Tufted laminate web

• US 20040265533A1
• Filed: 12/16/2003
• Published: 12/30/2004
• Est. Priority Date: 12/20/2002
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Hammons, John Lee, Turner, Robert Haines, Hoying, Jody Lynn, Curro, John Joseph, Lloyd, Susan Nicole
• Granted Patent: US 7,172,801 B2
• Time in Patent Office: Days
• US Class Current: 428/92
• CPC Class Codes: A44B 18/0011 Female or loop elements A44B18/0007 takes precedence
• CPC Class Codes: A47K 2010/3266 Wet wipes
• CPC Class Codes: A61F 13/15707 Mechanical treatment, e.g. notching, twisting, compressing, shaping
• CPC Class Codes: A61F 13/15731 Treating webs, e.g. for giving them a fibrelike appearance, e.g. by embossing
• CPC Class Codes: A61F 13/2068 Tampons made from several layers A61F13/2065, A61F13/206 take precedence
• CPC Class Codes: A61F 13/51113 comprising an additive, e.g. lotion or odour control A61F13/51108 takes precedence
• CPC Class Codes: A61F 13/51121 characterised by the material
• CPC Class Codes: A61F 13/512 characterised by its apertures, e.g. perforations
• CPC Class Codes: A61F 13/51305 having areas of different permeability
• CPC Class Codes: A61F 13/51476 being three-dimensional, e.g. embossed, textured, pleated, or with three-dimensional features, like gathers or loops
• CPC Class Codes: A61F 13/51478 being a laminate, e.g. multi-layered or with several layers
• CPC Class Codes: A61F 13/5148 having an impervious inner layer and a cloth-like outer layer
• CPC Class Codes: A61F 13/51484 being inhomogeneous in the plane of the sheet, i.e. having zones of different properties or structures
• CPC Class Codes: A61F 13/53436 having an undulated or corrugated cross-section
• CPC Class Codes: A61F 13/8405 Additives, e.g. for odour, disinfectant or pH control
• CPC Class Codes: A61F 2013/1543 with a density gradient in the horizontal plane
• CPC Class Codes: A61F 2013/15512 with specific hydrophilicity
• CPC Class Codes: A61F 2013/51007 characterized by the orientation of fibres
• CPC Class Codes: A61F 2013/51156 having integrally attached
• CPC Class Codes: A61F 2013/51165 with the combination of films and nonwovens
• CPC Class Codes: A61F 2013/51178 : with the combination of nonwoven webs
• CPC Class Codes: A61F 2013/5128 : characterized by open targets or acquisitions or vulnerability zones
• CPC Class Codes: A61F 2013/51344 : with pile webs or velvet-like tissues
• CPC Class Codes: A61F 2013/51355 : for improving fluid flow
• CPC Class Codes: A61F 2013/51366 : with hydrophilic lower face
• CPC Class Codes: A61F 2013/51372 : with valve or valve-like upper layer; Tapered capillary structures
• CPC Class Codes: A61F 2013/5386 : by the fibre orientation in the z plane or vertical direction
• CPC Class Codes: B29C 55/18 : by squeezing between surfaces, e.g. rollers
• CPC Class Codes: B32B 2307/728 : Hydrophilic
• CPC Class Codes: B32B 2555/02 : Diapers or napkins
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D04H 11/08 : formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking needling machines D04H18/00
• CPC Class Codes: Y10T 428/23914 : Interlaminar
• CPC Class Codes: Y10T 428/23929 : Edge feature or configured or discontinuous surface
• CPC Class Codes: Y10T 428/23943 : Flock surface
• CPC Class Codes: Y10T 428/2395 : Nap type surface
• CPC Class Codes: Y10T 428/23957 : Particular shape or structure of pile
• CPC Class Codes: Y10T 428/23964 : U-, V-, or W-shaped or continuous strand, filamentary material
• CPC Class Codes: Y10T 428/24289 : Embedded or interlocked
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24314 : Slit or elongated
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24339 : Keyed
• CPC Class Codes: Y10T 428/24347 : From both sides
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/2967 : Synthetic resin or polymer
• CPC Class Codes: Y10T 442/611 : Cross-sectional configuration of strand or fiber material is other than circular
• CPC Class Codes: Y10T 442/637 : Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• CPC Class Codes: Y10T 442/659 : Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/66 : Additional nonwoven fabric is a spun-bonded fabric
• CPC Class Codes: Y10T 442/666 : Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
• CPC Class Codes: Y10T 442/668 : Separate nonwoven fabric layers comprise chemically different strand or fiber material
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/676 : Vinyl polymer or copolymer sheet or film [e.g., polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, etc.]

Abstract

An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet is disclosed. The topsheet has a first side and a second side, the first side being a body-facing side and the second side being in fluid communication with the absorbent core. The topsheet also has a first relatively hydrophobic component and a second relatively hydrophilic component, the relatively hydrophilic component extending through the relatively hydrophobic component and being disposed on both of the sides of the topsheet. The absorbent article exhibits a rewet value of less than about 94 mg, and a fluid acquisition rate of at least about 0.10 ml/sec when tested by the Gush Acquisition and Rewet Test Method.

Claims

1. An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, the topsheet having a first side and a second side, the first side being a body-facing side and the second side being in fluid communication with the absorbent core, said topsheet further comprising:

a. a first relatively hydrophobic component and a second relatively hydrophilic component;

b. said relatively hydrophilic component extending through said relatively hydrophobic component and being disposed on both of said sides of said topsheet; and

c. wherein said absorbent article exhibits a rewet value of less than about 94 mg, and a fluid acquisition rate of at least about 0.10 ml/sec when tested by the Gush Acquisition and Rewet Test Method.

2. The absorbent article of claim 1, wherein the topsheet is a laminate of a relatively hydrophobic web and a relatively hydrophilic nonwoven web.

3. The absorbent article of claim 2, wherein the relatively hydrophobic web is a nonwoven web.

4. The absorbent article of claim 2, wherein the relatively hydrophobic web is a polymer film.

5. The absorbent article of claim 2, wherein the first side of the topsheet comprises a plurality of discrete tufts comprising fibers from said relatively hydrophilic nonwoven web.

6. The absorbent article of claim 5, wherein said plurality of discrete tufts is uniformly distributed on said laminate web.

7. The absorbent article of claim 3, wherein said fibers of either said relatively hydrophilic web or said relatively hydrophobic web comprise polymers selected from the group consisting of polyethylene, polypropylene, polyester, and blends thereof.

8. The absorbent article of claim 3, wherein said fibers of either said relatively hydrophilic web or said relatively hydrophobic web comprise bicomponent fibers.

9. The absorbent article of claim 3, wherein said fibers of either said relatively hydrophilic web or said relatively hydrophobic web comprise non-round fibers.

10. The absorbent article of claim 1, wherein said absorbent article exhibits a rewet value of less than about 50 mg, and a fluid acquisition rate of at least about 0.50 ml/sec when tested by the Gush Acquisition and Rewet Test Method.

11. The absorbent article of claim 1, wherein said absorbent article exhibits a rewet value of less than about 25 mg, and a fluid acquisition rate of at least about 0.50 ml/sec when tested by the Gush Acquisition and Rewet Test Method.

12. An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, the topsheet having a first side and a second side, the first side being a body-facing side and the second side being in fluid communication with the absorbent core, said topsheet further comprising:

a. a relatively hydrophobic component and a second relatively hydrophilic component;

b. said relatively hydrophilic component extending through said relatively hydrophobic component and being disposed on both sides of said topsheet;

c. wherein said relatively hydrophilic component comprises a spunbond nonwoven web; and

d. wherein said absorbent article exhibits a rewet value of less than about 94 mg when tested by the Rewet Test Method, and a fluid acquisition rate of at least about 0.10 ml/sec when tested by the Fluid Acquisition Test Method.

13. The absorbent article of claim 12, wherein the first side of the topsheet comprises a plurality of discrete tufts comprising fibers from said spunbond nonwoven web.

14. The absorbent article of claim 12, wherein said relatively hydrophobic component is a nonwoven web.

15. The absorbent article of claim 12, wherein said relatively hydrophobic component is a polymer film.

16. The absorbent article of claim 12, wherein said fibers of the relatively hydrophilic spunbond web comprise polymers selected from the group consisting of polyester, and blends thereof.

17. The absorbent article of claim 14, wherein said fibers of either the relatively hydrophilic spunbond web or the relatively hydrophobic web comprise bicomponent fibers.

18. The absorbent article of claim 14, wherein said fibers of either the relatively hydrophilic spunbond web or the relatively hydrophobic web comprise non-round fibers.

19. An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, the topsheet having a first side and a second side, the first side being a body-facing side and the second side being in fluid communication with the absorbent core, said topsheet further comprising:

a. a first relatively hydrophobic component and a second relatively hydrophilic component;

b. said relatively hydrophilic component being disposed on both sides of said topsheet;

c. said relatively hydrophilic component comprises a carded nonwoven web; and

d. wherein said absorbent article exhibits a rewet value of less than about 50 mg when tested by the Rewet Test Method, and a fluid acquisition rate of at least about 1.0 ml/sec when tested by the Fluid Acquisition Test Method.

20. The absorbent article of claim 19, wherein the first side of the topsheet comprises a plurality of discrete tufts comprising fibers from said carded nonwoven web.

21. The absorbent article of claim 19, wherein said relatively hydrophobic component is a nonwoven web.

22. The absorbent article of claim 19, wherein said relatively hydrophobic component is a polymer film.

23. The absorbent article of claim 19, wherein said fibers of the relatively hydrophilic carded nonwoven web comprise polymers selected from the group consisting of polyester, and blends thereof.

24. The absorbent article of claim 21, wherein said fibers of either the relatively hydrophilic carded web or the relatively hydrophobic web comprise bicomponent fibers.

25. The absorbent article of claim 21, wherein said fibers of either the relatively hydrophilic carded web or the relatively hydrophobic web comprise non-round fibers.

26. An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, the topsheet having a first side and a second side, the first side being a body-facing side and the second side being in fluid communication with the absorbent core, said topsheet further comprising a nonwoven web and tufted regions, said tufted regions comprising first, second and third zones, each said zone being characterized by the zone fiber orientation, wherein said first and third zones comprise fibers having portions orientated substantially parallel to a plane of the topsheet, and said second zone is intermediate and adjacent to said first and third zones, said second zone comprising fibers having substantially no portions oriented substantially parallel to said plane of the topsheet.

27. An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet, the topsheet having a first side and a second side, the first side being a body-facing side and the second side being in fluid communication with the absorbent core, said topsheet further comprising a nonwoven web comprising tufts, said tufts at least partially originating in said second side and extending to a distal body-facing portion, the distal body-facing portion being relatively hydrophobic with respect to the second side.

28. The absorbent article of claim 27 wherein said distal body-facing portion of said tufts is rendered hydrophobic by a lotion composition disposed thereon.

29. The absorbent article of claim 28 wherein said lotion composition comprises a hydrophilic/lipophilic balance (HLB) of less than or equal to 7.

30. The absorbent article of claim 28 wherein said lotion composition comprises petrolatum.