of thermal bonding, through-air bonding, ultrasonic bonding, adhesive bonding and combinations thereof.

47. The method of claim 45 wherein the fine denier fibers and the large denier filaments comprise spunbond fibers.

48. The method of claim 45 wherein the fine denier fibers and the large denier filaments are spun from a spinning plate.

49. The method of claim 45 wherein the fine denier fibers are spun from a first spinning plate and the large denier filaments are spun from a second spinning plate.

50. The method of claim 45 wherein the fine denier fibers and the large denier filaments comprise a polypropylene polymer.

51. The method of claim 45 wherein the fine denier fibers and the large denier filaments each comprises a polymer selected from the group consisting of polypropylene, polyethylene (high and low density), ethylene copolymers with C₃-C₂₀ α

-olefins, propylene copolymers with ethylene or C₄-C₂₀ α

-olefins, butene copolymers with ethylene, propylene, or C₅-C₂₀ α

-olefins, polyvinyl chloride, polyesters, polyamides, polyfluorocarbons, polyurethane, polystyrene, polyvinyl alcohol, caprolactams, and cellulosic and acrylic resins.

52. The method of claim 45 wherein the large denier filaments are added to the nonwoven material in an of-line process.

53. The cover material of claim 45 wherein the large denier filaments are intermixed with the fine denier fibers.