Absorbent product with nonwoven dampness inhibitor

• US 6,177,607 B1
• Filed: 06/25/1999
• Issued: 01/23/2001
• Est. Priority Date: 06/25/1999
• Status: Expired due to Term

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: McCormack, Ann Louis, Paul, Susan Carol, Blaney, Carol Ann
• Primary Examiner(s): Weiss, John G.
• Assistant Examiner(s): KIDWELL, MICHELE M
• Application Number:
  US09/344,025
• Time in Patent Office: 578 Days
• Field of Search: 442/370, 442/394, 442/398, 525/240, 428/315.5, 604/378, 604/384, 604/385.1
• US Class Current: 604/378
• CPC Class Codes: A61F 13/51462 being defined by a value or parameter
• CPC Class Codes: A61F 2013/51011 characterized by the count of the fibres, e.g. denier or tex
• CPC Class Codes: Y10T 442/647 Including a foamed layer or component
• CPC Class Codes: Y10T 442/674 Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/678 Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]

Abstract

An absorbent article including a liquid-permeable top layer, an absorbent core layer, a breathable outer cover, and an inner nonwoven filament layer between the absorbent core and breathable outer cover. The outer cover includes a breathable film and an outer nonwoven filament layer. The inner nonwoven filament layer has a mean fiber denier which is higher than the mean fiber denier of the outer nonwoven filament layer. The inner nonwoven filament layer serves as a dampness inhibitor which reduces or prevents perceived dampness on the external surface of the outer cover by lowering thermal conductivity between the absorbent core and the outer cover surface.

Claims

1. An absorbent article, comprising:

a liquid-permeable top layer;

an absorbent core layer;

a hydrophobic inner nonwoven filament web; and

a breathable outer cover having a WVTR of at least about 300 grams/m²-24 hours;

the breathable outer cover including at least a breathable film and an outer nonwoven filament web having a mean fiber denier;

wherein the inner nonwoven filament web has a mean fiber denier higher than the mean fiber denier of the outer nonwoven filament web.

2. The absorbent article of claim 1, wherein the inner nonwoven filament web has a mean fiber denier of at least 2.0.

3. The absorbent article of claim 1, wherein the inner nonwoven filament web has a mean fiber denier of about 2.2-10.

4. The absorbent article of claim 1, wherein the inner nonwoven filament web has a mean fiber denier of about 2.5-6.0.

5. The absorbent article of claim 1, wherein the outer nonwoven filament web has a mean fiber denier less than 2.0.

6. The absorbent article of claim 1, wherein the outer nonwoven filament web has a mean fiber denier of about 0.1-1.8.

7. The absorbent article of claim 1, wherein the outer nonwoven filament web has a mean fiber denier of 0.5-1.5.

8. The absorbent article of claim 1, wherein the inner nonwoven filament web has a mean fiber denier at least about 10% higher than the mean fiber denier of the outer nonwoven filament web.

9. The absorbent article of claim 1, wherein the inner nonwoven filament web has a mean fiber denier at least about 20% higher than the mean fiber denier of the outer nonwoven filament web.

10. The absorbent article of claim 1, wherein the inner nonwoven filament web has a mean fiber denier at least about 30% higher than the mean fiber denier of the outer nonwoven filament web.

11. The absorbent article of claim 1, wherein the breathable outer cover has a WVTR of at least about 1500 grams/m²-24 hours.

12. The absorbent article of claim 1, wherein the breathable outer cover has a WVTR of at least about 3000 grams/m²-24 hours.

13. The absorbent article of claim 1, wherein the outer cover is positioned with the breathable film facing the inner nonwoven filament web.

14. The absorbent article of claim 1, wherein the inner nonwoven filament web comprises a polymer selected from the group consisting of polyethylene, polypropylene, copolymers of mainly ethylene and C₃-C₁₂ alpha-olefins (commonly known as linear low density polyethylene), copolymers of mainly propylene with ethylene and/or C₄-C₁₂ alpha-olefins, flexible polyolefins including propylene-based polymers having both atactic and isotactic propylene groups in the main polypropylene chain, polyamides, polyesters, and combinations thereof.

15. The absorbent article of claim 1, wherein the inner nonwoven filament web comprises a polymer selected from the group consisting of polyurethanes, copolyether esters, polyamide polyether block copolymers, ethylene vinyl acetate copolymers, block copolymers having the general formula A-B-A′

or A-B such as copoly (styrene/ethylene-butylene), styrene-poly (ethylene-propylene)-styrene, styrene-poly (ethylene-butylene)-styrene, polystyrene/poly(ethylene-butylene)/polystyrene, poly (styrene/ethylene-butylene/styrene), and combinations thereof.

16. The absorbent article of claim 1, wherein the inner nonwoven filament web comprises a polyolefin.

17. The absorbent article of claim 1, wherein the inner nonwoven filament web comprises a metallocene-catalyzed polyolefin.

18. An absorbent article, comprising:

a liquid-permeable top layer;

an absorbent core layer;

a hydrophobic inner nonwoven filament web having a first mean fiber denier, and

a breathable outer cover having a WVTR of at least about 300 grams/m²-24 hours;

the breathable outer cover including a breathable film facing the inner nonwoven filament web and an outer nonwoven filament web having a second mean fiber denier, facing away from the inner nonwoven filament web;

wherein the first mean fiber denier is at least about 10% higher than the second mean fiber denier.

19. The absorbent article of claim 18, wherein the inner nonwoven filament web has a basis weight of about 0.1-4.0 osy.

20. The absorbent article of claim 18, wherein the inner nonwoven filament web has a basis weight of about 0.3-2.0 osy.

21. The absorbent article of claim 18, wherein the inner nonwoven filament web has a basis weight of about 0.4-1.0 osy.

22. The absorbent article of claim 18, wherein the inner nonwoven filament web comprises a spunbond web.

23. The absorbent article of claim 18, wherein the inner nonwoven filament web comprises a meltblown web.

24. The absorbent article of claim 18, wherein the inner nonwoven filament web comprises a bonded carded web.

25. The absorbent article of claim 18, wherein the inner nonwoven filament web comprises an air laid web.

26. The absorbent article of claim 18, wherein the inner nonwoven filament web comprises a plurality of nonwoven layers.

27. An absorbent article, comprising:

a liquid-permeable top layer;

an absorbent core layer;

a hydrophobic inner nonwoven filament web having a basis weight of about 0.1-4.0 osy and a first mean fiber denier; and

a breathable outer cover including a breathable microporous film facing the inner nonwoven filament web, and an outer nonwoven filament web facing away from the inner nonwoven filament web and having a second mean fiber denier;

wherein the first mean fiber denier is higher than the second mean fiber denier.

28. The absorbent article of claim 27, comprising a diaper.

29. The absorbent article of claim 27, comprising a training pant.

30. The absorbent article of claim 27, comprising an adult incontinence garment.

31. The absorbent article of claim 27, comprising swim wear.

32. The absorbent article of claim 27, comprising a medical absorbent product.