Tufted fibrous web

• US 7,682,686 B2
• Filed: 06/17/2005
• Issued: 03/23/2010
• Est. Priority Date: 12/20/2002
• Status: Expired due to Term

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Peck, Daniel Charles, Benson, Douglas Herrin, Curro, John Joseph
• Primary Examiner(s): JOHNSON, JENNA LEIGH
• Application Number:
  US11/156,020
• Publication Number:
  US 20060286343A1
• Time in Patent Office: 1,740 Days
• Field of Search: 428/171, 428/172, 428156-173, 428131-140
• US Class Current: 428/172
• CPC Class Codes: A61F 13/00 Bandages or dressings radioactive dressings A61N5/1029; Absorbent pads
• CPC Class Codes: A61F 13/15577 Apparatus or processes for manufacturing
• CPC Class Codes: A61F 13/51108 the top sheet having corrugations or embossments having one axis relatively longer than the other axis, e.g. forming channels or grooves in a longitudinal direction
• CPC Class Codes: A61F 13/5116 being formed of multiple layers A61F13/5123 takes precedence
• 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: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2459/00 Nets, e.g. camouflage nets
• CPC Class Codes: B32B 2555/02 Diapers or napkins
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• 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 5/06 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 5/26 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 1/5412 sheath-core
• CPC Class Codes: D04H 1/5414 side-by-side
• CPC Class Codes: D04H 1/5416 sea-island
• CPC Class Codes: D04H 1/5418 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/544 Olefin series
• CPC Class Codes: D04H 1/55 : Polyesters
• CPC Class Codes: D04H 1/559 : the fibres being within layered webs
• 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: D10B 2505/04 : Filters
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/24289 : Embedded or interlocked
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24479 : including variation in thickness
• CPC Class Codes: Y10T 428/24603 : Fiber containing component
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 442/659 : Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet

Abstract

A fibrous web having a first surface and a second surface. The fibrous web has a first region and at least one discrete second region, the second region being a discontinuity on the second surface and being a tuft comprising a plurality of tufted fibers extending from the first surface. The tufted fibers define a distal portion, the distal portion comprising portions of the tufted fibers being bonded together. Bonding can be thermal melt-bonding. In another embodiment the second surface of the web can have non-intersecting or substantially continuous bonded regions, which also can be thermal melt-bonding.

Claims

1. A fibrous web having a first surface and a second surface, said fibrous web further comprising a first region and at least one discrete second region, the second region being a discontinuity on said second surface and being a tuft comprising a plurality of looped tufted fibers extending from said first surface, said looped tufted fibers defining a distal portion and a proximal portion, said looped tufted fibers generally converging near said proximal portion, said distal portion comprising portions of said looped tufted fibers being bonded together wherein a plurality of bonded portions that are coincident with and substantially aligned along a longitudinal axis of said distal portion are defined.

2. The fibrous web of claim 1, wherein said web comprises a plurality of discrete integral second regions.

3. The fibrous web of claim 2, wherein said plurality of discrete integral second regions is uniformly distributed on said fibrous web.

4. The fibrous web of claim 1, wherein said fibrous web comprises a nonwoven web of substantially randomly oriented fibers.

5. The fibrous web of claim 1, where said fibrous web comprises a nonwoven web having a substantial number of fibers having a predetermined orientation measured as a predetermined angle from the machine direction.

6. The fibrous web of claim 2, wherein said fibers comprise polymers selected from the group consisting of polyethylene, polypropylene, polyester, and blends thereof.

7. The fibrous web of claim 2, wherein said fibers comprise fibers chosen from the group consisting of bicomponent fibers, hollow fibers, non-round fibers, and capillary channel fibers.

8. The fibrous web of claim 1, wherein said fibrous web comprises a laminate of at least two precursor webs.

9. The fibrous web of claim 8, wherein a said laminate comprises a polymer film.

10. A fibrous web having a first surface and a second surface, said fibrous web further comprising a first region and a plurality of discrete second regions, each said second region comprising a discontinuity on said second surface and a tuft comprising a plurality of looped tufted fibers integral with but extending from said first surface, said looped tufted fibers defining a distal portion and a proximal portion, said looped tufted fibers, generally converging near said proximal portion, said second surface having thereon a plurality of bonded regions in the form of stripes or bands of melt-bonded regions.

11. The fibrous web of claim 10, wherein at least some of said stripes or bands of melt-bonded regions are discontinuous.

12. The fibrous web of claim 10, wherein said fibers comprise polymers selected from the group consisting of polyethylene, polypropylene, polyester, and blends thereof.

13. The fibrous web of claim 10, wherein said fibers comprise fibers chosen from the group consisting of bicomponent fibers, hollow fibers, non-round fibers, and capillary channel fibers.

14. The fibrous web of claim 10, wherein said fibrous web comprises a laminate of at least two precursor webs.

15. The fibrous web of claim 14, wherein said laminate comprises a polymer film.

16. A fibrous web having a first surface and a second surface, said fibrous web further comprising a first region and a plurality of discrete second regions, each said second region comprising a discontinuity on said second surface and a tuft comprising a plurality of looped tufted fibers integral with but extending from said first surface, said looped tufted fibers defining a distal portion and a proximal portion, said looped tufted fibers, generally converging near said proximal portion, said distal portion comprising portions of said looped tufted fibers being bonded together to define a bonded area that extends along a longitudinal axis of said tuft, and wherein said second surface comprises thereon a plurality of non-intersecting, substantially continuous bonded regions.

17. The fibrous web of claim 16, wherein said fibers comprise polymers selected from the group consisting of polyethylene, polypropylene, polyester, and blends thereof.

18. The fibrous web of claim 16, wherein said fibers comprise fibers chosen from the group consisting of bicomponent fibers, hollow fibers, non-round fibers, and capillary channel fibers.

19. The fibrous web of claim 16, wherein said bonded area comprises adhesive-bonded portions.

20. The fibrous web of claim 16, wherein said bonded area comprises distally-disposed melt-bonded portions.

21. A disposable absorbent article, the article having at least one component comprising a fibrous web comprising a first region and a plurality of discrete integral second regions, the second regions having at least one portion being a region of fiber discontinuity and at least another portion being a tuft comprising a plurality of looped tufted fibers integral with but extending from the first region, wherein said web comprises bonded regions on distal portions of said tufts, wherein each of said bonded regions comprises a plurality of adjacent fiber bonds that are coincident with and substantially aligned along a longitudinal axis of said distal portion, and wherein said looped tufted fibers generally converge near a proximal portion of said tufts.

22. The article of claim 21, wherein said article is selected from the group consisting of a catamenial article, a tampon, an incontinence article, and a diaper.

23. A multilayer tufted web comprising at least a first and second precursor webs, said multilayer fibrous web further comprising a first surface and a second surface, and a first region and a plurality of discrete integral second regions, the second regions having at least one portion being a region of fiber discontinuity and at least another portion being a tuft comprising a plurality of looped tufted fibers integral with but extending from the first surface, wherein the looped tufted fibers comprise fibers from at least one of said first or second precursor webs, and said looped tufted fibers defining a distal portion and a proximal portion, said looped tufted fibers generally converging near said proximal portion, said distal portion comprising portions of said looped tufted fibers being bonded together to define a bonded area that extends along a longitudinal axis of said tuft.

24. The fibrous web of claim 23, wherein said first and second precursor webs each comprise a nonwoven web of substantially randomly oriented fibers.

25. The fibrous web of claim 23, wherein one of said first or second precursor webs comprise a polymer film web.

26. A multilayer tufted web comprising first and second precursor webs joined together to form a laminate having first and second opposed outwardly facing surfaces, said first precursor web comprising a nonwoven having looped tufted fibers facing outwardly from said first surface and being bonded together to define a bonded area that extends along a longitudinal axis of said tuft, said looped tufted fibers defining a distal portion and a proximal portion, said looped tufted fibers generally converging near said proximal portion, said second precursor web comprising cellulose.

27. A multilayer tufted web according to claim 26 further comprising a third precursor web, wherein said second precursor web is positioned between said first and third precursor webs to form a laminate.

28. A multilayer tufted web according to claim 27, wherein said second precursor web comprises tissue grade paper.

29. A multilayer tufted web according to claim 28, wherein said second precursor web further comprises thermoplastic fibers.

30. A multilayer tufted web according to claim 28, wherein said third precursor web comprises a polymer film.

31. A fibrous web comprising a first surface;

an opposing second surface;

a web body disposed between said first surface and said second surface;

a tuft extending from said first surface;

wherein said tuft comprises fibers that have been repositioned from within said web body to a position extending from said first surface;

wherein a plurality of bonds exist at distal portions of adjacent fibers associated with said tuft, and wherein said plurality of bonds are substantially aligned with one another to define a bond region.

32. The fibrous web of claim 31, further comprising a second bond region associated with said second surface, said second bond region in the form of stripes or bands.