Personal care articles with abrasion resistant meltblown layer

• US 6,117,803 A
• Filed: 08/29/1997
• Issued: 09/12/2000
• Est. Priority Date: 08/29/1997
• Status: Expired due to Fees

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Odorzynski, Thomas Walter, Morman, Michael Tod, Sudduth, Gregory Todd, Jackson, Wanda Walton
• Primary Examiner(s): RAIMUND, CHRISTOPHER W
• Application Number:
  US08/920,497
• Time in Patent Office: 1,110 Days
• Field of Search: 442/351, 442/381, 442/382, 442/392, 442/394, 442/400, 442/401, 604/358, 604/370, 604/372, 604/378
• US Class Current: 442/381
• CPC Class Codes: A61F 13/51401 characterised by the material
• CPC Class Codes: A61F 13/51456 characterised by its properties
• CPC Class Codes: A61F 13/51478 being a laminate, e.g. multi-layered or with several layers
• CPC Class Codes: A61F 2013/15406 Basis weight
• CPC Class Codes: A61F 2013/51011 characterized by the count of the fibres, e.g. denier or tex
• CPC Class Codes: A61F 2013/51445 comprising microfibres, e.g. Gore-Tex
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2535/00 Medical equipment, e.g. bandage, prostheses or catheter
• CPC Class Codes: B32B 2555/00 Personal care
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• CPC Class Codes: B32B 5/022 Non-woven fabric
• 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 1/559 the fibres being within layered webs
• CPC Class Codes: D04H 1/56 in association with fibre formation, e.g. immediately following extrusion of staple fibres
• CPC Class Codes: D04H 3/14 with bonds between thermoplastic yarns or filaments produced by welding
• CPC Class Codes: Y10T 442/626 Microfiber is synthetic polymer
• 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 442/671 Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material
• CPC Class Codes: Y10T 442/674 Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/68 : Melt-blown nonwoven fabric
• CPC Class Codes: Y10T 442/681 : Spun-bonded nonwoven fabric

Abstract

A diaper outer cover of a layered nonwoven material having an outer meltblown fiber layer of a meltblown material having an average basis weight in the range of about 1 g/m² to about 7 g/m² disposed on an inner nonwoven material layer, preferably a spunbond web.

Claims

1. A diaper comprising:

a body side liner;

an outer cover comprising an outer meltblown fiber layer of a meltblown material having an average basis weight in a range of about 1 g/m² to about 7 g/m² disposed on an inner nonwoven material layer; and

an absorbent material disposed between said body side liner and said outer cover.

2. A diaper in accordance with claim 1, wherein said basis weight of said meltblown fiber layer is in the range of about 3 g/m² to about 7 g/m².

3. A diaper in accordance with claim 1, wherein said basis weight of said meltblown fiber layer is about 5 g/m².

4. A diaper in accordance with claim 1, wherein the average basis weight of said outer cover is less than about 23 g/m².

5. A diaper in accordance with claim 1, wherein said inner nonwoven material layer is a spunbond.

6. A diaper in accordance with claim 5, wherein said spunbond has an average spunbond basis weight of about 17 g/m² and said average basis weight of said outer meltblown fiber layer is about 4 g/m².

7. A diaper in accordance with claim 1 further comprising a film layer disposed on an inner facing face of said nonwoven material layer.

8. A diaper in accordance with claim 7, wherein said film layer is a breathable film layer.

9. A diaper in accordance with claim 1, wherein said meltblown fiber layer is comprised of microfibers having a microfiber denier per filament of less than about 0.67.

10. A diaper in accordance with claim 9, wherein said microfiber denier per filament is less than about 0.06.

11. A diaper in accordance with claim 1, wherein said microfiber denier per filament is in a range of about 0.01 to about 0.67.

12. A diaper in accordance with claim 1, wherein said outer meltblown fiber layer has a uniformity such that no 1/2-inch diameter circle of said meltblown fiber layer has a basis weight of less than about 1 g/m² and greater than about 7 g/m².

13. A personal care article comprising:

a body side liner;

an outer cover comprising an outer meltblown fiber layer of a meltblown material having an average basis weight in a range of about 1 g/m² to about 7 g/m² disposed on an inner nonwoven material layer; and

an absorbent material disposed between said body said liner and said outer cover.

14. A personal care article in accordance with claim 13, wherein said basis weight of said meltblown fiber layer is in the range of about 3 g/m² to about 7 g/m².

15. A personal care article in accordance with claim 13, wherein said basis weight of said meltblown fiber layer is about 5 g/m².

16. A personal care article in accordance with claim 13, wherein said inner nonwoven material layer is a spunbond.

17. A personal care article in accordance with claim 13, wherein said meltblown fiber layer is comprised of microfibers having a microfiber denier per filament of less than about 0.67.

18. A personal care article in accordance with claim 17, wherein said microfiber denier per filament is in a range of about 0.01 to about 0.67.

19. A personal care article in accordance with claim 13, wherein said personal care article is a training pants.

20. A personal care article in accordance with claim 13, wherein said personal care article is an adult incontinence garment.