Absorbent material

• US 5,677,028 A
• Filed: 04/09/1996
• Issued: 10/14/1997
• Est. Priority Date: 04/09/1996
• Status: Expired due to Fees

• Current Assignee: Finova Mezzanine Capital, Inc.
• Original Assignee: Wearever Health Care Products LLC
• Inventors: Ravella, Joseph A.
• Primary Examiner(s): Bell, James J.
• Application Number:
  US08/629,975
• Time in Patent Office: 553 Days
• Field of Search: 428/102, 428/212, 428/220, 442/118, 442/123, 442/388, 442/403, 156/148, 156/62.6, 156/209, 28/107, 28/112
• US Class Current: 428/102
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 2323/10 Polypropylene
• 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 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: D04H 1/46 by needling or like operations to cause entanglement of fibres D04H1/45 takes precedence; needling machines D04H18/00
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24033 including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 442/2484 Coating or impregnation is water absorbency-increasing or hydrophilicity-increasing or hydrophilicity-imparting
• CPC Class Codes: Y10T 442/2525 Coating or impregnation functions biologically [e.g., insect repellent, antiseptic, insecticide, bactericide, etc.]
• CPC Class Codes: Y10T 442/2861 Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/667 Needled
• CPC Class Codes: Y10T 442/684 Containing at least two chemically different strand or fiber materials
• CPC Class Codes: Y10T 442/689 Hydroentangled nonwoven fabric

Abstract

An absorbent material and method for making same comprising a fiber web, including a fiber blend comprising from about 50 to about 75 weight percent of a fiber having fineness less than about 3 denier and from about 25 to about 50 weight percent of a fiber having fineness ranging from about 3 to about 5 denier wherein the fiber web is bound together by fiber bundles transverse to the plane of the web. The fiber blend may further comprise from about 3 to about 7 percent by weight of a fiber having fineness greater than about 5 denier. The fibers comprising the fiber blend may be entirely hydrophobic, or the about 3 to about 5 denier fiber may be hydrophilic. The absorbent material exhibits a high degree of absorption and fluid retention and does not wet back even under compression. The transverse fiber bundles formed during the mechanical bonding of the web function as wicks for transferring fluid from the surface of the material to the inner portion of the material. The fiber bundles also act as support structures resisting compression and maintaining void space and absorbent surface area within the material, even when wet. The material is reusable and is strong enough to withstand numerous washings. The material is useful as a component of reusable absorbent products further comprising an outer layer or body-side layer. The outer layer may be fluid impermeable, gas permeable or both.

Claims

1. An absorbent material, the absorbent material comprising:

a fiber web including a blend of fibers, the fiber blend comprising;

from about 50 to about 75 weight percent of a fiber having fineness less than about 3 denier, based on a total weight of the blend, and

from about 25 to about 50 weight percent of a fiber having fineness ranging from about 3 to about 5 denier, based on a total weight of the blend,

wherein the fiber web is bonded together by fiber bundles transverse to the plane of the web.

2. An absorbent material as recited in claim 1, wherein the fiber comprising the fiber blend is hydrophobic fiber.

3. An absorbent material as recited in claim 2, wherein the hydrophobic fiber is treated with a hydrophilic finish.

4. An absorbent material as recited in claim 2, wherein the fiber is polyester.

5. An absorbent material as recited in claim 1, wherein the fiber having fineness ranging from about 3 to about 5 denier is hydrophilic fiber.

6. An absorbent material as recited in claim 5, wherein the about 3 to about 5 denier fiber is rayon.

7. An absorbent material as recited in claim 1, wherein the fiber blend further comprises from about 3 to about 7 percent by weight of a fiber having fineness greater than about 5 denier, based on a total weight of the blend.

8. An absorbent material as recited in claim 7, wherein the fiber comprising the fiber blend is hydrophobic fiber.

9. An absorbent material as recited in claim 8, wherein the fiber is polyester.

10. An absorbent material as recited in claim 8, wherein the hydrophobic fiber is treated with a hydrophilic finish.

11. An absorbent material as recited in claim 7, wherein the fiber having fineness ranging from about 3 to about 5 denier is hydrophilic fiber.

12. An absorbent material as recited in claim 11, wherein the about 3 to about 5 denier fiber is rayon.

13. An absorbent material as recited in claim 1, wherein the fiber blend comprises:

from about 60 to about 70 weight percent of a fiber having fineness less than about 3 denier, based on a total weight of the blend, and

from about 30 to about 40 weight percent of a fiber having fineness ranging from about 3 to about 5 denier, based on a total weight of the blend.

14. An absorbent material as recited in claim 1, wherein the fiber blend comprises:

about 70 weight percent of a fiber having fineness less than about 3 denier, based on a total weight of the blend, and about 30 weight percent of a fiber having fineness ranging from about 3 to about 5 denier, based on a total weight of the blend.

15. An absorbent material as recited in claim 1, wherein the fiber blend further comprises from about 4 to about 6 percent by weight of a fiber having fineness greater than about 5 denier, based on a total weight of the blend.

16. An absorbent material as recited in claim 1, wherein the fiber blend further comprises about 5 percent by weight of a fiber having fineness greater than about 5 denier, based on a total weight of the blend.

17. An absorbent article, the article comprising:

an outer layer, and

an absorbent layer disposed against the outer layer, the absorbent layer comprising;

a fiber web including a blend of fibers, the fiber blend comprising;

from about 50 to about 75 weight percent of a fiber having fineness less than about 3 denier, based on a total weight of the blend, and

from about 25 to about 50 weight percent of a fiber having fineness ranging from about 3 to about 5 denier, based on a total weight of the blend,

wherein the fiber web is bonded together by fiber bundles transverse to the plane of the web.

18. An absorbent article as recited in claim 17, wherein the outer layer is fluid impermeable.

19. An absorbent article as recited in claim 18, wherein the outer layer is gas permeable.

20. An absorbent article as recited in claim 17, wherein the outer layer further comprises an inner surface and an outer surface, the outer surface having slip-resistant properties.

21. An absorbent article as recited in claim 17, further comprising a body-side layer wherein the absorbent layer is disposed between the outer layer and the body-side layer.

22. The absorbent pad as recited in claim 21, wherein the body-side layer is a fluid permeable.

23. The absorbent pad as recited in claim 21, wherein the body-side layer and the absorbent layer are held together by stitch means defining a quilted construction.