Note: Descriptions are shown in the official language in which they were submitted.
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RESILIENT, THREE DIMENSIONAL POLYMERIC FILM COMPRISING
CAPILLARY APERTURES, AND ABSORBENT ARTICLE WITH IMPROVED
BACKSHEET COMPRISING THE FILM
15
FIELD OF THE INVENTION
The present invention relates to resilient, three dimensional, perforated
plastic webs which are breathable, but are resistant to the transmission of
aqueous fluids at least in one direction. According to the present invention
the
perforated plastic webs consist of a liquid impervious polymeric film
comprising
apertures which form capillaries having a length which is at least twice if
compared to the dimension of the respective aperture in the polymeric film
surface. Resilient, three dimensional, perforated plastic webs according to
the
present invention are preferably comprised in absorbent articles like baby
diapers, adult incontinence articles and in particular sanitary napkins or
pantiliners, preferably in a breathable backsheet structure. The present
invention
also relates to absorbent articles like baby diapers, adult incontinence
articles
and in particular to sanitary napkins or pantiliners provided with a backsheet
comprising said webs, preferably to provide breathability.
BACKGROUND OF THE INVENTION
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The primary consumer needs which underlie development in the absorbent
article field, in particular sanitary napkins, catamenials, or pantiliners is
the
provision of products providing both a high protection and comfort level.
One means for providing consumer comfort benefits in absorbent articles is
by the provision of breathable products. Breathability has typically
concentrated
on the incorporation of so called 'breathable backsheets' in the absorbent
articles. Commonly utilised breathable backsheets are microporous films and
apertured formed films having directional fluid transfer as disclosed in for
example US 4591523. Both these types of breathable backsheets are vapour
permeable allowing gaseous exchange with the environment. This thereby allows
for the evaporation of a portion of the fluid stored in the core and increases
the
circulation of air within the absorbent article. The latter is particularly
beneficial as
it reduces the sticky and soiled feeling experienced by wearers of or
associated
with articles comprising an apertured formed film or film like topsheet.
The use of apertured film topsheets has long been recognized as providing
particular benefits in controlling the liquid flow through this layer into an
absorbent structure and reducing the liquid flow out of the absorbent
structure
towards the skin of a wearer. In this respect apertured film topsheets have
provided an exceptional dryness comfort to the wearers of absorbent articles,
particularly sanitary napkins. This comfort benefit, however, started to wear
off
under stress conditions of such articles, such as physical exercising of the
wearer
(which also caused transpiration from the skin opposite the article to emanate
more strongly), heavy loading of the article or extended wearing duration.
A drawback associated with the use of breathable backsheets in absorbent
articles is the negative effect on the protection level performance by
leakage,
known as wet through, onto the users garment. Although, breathable backsheets
in principle only allow the transfer of materials in the gaseous state,
physical
mechanisms such as extrusion, diffusion and capillary action may still occur
and
result in the transfer of the fluids from the absorbent core through the
backsheet
and onto the user's garments. In particular, these mechanisms become more
dominant if the product is utilised during physical exertion, or for heavy
discharge
loads or over extended periods of time. Thus, whilst the incorporation of
breathable backsheets in absorbent articles is highly desirable from a comfort
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standpoint, since the primary rote of a backsheet still remains the prevention
of
liquid leakage, conventional breathable backsheets have not been successfully
incorporated into products.
The problem of wet through onto users garments due to the incorporation of
such breathable backsheets in absorbent articles has indeed also been
recognized in the art. Attempts to solve the problem have mainly resided in
the
use of multiple layer backsheets such as those illustrated in US 4341216.
Similarly European patent application no.710471 discloses a breathable
backsheet comprising an outer layer of a gas permeable, hydrophobic, polymeric
fibrous fabric and an inner layer comprising an apertured formed film having
directional fluid transport. The backsheet construction preferably has no
liquid
transport/wet through under certain specified test conditions. Also European
patent application no. 710472 discloses a breathable backsheet consisting of
at
least two breathable layers which are unattached to one another over the core
area. The backsheet construction preferably has no liquid transport/wet
through
under certain specified test conditions.
US 4,713,068 discloses a breathable clothlike barrier for use as an outer
cover for absorbent articles. The barrier comprises at least 2 layers, a first
layer
having a specified basis weight, fiber diameter and pore size and a second
layer
comprising a continuous film of poly (vinyl alcohol) having a specified
thickness.
The barrier also has a specified water vapour transmission rate and level of
impermeability.
However, these proposed solutions have not been able to provide a fully
satisfactory solution to the problem of breathable backsheet wet through under
stress conditions. But especially under such stress conditions breathability
would
have most pronounced comfort benefits especially for articles comprising film
topsheets. For such articles the experienced or assumed stickiness,
stuffiness, or
soil residue between film and skin is greatest under stress conditions.
US 5,591,510 as well as WO 97/03818 and WO 97/03795 disclose an
apertured film layer having capillaries which are disposed at an angle
relative to
the plain of the film, which films are referred to as slanted capillary films.
This film
structure is provided as an improvement for incorporation into clothing and
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garments which are breathable, yet non transmitting liquids toward the wearer
of
such garments. Also the use of such slanted capillary films is indicated in
the
context of absorbent articles but as a topsheet, particularly in figure 16 of
US 5,591,510 the combination of such slanted capillary films together with an
absorbent material is disclosed, however not in the context of disposable
absorbent articles according to the present invention.
In European patent applications Nos.98101867.4 and 98101868.2,
respectively entitled "Absorbent article with breathable dual layer backsheet
comprising one layer with slanted capillary apertures", and "Absorbent article
with
breathable backsheet comprising slanted capillary apertures and an apertured
film topsheet", disposable absorbent articles are described such as baby
diapers,
adult incontinence articles and in particular sanitary napkins or panty
liners.
Typically such articles comprise a liquid pervious topsheet forming the wearer
facing surface of the article, an absorbent core and a breathable backsheet
forming the garment facing surface of the article. The absorbent core is
interposed between the topsheet and the backsheet.
The breathable backsheet is located on the garment facing surface of the
absorbent core and comprises at least one backsheet layer. The backsheet
comprises a resilient three dimensional web, which consists of a liquid
impervious polymeric backsheet film which backsheet film has apertures. The
apertures form capillaries which have side walls which extend away from the
wearer facing surface of the backsheet film and towards the absorbent core
providing the web with three dimensionality. The capillaries have a first
opening
in the garment facing surface of the backsheet film and a second opening at
the
end of the capillaries spaced apart from the wearer facing surface of the
backsheet film. The capillaries extend away from the wearer facing surface of
the
backsheet film at an angle which is less than 90° in respect to the
plane of the
backsheet film, or, in other embodiments, are curved or bent towards the plane
of the backsheet film. Further, in alternative or in addition thereto, the
capillaries
can have a first and a second portion which are different in direction, form,
shape, size or combinations thereof.
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Also the second opening of at least some of the capillaries may be provided
as slits. Slits are considered to be such forms in which the longest extent of
an
opening is at least 5 times the length of the smallest length of the opening.
5 Owing to the directional liquid transport capability of the polymeric
backsheet film and to the ability to close under pressure derivable from the
angled capillaries the breathable backsheets of the above mentioned European
patent applications provide a sanitary article with a good leak through
protection
while maintaining optimum breathability for improved comfort.
However, the performances of resilient, three dimensional, polymeric films
having apertures that form capillaries, and preferably slanted capillaries as
described above, can still be improved in terms of resiliency, and of
breathability
combined with directional fluid transport capability under the pressure and
stress
exerted on the resilient three dimensional film during the use, which is
particularly
desirable when said films are preferably comprised in breathable articles, for
example in a breathable backsheet structure of breathable disposable absorbent
articles.
It is therefore an object of the present invention to provide an improved
resilient three dimensional perforated plastic web consisting of a polymeric
film
with apertures that form capillaries.
Also, the performances of disposable absorbent articles with preferably
breathable backsheets comprising at least a resilient three dimensional
polymeric
film having apertures that form capillaries, and preferably slanted
capillaries as
described above, can still be improved in terms of breathability combined with
better wet through resistance of the backsheet structure under the pressure
and
stress experienced during the use of the absorbent articles comprising said
backsheets.
The performances of said disposable absorbent articles can also be
improved in terms of resiliency of said backsheet structures, since backsheets
comprising a resilient polymeric three dimensional film having apertures that
form
capillaries can also be used in disposable absorbent articles in a context
different
from breathability, for example taking advantage of the resiliency of these
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structures in response to compression forces typically exerted in use
perpendicularly to the film surface.
It is therefore a further object of the present invention to provide a
disposable absorbent article having a backsheet comprising an improved
resilient
three dimensional polymeric film with apertures that form capillaries.
It is still a further object of a present invention to provide a preferably
breathable disposable absorbent article having improved comfort while
maintaining an even better leakage protection, i.e. being exceptionally wet
through resistant under the stress and pressure experienced during the use.
SUMMARY OF THE INVENTION
The present invention relates to resilient, three dimensional, perforated
plastic webs which consist of a liquid impervious polymeric film having a
first
surface, a second surface, and apertures which form capillaries. The
capillaries
have side walls which extend away from the second surface of the film
providing
the web with three dimensionality. The capillaries have a first opening having
a
smallest dimension Dmin in the first surface of the film and a second opening
at
the end of the capillaries spaced apart from the second surface of the film.
Each of the capillaries defines a conduit constituted by the first opening,
the
second opening and the side walls. Each of the capillaries also has a
centreline
defined as the geometrical axis of the conduit, and a length L measured along
the centreline between the first opening and the second opening.
For each capillary the ratio between the length L of the conduit and the
smallest dimension Dm~n of the respective first opening is larger than 2.
The present invention also relates to disposable absorbent articles of a
layered construction for absorption of body fluids such as baby diapers, adult
incontinence articles and in particular sanitary napkins or panty liners,
which are
preferably also breathable. Also articles such as underarm sweat pads or
scholar
shirts may benefit from the present invention. Typically such articles are of
layered construction with each layer or group of layers having a garment
facing
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surface which is oriented to face in the direction of a garment during use of
the
article and a wearer facing surface facing in the opposite direction.
Typically such
articles comprise a liquid pervious topsheet forming the wearer facing surface
of
the article, an absorbent core and a preferably breathable backsheet forming
the
garment facing surface of the article. The absorbent core is interposed
between
the topsheet and the backsheet.
The preferably breathable backsheet is located on the garment facing
surface of the absorbent core and comprises at least one backsheet layer. The
backsheet comprises a resilient three dimensional web, which consists of a
liquid
impervious polymeric backsheet film with apertures as described above, wherein
the apertures form capillaries which have side walls which extend away from
the
wearer facing surface of the backsheet film towards the absorbent core
providing
the web with three dimensionality.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a cross-sectional view of an absorbent article comprising all
usual elements of such articles including a resilient, three dimensional,
perforated plastic web according to the present invention.
Figure 2 shows an enlarged cross section of a capillary in a resilient, three
dimensional, perforated plastic web according to the present invention.
Figures 3 - 7 show particular alternative embodiments of slanted capillaries
used for the three dimensional web according to the present invention.
Figure 8 shows a cross sectional view of an absorbent article similar to that
of Figure 1, with a different embodiment of a resilient, three dimensional,
perforated plastic web comprised in an alternative backsheet structure.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to resilient, three dimensional, perforated
plastic webs consisting of a liquid impervious polymeric film having apertures
which form capillaries. More briefly, the webs of the present invention are
also
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identified as resilient, three dimensional, polymeric webs having capillary
apertures. In a preferred embodiment of the present invention, the resilient,
three
dimensional, perforated plastic webs are comprised in disposable absorbent
articles for absorption of body fluids such as sanitary napkins, panty liners,
incontinence products, and baby diapers, more preferably in a breathable
backsheet structure of such disposable absorbent articles.
The present invention also relates to said disposable absorbent articles for
absorption of body fluids such as sanitary napkins, panty liners, incontinence
products, sweat pads and baby diapers. Typically such articles comprise the
elements of a liquid pervious topsheet, a backsheet and an absorbent core
intermediate said topsheet and said backsheet. According to the present
invention the topsheet, backsheet and core may be selected from any of the
known types of these components provided that they meet the desired comfort
and protection performance requirements and conditions noted below and in the
appended claims.
The resilient, three dimensional, perforated plastic webs according to the
present invention can however be comprised in any other type of articles, or
also
be used as such, as a web providing breathability, i.e. water vapour
permeability
and preferably air permeability, and directional liquid transport capability,
e.g. in
agriculture.
For example, resilient, three dimensional, perforated plastic webs according
to the present invention can take advantage of an increased wet through
resistance, provided by a better directional fluid transfer capability under
stressed
conditions, e.g. under pressure, and combined with water vapour and preferably
air permeability, when comprised in e.g. other articles distinct from
disposable
absorbent articles, such as for example gowns, face masks, bandages, where
breathability and resistance to fluid transmission in at least one direction
under
particularly stressed conditions are highly desirable. Also articles such as
underarm sweat pads or scholar shirts may benefit from the present invention.
Resilient, three dimensional polymeric webs according to the present
invention can also be used in a context different from breathability, for
example
taking advantage of an improved resiliency of these structures in response to
compression forces typically exerted in use perpendicularly to the film
surface.
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They can be used for example in a backsheet of a disposable absorbent article
which is not breathable in order to provide resiliency and cushioning effect.
The resilient, three dimensional, perforated plastic webs of the present
invention will be hereinafter described in preferred embodiments where they
are
comprised in a preferably breathable backsheet structure of a disposable
absorbent article such as a sanitary napkin, but the webs of the present
invention
can also be comprised in other elements distinct form a backsheet structure,
e.g.
as a topsheet, in disposable absorbent articles, or also in other types of
articles,
as explained above. Therefore, in the following description, references to the
resilient, three dimensional, perforated plastic webs of the present invention
as a
polymeric backsheet film only represent an example of a preferred embodiment
of the present invention.
Typically such preferred disposable absorbent articles comprise the
elements of a liquid pervious topsheet, a backsheet and an absorbent core
intermediate said topsheet and said backsheet. According to a preferred
embodiment of the present invention the topsheet, backsheet and core may be
selected from any of the known types of these components provided that they
meet the desired comfort and protection performance requirements and
conditions noted below and in the appended claims.
In general, the topsheet - if present - should have such a liquid retention to
maintain a dry surface and thereby keep the skin of the wearer dry; the
absorbent core needs to provide enough absorbent capacity and allow the flow
of
vapour and/or air through it and the backsheet should prevent wet through
(liquid
permeability) to retain the absorbed fluid while also being preferably
breathable.
Furthermore, the individual elements are joined, preferably using techniques
such that the final product has the desired comfort and performance level.
In the following description of the invention the surface facing in the
direction of the wearer is called wearer facing surface. In the drawings this
direction is indicated by arrow 20. Further the surface facing in the
direction of
the garment is called garment facing surface and in the drawings this
direction is
indicated by arrow 21.
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The disposable absorbent article is described below with reference to a
preferred embodiment of the present invention, wherein the article is also
breathable and has a breathable backsheet comprising the resilient three
dimensional web having capillary apertures of the present invention. However,
5 the resilient three dimensional polymeric web having capillary apertures
comprised in a backsheet can also be used in the context of a non breathable
absorbent article, e.g. in order to provide an improved resiliency and
cushioning
effect in response to compression forces typically exerted in use
perpendicularly
to the web surface.
Absorbent article components
The topsheet
According to a preferred embodiment of the present invention the absorbent
article usually comprises a topsheet. In a disposable absorbent article the
topsheet generically comprises the topmost layer or layers intended to
directly
contact the wearer's body. The topsheets suitable for use herein may be any
topsheet known in the art. In Figure 1 the topsheet is indicated with
reference
numera130.
The topsheets for use herein may comprise a single layer or a multiplicity of
layers. In a preferred embodiment the topsheet comprises a first layer which
provides the user facing surface of the topsheet and a second layer between
the
first layer and the absorbent structure/core. In addition another layer on the
wearer facing surface of the first layer but only extending in the central
zone or in
parts of the peripheral zone of the article can be desirable to provide extra
softness or extra liquid handling/retaining abilities (this design is usually
referred
to as "hybrid topsheet"). The topsheet typically extends across the whole of
the
absorbent structure and can extend into and form part of or all of the
preferred
sideflaps, side wrapping elements or wings. Also the topsheet (or rather at
least
one layer thereof) can wrap around the absorbent core, thereby providing a
topsheet layer and a layer which is considered part of the backsheet.
The topsheet as a whole and hence each layer individually needs to be
compliant, soft feeling, and non-irritating to the wearer's skin. It also can
have
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elastic characteristics allowing it to be stretched in one or two directions.
As used
herein the topsheet hence refers to any layer or combination of layers whose
principle function is the acquisition and transport of fluid from the wearer
towards
the absorbent core and containment of the absorbent core. In addition the
topsheet of the present invention should have a high vapour permeability,
preferably also a high air permeability.
According to the preferred embodiment of the present invention the
topsheet may be formed from any of the materials available for this purpose
and
known in the art, such as wovens, nonwovens, films or combinations thereof. In
a preferred embodiment of the present invention at least one of the layers of
the
topsheet comprises a liquid permeable apertured polymeric film. One layer, but
preferably the wearer facing and contacting layer, is provided by a film
material
having apertures which are provided to facilitate liquid transport from the
wearer
facing surface towards the absorbent structure. Such liquid permeable,
apertured
films are well-known in the art. They provide a resilient three dimensional
fiber-
like structure. Such films have been disclosed in detail for example in
US 3,929,135, US 4,151,240, US 4,319,868, US 4,324,246, US 4,342,314,
US 4,591,523, US 4,609,518, US 4,629,643, US 4,695,422 or WO 96/00548.
An example of such film is available from the Procter 8~ Gamble Company,
Cincinnati, Ohio, USA under the trade name Dryweave. Also such films are
available from the Company Pantex from Pistoia, Italy under the designation
"PF-
films". Also film according to US 5,591,510 or WO 97/03818 and WO 97/03795
described for use as a layer in breathable backsheets can be employed but may
require modification of the apertures to ensure liquid permeability from the
wearer facing surface to the absorbent core which is the primary objective of
the
topsheet and the layers constituting it. Such modification can e.g. be a
surface
energy alteration which actively drives liquids into and through apertures by
creating a gradient of surface tension of the film. A method to provide
surface
energy gradients is disclosed e.g. in WO 96/00548.
A particularly preferred design would then be to use the same film for the
topsheet and the backsheet both possibly supplemented by additional layers.
Such a film is e.g. wrapped around and encircles the absorbent core and is
treated for liquid transport into the absorbent core in the area corresponding
to
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the topsheet but is not treated in the area corresponding to the longitudinal
sides
and to the backsheet (or treated to prevent liquid migration from the
absorbent
core through the backsheet). Treatment in the area corresponding to the
topsheet can e.g. provide a discontinuous coating of hydrophobic silicone on
the
wearer facing surface in line with WO 96100548. In addition or alternatively
the
characteristics of the apertures can be made differently (i.e. for liquid
transport) in
the film area corresponding to the topsheet.
Absorbent core
According to a preferred embodiment of the present invention the absorbent
cores suitable for use herein may be selected from any of the absorbent cores
or
core system known in the art. As used herein the term absorbent core refers to
any material or multiple material layers whose primary function is to absorb,
store
and distribute fluid. In Figure 1 the absorbent structure is shown to comprise
3
layers 40, 42, and 44.
The absorbent core of the present invention should have a high vapour
permeability preferably also a high air permeability. The absorbent core
preferably has a caliper or thickness of less than 12 mm, preferably less than
8 mm, more preferably less than 5 mm, most preferably from 4 mm to 2 mm.
According to the preferred embodiment of the present invention, the
absorbent core can include the following components: (a) an optional primary
fluid distribution layer preferably together with a secondary optional fluid
distribution layer; (b) a fluid storage layer; (c) an optional fibrous
("dusting") layer
underlying the storage layer; and (d) other optional components.
Primary/Secondary Fluid Distribution Layer
One optional component of the absorbent core according to the present
invention, indicated as layer 40 in Figure 1, is a primary fluid distribution
layer
and a secondary fluid distribution layer. The primary distribution layer
typically
underlies the topsheet and is in fluid communication therewith. The topsheet
transfers the acquired fluid to this primary distribution layer for ultimate
distribution to the storage layer. This transfer of fluid through the primary
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distribution layer occurs not only in the thickness, but also along the length
and
width directions of the absorbent product. The also optional but preferred
secondary distribution layer typically underlies the primary distribution
layer and
is in fluid communication therewith. The purpose of this secondary
distribution
layer is to readily acquire fluid from the primary distribution layer and
transfer it
rapidly to the underlying storage layer. This helps the fluid capacity of the
underlying storage layer to be fully utilised. The fluid distribution layers
can be
comprised of any material typical for such distribution layers.
b Fluid Storage Layer
Positioned in fluid communication with, and typically underlying the primary
or secondary distribution layers, is a fluid storage layer 42. The fluid
storage layer
can comprise any usual absorbent material or combinations thereof. It
preferably
comprises absorbent gelling materials usually referred to as "hydrogel",
"superabsorbent", hydrocolloid" materials in combination with suitable
carriers,
which are indicated as particles 43 in Figure 1.
The absorbent gelling materials are capable of absorbing large quantities of
aqueous body fluids, and are further capable of retaining such absorbed fluids
under moderate pressures. The absorbent gelling materials can be dispersed
homogeneously or non-homogeneously in a suitable carrier. The suitable
carriers, provided they are absorbent as such, can also be used alone.
Suitable absorbent gelling materials for use herein will most often comprise
particles of a substantially water-insoluble, slightly cross-linked, partially
neutralised, polymeric gelling material. This material forms a hydrogel upon
contact with water. Such polymer materials can be prepared from polymerizable,
unsaturated, acid-containing monomers which are well known in the art.
Suitable carriers include materials which are conventionally utilised in
absorbent structures such as natural, modified or synthetic fibers,
particularly
modified or non-modified cellulose fibers, in the form of fluff and/or
tissues.
Suitable carriers can be used together with the absorbent gelling material,
however, they can also be used alone or in combinations. Most preferred are
tissue or tissue laminates in the context of sanitary napkins and panty
liners.
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An embodiment of the absorbent structure made according to the present
invention comprises a double layer tissue laminate. These layers can be joined
to
each other for example by adhesive or melting a polymeric powder binder (e.g.
PE powder), by mechanical interlocking, or by hydrogen bridge bends. Absorbent
gelling material or other optional material can be comprised between the
layers.
Modified cellulose fibers such as the stiffened cellulose fibers can also be
used. Synthetic fibers can also be used and include those made of cellulose
acetate, polyvinyl fluoride, polyvinylidene chloride, acrylics (such as
Orlon),
polyvinyl acetate, non-soluble polyvinyl alcohol, polyethylene, polypropylene,
polyamides (such as nylon), polyesters, bicomponent fibers, tricomponent
fibers,
mixtures thereof and the like. Preferably, the fiber surfaces are hydrophilic
or are
treated to be hydrophilic. The storage layer can also include filler
materials, such
as Perlite, diatomaceous earth, Vermiculite, etc., to improve liquid
retention.
If the absorbent gelling material is dispersed non-homogeneously in a
carrier, the storage layer can nevertheless be locally homogenous, i.e. have a
distribution gradient in one or several directions within the dimensions of
the
storage layer. Non-homogeneous distribution can also refer to laminates of
carriers enclosing absorbent gelling materials partially or fully.
An alternative are foam like or actual foam structures as liquid storage.
There are open cell foams which absorb liquid and through chemical or surface
interaction retain the liquid also under pressure. Typical foams in this
context are
e.g. those disclosed in PCT publications WO 93/03699, WO 93/04092,
WO 93/04113.
c Optional Fibrous ("Dusting") Layer
An optional component for inclusion in the absorbent core according to the
present invention is a fibrous layer adjacent to, and typically underlying the
storage layer identified by reference numeral 44 in Figure 1. This underlying
fibrous layer is typically referred to as a "dusting" layer since it provides
a
substrate on which to deposit absorbent gelling material in the storage layer
during manufacture of the absorbent core. Indeed, in those instances where the
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absorbent gelling material is in the form of macro structures such as fibers,
sheets or strips, this fibrous "dusting" layer need not be included. However,
this
"dusting" layer provides some additional fluid-handling capabilities such as
rapid
wicking of fluid along the length of the pad.
5
d Other Optional Components of the absorbent structure
The absorbent core according to the preferred embodiment of the present
invention can include other optional components normally present in absorbent
10 webs. For example, a reinforcing scrim can be positioned within the
respective
layers, or between the respective layers, of the absorbent core. Such
reinforcing
scrims should be of such configuration as to not form interfacial barriers to
fluid
transfer. Given the structural integrity that usually occurs as a result of
thermal
bonding, reinforcing scrims are usually not required for thermally bonded
15 absorbent structures.
Another component which can be included in the absorbent core according
to the invention, and preferably is provided close to or as part of the
primary or
secondary fluid distribution layer or the fluid storage layer, are odor
control
agents such as zeolites, carbon black, silicates, EDTA or other chelates. Such
agents are preferably provided in particulate form or as part of particles and
can
be provided together with the absorbent gelling material mentioned supra.
Backsheet
The absorbent article according to the preferred embodiment of the present
invention also comprises a breathable backsheet. The backsheet primarily has
to
prevent the exudates absorbed and contained in the absorbent structure from
wetting articles that contact the absorbent product such as underpants, pants,
pyjamas, undergarments, and shirts or jackets, thereby acting as a barrier to
fluid
transport. In addition however, a preferred breathable backsheet of the
present
invention permits the transfer of at least water vapour, preferably both water
vapour and air through it and thus allows the circulation of air into and
water
vapour out of the article. The backsheet typically extends across the whole of
the
absorbent structure and can extend into and form part or all of side flaps,
side
wrapping elements or wings, if present.
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16
According to the preferred embodiment of the present invention suitable
preferably breathable backsheets for use herein comprise at least one liquid
impervious polymeric backsheet layer. The backsheet comprises a resilient
three
dimensional web according to the present invention, which consists of a liquid
impervious film which has capillary apertures and is air permeable. Preferred
breathable backsheets for use herein are those having a high vapour exchange,
most preferably both a high vapour and high air exchange. The film with
capillary
apertures is oriented such that it retards or prevents liquid from passing
from the
absorbent core towards the outside while allowing free air flow through it.
According to the preferred embodiment of the present invention any
additional backsheet layer needs to provide at least water vapour permeability
so
as to support breathability of the article. It is not required but desirable
that it also
supports air permeability in order to further improve the comfort benefit from
the
breathability of the article. In this context suitable water vapour and air
permeable
layers include two-dimensional micro- or macro-apertured films, which can also
be micro- or macroscopically expanded films, formed apertured films and
monolithic films, as well as nonwovens, or wovens. Such films are disclosed in
detail e.g. in EP 293482 and the references therein, or US 3,929,135,
US 4,637,819 and US 4,591,523.
The resilient, three dimensional, polymeric web according to the preferred
embodiment of the present invention provides air and water vapour permeability
by being apertured. In a preferred embodiment of the present invention
illustrated
in figure 1 the breathable disposable absorbent article, which can be for
example
a sanitary napkin or a pantiliner, comprises a breathable backsheet 50. The
breathable backsheet 50 comprises a resilient, three dimensional liquid
impervious polymeric backsheet film 55 constituted by the resilient, three
dimensional polymeric web of the present invention and having a first surface
corresponding in this embodiment to a garment facing surface and a second
surface corresponding to a wearer facing surface, both surfaces being planar
and
parallel to each other, and also parallel to the plane P of the backsheet film
55. In
the embodiment of the present invention shown in Figure 1, the plane P
actually
corresponds to the garment facing surface of the backsheet film 55.
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17
The terms "planar'' and "plane" as used herein refer to the configuration of
the backsheet film 55 as such, as if the backsheet film alone were laid on a
flat
surface, even if the backsheet film 55 may also be not planar when comprised
in
an e.g. non planar absorbent article according to an alternative embodiment of
the present invention.
The backsheet film 55 also comprises apertures 53 which form capillaries
54. As better illustrated in figure 2, which shows a cross-sectional view of a
single
capillary 54 of the polymeric backsheet film 55, the capillaries 54 have side
walls
56 which extend away from the wearer facing surface of the polymeric backsheet
film 55 towards the absorbent core 40, 42, 44. The capillaries 54 have a first
opening 57 in the plane of the garment facing surface of the polymeric
backsheet
film 55, and a second opening 58 at the end of the capillaries 54 which is
spaced
apart from the wearer facing surface of the polymeric backsheet film 55. Each
capillary 54 defines a conduit 70 constituted by the first opening 57, the
second
opening 58, and the side walls 56. Each capillary 54 also has a centreline A
defined as the geometrical axis of the conduit 70. In the embodiment of figure
2,
where the conduit 70 has a cylindrical shape, the centreline A simply
corresponds to the straight line constituting the axis of the cylinder and
being
perpendicular to the plane P of the backsheet film 55.
In alternative embodiments of the present invention, where the conduit 70
defined by the capillaries 54 can have different shapes, such as for example
those illustrated in Figures 3 - 7, the centreline A is not necessarily a
straight line,
but can be an at least partially curved line corresponding to the geometrical
axis
of the conduit, identified as known from solid geometry.
In most preferred embodiments of the present invention as those illustrated
in the attached drawings, where the sectional views of Figures 2 to 7 are
taken
from a symmetry plane perpendicular to the plane P of the backsheet film, the
identification of the centreline A of the conduit 70 can be more simply done
on
these same sectional views, since said centreline A entirely lies on this
symmetry
plane. For example, in the region where the conduit 70 merges the plane P of
the
backsheet film 55 in Figures 3 - 7 the identification of the centreline A as
the
geometrical axis of the conduit 70 must take into account the fact that the
conduit
70 typically has not a regular shape in this region, as compared to the
remaining
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18
portion of the capillary 54 where the conduit 70 is entirely defined as a
cylinder or
a truncated cone, and where the centreline A is straightforwardly defined. A
good
approximation to identify the centreline A in this merging region is to
connect the
points at the centre of some sections of the conduit 70 which are parallel to
the
plane P, and are taken at different distances from the plane P (which surfaces
of
course correspond to segments parallel to the plane P in the section views of
the
drawings). This practical method can be used to draw the centrelines in the
conduits 70 illustrated in Figures 3 to 7. This is also consistent with the
identification of the intersection point between the centreline A and the
surface of
the first opening 57 in the plane P of the backsheet film 55, as will be
explained
hereinafter.
The first opening 57 of the capillary 54 in the garment facing surface of the
polymeric backsheet film 55 has a smallest dimension Dm;n and a largest
dimension Dmax respectively defined as the minimum and the maximum open
measurements within the area of the first opening 57 in the plane of the
garment
facing surface of the polymeric backsheet film 55 (plane P), i.e., being
measured
when said garment facing surface of the polymeric backsheet film 55 is laying
on
a flat surface. The smallest and the largest dimensions Drt,~n and DmaX can be
evaluated with means known in the art, such as for example by image analysis
techniques.
An average dimension Da" can also be evaluated for the first opening 57, as
corresponding to the hydraulic diameter of a conduit having the same cross-
section as the first opening 57 in the plane of the garment facing surface of
the
polymeric backsheet film 55, wherein the whole perimeter of said first opening
57
is wetted by the fluid. Of course the concept of "hydraulic diameter" is used
herein by way of definition only, since the conduit 70 of the capillaries 54
is not
intended for transport of liquids, and the term "fluid" is therefore used in
its
broader meaning comprising gaseous fluids, namely air and/or water vapour. As
it is well known from hydraulics, the hydraulic diameter of a conduit having a
cross-sectional area and a wetted perimeter corresponds to four times the
ratio
between said cross-sectional area and said wetted perimeter, that in turn
corresponds in this context to the entire perimeter of the cross-sectional
area of
the first opening 57.
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19
In the embodiment illustrated in figure 2, where the conduit 70 has the
shape of a cylinder having a certain diameter, the first opening 57 in the
garment
facing surface of the polymeric backsheet film 55 has typically a circular
shape
with a diameter slightly larger than the diameter of the cylindrical conduit
70,
owing to the curvature imparted to the film 55 around the first opening by
e.g. the
manufacturing method and apparatus used for the formation of the polymeric
backsheet film 55.
In this case it is this larger diameter that corresponds to the largest
dimension DmaX of the first opening 57. Of course in the case of figure 2,
where
the first opening 57 has a circular shape, the values of Dm~~, Dav, and Dmax
correspond.
Each capillary 54 also has a length L measured along the centreline A
between the first opening 57 and the second opening 58. The length L is
intended to be measured along the centreline A between two points of
intersection P, and P2 defined as follows.
The first point P~ corresponds to the intersection of said centreline A with
the surface S, of the first opening 57. Said surface S, is flat, as can be
seen in
the embodiments illustrated in the drawings, and belongs to the plane of the
garment facing surface of the polymeric backsheet film 55 (plane P). From a
practical point of view, in the embodiments of the present invention such as
those illustrated in Figures 2 to 7, the first point P, corresponds to the
centre of
the first surface S,, as already explained with reference to the
identification of the
centreline A of the conduit 70 of the capillaries 54 having different shapes.
The second point Pz corresponds to the intersection between the centreline
A of the conduit 70 and a flat surface S2 which is perpendicular to said
centreline
and passes through the point or points of the perimeter of the second opening
58
which is/are closer to the respective first opening 57 of the capillary 54,
wherein
said distance is evaluated along the inner surface of the side wall 56 of the
capillary 54.
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Also these measurements can be obtained with methods known in the art,
for example by means of image analysis performed on photomicrographs of the
polymeric backsheet film 55 taken with a scanning electron microscope.
5 In the embodiment of Figure 2, where the capillary 54 has a regular
cylindrical shape, and the second opening 58 also has a regular circular
perimeter, the flat surface S2 perpendicular to the centreline A which
identifies
the intersection point P2 corresponds to a flat circular surface passing
through
the whole perimeter of the second opening 58. It is generally preferred that
said
10 second opening 58 be as smooth as possible so as not to create a liquid
transport entanglement between the extending elements at the end of the
second opening 58 of the capillary 54 with the absorbent core 44 in the
absorbent article (in contrast this may be desirable for use of such a film as
an
apertured film topsheet where such loose elements provide the function of
15 sucker feet to enhance liquid transport). However, in other cases, and
depending
on the method used for the formation of the polymeric backsheet film 55, the
perimeter and shape of the second aperture 58 may not be regular.
For example, the edge of the second opening 58 may be rugged or uneven,
20 comprising loose elements extending from the edge of the opening, as
illustrated
in Figure 4. In this embodiment, the surface S, of course lies in the plane of
the
garment facing surface of the polymeric backsheet film 55, such as the
corresponding surface S, of figure 2, while the surface S2, defined as
explained
above with reference to the identification of the second point P2, is
indicated as a
section in Figure 4 with a dotted line.
In Figures 3 to 7 are shown by way of example the centrelines A and the
corresponding features S,, S2, P,, P2, in capillaries 54 having different and
less
regular shapes, as compared to the regular shape of a straight cylinder
perpendicular to the plane of the polymeric film 55. Usually the centreline A
passes through a first point P~ which corresponds to the centre of the surface
S,,
identified for regular and irregular shapes of the surface S, as it is known
from
plane geometry. In the sectional view of Figure 6 the dimensions Drn~n, Da~,
and
~maX of the first opening 57 coincide, as it is the case with the capillary of
Figure
2, since it is considered that the first opening 57 has a circular shape in
said
figure.
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21
On the contrary, in Figures 3-5 and 7 the surface S, has typically an
elliptical shape, with the longer axis shown in the sectional views. In these
cases
the dimension shown in these figures corresponds to the largest dimension Dmax
as defined herein.
For each capillary 54 of the polymeric backsheet film 55 comprised in the
breathable absorbent article of the present invention a ratio can be defined
between the length L of the capillary 54, and the dimension D of the
respective
first opening 57, wherein D can correspond to Dm;", Da", or DmaX.
It has been discovered that by selecting this ratio it is possible to improve
the performances of the resilient, three dimensional, polymeric web according
to
the present invention, preferably incorporated as the polymeric backsheet film
55
with capillaries 54 in the breathable backsheet of the disposable absorbent
article
described so far, in terms of increased breathability combined with a better
wet
through resistance of the structure of the resilient, three dimensional
polymeric
web under pressure and stress, e.g. typically exerted by the user on a
disposable
absorbent article incorporating the resilient, three dimensional polymeric web
in a
backsheet structure, for example a sanitary napkin or pantiliner, during the
wearing time.
Resiliency and cushioning effect in response to compressive forces exerted
substantially perpendicularly to the polymeric backsheet film surface can also
be
improved according to the present invention. This effect can be also desirable
in
the context of a non breathable structure, e.g. a non breathable backsheet.
The ratio between the length L of the capillaries 54 and the smallest
dimension Dm;n of the first opening 57 must be greater than 2. Preferably, the
ratio between the length L and the average dimension Da" of the first aperture
57
should be greater than 2, more preferably the ratio between the length L and
the
largest dimension Dmax of said first aperture 57 should be greater than 2.
Even
more preferably the ratio between the length L and any of Dm;~, Da", or Dmax
must
be greater than 2.5.
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22
Without wishing to be bound by theory it is believed that the capillaries in
the preferred polymeric backsheet film of the preferably breathable backsheet
in
the disposable absorbent article according to a preferred embodiment of the
present invention allow air and water vapour permeability, and at the same
time
they can easily bend owing to the preferred LID ratio under the pressure
exerted
from the wearer facing side on them by the user during the wearing time. The
bending causes the capillaries to close under pressure such that liquid
transport
through them, and towards the outside of the article in the preferred
embodiment
described so far, becomes nearly impossible. Hence the resilient, three
dimensional, polymeric webs of the present invention are highly preferable in
the
context of breathable absorbent articles. This also gives the resilient, three
dimensional polymeric web of the present invention, corresponding to the
polymeric backsheet film 55 of the preferred embodiment, a better resilience
and
the capability of providing a cushioning effect under the pressures in use.
20
As explained hereinbefore, in case of a capillary having a circular first
opening 57, no distinction between Dm~n, Da", and DmaX is necessary or
possible
since the three relevant dimensions D of the first opening 57 correspond to
one
another.
In case of capillaries 54 with a first aperture 57 having a shape different
from a circle the three relevant dimensions Dm,n, Da", and DmaX actually
differ from
one another. In order to better express the easiness of bending under an
external pressure of a capillary having the preferred LID ratio, one of the
three
relevant dimensions of the first aperture can be more indicated, depending on
the particular shape of said first opening, i.e., whether it is regular or
irregular, or
having a perimeter which is internally totally concave, such as for example
circular, oval, or elliptic, or alternatively partially concave and partially
convex. In
this latter case, the use of Da" or, more preferably, Of Dmax in the ratio UD
are
preferred.
In a particularly preferred embodiment of the present invention illustrated in
figures 3 to 8 the capillaries 54 of the polymeric backsheet film 55 can be
also
slanted, i.e., disposed at an angle relative to the plane of the polymeric
backsheet film which is less than 90 degrees, or, alternatively, curved or
bent
towards the plane of the polymeric backsheet film.
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23
Preferably a polymeric backsheet film 55 can be made in accordance with
the aforementioned US 5,591,510 or PCT WO 97/03818, WO 97/03795. In
Figures 3 through 7 alternative embodiments of such capillaries are shown.
Preferably the capillaries are evenly distributed across the entire surface of
the
layer, and are all identical. However, layers having only certain regions of
the
surface provided with apertures, for example only an area outside the region
aligned with the central loading zone of the absorbent core, may be provided
with
capillaries according to the present invention.
Methods for making such three-dimensional polymeric films with capillary
apertures are identical or similar to those found in the apertured film
topsheet
references, the apertured formed film references and the micro-
/macroscopically
expanded film references cited above. Typically a polymeric film such as a
polyethylene (LDPE, LLDPE, MDPE, HDPE or laminates thereof) is heated close
to its melting point and exposed through a forming screen to a suction force
which pulls those areas exposed to the force into the forming apertures which
are
shaped such that the film is formed into that shape and, when the suction
force is
high enough, the film breaks at its end thereby forming an aperture through
the
film. Other film materials include polyesters, polyethers, polyvinyl alcohols
and
others.
Hydrophilic continuous films that are substantially liquid impervious, but
moisture vapour permeable per se can also be used for the manufacture of the
three dimensional polymeric films with capillary apertures according to the
present invention. Such films do not allow the flow of moisture vapour through
open pores or apertures in the material, but do transfer substantial amounts
of
moisture vapour through the film by absorbing water on one side of the film
where the moisture vapour concentration is higher, and desorbing or
evaporating
it on the opposite side of the film where the moisture vapour concentration is
lov~,~er. These films, referred to as monolithic films, are known in the art,
such as
e.g. Hytrel (TM) film from DuPont, Corporation, USA.
When a monolithic film is used to manufacture a three dimensional
polymeric film with capillary apertures according to the present invention, it
is
capable of maintaining breathability of the polymeric film with capillaries
even in
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24
areas of the film where, under particularly stressed use conditions, the
capillaries
are totally closed due to bending, under e.g. high pressure exerted by the
user.
Various forms, shapes, sizes and configurations of the capillaries are
possible and will be discussed in reference to Figures 3 through 7 in the
following.
Figure 5 shows a cross-sectional view of a single slanted capillary 54 of a
preferred polymeric backsheet film 55 made in accordance with US 5,591,510 or
PCT WO 97/03818, WO 97/03795, and also having the preferred ratio between
the length L and the dimension D of the first opening (57) according to the
present invention, wherein elements corresponding to those already described
in
figure 2 are identified by the same numerals. The centreline A forms along at
least part of its length an angle of less than 90 degrees with the plane P of
the
film which is the same plane as the garment facing surface of the film 55.
This
angle should be preferably in the range between 85 and 20 degrees, more
preferably between 65 degrees and 25 degrees, and most preferably between 55
and 30 degrees.
An angle of less than 90 degrees with the plane P can be formed by the
centreline A along its entire length when, as illustrated in figures 3 and 4,
the
centreline A is substantially rectilinear or, as in figure 5, where the
centreline A is
rectilinear along most of its length. This angle can be said to actually
corresponds to the angle of the slanted capillary.
In alternative embodiments where the centreline A is curved entirety or in
part, such as for example those illustrated in figures 6 and 7, the angle of
the
centreline A, as it is known from geometry, corresponds to the angle of the
tangent to the centreline A at a given point, as measured in the sectional
view
illustrated in the figures themselves. Of course in these cases the angle can
vary
along the length of the centreline A. It is within the scope of the present
invention
that the centreline A forms an angle of less than 90 degrees along at least a
portion of its length, but it is preferred that substantially the whole
centreline A, or
at least most of it, forms a constant angle of less than 90 degrees with the
plane
P, as illustrated in figures 3, 4, and 5, or that alternatively the angle
changes
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continuously along the whole length of the centreline A, as illustrated for
example
in figures 6 (curved capillary).
It is of course possible to allow the capillaries to take the shape of a
funnel
5 such that the second opening 58 is (substantially) smaller than the first
opening
57 when considering the opening size in a plain perpendicular to the
centreline A.
Such an embodiment is shown in Figure 4 and Figure3. In Figure 3 it is also
shown that the wall 56 of the capillary may not end in the second opening 58
such that the opening forms a surface perpendicular to the centreline A but
such
10 that the wall on the portion of the capillary further apart from the wearer
facing
surface of the film 55 extends over the opening to further aid the film in
reducing
the probability of liquid migrating through the capillaries from the absorbent
core
on the wearer facing side of the film 55 to the garment facing side of the
film (and
cause leakage).
In Figure 6 another embodiment of the capillaries useful for the present
invention is shown which is curved along its length towards the wearer facing
surface of the film 55. This has a similar effect as the extension of the wall
56 as
shown in Figure 3.
In Figure 7 another preferred embodiment of a capillary according to the
present invention is shown which has a first portion 257 and a second portion
258. The first portion 257 of the capillary is different in direction than the
second
portion 258 of the capillary 54. This difference can also be in shape, size,
and
form of the portions of the capillary in order to achieve the desired level of
breathability while preventing liquid passage through the film in a direction
from
the wearer facing side towards the garment facing side.
Preferred shape and size of the capillaries 54 having the required L/D ratio
in a resilient, three dimensional polymeric web preferably constituting the
three-
dimensional polymeric film 55 comprised in a preferably breathable backsheet
structure of an absorbent article, according to the preferred embodiment of
the
present invention described so far, can be determined by the skilled man
taking
into account the final use of the polymeric web, for example in order to allow
a
good water vapour permeability, preferably also air permeability, to the
backsheet
structure preferably comprising such a web.
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26
Preferably, the capillaries 54 have a first opening 57 with a dimension D
generically comprised between 0.2 mm and 5 mm, wherein D comprises the
smallest dimension Dm;~, the average dimension Da", and the largest dimension
DmaX, as defined herein. When the first opening 57 has a circular shape,
dimensions D",in, Da~, and DmaX coincide, and correspond to said dimension D.
They are preferably comprised between 0.4 mm and 2 mm, more preferably
between 0.7 mm and 1.5 mm. If, as it is preferred, the first opening 57 has a
substantially elliptical shape, with a Dm;" and a Dmax corresponding to the
two
axes of the ellipse, both Dm;~ and DmaX are also more preferably comprised
between 0.7 mm and 1.5 mm.
In an example according to the present invention, where the resilient, three
dimensional polymeric web is preferably comprised in a backsheet structure as
the three dimensional polymeric backsheet film 55 of figure 1, the capillaries
54
have a funnel shape substantially corresponding to that illustrated in Fig. 4,
with
the centreline A forming an angle of about 35 degrees with the plane P of the
film, wherein Dm;" is 0.9 mm, Dmax is 1.1 mm, and L is 1.9 mm.
In the preferred embodiments of the present invention comprising the
resilient, three dimensional polymeric web as the polymeric film backsheet 55
with slanted capillaries it is believed that said capillaries allow air and
water
vapour permeability which is not hindered by them being slanted at an angle or
by the shape as indicated above. At the same time the slanting and shaping
according to the present invention further help the capillaries having the
preferred
ratio between length L and dimension D of the first opening 57 to close under
pressure exerted from the wearer facing side on them such that liquid
transport
through the capillaries towards the outside of the article becomes nearly
impossible. Hence these three-dimensional formed film layers are highly
preferable in the context of breathable absorbent articles.
A further advantage related to a resilient, three dimensional polymeric web
having slanted capillaries and being comprised in a backsheet of a disposable
absorbent article is the fact that such a three dimensional film does not
allow a
direct passage through its thickness, i.e., along a direction perpendicular to
the
overall film surface: Therefore this prevents portions of a further layer or
of a
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27
material adjacent or applied to one surface of the polymeric three dimensional
film with slanted capillaries from getting direct access to the opposite
surface
through the thickness of the film, i.e., through the slanted capillaries. This
is
particularly useful in the context of a breathable backsheet. The slanted
capillaries in fact prevent that a bridge can be created between the two
surfaces
of the polymeric three dimensional film, e.g. by allowing fibres of an
adjacent
fibrous layer to penetrate into the capillary apertures and get in contact
with a
further layer adjacent to the opposite surface, so creating a preferred
passage for
the fluid. Further, when adhesive is used to join a polymeric three
dimensional
film to an adjacent layer, the slanted geometry of the capillaries does not
allow
that part of the adhesive can penetrate through the capillaries and emerge on
the
opposite surface, possibly contacting another layer and again creating a
bridge
trough the three dimensional film.
~ 5 According to an alternative preferred embodiment of the present invention
a
preferably breathable backsheet 50 which is a dual or multiple layer composite
can also be used in the absorbent article. Suitable breathable backsheets for
use
herein can therefore comprise a first layer such as the polymeric backsheet
film
55 as described above and a second layer with said first layer being an air
permeable layer. Preferred composite breathable backsheets are those having a
high vapour exchange, most preferably both a high vapour and high air
exchange.
As illustrated in Figure 8, the first layer is a polymeric backsheet film 55
similar to that already described with reference to Figure 1, but with
capillaries 54
which are slanted. It has to be noted that the polymeric backsheet film 55 is
represented in Figure 8 only schematically, in order to show the general
arrangement of the layers comprised in a composite breathable backsheet, since
in the drawing it does not actually show the required LID ratio according to
the
present invention. Of course, according to the present invention, the
embodiment
of figure 8 has to be actually intended as also comprising the required LID
ratio
for the capillaries 54 of the polymeric backsheet film 55. The polymeric
backsheet film 55 is positioned between the garment facing surface of the
absorbent core 40, 42, 44 and the wearer facing surface of the second layer
which is indicated as layer 52 in Figure 8. It is oriented such that it
retards or
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28
prevents liquid from passing from the absorbent core 40, 42, 44 towards the
outside while allowing free air flow through it.
The second layer 52 needs to provide at least water vapour permeability so
as to support breathability of the article. It is not required but desirable
that it also
supports air permeability in order to further improve the comfort benefit from
the
breathability of the article. In this context suitable water vapour and air
permeable
layers include two-dimensional micro- or macro-apertured films, which can also
be micro- or macroscopically expended films, formed apertured films and
monolithic films, as well as nonvirovens, or wovens.
Suitable two dimensional planar layers of the backsheet may be made of
any material known in the art, but are preferably manufactured from commonly
available polymeric materials. Suitable materials are for example Goretex (TM)
or
Sympatex (TM) type materials well known in the art for their application in so-
called breathable clothing. Other suitable materials include XMP-1001 of
Minnesota Mining and Manufacturing Company, St. Paul, Minnesota, USA and
Exxaire XBF-101 W, supplied by the Exxon Chemical Company. As used herein
the term two dimensional planar layer refers to layers having a depth of less
than
1 mm, preferably less than 0.5 mm, wherein the apertures do not protrude out
of
the plane of the layer. The apertured materials for use as a backsheet in the
present invention may be produced using any of the methods known in the art
such as described in EP 293482 and the references therein. In addition the
dimensions of the apertures produced by this method may be increased by
applying a force across the plane of the backsheet layer (i.e. stretching the
layer).
Suitable apertured formed films include films which have discrete apertures
which extend beyond the horizontal plane of the garment facing surface of the
layer towards the core thereby forming protuberances. The protuberances have
an orifice located at its terminating end. Preferably said protuberances are
of a
funnel shape, similar to those described in US 3,929,135. The apertures
located
within the plane and the orifices located at the terminating end of
protuberance
themselves maybe circular or non circular provided the cross sectional
dimension
or area of the orifice at the termination of the protuberance is smaller than
the
cross sectional dimension or area of the aperture located within the garment
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29
facing surface of the layer. Preferably said apertured preformed films have a
directional liquid transport and are positioned such that they support the
prevention of liquid loss (leakage) through the backsheet. Suitable
macroscopically expanded films for use herein include films as described for
example in US 4,637,819 and US 4,591,523.
Suitable monolithic films include Hytrel (TM), available from DuPont
Corporation, USA, and other such materials as described in Index 93 Congress,
Session 7A "Adding value to Nonwovens", J-C. Cardinal and Y. Trouilhet,
DuPont de Nemours international S.A, Switzerland. Suitable non-wovens and/or
wovens are any of those well known in the art. Non-wovens such as
spunbonded, melt blown or carded which are thermobonded airlayed, drylayed or
even wetlaid with or without binder can be used. Particularly preferred non-
wovens are multilayer non-wovens such as a composite of fine melt blown fibers
with more coarse spunbonded fibers with the meltblown fibers forming the
wearer
facing surface of the non-woven layer.
Absorbent article construction
A further aspect of the present invention relates to the joining of the
elements, e.g. topsheet, backsheet and absorbent core, to provide the article
comprising the resilient, three dimensional polymeric web of the present
invention, e.g. the disposable absorbent article described so far, when the
resilient, three dimensional polymeric web of the present invention is
actually
comprised in an article, rather than being used as such. According to the
present
invention at least two, preferably all of the elements of the article are
joined.
Each of said elements comprising at least one layer has a wearer facing
surface and a garment facing surface. Typically, adjacent garment facing
surfaces form a common interface with the wearer facing surface of an adjacent
element or layer. The elements or layers are joined together across this
common
interface. In this manner the topsheet is joined to the absorbent core, and
the
core is joined to the backsheet. Furthermore, each of said topsheet, backsheet
and core elements may comprise more than one layer and these layers may also
be similarly joined. In addition the topsheet may be directly or indirectly
joined to
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the backsheet at the periphery of the absorbent article to contain the
absorbent
core.
The elements and layers thereof may be joined by any means known in the
5 art for affixing two adjacent layers of material, such that the layers are
directly
attached to one another or directly attached to one another via the joining
means. Suitable joining means include adhesive, fusion bonding, ultra sonic
bonding, stitching, heat (e.g. thermobonding by welding fibers at
intersections or
melting a polymer to attach fibers or films to each other), embossing,
crimping,
pressure bonds, dynamic mechanical bonds or combinations thereof. According
to an embodiment of the present invention the preferred means of joining is
adhesive. Suitable adhesives include non pressure sensitive and cold
adhesives.
The adhesive may be applied by any means known in the art such as spiral
application, slot coating, spraying, spiral spraying, curtain coating, contact
15 coating and printing, provided that the adhesive does not substantially
affect the
breathability, in the preferred embodiment of the present invention of a
breathable absorbent article, and other functions of the elements of the
article.
One means of achieving this is to use particular adhesive application
20 methods such as open adhesive application techniques, whereby areas of the
common interface are adhesive free, whilst retaining the required level of
attachment/joining of the two adjacent layers or elements. In particular
spiral
spraying is preferred.
25 In a preferred embodiment of the present invention wherein the absorbent
article finds utility as a sanitary napkin or panty liner, the absorbent
article is also
provided with a panty fastening means which provides means to attach the
article
to an undergarment. For example the panty fastening means may comprise a
mechanical fastener such as hook and loop fasteners such as marketed under
30 the tradename VELCRO, snaps or holders. Alternatively, the article is
fastened to
the undergarment by means of panty fastening adhesive on the backsheet. The
panty fastening adhesive provides a means for securing the article to the
panty
and preferably a means for securing the article when soiled, to the fold and
wrap
package for convenient disposal. Typically, at least a portion of the garment
facing surface of the backsheet is coated with adhesive to form the panty
fastening adhesive. Any adhesive or glue used in the art for such purposes can
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31
be used for the panty fastening adhesive herein. Pressure sensitive adhesives
are most preferred. Suitable adhesives include Century A-305-IV manufactured
by the Century Adhesives Corporation of Columbus, Ohio, and Instant LOK 34-
2823 manufactured by the National Starch and Chemical Company of
Bridgewater, New Jersey, 3 Sigma 3153 manufactured by 3 Sigma and Fuller H-
2238ZP manufactured by the H.B. Fuller Co.
In order to reduce the adverse effect on breathabiiity of the backsheet (and
thus of the article as a whole) in preferred breathable absorbent articles,
the
adhesive is preferably applied such that at least 60%, preferably from at
least
80%, most preferably at least 90% of the surface of the backsheet is adhesive
free. The required adhesiveness can still be achieved even when using reduced
surface coverage by using a particular distribution such as thinner strips,
discontinuous strips of adhesive, intermittent dots, random patterns or
spirals.
The panty fastening adhesive is typically covered with a removable release
paper or film in order to prevent the adhesive from drying out or adhering to
another surface other than the panty prior to use. Any commercially available
release paper or film may be used. Suitable examples include BL 30MG-A
SILOX EI/O and BL 30 MG-A SILOX 4 P/O available from Akrosil Corporation.
According to the present invention the resilient, three dimensional polymeric
webs can be used beneficially in the context of sanitary napkins, panty
liners,
incontinence articles, sweat pads and diapers, and also of protective articles
such as gowns, face masks and bandages. However, sanitary napkins are
particularly susceptible to the present invention. The disposable article may
thus
also have all those features and parts which are typical for products in the
context of their intended use.
