CA2053831C - Fluid absorbing article utilizing a flow control cover sheet - Google Patents
Fluid absorbing article utilizing a flow control cover sheetInfo
- Publication number
- CA2053831C CA2053831C CA002053831A CA2053831A CA2053831C CA 2053831 C CA2053831 C CA 2053831C CA 002053831 A CA002053831 A CA 002053831A CA 2053831 A CA2053831 A CA 2053831A CA 2053831 C CA2053831 C CA 2053831C
- Authority
- CA
- Canada
- Prior art keywords
- layer
- filament
- layers
- coverstock
- comprised
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Abstract
A nonwoven fabric having flow control properties suitable for use in a fluid absorbing article such as a diaper, incontinence pad, or the like; and a process for preparation thereof by utilizing unbonded carded staple fiber elements or webs having different average dpf values compiled in graduated order from high-to-low average dpf, then compressed and bonded to a desired constant fabric density.
Claims (80)
1. A fluid-absorbing article comprising, in combination, a nonwoven coverstock component having fluid flow-controlling properties, a fluid-retaining core component, and a fluid impervious backing component, the core component being located between the coverstock and the backing components, the coverstock component having a generally constant density in the range of 0.2 g/cc to 0.02 g/cc and comprising an oriented non-woven material comprised of at least two layers, each of the layers being layered in a predetermined sequence, compressed together and bonded together, the layers comprising:
(a) a first exterior layer having a first denier value, the first exterior layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components, each of the components having a different denier value within the range of approximately 1-20 denier;
(b) a second interior layer adjacent the first exterior layer and having a second denier value lower than the first denier value, the second interior layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous mixed staple fibre or filament is comprised of at least two components each having a different denier value within the range of approximately 1-20 denier.
(a) a first exterior layer having a first denier value, the first exterior layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components, each of the components having a different denier value within the range of approximately 1-20 denier;
(b) a second interior layer adjacent the first exterior layer and having a second denier value lower than the first denier value, the second interior layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous mixed staple fibre or filament is comprised of at least two components each having a different denier value within the range of approximately 1-20 denier.
2. The combination of claim 1, wherein the layers additionally comprise a third layer adjacent the second layer, the third layer having a third denier value lower than the second denier value, the third layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous mixed staple fibre or filament is comprised of at least two components each having a different denier value.
3. The combination of claim 2, wherein the layers additionally comprise a fourth layer adjacent the third layer, the fourth layer having a fourth denier value lower than the third denier value, the fourth layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components each having a different denier value.
4. The combination of claim 3, wherein the layers additionally comprise a fifth layer adjacent the fourth layer, the fifth layer having a fifth denier value lower than the third denier value, the fourth layer being comprised of at least one carded homogeneous or mixed staple fibre or filament wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components each having a different denier value.
5. A nonwoven coverstock material having a generally constant density in the range of approximately 0.2 g/cc to 0.02 g/cc and exhibiting fluid-flow controlling properties, the material comprised of at least two layers, each of the layers being layered in a predetermined sequence, compressed together and bonded together, the layers comprising:
(a) a first exterior layer having a first denier value, the first exterior layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components, each of the components having a different denier value;
(b) a second interior layer adjacent the first exterior layer and having a second denier value lower than the first denier value the second interior layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous mixed staple fibre or filament is comprised of at least two components each having a different denier value.
(a) a first exterior layer having a first denier value, the first exterior layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components, each of the components having a different denier value;
(b) a second interior layer adjacent the first exterior layer and having a second denier value lower than the first denier value the second interior layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous mixed staple fibre or filament is comprised of at least two components each having a different denier value.
6. The coverstock material of claim 5, wherein the denier values of the first and second layers fall within a range of about 1-20 denier.
7. The coverstock material of claim 5, wherein at least one of the first and second layers comprise a fibrillated film.
8. The coverstock material of claim 6, wherein at least one of the first and second layers comprise a carded thermoplastic having at least one component staple.
9. The coverstock material of claim 6, wherein the first and second layers are calender bonded.
10. The coverstock material of claim 6, wherein the first and second layers are air bonded.
11. The coverstock material of claim 6, wherein the first and second layers are laser bonded.
12. The coverstock material of claim 6, wherein the first and second layers are sonic bonded.
13. The coverstock material of claim 8, wherein either one or both of the first and second layers comprise at least one carded staple or sheathed staple component selected from the group consisting of:
(a) polypropylene;
(b) at least one of the group consisting of polyethylene and polypropylene;
(c) at least one of the group consisting of low melting polyester and polyester;
(d) at least one of the group consisting of polyester and polypropylene; and (e) at least one of the group consisting of polyethylene and polyester fibre.
(a) polypropylene;
(b) at least one of the group consisting of polyethylene and polypropylene;
(c) at least one of the group consisting of low melting polyester and polyester;
(d) at least one of the group consisting of polyester and polypropylene; and (e) at least one of the group consisting of polyethylene and polyester fibre.
14. The coverstock material of claim 6, wherein the first and second layers are comprised of at least one of the components selected from the group consisting of a polypropylene monocomponent staple and polyethylene sheathed bicomponent staple, wherein the staple components do not exceed about 3 inches in length.
15. The coverstock material of claim 6, wherein the coverstock component comprises the first and second layers comprised of a staple fibre having at least one cross section selected from the group consisting of round, delta, diamond, Y and X.
16. The coverstock material of claim 5, wherein the layers additionally comprise a third layer adjacent the second layer, the third layer having a third denier value lower than the second denier value, the third layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components each having a different denier value.
17. The coverstock material of claim 16, wherein the layers additionally comprise a fourth layer adjacent the third layer, the fourth layer having a fourth denier value lower than the third denier value, the fourth layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components each having a different denier value.
18. The coverstock material of claim 17, wherein the layers additionally comprise a fifth layer adjacent the fourth layer, the fifth layer having a fifth denier value lower than the third denier value, the fourth layer being comprised of at least one carded homogeneous or mixed staple fibre or filament, wherein the homogeneous or mixed staple fibre or filament is comprised of at least two components each having a different denier value.
19. A fluid-absorbing article comprising, in combination, a nonwoven coverstock component having fluid-flow controlling properties, a fluid-retaining core component, and a fluid impervious backing component, the core component being located between the coverstock and the backing components, the coverstock component having a density in a range of 0.2 g/cc to 0.02 g/cc and comprising an oriented nonwoven material comprised of at least two layers having a generally constant density, each of the layers being layered in a predetermined sequence, compressed together and bonded together, the layers comprising:
(a) a first exterior layer having a first average denier per filament value, the first exterior layer being comprised of at least one carded staple fibre or filament; and (b) a second interior layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one carded staple fibre or filament.
(a) a first exterior layer having a first average denier per filament value, the first exterior layer being comprised of at least one carded staple fibre or filament; and (b) a second interior layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one carded staple fibre or filament.
20. A nonwoven coverstock material having a density in the range of approximately 0.2 g/cc to 0.02 g/cc and exhibiting fluid-flow controlling properties, comprised of at least two layers having a generally constant density, each of the layers being layered in a predetermined sequence, compressed together and bonded together, the layers comprising:
(a) a first layer having a first average denier per filament value, the first exterior layer being comprised of at least one carded staple fibre or filament; and (b) a second layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one carded staple fibre or filament.
(a) a first layer having a first average denier per filament value, the first exterior layer being comprised of at least one carded staple fibre or filament; and (b) a second layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one carded staple fibre or filament.
21. The coverstock material of claim 20, wherein about 2-5 layers are compiled and then laser bonded to obtain the nonwoven coverstock material.
22. The coverstock material of claim 20, wherein about 2-5 layers are compiled and then sonic bonded to obtain the nonwoven coverstock material.
23. The coverstock material of any one of claims 20, 21 or 22, wherein the compiled layers comprise carded polypropylene-staple and/or sheathed bicomponent-staple selected from polyethylene/polypropylene, low melting polyester/polyester, polyester/polypropylene and polyethylene/polyester fibre.
24. The coverstock material of claim 20, wherein the compiled layers comprise polypropylene monocomponent staple and/or polyethylene sheathed bicomponent staple not exceeding about 3 inches in length.
25. The coverstock material of claim 20, wherein the coverstock component comprises layers of staple fibre having a cross section selected from at least one of a round, delta, diamond, Y, X, or dog bone-type configuration.
26. The coverstock material of claim 20, wherein the layers additionally comprise a third layer adjacent the second layer, the third layer having a third average denier per filament value lower than the second average denier per filament value, the third layer being comprised of at least one carded staple fibre or filament.
27. The coverstock material of claim 26, wherein the layers additionally comprise a fourth layer adjacent the third layer, the fourth layer having a fourth average denier per filament value lower than the third average denier per filament value the fourth layer being comprised of at least one carded staple fibre or filament.
28. The coverstock material of claim 27, wherein the layers additionally comprise a fifth layer adjacent the fourth layer, the fifth layer having a fifth average denier per filament value lower than the fourth average denier per filament value, the fifth layer being comprised of at least one carded staple fibre or filament.
29. The coverstock material of claim 20, wherein the layers additionally comprise a third layer adjacent the second layer, the third layer having a third average denier per filament value lower than the second average denier per filament value, the third layer being comprised of at least one carded staple fibre or filament.
30. The coverstock material of claim 29, wherein the layers additionally comprise a fourth layer adjacent the third layer, the fourth layer having a fourth average denier per filament value lower than the third average denier per filament value, the fourth layer being comprised of at least one carded staple fibre or filament.
31. The coverstock material of claim 30, wherein the layers additionally comprise a fifth layer adjacent the fourth layer, the fifth layer having a fifth average denier per filament value lower than the fourth average denier per filament value, the fourth layer being comprised of at least one carded staple fibre or filament.
32. The fluid absorbing article of claim 19, wherein the coverstock component has a generally constant density in the range of .04 g/cc to .08 g/cc.
33. The nonwoven coverstock material of claim 20, wherein coverstock component has a generally constant density in the range of .04 g/cc to .08 g/cc.
34. The coverstock material of claim 20, wherein the first exterior layer consists essentially of one carded staple fibre or filament.
35. The coverstock material of claim 20, wherein the first exterior layer comprises at least two staple fibres or filaments each having a different denier value.
36. The coverstock material of claim 20, wherein the second interior layer consists essentially of at least one carded staple fibre or filament.
37. The coverstock material of claim 20, wherein the second interior layer comprises at least two staple fibres or filaments each having a different denier value.
38. The coverstock material of claim 34, wherein the second interior layer consists essentially of at least one carded staple fibre or filament.
39. The coverstock material of claim 34, wherein the second interior layer comprises of at least two staple fibres or filaments each having a different denier value.
40. The coverstock material of claim 26, wherein the third layer consists essentially of at least one carded staple fibre or filament.
41. The coverstock material of claim 26, wherein the third layer comprises at least two staple fibres or filaments each having a different denier value.
42. The coverstock material of claim 27, wherein the fourth layer consists essentially of at least one carded staple fibre or filament.
43. The coverstock material of claim 27, wherein the fourth layer comprises at least two staple fibres or filaments each having a different denier value.
44. The coverstock material of claim 28, wherein the fifth layer consists essentially of at least one carded staple fibre or filament.
45. The coverstock material of claim 28, wherein the fifth layer comprises at least two staple fibres or filaments each having a different denier value.
46. The fluid-absorbing article of claim 19, wherein the first exterior layer consists essentially of one carded staple fibre or filament.
47. The fluid-absorbing article of claim 19, wherein the first exterior layer comprises at least two staple fibres or filaments each having a different denier value.
48. The fluid-absorbing article of claim 19, wherein the second interior layer consists essentially of at least one carded staple fibre or filament.
49. The fluid-absorbing article of claim 19, wherein the second interior layer comprises at least two staple fibres or filaments each having a different denier value.
50. The fluid-absorbing article of claim 46, wherein the second interior layer consists essentially of at least one carded staple fibre or filament.
51. The fluid-absorbing article of claim 46, wherein the second interior layer comprises at least two staple fibres or filaments each having a different denier value.
52. The coverstock material of claim 29, wherein the third layer consists essentially of at least one carded staple fibre or filament.
53. The coverstock material of claim 29, wherein the third layer comprises at least two stape fibres or filaments each having a different denier value.
54. The coverstock material of claim 30, wherein the fourth layer consists essentially of at least one carded staple fibre or filament.
55. The coverstock material of claim 30, wherein the fourth layer comprises at least two staple fibres or filaments each having a different denier value.
56. The coverstock material of claim 31, wherein the fifth layer consists essentially of at least one carded staple fibre or filament.
57. The coverstock material of claim 32, wherein the fifth layer comprises at least two staple fibres or filaments each having a different denier value.
58. The coverstock material of claim 20, wherein one or more of the compiled layers comprise carded thermoplastic-mono-component and/or -bicomponent staple.
59. The coverstock material of claim 58, wherein about 2-5 unbonded layers are compiled and then calender bonded to obtain the nonwoven coverstock material.
60. The coverstock material of claim 59, wherein the compiled layers comprise carded polypropylene-staple and/or sheathed bicomponent-staple selected from polyethylene/polypropylene, low melting polyester/polyester, polyester/polypropylene and polyethylene/polyester fibre.
61. The coverstock material of claim 60, wherein the compiled layers comprise polypropylene monocomponent staple and/or polyethylene sheathed bicomponent staple not exceeding about 3 inches in length.
62. The coverstock material of claim 61, wherein coverstock component has a generally constant density in the range of .04 g/cc to .08 g/cc.
63. The fluid-absorbing article of claim 19, wherein the average dpf values of the respective layers of the coverstock material fall within a range of about 1-20 dpf.
64. A fluid-absorbing article comprising, in combination, a nonwoven coverstock component having fluid-flow controlling properties, a fluid-retaining core component, and a fluid impervious backing component, the core component being located between the coverstock and the backing components, the coverstock component having a generally constant density in a range of 0.2 g/cc to 0.02 g/cc and comprising an oriented nonwoven material comprised of at least two layers, each of the layers being layered in a predetermined sequence, compressed together and bonded together, the layers comprising:
(a) a first exterior layer having a first average denier per filament value, the first exterior layer being comprised of at least one filament; and (b) a second interior layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one filament.
(a) a first exterior layer having a first average denier per filament value, the first exterior layer being comprised of at least one filament; and (b) a second interior layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one filament.
65. A coverstock component having a generally constant density in a range of 0.2 g/cc to 0.02 g/cc and comprising an oriented nonwoven material comprised of at least two layers, each of the layers being layered in a predetermined sequence, compressed together and bonded together, the layers comprising:
(a) a first exterior layer having a first average denier per filament value, the first exterior layer being comprised of at least one filament; and (b) a second interior layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one filament.
(a) a first exterior layer having a first average denier per filament value, the first exterior layer being comprised of at least one filament; and (b) a second interior layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one filament.
66. A coverstock material comprising two or more layers of fibres or filaments exhibiting a density that is, to within about 0.04 to 0.08 g/cc, substantially constant, in the range of 0.02 to 0.2 g/cc, the fibres or filaments in a said layer exhibiting substantially uniform denier, and the fibres or filaments in adjacent layers exhibiting increasing denier.
67. A material as claimed in claim 66, comprising at least one layer of carded staple fibres or filaments.
68. A material as claimed in claim 67, comprising from 2 to 5 layers of said fibres or filaments, exhibiting an average denier of from 1 to 20.
69. A material as claimed in any one of claims 66 - 68, comprising thermoplastic monocomponent fibres or filaments, thermoplastic bicomponent fibres or filaments, or mixtures thereof.
70. A material as claimed in any one of claims 66 - 68, wherein said layers are bonded together.
71. A material as claimed in claim 69, wherein said layers are bonded together.
72. A material as claimed in any one of claims 66 - 68, wherein said layers are bonded together by a bonding technique selected from techniques including needle punch, thermal, laser, and sonic bonding.
73. A material as claimed in claim 69, wherein said layers are bonded together by a bonding technique selected from techniques including needle punch, thermal, laser, and sonic bonding.
74. A material as claimed in claim 69, wherein said fibres or filaments exhibit a cross section selected from the group including round, delta, diamond, X, Y, or dog bone-type configuration.
75. A fluid-absorbing article comprising, in combination, a nonwoven coverstock component having fluid flow-controlling properties, a fluid-retaining core component, and a fluid impervious backing component, the core component being located between the coverstock and the backing components, the coverstock component having a density in a range of 0.2 g/cc to 0.02 g/cc and comprising an oriented nonwoven material comprised of at least two layers having a generally constant density, each of the layers being layered in a predetermined sequence, compressed together and bonded together, the layers comprising:
(a) a first exterior layer having a first average denier per filament value, the first exterior layer being comprised of at least one carded staple fibre or filament; and (b) a second interior layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one carded staple fibre or filament.
(a) a first exterior layer having a first average denier per filament value, the first exterior layer being comprised of at least one carded staple fibre or filament; and (b) a second interior layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one carded staple fibre or filament.
76. A nonwoven coverstock material having a density in the range of approximately 0.2 g/cc to 0.02 g/cc and exhibiting fluid-flow controlling properties, comprised of at least two layers having a generally constant density each of the layers being layered in a predetermined sequence and bonded together, the layers comprising:
(a) a first layer having a first average denier per filament value, the first exterior layer being comprised of at least one carded staple fibre or filament; and (b) a second layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one carded staple fibre or filament.
(a) a first layer having a first average denier per filament value, the first exterior layer being comprised of at least one carded staple fibre or filament; and (b) a second layer adjacent the first exterior layer and having a second average denier per filament value lower than the first average denier per filament value, the second interior layer being comprised of at least one carded staple fibre or filament.
77. The article of claim 75, wherein the layers comprise carded polypropylene-staple and/or sheathed bicomponent-staple selected from polyethylene/polypropylene, low melting polyester /polyester, polyester/polypropylene and polyethylene/polyester fibre.
78. The material of claim 76, wherein the layers comprise carded polypropylene-staple and/or sheathed bicomponent-staple selected from polyethylene/polypropylene, low melting polyester /polyester, polyester/polypropylene and polyethylene/polyester fibre.
79. The article of claim 75, wherein the layers comprise polypropylene monocomponent staple and/or polyethylene sheathed bicomponent staple not exceeding about 3 inches in length.
80. The material of claim 76, wherein the layers comprise polypropylene monocomponent staple and/or polyethylene sheathed bicomponent staple not exceeding about 3 inches in length.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US63390790A | 1990-12-26 | 1990-12-26 | |
| US633,907 | 1990-12-26 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2053831A1 CA2053831A1 (en) | 1992-06-27 |
| CA2053831C true CA2053831C (en) | 1998-08-11 |
Family
ID=24541627
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002053831A Expired - Fee Related CA2053831C (en) | 1990-12-26 | 1991-10-21 | Fluid absorbing article utilizing a flow control cover sheet |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP3206670B2 (en) |
| CA (1) | CA2053831C (en) |
| MX (1) | MX9102167A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6100208A (en) | 1996-10-31 | 2000-08-08 | Kimberly-Clark Worldwide, Inc. | Outdoor fabric |
Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2698384B1 (en) * | 1992-11-20 | 1995-02-10 | Peaudouce | Multilayer nonwoven material and absorbent hygiene article comprising such material. |
| GB9307117D0 (en) * | 1993-04-06 | 1993-05-26 | Hercules Inc | Card bonded comfort barrier fabrics |
| FR2705697B1 (en) * | 1993-05-26 | 1995-08-04 | Peaudouce | Composite nonwoven material, manufacturing process and its application to any absorbent hygiene article. |
| GB9317490D0 (en) * | 1993-08-23 | 1993-10-06 | Hercules Inc | Diaper barrier leg-cuff fabrics |
| JP4312939B2 (en) * | 1999-11-05 | 2009-08-12 | ユニ・チャーム株式会社 | Top sheet of body fluid absorbing article |
| US7919169B2 (en) | 2001-06-08 | 2011-04-05 | Sca Hygiene Products Ab | Laminate made of fibrous layers for use in absorbent articles |
| BR112018009919B1 (en) * | 2015-12-02 | 2022-04-05 | Kimberly-Clark Worldwide, Inc | Non-woven take-up distribution layer and absorbent article |
-
1991
- 1991-10-21 CA CA002053831A patent/CA2053831C/en not_active Expired - Fee Related
- 1991-11-21 MX MX9102167A patent/MX9102167A/en not_active IP Right Cessation
- 1991-12-26 JP JP36142191A patent/JP3206670B2/en not_active Ceased
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6100208A (en) | 1996-10-31 | 2000-08-08 | Kimberly-Clark Worldwide, Inc. | Outdoor fabric |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH05247816A (en) | 1993-09-24 |
| JP3206670B2 (en) | 2001-09-10 |
| CA2053831A1 (en) | 1992-06-27 |
| MX9102167A (en) | 1992-06-01 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |