Note: Descriptions are shown in the official language in which they were submitted.
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FEMININE HYGIENE PRODUCT INCLUDING COMPOSITE
HAVING IMPROVED IN-PLANE PERMEABILITY
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Patent Application No. 63/158,471,
filed
March 9, 2021 and U.S. Patent Application No. 17/678,588, filed February 23,
2022, the
disclosure of each of which is incorporated herein by reference in its
entirety.
BACKGROUND
Personal care absorbent products, such as baby diapers, adult incontinent pads
and
undergarments, and feminine care products, typically contain a fluid absorbent
core. Many
absorbent articles include the fluid absorbent core disposed between a
topsheet and a backsheet.
The topsheet is typically formed from a fluid-permeable material adapted to
promote fluid
transfer into the absorbent core, such as upon a liquid insult, usually with
minimal fluid
retention by the topsheet. U.S. southern pine fluff pulp is commonly used in
the absorbent
core, generally in the form of a fibrous matrix, and sometimes in conjunction
with a
superabsorbent polymer (SAP) dispersed throughout the fibrous matrix. This
fluff pulp is
recognized worldwide as the preferred fiber for absorbent products, based on
factors such as
the fluff pulp's high fiber length, fiber coarseness, and its relative ease of
processing from a
wet-laid and dried pulp sheet to an air-laid web. The raw material for this
type of cellulosic
fluff pulp is Southern Pine (e.g., Loblolly Pine, Pinus taeda L.). The raw
material is renewable,
and the pulp is easily biodegradable. Compared to SAP, these fibers are
inexpensive on a per
mass basis but tend to be more expensive on per unit of liquid held basis.
These fluff pulp
fibers mostly absorb within the interstices between fibers.
SAPs are water-swellable, generally water-insoluble absorbent materials having
a high
absorbent capacity for fluids. SAP, upon absorption of fluids, swells and
becomes a gel holding
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more than its weight of such fluids. The SAPs in common use are mostly derived
from acrylic
acid. Acrylic acid based polymers also include a meaningful portion of the
cost structure of
diapers, incontinent pads and undergarment. SAPs are designed to have high gel
strength (as
demonstrated by high absorbency under load or AUL). The high gel strength
(upon swelling)
of currently used SAP particles helps them to retain significant void space
between particles,
which is helpful for rapid fluid uptake. However, this high "void volume"
simultaneously
results in significant interstitial (between particles) liquid in the product
in the saturated state.
While fluff pulp fibers and SAP can store very large amounts of liquid, they
are often
not able to distribute the liquid from the point of insult to more remote
areas of the absorbent
article and to acquire the liquid as fast as it may be received by the
article. For this reason,
acquisition members are used, which provide for the interim acquisition of
large amounts of
liquid and which often also allow for the distribution of liquid. Thereby the
acquisition member
plays an important role in using the whole absorbent capacity provided by the
storage member.
Materials suitable to meet the above outlined requirements for a liquid
acquisition layer
must meet these requirements not only in standard or ideal conditions, but in
a variety of
conditions, namely at different temperatures and pressures, occurring in use,
but also during
storage and handling.
Some absorbent articles, such as diapers or adult incontinence pads, include
an
acquisition and distribution layer (ADL) for the collection and uniform and
timely distribution
of fluid from a fluid insult to the absorbent core. An ADL is usually placed
between the
topsheet and the absorbent core, and can, for example, take the form of
composite fabric with
the top-one third of the fabric having higher denier fiber with relatively
large voids and higher
void volume for the effective acquisition of the presented fluid, even at
relatively higher
discharge rates. The middle one-third of the composite fabric of the ADL can
be made of low
denier fibers with smaller voids, while the lower one-third of the fabric can
be made of even
lower and smaller denier fibers and yet with finer voids. The higher density
portions of the
composite have more and finer capillaries and hence develop greater capillary
pressure, thus
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moving greater volumes of fluid to the outer regions of the structure thus
enabling the proper
channelization and distribution of the fluid in an even fashion to allow the
absorbent core to
take up all of the liquid insult in a time bound manner to allow SAP within
the absorbent core
to hold and to gel the insult neither too slow nor too fast. The ADL provides
for more rapid
liquid acquisition (minimizing flooding in the target zone) and ensures more
rapid transport
and thorough distribution of the fluid into the absorbent core.
There is a need for a fluid distribution layer or a core-wrap material having
improved
liquid handling characteristics as compared to the above-disclosed articles.
There is a need for
an absorbent article, which is more comfortable to wear, and which in
particular provides
superior dryness. The present disclosure seeks to fulfill these needs and
provides further related
advantages.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified
form that
are further described below in the Detailed Description. This summary is not
intended to
identify key features of the claimed subject matter, nor is it intended to be
used as an aid in
determining the scope of the claimed subject matter.
In one aspect, the present disclosure features a composite fabric, including:
a nonwoven
layer including polymeric fibers and/or filaments; a crosslinked cellulose
layer including
crosslinked cellulose fibers; wherein the crosslinked cellulose layer is
positioned opposed to
the nonwoven layer (e.g., without an intervening layer different from the
crosslinked cellulose
layer and the nonwoven layer; in some embodiments, the crosslinked cellulose
layer is
immediately adjacent to the nonwoven layer); and an interfacial region between
the nonwoven
layer and the crosslinked cellulose layer, including physically entangled
polymeric fibers
and/or filaments from the nonwoven layer and crosslinked cellulose fibers from
the crosslinked
cellulose layer, wherein the nonwoven layer and the crosslinked cellulose
layer are
mechanically inseparable in a dry state, and wherein the composite fabric has
a density of from
0.06 g/cm3 to 0.15 g/cm3 (e.g., 0.06 g/cm3, 0.12 g/cm3, 0.08 g/cm3, or 0.06-
0.08 g/cm3).
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In another aspect, the present disclosure features an absorbent article,
including the
composite fabric described herein.
In yet another aspect, the present disclosure features an absorbent article,
including: a
liquid-impermeable backsheet defining an inner surface and an outer surface;
an absorbent
core, disposed on the inner surface of the backsheet, and a topsheet overlying
the upper surface
of the absorbent core and contacting the inner surface of the backsheet. The
absorbent core
includes: an absorbent material defining an upper surface and a lower surface
of the absorbent
core; and a composite fabric surrounding at least a portion of the upper
surface and the lower
surface, including: a nonwoven layer including polymeric fibers and/or
filaments; a crosslinked
cellulose layer including crosslinked cellulose fibers, wherein the
crosslinked cellulose layer is
positioned opposed to the nonwoven layer; and an interfacial region between
the nonwoven
layer and the crosslinked cellulose layer, including physically entangled
polymeric fibers
and/or filaments from the nonwoven layer and crosslinked cellulose fibers from
the crosslinked
cellulose layer, wherein the nonwoven layer and the crosslinked cellulose
layer are
mechanically inseparable in a dry state.
In yet a further aspect, the present disclosure features a feminine hygiene
product,
including: a composite fabric including a nonwoven layer including polymeric
fibers and/or
filaments; a crosslinked cellulose layer including crosslinked cellulose
fibers, wherein the
crosslinked cellulose layer is positioned opposed to the nonwoven layer; and
an interfacial
region between the nonwoven layer and the crosslinked cellulose layer,
including physically
entangled polymeric fibers and/or filaments from the nonwoven layer and
crosslinked cellulose
fibers from the crosslinked cellulose layer, wherein the nonwoven layer and
the crosslinked
cellulose layer are mechanically inseparable in a dry state.
In yet a further aspect, the present disclosure features a method of making a
composite
fabric of the present disclosure, including supplying polymeric fibers and/or
filaments;
supplying crosslinked cellulose fibers; air-laying or wet-laying the
crosslinked cellulose fibers
to provide a crosslinked cellulose layer on a nonwoven layer of polymeric
fibers and/or
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filaments, wherein the crosslinked cellulose layer is positioned opposed to
the nonwoven layer;
and physically entangling the polymeric fibers and/or filaments from the
nonwoven layer and
the crosslinked cellulose fibers from the crosslinked cellulose layer to
provide the composite
fabric, wherein the composite fabric includes an interfacial region between
the nonwoven layer
and the crosslinked cellulose layer, wherein the nonwoven layer and the
crosslinked cellulose
layer are mechanically inseparable in a dry state.
DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this disclosure
will
become more readily appreciated as the same become better understood by
reference to the
following detailed description, when taken in conjunction with the
accompanying drawings,
wherein:
FIG. 1 is a schematic representation of a hydro-entangling process of the
present
disclosure.
FIG. 2A is a schematic representation of an embodiment of a fluid acquisition
and
distribution layer (ADL) of the present disclosure.
FIG. 2B is schematic cross-sectional representation of an embodiment of a core-
wrap
of the present disclosure.
FIG. 3 is a schematic cross-sectional representation of an embodiment of a
core-wrap
of the present disclosure.
FIG. 4 is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 5A is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 5B is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 5C is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
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FIG. 5D is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 5E is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 6A is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 6B is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 6C is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 6D is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 7A is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 7B is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 8A is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 8B is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 8C is a schematic cross-sectional representation of an embodiment of an
absorbent
article of the present disclosure.
FIG. 9 is a bar graph showing a comparison of wicking distance from insult
point of an
embodiment of an ADL diaper construct of the present disclosure vs. a
commercial diaper in a
no load saddle Ivicking test.
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FIG. 10 is a bar graph showing a comparison of intake times of an embodiment
of an
ADL diaper construct of the present disclosure vs. a commercial diaper in a
flat acquisition
under load test.
FIG. 11 is a bar graph showing a comparison of rewet values of an embodiment
of an
ADL diaper construct of the present disclosure vs. a commercial diaper in a
flat acquisition
under load test.
FIG. 12 is a bar graph showing a comparison of wicking distances of an
embodiment
of an ADL diaper constructs of the present disclosure vs. a commercial diaper
in a flat
acquisition under load test.
FIG. 13 is a bar graph showing a comparison of intake times of embodiments of
a core-
wrap diaper construct of the present disclosure vs. a commercial diaper in a
no load saddle
wicking test.
FIG. 14 is a bar graph showing a comparison of wicking distances from insult
point of
an embodiment of a core-wrap diaper construct of the present disclosure vs. a
commercial
diaper in a no load saddle wicking test.
FIG. 15 is a bar graph showing a comparison of intake times of an embodiment
of a
core-wrap diaper construct of the present disclosure vs. a commercial diaper
in a flat acquisition
under load test.
FIG. 16 is a bar graph showing a comparison of rewet values of an embodiment
of a
core-wrap diaper construct of the present disclosure vs. a commercial diaper
in a flat acquisition
under load test.
FIG. 17 is a bar graph showing a comparison of wicking distances of an
embodiment
of a core-wrap diaper construct of the present disclosure vs. a commercial
diaper in a flat
acquisition under load test.
FIG. 18 is a bar graph showing intake times of an embodiment of a core-wrap
diaper
construct of the present disclosure vs. an average of commercial fluffless
diapers in a no load
saddle wicking test.
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FIG. 19 is a bar graph showing a comparison of wicking distance from insult
point of
an embodiment of a core-wrap diaper construct of the present disclosure vs. an
average of
commercial fluffless diapers in a no load saddle wicking test.
FIG. 20 is a bar graph showing intake times of an embodiment of a core-wrap
diaper
construct of the present disclosure vs. an average of commercial fluffless
diapers in a flat
acquisition under load test.
FIG. 21 is a bar graph showing a comparison of rewet values of an embodiment
of a
core-wrap diaper construct of the present disclosure vs. an average of
commercial fluffless
diapers in a flat acquisition under load test.
FIG. 22 is a bar graph showing a comparison of wicking distances of an
embodiment
of a core-wrap diaper construct of the present disclosure vs. an average of
commercial fluffless
diapers in a flat acquisition under load test.
FIG. 23 is a bar graph showing a comparison of wicking distances from insult
point of
an embodiment of an ADL diaper construct of the present disclosure vs. an
average of
commercial fluff core diapers in a no load saddle wicking test.
FIG. 24 is a bar graph showing a comparison of wicking distances from insult
point of
an embodiment of an ADL diaper construct of the present disclosure vs. an
average of
commercial fluff core diapers in a flat acquisition under load test.
FIG. 25 is a photograph of an embodiment of a feminine hygiene absorbent core
of the
present disclosure following a rewet and distribution test.
FIG. 26A is a schematic diagram illustrating an example feminine hygiene
product
2600A including an absorbent composite 2610A, in accordance with embodiments
of the
present disclosure.
FIG. 26B is a schematic diagram illustrating a multilayer configuration where
an
absorbent composite includes one or more stacked layers of the physically
entangled composite
fabric described in reference to FIG. 1, in accordance with embodiments of the
present
disclosure.
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FIG. 27A illustrates a comparative example feminine hygiene product 2700 as
available
in the North American market.
FIG. 27B illustrates a comparative example feminine hygiene product 2750 as
available
in the East Asian market.
FIG. 28A is a schematic diagram of a cross section of example feminine hygiene
product of FIG. 26A illustrating material layers of absorbent composite
material, in accordance
with embodiments of the present disclosure.
FIG. 28B is a schematic diagram illustrating a cross section of example
feminine
hygiene product of FIG. 26B, including absorbent composite material formed of
multiple
stacked layers of composite formed of crosslinked cellulose layer physically
entangled with
nonwoven layer, with interfacial region formed therebetween, in accordance
with embodiments
of the present disclosure.
Fig. 29 is a graph of intake time data demonstrating improvement of a shared
property
between a negative control product without cellulosic materials, comparative
example 1,
comparative example 2, and example 1 and example 2 in accordance with
embodiments of the
present disclosure.
FIG. 30 is a graph of performance assay data of intake time for comparative
example 1
and example 1, highlighting improved intake time performance of example
feminine hygiene
products relative to comparative products from the North American market, in
accordance with
embodiments of the present disclosure.
FIG. 31 is a graph of data from rewet mass assays for the same set of five
products. As
previously described, rewet mass measures a quantity of liquid that is exuded
from an absorbent
article following application of a set pressure, in accordance with
embodiments of the present
disclosure.
FIG. 32 is a graph of data from wicking distance assays for the same set of
five products.
As previously described, wicking distance measures the performance of feminine
hygiene
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products to accept and distribute a liquid insult during a prescribed period
of time, in
accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
DEFINITIONS
Unless otherwise defined, all technical and scientific terms used herein have
the same
meaning as commonly understood by one of ordinary skill in the art. Although
methods and
materials similar or equivalent to those described herein can be used in the
practice or testing
of the present disclosure, suitable methods and materials are described below.
All publications,
patent applications, patents, and other references mentioned herein are
incorporated by
reference in their entirety. In case of conflict, the present specification,
including definitions,
will control. In addition, the materials, methods, and examples are
illustrative only and not
intended to be limiting.
It is appreciated that certain features of the disclosure, which are, for
clarity, described
in the context of separate embodiments, can also be provided in combination in
a single
embodiment.
Conversely, various features of the disclosure which are, for brevity,
described in the
context of a single embodiment, can also be provided separately or in any
suitable
subcombination.
Moreover, the inclusion of specific elements in at least some of these
embodiments may
be optional, wherein further embodiments may include one or more embodiments
that
specifically exclude one or more of these specific elements. Furthermore,
while advantages
associated with certain embodiments of the disclosure have been described in
the context of
these embodiments, other embodiments may also exhibit such advantages, and not
all
embodiments need necessarily exhibit such advantages to fall within the scope
of the
disclosure.
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As used herein and unless otherwise indicated, the terms "a" and "an" are
taken to mean
"one-, "at least one- or "one or more-. Unless otherwise required by context,
singular terms
used herein shall include pluralities and plural terms shall include the
singular.
Unless the context clearly requires otherwise, throughout the description and
the claims,
the words 'comprise', 'comprising', and the like are to be construed in an
inclusive sense as
opposed to an exclusive or exhaustive sense; that is to say, in the sense of
"including, but not
limited to." Words using the singular or plural number also include the plural
and singular
number, respectively. Additionally, the words "herein," "above," and "below"
and words of
similar import, when used in this application, shall refer to this application
as a whole and not
to any particular portions of the application.
As used herein, "absorbent article" refers to products that absorb and contain
liquid,
and more specifically, refers to products that are placed against or in
proximity to the body of
the wearer to absorb and contain the various exudates discharged from the
body. Absorbent
articles include but are not limited to diapers, adult incontinent briefs,
training pants, diaper
holders and liners, sanitary napkins and the like. These articles can include
a topsheet, a
backsheet, an absorbent core, and optionally a receiving layer and / or a
distribution layer, and
other components, wherein the absorbent core is normally disposed between the
backsheet and
the receiving system or the topsheet. Absorbent articles also include wipes,
such as household
cleaning wipes, baby wipes, and the like.
As used herein, the term "absorbent core" refers to a single component that is
disposed
or disposed in an absorbent article and that includes an absorbent material
encased in a core-
wrap. The core-wrap can be a sheet that envelops the absorbent material and
can, for example,
include the composite fabric of the present disclosure. The term "absorbent
core" does not
extend to a receiving or distribution layer or any other component of an
absorbent article that
is not an integral part of the core-wrap or that is not disposed within the
core-wrap. The
absorbent core can have the highest absorbency in the absorbent article and
can include
superabsorbent polymers (SAP) and/or fluff pulp.
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As used herein, the term "disposable" refers to articles that are generally
not intended
to be laundered or otherwise restored or reused, i.e., they are intended to be
discarded after a
single use and, possibly, to be recycled, composted or otherwise disposed of
in an
environmentally compatible manner.
As used herein, the term "disposed" refers to an element(s) that is formed
(joined and
positioned) in a particular place or position as a unitary structure with
other elements or as a
separate element joined to another element.
As used herein, the term "diaper" refers to an absorbent article generally
worn by
infants and incontinent persons about the lower torso.
The terms "thickness" and "caliper" are used herein interchangeably.
As used herein, the terms "nonwoven," "nonwoven fabric," and "nonwoven web"
are
interchangeable and refer to a sheet, web or mat product made of directionally
or randomly
disposed fibers and/or filaments bonded together by friction and / or by
cohesion and / or
adhesion. The fibers can be of natural (e.g., cotton) or regenerated (e.g.,
regenerated cellulose)
or synthetic origin and can be staple or continuous fibers or formed in situ.
The fibers can have
diameters ranging from less than about 0.001 mm to more than 0.2 mm, and can
be available
in several different forms, for example, as short fibers (so-called staple or
cut fibers),
continuous single fibers (filaments or monofilaments), untwisted bundles of
continuous
filaments (cables) and twisted bundles of continuous fibers (yarn). Nonwoven
webs can be
formed by various processes, such as meltblowing, spunbonding, solvent
spinning,
electrospinning, carding and aerodynamic laying or air-laying, or any
combination thereof
The basis weight of nonwoven webs is usually expressed in grams per square
meter (g/m2, G,
or gsm), respectively. Synthetic fibers and/or filaments include but are not
limited to
poly olefins such as polypropylene, polyethylene, and polyester (e.g.,
polyethylene
terephthalate), and any combination thereof (e.g., a bicomponent fiber).
As used herein, HelixTM is a crosslinked cellulose fiber based on untreated
fluff pulp
(such as SuperSoft from International Paper Company). Methods of
manufacturing HelixTM
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are described, for example, in U.S. Patent No. 5,399,240, 5,437,418, and
6,436,231, each of
which is herein incorporated by reference in its entirety.
As used herein, HelixTM Airc4 is a crosslinked fiber based on a treated or
debonded
fluff grade (such as SuperSoft Air and/or SuperS off Air +). Methods of
manufacturing
Helix" are described, for example, in U.S. Patent No. 5,399,240, 5,437,418,
and 6,436,231,
each of which is herein incorporated by reference in its entirety. Debonded
pulp is described,
for example, in U.S. Patent No. 6,306,251, herein incorporated in its
entirety.
In case of conflict, the present specification, including definitions, will
control. In
addition, the materials, methods, and examples are illustrative only and not
intended to be
limiting.
It will be readily understood that the aspects of the present disclosure, as
generally
described herein, and illustrated in the figures, can be arranged,
substituted, combined,
separated, and designed in a wide variety of different configurations, all of
which are explicitly
contemplated herein.
Furthermore, the particular arrangements shown in the FIGURES should not be
viewed
as limiting. It should be understood that other embodiments may include more
or less of each
element shown in a given FIGURE. Further, some of the illustrated elements may
be combined
or omitted. Yet further, an example embodiment may include elements that are
not illustrated
in the FIGURES.
As used herein, with respect to measurements, "about" means +/- 5%. As used
herein,
a recited range includes the end points, such that from 0.5 mole percent to
99.5 mole percent
includes both 0.5 mole percent and 99.5 mole percent.
The principles and conceptual aspects of various embodiments of the
disclosure. In
this regard, no attempt is made to show structural details of the disclosure
in more detail than
is necessary for the fundamental understanding of the disclosure, the
description taken with the
drawings and/or examples making apparent to those skilled in the art how the
several forms of
the disclosure may be embodied in practice.
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COMPOSITE FABRIC
Absorbent products are increasingly thin and flexible. Consequently, a loss of
void
volume in the absorbent core has occun-ed, which in turn requires more
powerful absorbent
systems for fluid management to deliver acceptable leakage protection for the
consumer.
The present disclosure describes a composite fabric that includes crosslinked
cellulose
fiber and a nonwoven that can be used in an absorbent article, such as in an
acquisition and
distribution layer ("ADL") and/or in a core-wrap of the absorbent article.
Crosslinked cellulose
fiber has unique properties such as excellent wet bulk and resiliency that are
advantageous in
absorbent articles. However, commercially available crosslinked cellulose
fiber is in a
compressed bale format that limits its application in most manufacturing
facilities due to the
lack of bale openers in many commercial operations. A rolled format of
crosslinked cellulose
fiber can increase convenience and simplify manufacturing processes. As will
be described in
more detail below, a web composed of crosslinked cellulose fibers can be
formed by an air-
laid or wet-laid process, and subsequently entangled into a nonwoven fabric,
such as bonded
carded web (BCW) to form a composite fabric. The cellulosic fiber penetration
into the
nonwoven fabric can be controlled (e.g., by controlling water jet pressure in
a hydroentangling
process), and the composite fabric can have a dual layer structure with little
crosslinked
cellulose fiber penetration in the nonwoven to a completely interpenetrated
network of
crosslinked cellulose fiber in the nonwoven.
Thus, the present disclosure features a composite fabric, including a nonwoven
layer
including polymeric fibers and/or filaments; a crosslinked cellulose layer
including crosslinked
cellulose fibers; wherein the crosslinked cellulose layer is positioned
opposed to the nonwoven
layer; and an interfacial region between the nonwoven layer and the
crosslinked cellulose layer,
the interfacial region including physically entangled polymeric fibers and/or
filaments from the
nonwoven layer and crosslinked cellulose fibers from the crosslinked cellulose
layer. The
nonwoven layer and the crosslinked cellulose layer of the composite fabric are
mechanically
inseparable in a dry state. The composite fabric has a density of from 0.06
g/cm3 to 0.15 g/cm3
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(e.g., 0.06 g/cm3, 0.12 g/cm3, 0.08 g/cm3, or 0.06-0.08 g/cm3). The density is
measured
according to the method "Thickness, Bulk, and Density Measurement" described
below.
Average density is the average of at least 5 density values measured in a
sample. The
crosslinked cellulose layer is position opposed to the nonwoven layer without
an intervening
layer different from the crosslinked cellulose layer and the nonwoven layer.
In some
embodiments, the crosslinked cellulose layer is immediately adjacent to and
entangled in the
nonwoven layer. In some embodiments, the composite fabric consists essentially
of the
nonwoven layer and the crosslinked cellulose laver, and an interfacial region
between the
nonwoven layer and the crosslinked cellulose layer. In some embodiments, the
composite
fabric consists of the nonwoven layer and the crosslinked cellulose layer, and
an interfacial
region between the nonwoven layer and the crosslinked cellulose layer.
In some embodiments, the polymeric fibers and/or filaments of the nonwoven
layer
include synthetic polymer fibers and/or filaments, such as poly olefm and/or
polyester fibers
and/or filaments. The nonwoven layer can include webs, which can be produced
by a melt
spun process. In some embodiments, the nonwoven layer is a bonded carded web.
In some
embodiments, the nonwoven layer includes a bonded carded web fabric, a carded
web, a
spunbond fabric, a melt blown fabric, an unbonded synthetic fiber, or any
combination thereof
In some embodiments, the nonwoven layer and the crosslinked cellulose layer
overlap
(i.e., overlay one another) and interpenetrate at the interfacial region. In
some embodiments,
the crosslinked cellulose layer and the nonwoven layer fully interpenetrate.
The composite fabric can have an "x" dimension and a "y" dimension
corresponding to
the width and length of the composite fabric. The composite fabric can further
have a
dimension, corresponding to the thickness of the composite fabric. In some
embodiments, the
nonwoven layer has a first thickness, the crosslinked cellulose layer has a
second thickness,
and the interfacial region has a thickness that is less than or equal to the
thickness of the first
or the second thickness. In some embodiments, the interfacial region can have
a thickness that
spans the entire thickness of the nonwoven layer, when the crosslinked
cellulose layer is fully
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entangled in the nonwoven layer. In some embodiments, the interfacial region
can have a
thickness that is less than the thickness of the nonwoven layer and/or the
crosslinked cellulose
layer when the crosslinked cellulose layer is partially entangled in the
nonwoven layer.
In some embodiments, the composite fabric has regions where the crosslinked
cellulose
layer has greater entanglement into the nonwoven layer than other regions,
such that the
interfacial region can vary in thickness. Without wishing to be bound by
theory, it is believed
that when the composite fabric has interfacial regions of greater
entanglement, pathways or
channels can form in the composite fabric to guide the flow of liquids through
the composite
fabric.
In some embodiments, the nonwoven layer can include a bonded carded web fabric
(e.g., a resin bonded carded web fabric), a carded web, a spunbond fabric, a
melt directionally
or blown fabric, an unbonded synthetic fiber, staple fibers (e.g., synthetic
fibers laid down as a
mat and not bonded by any mechanism), or any combination thereof. A nonwoven
fabric can
include a manufactured sheet, web or batt of randomly orientated fibers and/or
filaments,
bonded by friction, and/or cohesion and/or adhesion, excluding paper and
products which are
woven, knitted, tufted, stitch-bonded incorporating binding yams or filaments,
or felted by wet-
milling, whether or not additionally needled. The fibers and/or filaments in
the nonwoven
fabric layer can be synthetic or of natural origin, such as poly olefins
(e.g., polypropylene,
polyethylene), polyesters, or any combination thereof (e.g., a bicomponent
fiber).
Commercially available fibers can have diameters ranging from less than about
0.001
mm to more than about 0.2 mm and take the form of short fibers (staple or
chopped), continuous
single fibers (filaments or monofilaments), untwisted bundles of continuous
filaments (tow),
and twisted bundles of continuous filaments (yam). Fibers are classified
according to their
origin, chemical structure, or both.
Nonwoven webs can be formed by direct extrusion processes during which the
fibers
and webs are formed at about the same point in time, or by preformed fibers,
which can be laid
into webs at a distinctly subsequent point in time. Example direct extrusion
processes include
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but are not limited to: spunbonding, meltblowing, solvent spinning,
electrospinning, and
combinations thereof typically forming layers.
All of the above-described fibers and manufacturing techniques can be useful
for
providing the composite fabric according to the present disclosure.
The crosslinked cellulose fibers can include polyacrylic acid crosslinked
cellulose
fibers. Crosslinked cellulose fibers are described, for example, in U.S.
Patent No. 7,513,973,
8,722,797, 6,716,306, 6,736,933, 6,748,671, 7,018,508, 6,782,637, 6,865,822;
7,290,353,
6,769,199, 7,147,446, 7,399,377, 6,306,251, 5,183,707, and 5,998,511, each of
which is
incorporated herein in its entirety. Example crosslinking mechanisms include
esterification
reactions, etherification, ionic reactions, and radical reactions. As example,
the crosslinked
cellulose fibers include bleached polyacrylic acid crosslinked cellulosic
fibers, where
polyacrylic acid crosslinked cellulosic fibers are treated with one or more
bleaching agents to
provide crosslinked cellulosic fibers having high bulk and improved whiteness.
In another
example, the crosslinked cellulose fibers can include polyacrylic acid
crosslinking agent that
includes a polyacrylic acid, having phosphorous incorporated into the polymer
chain (as a
phosphinate) by introduction of sodium hypophosphite during the polymerization
process.
For example, individualized, chemically crosslinked cellulosic fibers can be
intrafiber
crosslinked with a polymeric polycarboxylic acid crosslinking agent. As used
herein, the term
"polymeric polycarboxylic acid" refers to a polymer having multiple carboxylic
acid groups
available for forming ester bonds with cellulose (i.e. crosslinks). Suitable
crosslinking agents
useful in forming the crosslinked fibers of the present disclosure include
polyacrylic acid
polymers, polymaleic acid polymers, copolymers of acrylic acid, copolymers of
maleic acid,
and mixtures thereof Other suitable polymeric polycarboxylic acids include
commercially
available polycarboxylic acids such as polyaspartic, polyglutamic, poly(3-
hydroxy)butyric
acids, and polyitaconic acids. Polyacrylic acid polymers include polymers
formed by
polymerizing acrylic acid, acrylic acid esters, and mixtures thereof.
Polymaleic acid polymers
include polymers formed by polymerizing mal ei c acid, mal ei c acid esters,
mal ei c anhydride,
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and mixtures thereof
Examples of suitable polyacrylic acid copolymers include
poly(acrylamide-co-acrylic acid), poly(acrylic acid-co-maleic acid),
poly(ethylene-co-acrylic
acid), and poly(1-vinylpyrolidone-co-acrylic acid), as well as other
polyacrylic acid derivatives
such as poly(ethylene-co-methacrylic acid) and poly(methyl methacrylate-co-
methacrylic
acid). Suitable polymaleic acid copolymers include poly(methyl vinyl ether-co-
maleic acid),
poly(styrene-co-maleic acid), and poly(vinyl chloride-co-vinyl acetate-co-
maleic acid).
Suitable comonomers for forming polyacrylic and polymaleic acid copolymers
include any
comonomer that, when copolymerized with acrylic acid or maleic acid (or their
esters),
provides a polycarboxylic acid copolymer crosslinking agent that produces
crosslinked
cellulose fibers having the advantageous properties of bulk, absorbent
capacity, liquid
acquisition rate, and stable intrafiber crosslinks. Representative comonomers
include, for
example, ethyl acrylate, vinyl acetate, acrylamide, ethylene, vinyl
pyrrolidone, methacrylic
acid, methylvinyl ether, styrene, vinyl chloride, itaconic acid, and tartrate
monosuccinic acid.
Preferred comonomers include vinyl acetate, methacrylic acid, methylvinyl
ether, and itaconic
acid. Polyacrylic and polymaleic acid copolymers prepared from representative
comonomers
noted above are available in various molecular weights and ranges of molecular
weights from
commercial sources. In a preferred embodiment, the polycarboxylic acid
copolymer is a
copolymer of acrylic and maleic acids.
The polycarboxylic acid polymers useful in forming the crosslinked cellulose
fibers
include self-catalyzing polycarboxylic acid polymers.
For example, self-catalyzing
polycarboxylic acid crosslinking agent can include copolymers of acrylic acid
or maleic acid
and low molecular weight monoalkyl substituted phosphinates and phosphonates.
These
copolymers can be prepared with hypophosphorous acid and its salts, for
example, sodium
hypophosphite, and/or phosphorus acids as chain transfer agents. The
polycarboxylic acid
polymers and copolymers can be used alone, in combination, or in combination
with other
crosslinking agents known in the art.
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In some embodiments, the polymeric polycarboxylic acid crosslinking agents can
be
used with a crosslinking catalyst to accelerate the bonding reaction between
the crosslinking
agent and the cellulose fiber to provide the crosslinked cellulose fibers.
Suitable crosslinking
catalysts include any catalyst that increases the rate of ester bond formation
between the
polycarboxylic acid crosslinking agent and cellulose fibers. For example,
crosslinking
catalysts include alkali metal salts of phosphorous containing acids such as
alkali metal
hypophosphites, alkali metal phosphites, alkali metal polyphosphonates, alkali
metal
phosphates, and alkali metal sulfonates.
In some embodiments, suitable crosslinking agents for making crosslinked
cellulose
fibers are bifunctional which are capable of bonding with the hydroxyl groups,
and create
covalently bonded bridges between hydroxyl groups on the cellulose molecules
within the
fiber. The crosslinking agents include polycarboxylic acids or selected from
urea derivatives
such as methylolated urea, methylolated cyclic ureas, methylolated lower alkyl
substituted
cyclic ureas, methylolated dihydroxy cyclic ureas. Preferred urea derivative
crosslinking
agents would be dimethyloldihydroxy ethylene urea (DMDHEU),
dimethyldihydroxyethylene
urea. Mixtures of the urea derivatives may also be used. Preferred
polycarboxylic acid
crosslinking agents are citric acid, tartaric acid, malic acid, succinic acid,
glutaric acid, or
citraconic acid. These polycarboxylic crosslinking agents are particularly
useful when the
proposed use of the paperboard is food packaging. Other polycarboxylic
crosslinking agents
that may be used are poly(acrylic acid), poly(methacrylic acid), poly(maleic
acid),
poly(methylvinylether-co-maleate) copolymer,
poly(methylvinylether-co-itaconate)
copolymer, maleic acid, itaconic acid, and tartrate monosuccinic acid.
Mixtures of the
polycarboxylic acids may also be used. The crosslinking agent can include a
catalyst to
accelerate the bonding reaction between the crosslinking agent and the
cellulose molecule, but
most crosslinking agents do not require a catalyst. Suitable catalysts include
acidic salts that
can be useful when urea-based crosslinking substances are used. Such salts
include ammonium
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chloride, ammonium sulfate, aluminum chloride, magnesium chloride, or mixtures
of these or
other similar compounds. Alkali metal salts of phosphorus containing acids may
also be used.
Other crosslinking agents are described in Chung U.S. Pat. No. 3,440,135; Lash
et al.
U.S. Pat. No. 4,935,022; Herron et al. U.S. Pat. No, 4,889,595; Shaw et al.
U.S. Pat. No.
3,819,470; Steijer et al. U.S. Pat. No. 3,658,613; Dean et al. U.S. Pat. No.
4,822,453; and Graef
et al. U.S. Pat. No. 4,853,086, all of which are in their entirety
incorporated herein by reference.
In some embodiments, polyacrylic acid crosslinked cellulosic fibers can be
prepared by
applying polyacrylic acid to the cellulosic fibers in an amount sufficient to
effect intrafiber
crosslinking. The amount applied to the cellulosic fibers can be from about 1
to about 10
percent by weight based on the total weight of fibers. In one embodiment,
crosslinking agent
in an amount from about 4 to about 6 percent by weight based on the total
weight of dry fibers.
In some embodiments, polyacrylic acid crosslinked cellulosic fibers can be
prepared using a
crosslinking catalyst. Suitable catalysts can include acidic salts, such as
ammonium chloride,
ammonium sulfate, aluminum chloride, magnesium chloride, magnesium nitrate,
and more
preferably alkali metal salts of phosphorous-containing acids, like
phosphoric, polyphosphoric,
phosphorous and hypophosphorous acids. In one embodiment, the crosslinking
catalyst is
sodium hypophosphite. The amount of catalyst used can vary from about 0.1 to
about 5 percent
by weight based on the total weight of dry fibers.
In certain embodiments, the crosslinked cellulosic fibers can include
crosslinked rayon
or lyocell derivatives.
The cellulosic fibers useful for crosslinked cellulosic fibers can be derived
primarily
from wood pulp. Suitable wood pulp fibers can be obtained from well-known
chemical
processes such as the kraft and sulfite processes, with or without subsequent
bleaching. The
pulp fibers may also be processed by thermomechanical, themithermomechanical
methods, or
combinations thereof The preferred pulp fiber is produced by chemical methods.
Ground
wood fibers, recycled or secondary wood pulp fibers, and bleached and
unbleached wood pulp
fibers can be used. A preferred starting material is prepared from long-fiber
coniferous wood
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species, such as southern pine, Douglas fir, spruce, and hemlock. Details of
the production of
wood pulp fibers are well-known to those skilled in the art. Suitable fibers
are commercially
available from a number of companies, including International Paper Company.
For example,
suitable cellulose fibers produced from southern pine that are usable in
making the present
disclosure are available from International Paper Company under the
designations SuperSoft',
SuperSoft Air , and SuperSoft Air +.
In some embodiments, the nonwoven layer has a dry basis weight of from 15 g/m2
(e.g.,
from 20 g/m2, from 25 g/m2, from 30 g/m2, from 35 g/m2, from 40 g/m2, or from
45 g/m2) to
50 g/m2 (e.g., to 45 g/m2, to 40 g/m2, to 35 g/m2, to 30 g/m2, to 25 g/m2, or
20 g/m2) in the
composite fabric. The composite fabric can be used, for example, as an
acquisition distribution
layer in an absorbent article.
In some embodiments, the crosslinked cellulose layer includes a dry basis
weight of
from 20 g/m2 (e.g., from 40 g/m2, from 60 g/m2, from 80 g/m2, from 100 g/m2,
from 120 g/m2,
from 140 g/m2, or from 160 g/m2) to 185 g/m2 (e.g., to 160 g/m2, 140 g/m2, 120
g/m2, 100
g/m2, 80 g/m2, 60 g/m2, or 40 g/m2) in the composite fabric. The composite
fabric can be used,
for example, to envelop an absorbent material in an absorbent core of an
absorbent article (e.g.,
as a core-wrap). In some embodiments, the composite fabric can be used to
sandwich an
absorbent material, such that a first layer of composite fabric overlies an
absorbent material,
and a second layer of composite fabric underlies the absorbent material.
In some embodiments, the composite fabric in the absorbent article has a
nonwoven
layer at a dry basis weight of 20 g/m2 or more (e.g., 30 g/m2 or more, 40 g/m2
or more) and/or
50 g/m2 or less (e.g., 40 g/m2 or less, or 30 g/m2 or less), such as a dry
basis weight of from 20
g/m2 to 50 g/m2 (e.g., from 30 g/m2 to 40 g/m2) and a crosslinked cellulose
layer at a dry basis
weight of 70 g/rd or more (e.g., 80 g/m2 or more, 90 g/m2 or more, 100 g/m2 or
more, 110 g/m2
or more) and/or 120 g/m2 or less (e.g., 110 g/m2 or less, 100 g/m2 or less, 90
g/m2 or less, or 80
g/m2 or less), such as a dry basis of from 70 g/m2 to 120 g/m2 (e.g., from 80
g/m2 to 110 g/m2).
The absorbent article can include a fluid acquisition distribution layer that
includes the
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composite fabric. For example, the composite fabric can be disposed over an
absorbent core
or a superabsorbent polymer. The crosslinked cellulose layer of the composite
fabric can face
the surface of the absorbent core. The absorbent article can have a wicking
distance percentage
of at least 60% after a third fluid exposure in a no load saddle wicking test
when the absorbent
article includes a fluid acquisition distribution layer including the
composite fabric. In some
embodiments, the absorbent article is a diaper or an incontinence product.
In certain embodiments, the composite fabric includes the nonwoven layer at a
dry basis
weight of 20 g/m2 or more (e.g., 30 g/m2 or more, or 40 g/m2 or more) to 50
g/m2 or less (e.g,
40 g/m2 or less, or 30 g/m2 or less) and the crosslinked cellulose layer at a
dry basis weight of
40 g/m2 or more (e.g., 50 g/m2 or more, 60 g/m2 or more) and/or 70 g/m2 or
less (e.g., 60 g/m2
or less, or 50 g/m2 or less). In some embodiments, the composite fabric
includes the nonwoven
layer at a dry basis weight of 20 g/m2 to 50 g/m2 (e.g., 30 g/m2 to 40 g/m2)
and the crosslinked
cellulose layer at a dry basis weight of 40 g/m2 to less than 70 g/m2 (e.g.,
40 g/m2 to 60 g/m2,
or 50 g/m2). The absorbent article can include the composite fabric, which can
envelop an
absorbent material in an absorbent core (e.g., as a core-wrap). For example,
the composite
fabric can envelop an absorbent material, such as a superabsorbent polymer, in
an absorbent
core. In some embodiments, the composite fabric fully envelops the absorbent
material (e.g.,
the bulk absorbent material, such as a bulk superabsorbent polymer) in the
absorbent core. In
some embodiments, the composite fabric can be used to sandwich an absorbent
material, such
that a first layer of composite fabric overlies an absorbent material, and a
second layer of
composite fabric underlies the absorbent material. The crosslinked cellulose
layer of the
composite fabric can contact the surface of the absorbent material. The
absorbent article can
have a wicking distance percentage of at least 60% after a third fluid
exposure in a no load
saddle wicking test when the absorbent article includes the composite fabric
enveloping the
absorbent material. In some embodiments, the absorbent article is a diaper or
an incontinence
product.
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Absorbent cores are described, for example, in U.S. Patent No. 8,674,169 and
PCT
publication no. W02020/046627, each of which is incorporated herein in its
entirety. In some
embodiments, the absorbent core can include a traditional fluff core,
channeled fluff core, a
complex core (e.g., a multilayered core), and/or an SAP. In some embodiments,
the SAP is in
the form of particles, which can be contained inside the absorbent article
with the aid of an
adhesive.
The composite fabric of the present disclosure can be embossed, folded, and/or
perforated with one or more patterns. When used in an absorbent article, the
embossing, folds,
and/or perforation can physically distribute, channel, or otherwise influence
the flow of a liquid
insult. For example, the composite fabric can be embossed with a pattern, such
as a repeated
pattern. For example, the composite fabric can be pleated, folded, or
otherwise have a textured
surface, such that a cross section of the composite fabric has hills and
valleys formed by the
pleats or folds. An absorbent material, such as SAP, can be present in the
valleys of the
composite fabric. When the composite fabric is pleated, folded, or otherwise
has a textured
surface, either the nonwoven layer or the crosslinked cellulose layer can face
an absorbent
material of an absorbent core of the absorbent article. In some embodiments,
the composite
fabric can be perforated with through-openings, such as slits, channels,
and/or holes.
In some embodiments, the composite fabric neutralizes odor when subjected to
(e.g.,
wetted with) biological fluids.
In any one of the above-described embodiments, the composite fabric can be
devoid of
latex, latex-bonded fibers, a hydroengorged layer, a pretreated nonwoven
layer, lyocell, and/or
rayon.
The composite fabric of the present disclosure can be incorporated into an
absorbent
article, such as a personal care absorbent product, as will be described
below. The personal
care absorbent product can include, a diaper, an incontinence product, a
feminine hygiene
product, a wipe, a towel, and a tissue.
Methods of Making the Composite Fabric
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In some embodiments, the crosslinked cellulose layer is air-laid or dry-laid
onto the
nonwoven layer to provide the composite fabric of the present disclosure. In
some
embodiments, the crosslinked cellulose layer is wet-laid onto the nonwoven
layer. The
crosslinked cellulose fibers from the crosslinked cellulose layer can be hydro-
entangled into
polymeric fibers and/or filaments from the nonwoven layer in the interfacial
region. For
example, in a hydro-entangling process, the hydro-entanglement water jets
first contact the
cellulosic fibers and drive the cellulosic fibers into the nonwoven polymeric
fibers. Hydro-
entangling processes are described, for example, in U.S. Publication No.
2018/0326699 and
CA patent no. 841,938, each of which is incorporated herein by reference in
its entirety.
The hydroentangling step causes the different fiber types to be entangled by
the action
of a plurality of thin jets of high-pressure water impinging on the fibers.
The fine mobile spun-
laid filaments are twisted around and entangled with themselves and with the
other fibers,
which gives a material with a very high strength in which all fiber types are
intimately mixed
and integrated. Entangling water is drained off through the forming fabric,
and can be recycled,
if desired after purification. The energy supply needed for the
hydroentangling is relatively
low, i.e., the material is easy to entangle.
A hydroentangling process for forming a fabric occurs by mechanically wrapping
and
knotting fibers in a web about each other through the use of high velocity
jets of water. The
process uses fine, high velocity jets of water to impact a fibrous web and
cause the fibers to
curl and entangle about each other. The water jets perforate the web and
entangle the fibers,
producing fabrics that reflect the pattern of a forming belt which carries the
web under the
water jets. This produces a fabric with a textile fabric appearance and good
drapability. A
binder can be added to some hydroentangled fabrics to increase their strength
and dimensional
stability to make them liquid repellant. The process can be used on dry-laid
webs and on wet
laid webs. A lower energy hydroentangling process, using lower velocity water
jets, can
provide a product that has less entanglement, which can optionally include a
binder. The
hydroentangling process is described, for example, in The Nonwovens Fabric
Handbook
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published by Association of the Nonwoven Fabrics Industry (INDA), Cary NC
1999, herein
incorporated by reference in its entirety.
Examples of "laying" processes include wet-laying and air-laying (the latter
occasionally also referred to as dry-laying). Example dry-laying processes
include but are not
limited to air-laying, carding, and combinations thereof typically forming
layers. Examples of
combinations include but are not limited to spunbond-meltblown-spunbond (SMS),
spunbond-
carded (SC), spunbond-airlaid (SA), meltblovvn-airlaid (MA), and combinations
thereof,
typically in lavers. Combinations which include direct extrusion can be
combined at about the
same point in time as the direct extrusion process (e.g., spinform and coform
for SA and MA),
or at a subsequent point in time. In the above examples, one or more
individual layers can be
created by each process. For instance, SMS can mean a three layer, 'sms' web,
a five layer
'ssmms' web, or any reasonable variation thereof wherein the lower case
letters designate
individual layers and the upper case letters designate the compilation of
similar, adjacent layers.
FIG. 1 shows a hydro-entangling process for entangling crosslinked cellulose
fibers
into a nonwoven material, which can be in the form of a fabric or fibers.
Referring to FIG. 1,
crosslinked cellulose fibers 114 is provided onto a nonwoven material 112, and
water jets 102
are directed toward the crosslinked cellulose fibers to push the cellulose
fibers into the
nonwoven material, thereby providing composite fabric 110. The water jet
pressure can be
varied, such that at higher water pressures, the degree of crosslinked
cellulose fiber penetration
into the nonwoven material increases, and interfacial region 116 can increase
in thickness.
In some embodiments, the present disclosure features a method of making a
composite
fabric, including supplying polymeric fibers and/or filaments; supplying
crosslinked cellulose
fibers; air-laying or wet-laving the crosslinked cellulose fibers to provide a
crosslinked
cellulose layer on a nonwoven layer of polymeric fibers and/or filaments,
wherein the
crosslinked cellulose layer is positioned opposed to the nonwoven layer (e.g.,
without an
intervening layer different from the crosslinked cellulose layer and the
nonwoven layer; in
some embodiments, the crosslinked cellulose layer is immediately adjacent to
the nonwoven
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layer); and physically entangling the polymeric fibers and/or filaments from
the nonwoven
layer and the crosslinked cellulose fibers from the crosslinked cellulose
layer to provide an
interfacial region between the nonwoven layer and the crosslinked cellulose
layer, wherein the
nonwoven layer and the crosslinked cellulose layer are mechanically
inseparable in a dry state.
In some embodiments, physically entangling the polymeric fibers and/or
filaments from
the nonwoven layer and the crosslinked cellulose fibers from the crosslinked
cellulose layer
includes hydro-entangling the crosslinked cellulose fibers into the polymeric
fibers and/or
filaments. The polymeric fibers and/or filaments can be in the form of a
bonded carded web
fabric, a carded web, a spunbond fabric, a melt blown fabric, or any
combination thereof. In
some embodiments, the polymeric fibers are synthetic.
In some embodiments, the nonwoven layer is a top layer, and the crosslinked
cellulose
layer is a bottom layer. In certain embodiments, the nonwoven layer is a
bottom layer, and the
crosslinked cellulose layer is atop layer. The crosslinked cellulose layer can
pre-formed prior
to entangling with the nonwoven layer. In some embodiments, the crosslinked
cellulose layer
is not pre-formed prior to entangling with the nonwoven layer, and/or the
nonwoven layer is
not pre-formed prior to entangling with the crosslinked cellulose layer. In
certain
embodiments, the nonwoven layer can be pre-formed, or formed in situ, during
the entangling
process.
This present disclosure combines the integrity of nonwovens and absorbency of
crosslinked cellulose fiber together to offer both excellent fluid management
capability and
physical characteristics such as resiliency/bunching free.
ABSORBENT ARTICLES
The composite fabric of the present disclosure can be used in an absorbent
article.
Referring to FIG. 2A, composite fabric 110 can be used in an absorbent article
as a fluid
acquisition and distribution layer (ADL) over absorbent material 210 that can
include, for
example, fluff or an SAP. The composite fabric 110 can be disposed over an
absorbent core
that includes fluff or a superabsorbent polymer, and the crosslinked cellulose
layer 114 faces
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and/or contacts the surface of the absorbent material. In some embodiments,
referring to FIG.
2B and FIG. 3, the composite fabric 110 of the present disclosure can be used
to envelop
absorbent material 220 (e.g., as a core-wrap around absorbent material 220),
where the
crosslinked cellulose layer 114 faces and/or contacts the surface of absorbent
material 220. In
some embodiments, the composite fabric can be used to sandwich an absorbent
material, such
that a first layer of composite fabric overlies an absorbent material, and a
second layer of
composite fabric underlies the absorbent material. Absorbent material 220 can
include a fluff
pulp (i.e., fluff), high-loft through air bonded carded web (TABCW), and/or an
SAP 330. In
some embodiments, absorbent material 220 can include a highly densified fluff
pulp and SAP.
As shown in FIG. 3, the enveloped absorbent material can be sandwiched between
a liquid
permeable topsheet 310 and a backsheet 320 to provide absorbent article 300.
Backsheet 320
can be liquid-impermeable.
In some embodiments, the absorbent material includes 30% or more (e.g., 40% or
more,
50% or more, 60% or more, 70% or more, 80% or more) and/or 90% or less (e.g.,
80% or less,
70% or less, 60% or less, 50% or less, or 40% or less) by weight of the
absorbent synthetic
polymer and 10% or more (e.g., 20% or more, 30% or more, 40% or more, 50% or
more, 60%
or more) and/or 70% or less (e.g., 60 % or less, 50% or less, 40% or less, 30%
or less, or 20%
or less) by weight of the fluff pulp. In some embodiments, the absorbent
material can include
a highly densified mixture of fluff pulp and SAP.
When the composite fabric is used as the ADL, as an envelope around, or
otherwise
sandwiches an absorbent material, improved fluid management can be observed in
the
absorbent articles, compared to an absorbent article that includes
conventional ADL or core-
wrap materials, or compared to an absorbent article having one of the nonwoven
layer or the
crosslinked cellulose layer, or a combination of a non-entangled nonwoven
layer and
crosslinked cellulose layer.
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In some embodiments, when the absorbent material includes an SAP, the SAP can
be
in the form of particles held inside the absorbent article by the fabric with
the aid, for example,
of an adhesive.
When the composite fabric wraps around an absorbent material (e.g., fluff
and/or the
SAP) to provide an absorbent core (e.g., FIGS. 2B and 3), the absorbent
material can be fully
wrapped or partially wrapped by composite wrap. In function, the composite
fabric can also
serve as the fluid acquisition distribution layer in this simplified design.
The absorbent article can include a personal care absorbent product. For
example, the
personal care absorbent product can include a diaper, an incontinence product,
a feminine
hygiene product (e.g., a sanitary napkin, a panty liner), a wipe, a towel,
and/or a tissue. In
certain embodiments, the absorbent article is a diaper, an incontinence
product, or a feminine
hygiene product.
In some embodiments, the absorbent article of the present disclosure has an
intake time
decrease of at least 23% from a first fluid exposure to a second subsequent
fluid exposure in a
flat acquisition under load test, when the absorbent article includes a fluid
acquisition
distribution layer including the composite fabric.
In some embodiments, the absorbent article has an intake time decrease of at
least 25%
from a first fluid exposure to a second subsequent fluid exposure in a flat
acquisition under
load test, when the absorbent article includes the composite fabric enveloping
the absorbent
material.
In some embodiments, the absorbent article has an intake time decrease of at
least 8%
from a second fluid exposure to a third subsequent fluid exposure in a flat
acquisition under
load test, when the absorbent article includes a fluid acquisition
distribution layer including the
composite fabric.
In some embodiments, the absorbent article has an intake time decrease of at
least 12%
from a second fluid exposure to a third subsequent fluid exposure in a flat
acquisition under
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load test, when the absorbent article includes the composite fabric enveloping
the absorbent
material.
In some embodiments, the absorbent article has a wicking distance percentage
of at
least 60% after a third fluid exposure in a no load saddle wicking test when
the absorbent article
includes a fluid acquisition distribution layer including the composite
fabric.
In some embodiments, the absorbent article has a wicking distance percentage
of at
least 60% after a third fluid exposure in a no load saddle wicking test when
the absorbent article
includes the composite fabric enveloping the absorbent material.
In some embodiments, the absorbent article has a rewet amount less than 0.5 g
from a
first fluid exposure in a flat acquisition under load test when the absorbent
article includes a
fluid acquisition distribution layer including the composite fabric, or the
composite fabric
enveloping the absorbent material.
In some embodiments, the absorbent article has a rewet amount less than 0.5 g
from a
second fluid exposure in a flat acquisition under load test when the absorbent
article includes
a fluid acquisition distribution layer including the composite fabric.
In some embodiments, the absorbent article has a rewet amount less than or
equal to
0.8 g from a second fluid exposure in a flat acquisition under load test when
the absorbent
article includes the composite fabric enveloping the absorbent material.
In some embodiments, the absorbent article has a rewet amount increase of less
than
11.9 g from a second fluid exposure to a third subsequent fluid exposure in a
flat acquisition
under load test when the absorbent article includes a fluid acquisition
distribution layer
including the composite fabric.
In some embodiments, the absorbent article has a rewet amount increase of less
than
0.35 g from a first fluid exposure to a second subsequent fluid exposure in a
flat acquisition
under load test when the absorbent article includes a fluid acquisition
distribution layer
including the composite fabric.
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In some embodiments, the absorbent article has a rewet amount increase of less
than
4.42 g from a second fluid exposure to a third subsequent fluid exposure in a
flat acquisition
under load test when the absorbent article includes the composite fabric
enveloping the
absorbent material.
In some embodiments, the absorbent article has a rewet amount increase of less
than
0.73 g from a first fluid exposure to a second subsequent fluid exposure in a
flat acquisition
under load test when the absorbent article includes the composite fabric
enveloping the
absorbent material.
An exemplary rewet amount range per fluid exposure for some embodiments of
diapers
including an ADL or the composite fabric enveloping the absorbent material is
shown in Table
1.
Table 1. Rewet amount per fluid exposure for diapers including an ADL or core-
wrap
composite fabric.
Fluid Exposure (#) Composite as ADL Rewet Composite as Core-
Wrap
(grams) Rewet (grams)
1 0.09¨ 0.28 0.07 ¨ 0.4
2 0.1 ¨ 0.41 0.08 ¨ 0.8
3 0.1 - 12 0.09 ¨ 4.5
FEMININE HYGIENE PRODUCT
The composite fabric of the present disclosure can be used in an absorbent
article, such
as a feminine hygiene product (e.g., a sanitary napkin, a panty liner). The
feminine hygiene
product can include a composite fabric including a nonwoven layer including
polymeric fibers
and/or filaments; a crosslinked cellulose layer including crosslinked
cellulose fibers, wherein
the crosslinked cellulose layer is positioned opposed to the nonwoven layer;
and an interfacial
region between the nonwoven layer and the crosslinked cellulose layer,
including physically
entangled polymeric fibers and/or filaments from the nonwoven layer and
crosslinked cellulose
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fibers from the crosslinked cellulose layer, wherein the nonwoven layer and
the crosslinked
cellulose layer are mechanically inseparable in a dry state.
The feminine hygiene product can include an absorbent core including an
absorbent
material. In some embodiments, the composite fabric is disposed over the
absorbent core. In
some embodiments, the composite fabric envelops at least a portion of the
absorbent material.
In some embodiments, the composite fabric can be used to sandwich the
absorbent material,
such that a first layer of composite fabric overlies an absorbent material,
and a second layer of
composite fabric underlies the absorbent material.
When subjected to a fluid insult, the composite fabric distributes the fluid
to a front
portion, a middle portion, and a back portion of the feminine hygiene product.
In some
embodiments, when subjected to fluid insult, the front portion, middle
portion, and back portion
of the composite fabric of the feminine hygiene product each includes an
amount of fluid within
wt% to 45 wt % of each portion. As used herein, the middle portion is 7.5 cm
in length and
is situated between the front and back portions, with the remaining length
equally divided
15 between the front and back portions.
ABSORBENT ARTICLE CONFIGURATIONS ¨ ABSORBENT CORE
The composite fabric of the present disclosure can be included in absorbent
articles
and can serve, among other purposes, as acquisition-distribution layers (ADL),
or used to wrap
at least partially around an absorbent material, which can be or include one
or more of a number
20 of absorbent materials. Various exemplary configurations of the "core-
wrap" absorbent articles
are described in reference to FIGS. 4-8C in the forthcoming paragraphs.
FIG. 4 is a schematic diagram illustrating an example absorbent article 400,
in
accordance with embodiments of the present disclosure. In some embodiments,
the example
absorbent article 400 includes: a backsheet 405, an absorbent core 410, and a
topsheet 415.
The example absorbent article 400 is structured to receive a liquid insult via
the topsheet 415,
to distribute the liquid through the absorbent core 410, and to absorb the
liquid, while inhibiting
the liquid from circumventing the backsheet 405, thereby reducing or
eliminating wetness,
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discomfort, and/or irritation from being experienced by a wearer of the
absorbent article 400.
Example absorbent article 400 is an example of absorbent article 300 described
in reference to
FIG. 3.
In some embodiments, the backsheet 405 includes constituent materials that are
impermeable to liquids, such as one or more layers of polymeric, elastomeric,
and/or metallic
material creating a liquid-impermeable barrier. Conversely, the topsheet 415
can include
materials that are permeable to liquids, such that a liquid insult incident on
the topsheet 415
can be wicked, channeled, or otherwise pass through the topsheet 415 to the
absorbent core
410 with negligible physical resistance. When assembled, the topsheet 415 can
overlie the
absorbent core 410 and can contact the inner surface of the backsheet 405. In
this way,
contacting the inner surface of the backsheet 405 can include contacting the
backsheet 405 at
one or more points, around the periphery of the absorbent core 410 and/or
coextensive with the
backsheet 405. The various configurations can permit the absorbent article to
bend or twist
without significant bunching or squeezing of the absorbent core 410.
The backsheet 405 can define an inner surface 420 and an outer surface 425.
The inner
surface 420 can be or include physical clasps, latches, tabs, adhesives or
another configuration
whereby the backsheet 405 can mechanically couple with the absorbent core 410
and/or the
topsheet 415, and whereby the backsheet 405 can removably couple with a
garment of the
wearer. In some embodiments, the absorbent article can be in a pant form,
without any
fasteners. For example, the absorbent core 410 can be disposed on the inner
surface 420 of the
backsheet 405, and can be retained, held, fixed, or otherwise mechanically
coupled with the
backsheet 405. In some embodiments, the backsheet 405 and the topsheet 415
together define
a pocket into which the absorbent core 410 can be removably disposed. In this
way, the
absorbent article 400 can be reusable or can be disassembled to facilitate
disposal of
compostable materials and recycling of plastic components.
In some embodiments, the backsheet 405, the topsheet 415, the absorbent core
410, and
the composite fabric of the present disclosure can be embossed folded,
pleated, and/or
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perforated to physically distribute, channel, or otherwise influence the flow
of a liquid insult
incident on the topsheet 415, wherein the folded or pleated composite fabric
optionally includes
an absorbent material within the folds or pleats. When the composite fabric is
pleated, folded,
or otherwise has a textured surface, either the nonwoven layer or the
crosslinked cellulose layer
can face an absorbent material of an absorbent core of the absorbent article.
In some embodiments, the topsheet 415 is textured to improve the sensation of
the
wearer while donning the absorbent article. In an illustrative example, the
texture and/or
pattern can include one or more pores to improve circulation of air through
the absorbent article
400, thereby reducing humidity near the surface of the skin of the wearer and
sequestering
and/or denaturing odiferous gases. Similarly, the topsheet 415 can include a
micro-textured
surface to impart a soft feeling to the surface, without altering the liquid
permeability or
porosity of the topsheet 415.
Referring to FIGS. 5A-5E, various configurations of core-wrap absorbent
articles are
described. FIG. 5A illustrates one example of the constituent materials and
configurations
contemplated. FIGS. 5B-8C illustrate additional and/or alternative
configurations and/or
materials that can be included in embodiments of the absorbent articles.
FIG. 5A is a schematic diagram illustrating internal structures of the example
absorbent
article 400 of FIG. 4, in accordance with embodiments of the present
disclosure. The example
absorbent article 400 includes, as constituents of the absorbent core 410, a
distribution layer
505, which can include or be formed of the composite fabric of the present
disclosure, disposed
surrounding at least a portion of an absorbent material 510. The distribution
layer 505 and the
absorbent material 510 can together act to distribute and absorb a liquid
insult incident on the
topsheet 415 and to reduce rewetting subsequent initial absorption.
In some embodiments, the absorbent material 510 defines an upper surface 515
and a
lower surface 520 of the absorbent core 410. The distribution layer 505, in
turn, surrounds at
least a portion of the upper surface 515 and the lower surface 520. The
distribution layer 505
can fully surround the upper surface 515 and the lower surface 520 of the
absorbent core 410.
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For example, the distribution layer 505 can be or include a rectangular-planar
material having
four edges that is wrapped around the absorbent material 510 such that two
edges contact each
other along the lower surface 520 or along the upper surface 515 of the
absorbent core 410.
The distribution layer 505 can be or include composite fabric 110 including
two or more
constituent layers. The constituent layers can include nonwoven layer 112 and
a crosslinked
cellulose layer 114. The nonwoven layer 112 can be or include polymeric fibers
and/or
filaments, as described in more detail in reference to the preceding figures.
In contrast, the
crosslinked cellulose layer 114 can be or include crosslinked cellulose
fibers.
The crosslinked cellulose layer 114 can be positioned opposed to the nonwoven
layer
112 and can define the interfacial region 116 between the nonwoven layer 112
and the
crosslinked cellulose layer 114, as described in more detail in reference to
FIGS. 1-3. The
interfacial region 116 can include physically entangled polymeric fibers
and/or filaments from
the nonwoven layer 112 and crosslinked cellulose fibers from the crosslinked
cellulose layer
114. In this way, the nonwoven layer 112 and the crosslinked cellulose layer
114 can be
mechanically inseparable in a dry state.
Referring to FIG. 5B and FIG. 5C, alternatively, the distribution layer 505
can define a
gap 525 on the upper surface 515 or the lower surface 520 of the absorbent
core 410. Where
the gap 525 can retain liquid or can otherwise impair the distribution of
liquid through the
distribution layer 505, the absorbent core 410 can further include a cover
distribution layer 530
disposed over the gap 525. The cover distribution layer 530 can overlie at
least a portion of
the distribution layer 505, such that the distribution layer 505 is disposed
between at least a
portion of the cover distribution layer 530 and the absorbent material 510. In
terms of
assembly, the distribution layer 505 can be wrapped around the portion of the
absorbent
material 510, defining the gap 525 on the upper surface 515 or the lower
surface 520, and can
be coupled by pressure, adhesive, physical closures, or other approaches, over
which the cover
distribution layer 530 can be physically coupled with the distribution layer
505 by similar
techniques. In some embodiments, the cover distribution layer 530 is or
includes the composite
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fabric 110, such that where the cover distribution layer 530 contacts the
absorbent material
510, it serves to distribute liquid in a manner similar to the distribution
layer 505.
Referring to FIG. 5D and FIG. 5E, the cover distribution layer 530 can
underlie at least
a portion of the distribution layer 505, such that the cover distribution
layer 530 is disposed
between at least a portion of the distribution layer 505 and the absorbent
material 510. In terms
of assembly, the cover distribution layer 530 can be physically coupled with
the absorbent
material 510 by pressure, adhesive, physical closures, or other approaches,
over which the
distribution layer 505 can be wrapped around the portion of the absorbent
material 510,
defining the gap 525 on the upper surface 515 or the lower surface 520, and
thereby can be
coupled with the cover distribution layer 530 and the absorbent material 510.
Referring to FIGS. 6A-6D, the cover distribution layer 530 can be or include a
spunbond meltblown spunbond (SMS) material, a spunbound (SB) material,
spunbond-carded
(SC), spunbond-airlaid (SA), meltblown-airlaid (MA), or combinations thereof,
as described
previously. As described in reference to FIGS. 5B-5E, the SMS and SB materials
can be
disposed overlying at least a portion of the distribution layer 505 or
underlying the distribution
layer 505, and can be disposed on the upper surface 515 or the lower surface
520, corresponding
to the position of the gap 525 on the absorbent core 410.
Referring to FIG. 7A and FIG. 7B, in some embodiments, the distribution layer
505
overlaps on the upper surface 515 or the lower surface 520 of the absorbent
core 410 by at least
a portion 535 of a width of the distribution layer 505. In the example of the
rectangular-planar
material, the two edges can overlap on the upper surface 515 or on the lower
surface 520.
Advantageously, the configurations including the overlapping portion can be
manufactured
with fewer processes, rather than including the steps involved in preparing
and disposing the
cover distribution layer 530.
Referring to FIG. 8A, FIG. 8B, and FIG. 8C, absorbent materials 220 are
described in
reference to absorbent article 300, as may also be included as part of example
article 400 of
FIG. 4. The absorbent material 220 in the absorbent core can be or include one
or more
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constituent materials selected to provide improved absorbance, wicking, and/or
retention
properties of the absorbent article 300. For example, the absorbent material
220 can be or
include a synthetic absorbent polymer 330 and a high-loft through air bonded
carded web
(TABCW) 810. In another example, the absorbent material 220 can be or include
an absorbent
synthetic polymer 330 and a fluff pulp 815. The absorbent material 220 can
include the
aforementioned materials in combination. In some embodiments, the absorbent
material 220
includes from 30% to 90% by weight of the absorbent synthetic polymer 330 and
from 10% to
70% by weight of the fluff 815. The composition of the absorbent material can
be determined
at least in part by a balance of absorbency, weight, density, and other
wetting properties, as
described in reference to the absorbent article test procedures, below. For
example, while
absorbent synthetic polymer 330 can exhibit increased retention, fluff 815 can
improve
acquisition and wicking. In this way, overall performance of the absorbent
article can depend
on the specific application, for example when wicking can be more desirable,
as when
relatively high volumes of liquid are to be absorbed quickly, as opposed to
applications where
volumes are relatively low but are to be absorbed steadily over a period of
time.
In this way, the absorbent material 220 can include from 5% to 99% by weight
of the
absorbent synthetic polymer 330 and from 1% to 95% by weight of the fluff 815,
from 10% to
90% by weight of the absorbent synthetic polymer 330 and from 10% to 90% by
weight of the
fluff 815, from 15% to 90% by weight of the absorbent synthetic polymer 330
and from 10%
to 85% by weight of the fluff 815, from 20% to 90% by weight of the absorbent
synthetic
polymer 330 and from 10% to 80% by weight of the fluff 815, from 25% to 90% by
weight of
the absorbent synthetic polymer 330 and from 10% to 75% by weight of the fluff
815, from
30% to 90% by weight of the absorbent synthetic polymer 330 and from 10% to
70% by weight
of the fluff 815, from 35% to 90% by weight of the absorbent synthetic polymer
330 and from
10% to 65% by weight of the fluff 815, from 40% to 90% by weight of the
absorbent synthetic
polymer 330 and from 10% to 60% by weight of the fluff 815, from 45% to 90% by
weight of
the absorbent synthetic polymer 330 and from 10% to 55% by weight of the fluff
815, from
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50% to 90% by weight of the absorbent synthetic polymer 330 and from 10% to
50% by weight
of the fluff 815, from 55% to 90% by weight of the absorbent synthetic polymer
330 and from
10% to 45% by weight of the fluff 815, from 60% to 90% by weight of the
absorbent synthetic
polymer 330 and from 10% to 40% by weight of the fluff 815, from 65% to 90% by
weight of
the absorbent synthetic polymer 330 and from 10% to 40% by weight of the fluff
815, from
70% to 90% by weight of the absorbent synthetic polymer 330 and from 10% to
30% by weight
of the fluff 815, from 75% to 90% by weight of the absorbent synthetic polymer
330 and from
10% to 25% by weight of the fluff 815, from 80% to 90% by weight of the
absorbent synthetic
polymer 330 and from 10% to 20% by weight of the fluff 815, from 85% to 90% by
weight of
the absorbent synthetic polymer 330 and from 10% to 15% by weight of the fluff
815, including
fractions or interpolations thereof
ABSORBENT ARTICLE TEST PROCEDURES
No Load Saddle Wicking for Absorbent Articles
This test determines how quickly an absorbent hygiene product can absorb a
certain
amount of fluid while in constrained in a -U" shaped saddle simulating the
position of the
absorbent article when in human use. Additionally, the test determines the
distance wicked by
the fluid after all doses of fluid. This test assesses an absorbent article's
fluid intake and fluid
distribution capabilities in a configuration similar to real life usage.
Equipment and Materials Needed
Equipment and materials needed for this test are as follows: Ruler, simulated
urine
(0.9% saline solution), saddle device, peristaltic pump with dispensing tubing
that has
attachment to prevent dispensing tube from touching the diaper, timer,
stopwatch, magnetic
board, and 4 magnets.
Sample Preparation
1. Determine dimensions of sample.
2. If testing infant products, then measure product length and width.
3. Mark center of sample length.
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4. Measure 9 cm towards the front of the sample and mark with an "X"
ensuring
the "X- is centered in reference to the absorbent core width. The "X- will be
the insult point.
5. Optionally, the elastic leg gathers of the diaper may be cut for ease of
testing as
long as the cut does not interfere with the absorbent capabilities of the
diaper.
Calibration
1. Prepare the appropriate amount of 0.9% saline solution for testing in a
container
that can fit the inlet of the testing pump.
2. Set pump to desired flow rate and dose volume.
Infant products should have a rate of (900 ml/minute) and a dose of 85 ml.
3. Dispense 1
dose into a graduated cylinder. If the dose is incorrect, then calibrate
the tubing.
Testing Procedure
1.
Place dispensing tube perpendicular to insult point and as close as
possible to
the absorbent article surface without touching the surface with the dispensing
point.
2. Start
peristaltic pump, stopwatch, and timer (set to 20 minutes) simultaneously.
3. Stop stopwatch when fluid is absorbed.
4. When 20 minute timer ends, repeat steps 1-3 two more times.
5. After the third round of the 20 minute timer ending, remove the
absorbent article
and stretch out flat on a magnetic board and secure the absorbent article in
place.
6. Measure
distance fluid has wicked from the insult point towards the front and
back ends of the absorbent article. To determine the wicking distance, the
tester shall identify
the furthest wicking distance wicked by the bulk of the fluid and exclude
outlying wicking
distances.
Flat Acquisition Under Load for Absorbent Hygiene Products
This test determines how quickly the absorbent hygiene product can absorb a
certain
amount of fluid while under high pressure, as well as how well the product
retains that fluid.
Thus, this test assesses an absorbent article's fluid management capabilities
under load.
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Equipment and Materials Needed
Equipment and materials needed for this test are as follows: magnetic board
and
magnets, balance with a 1,000-gram capacity sensitive to 0.01 g, ruler,
simulated urine (0.9%
saline solution), insult plate, rewet plate, peristaltic pump with dispensing
tubing, blotter paper,
weights to generate 0.38 psi, 2 timers, stopwatch.
Sample Preparation
1. Use two magnets to attach sample onto a magnetic board from either the
front
or back two tabs.
2. Pull the diaper taut and use two more magnets to maintain tension by
holding
the diaper down at the two available tabs.
3. Label the insult point which is 150 mm from the front of the absorbent
core
and in the center width wise of the absorbent core
Calibration
1. Prepare the appropriate amount of 0.9% saline solution for testing in a
container that can fit the inlet of the testing pump.
2. Set pump to desired volume and rate.
3. Infant products should have a rate of 900 mL/min and a dose of 85 mL.
4. Dispense 1 dose into a graduated cylinder. If the dose is incorrect,
then
calibrate the pump.
Testing Procedure
1st intake/rewet
a) Place the insult board onto the product and align the
front edge of the insult
board to the front edge of the absorbent core. Be sure the insult point is
center of the
cylinder.
b) Load the board to 0.38 psi.
c) Dispense 85 ml of saline solution into the cylinder.
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d) Immediately after dispensing, simultaneously start the stopwatch and the
timer
set to 15 minutes.
e) When all the saline is absorbed into the product, stop the stopwatch and
record
the acquisition time.
Weigh 1 dry blotter and record the weight.
Place the pre-weighed rewet blotter paper with the short edge aligned with the
front edge of absorbent core and place the rewet plate centered over the top
of the blotter
paper.
h) Load the rewet plate with 0.38 psi.
i) Start the timer set to 2 minutes again.
I) After waiting 2 minutes for rewet, remove the rewet plate and rewet
blotter
paper.
k) Weigh blotter.
1) Measure distance wicked by fluid from the insult point towards the front
and
back ends of the absorbent article and record each separately as -front
wicking distance" and
-back wicking distance", respectively. To determine the wicking distance, the
tester shall
identify the furthest wicking distance wicked by the bulk of the fluid and
exclude outlying
fluid wicked.
2nd intake/rewet
a) Follow procedure for 1st intake, except use 2 dry blotter paper for
rewet.
3rd intake/rewet
Follow procedure for 1st intake, except use 3 dry blotter paper for rewet.
Calculations
Revvet value (g) = Blotter paper weight after rewet (g) ¨ blotter paper weight
before
rewet (g).
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In-Plane Radial Permeability (IPRP) Test
Permeability generally refers to the quality of a porous material that causes
it to allow
liquids or gases to pass through it and, as such, is generally determined from
the mass flow rate
of a given fluid through it. The permeability of an absorbent structure is
related to the material's
ability to quickly acquire and transport a liquid within the structure, both
of which are key
features of an absorbent article. Accordingly, measuring permeability is one
metric by which
a material's suitability for use in absorbent articles may be assessed. The In-
Plane Radial
Permeability (IPRP) of a porous material is measured according to the method
described in
U.S. Patent No. 10,287,383, herein incorporated by reference in its entirety.
The quantity of a
saline solution (0.9% NaCl) flowing radially through an annular sample of the
material under
constant pressure is measured as a function of time, and testing is performed
at 23 C 2C' and
a relative humidity 50% + 5%. All samples are conditioned in this environment
for twenty
four (24) hours before testing.
Thickness, Bulk, and Density
This method is used to determine the single sheet thickness of material by use
of a
motor driven micrometer using a specified load applied for a specified time.
The method is
based upon TAPPI T 411.
This method is suitable for using the 1PC Soft Platen technique for measuring
apparent
thickness. This technique employs a micrometer with pressure faces covered
with soft
neoprene rubber. This has the effect of reducing thickness readings due to the
ability of the
latex to conform to surface irregularities. This is useful when measuring
materials with rough
or irregular surfaces, such as linerboard and corrugating medium.
Equipment needed: Motor driven micrometer, accurate to 0.001 mm.
Wire, or other suitable calibration gauges, with thickness known to within
0.0005 mm.
Gauges should extend over a range of thicknesses (e. g. , 0.2-1.0 mm.)
Procedure:
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Step 1.1: Clean the surfaces of the platens with lint-free paper (Bausch and
Lomb
Sightsaver silicon wipes) and adjust the micrometer reading to zero.
Step 1.2: With the pressure faces closed, set the reading to zero. Do not
reset the zero
during the following steps.
Step 1.3: Open the gap between the pressure faces and allow it to close again.
Step 1.4: Insert one of the calibration gauges and read the thickness to the
nearest
0.001-mm. Repeat four times. Record each thickness reading and the average.
Step 1.5: Choose another gauge thickness and repeat Step 4. Continue for the
remaining thickness gauges (a total of four different thicknesses.)
Step 1.6: Calculate the average and coefficient of variance for readings taken
on each
gauge. Record. Readings should agree with the calibrated gauge readings to
within 0.5 %.
The coefficient of variance should be 0.5 % or less.
Step 2.1: Follow Steps 1.1 to 1.4 for the gauge nearest to the range being
worked with.
Step 2.2: Follow step 1.6.
Step 2.3: Check for parallelism of the upper and lower platens by inserting a
single
gauge on one side of the lower face (1 - 2 mm from the edge of the face) and
allow the faces
to close. Record to the nearest 0.001-mm. Repeat at the edge directly opposite
from this edge.
Step 2.4: Repeat Step 2.3, taking readings at positions rotated 90 from the
first two
(i.e., front and back edges of the lower platen if first readings were taken
on the left and right
edges). Calculate the error of parallelism (P):
P = 0.5 [(di)2+ (d2)211/2
Where: di = difference between readings, step
8.2.3.
d2 = difference between readings, step 8.2.4.
Record P to the nearest 0.001-mm in the logbook.
If P > 0.005 mm, the instrument should be checked by instrumentation before
proceeding.
Step 3: Samples should be sufficient to obtain 50 readings (as specified in
8.6).
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Step 4: Clean the surfaces of the platens with lint-free paper and adjust the
micrometer
reading to zero.
Step 5: Insert a single specimen into the caliper opening, allowing the
pressure faces
to close and the reading to stabilize. Avoid imposing any manual stress on the
specimen while
the reading is being made. Record the reading by manual or serial port entry
using Sample
Manager.
Step 6: complete 10 caliper readings in a random format (e.g. , 5 readings
from the outer
ring 15-25mm in and 5 reading from the center ring 15-25mm from the center).
Step 7: do 5 readings per sheet: two in the top area, one in the middle, and
two in the
lower area.
After each sample, check that the instrument "zero" still reads zero.
Calculations
Calculations are done by the computer.
Step 1: To calculate air-dry bulk, cubic centimeters per gram:
Bulk, cm3/g = 1000 A/B
Where: A = thickness, mm
B = air-dry basis weight, g/m2
Step 2: To calculate air-dry ("apparent") density, in kilograms per cubic
meter:
Density, kg/m3= B/A
Where: A = thickness, mm
B = air-dry basis weight, g/m2
Odor Control Evaluation
Method of Measuring a Reduction in Free TMA
A method of measuring a reduction of free trimethylamine (TMA) sequestered by
an
absorbent material, such as the composite fabric of the present disclosure or
an absorbent article
made therefrom. In an embodiment, the absorbent material is disposed in a
closed container
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and is contacted with an amount of TMA. After the absorbent material has had
an opportunity
to sequester at least a portion of the amount TMA and, for example, the amount
of TMA has
reached an equilibrium between a gas headspace of the closed container and the
absorbent
material, a portion of the gas headspace is withdrawn from the closed
container. In an
embodiment, the amount of TMA is allowed to contact the absorbent material for
sufficient
time to reach equilibrium before a portion of the gas headspace is withdrawn
from the closed
container, thereby also providing sufficient time for at least a portion of
the initial amount of
TMA to be sequestered within the absorbent material. A person of ordinary
skill in the art
would readily know how to generate an equilibrium curve or other appropriate
tool to monitor
for and identify equilibrium.
In an embodiment, the closed container is a flexible container configured to
at least
partially collapse in response to the portion of the gas headspace being
withdrawn. In this
regard, it is easier for a user to withdraw the portion of the gas headspace
from the closed
container.
The withdrawn portion of the gas headspace is assayed to determine a gaseous
concentration of free TMA present in the headspace. In an embodiment,
measuring the amount
of free TMA in the withdrawn portion includes passing the withdrawn portion of
the gas
headspace over a stationary phase loaded with a colorimetric marker that
changes color when
contacted with TMA; and measuring an amount of color change in the stationary
phase in
response to passing the withdrawn portion of the gas headspace over the
stationary phase. In
an embodiment, assaying the withdrawn portion of the gas headspace to measure
the gaseous
concentration of free TMA includes using a colorimetric gas detector tube,
such as a
Sensidyne gas detector tube system. While colorimetric detection methods are
described, it
will be understood that other methods of TMA detection, for example, and not
limited to, gas
chromatography, can be used consistent with the methods of the present
disclosure.
Reduction of free TMA is measured relative to a control. In an embodiment, the
control
is a null control, where a null control includes a control that does not
include contacting a TMA
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molecule with an absorbent material. In an embodiment, the control is an
absorbent material
control, where an absorbent material control is an absorbent material having
substantially no
or no added carboxylic acid coupled to a fiber matrix (in this case,
"substantially no added
carboxylic acid" or "substantially free of added carboxylic acid- should be
understood to mean
no added carboxylic acid or an amount of added carboxylic acid between 0 wt %
and 1 wt %
as limited by known detection methods). As used herein, "added carboxylic
acid" should be
understood to mean an amount of carboxylic acid added or otherwise coupled to
an absorbent
material during processing or manufacturing over and above any carboxylic
present in an
untreated absorbent material. In an embodiment, the control absorbent material
includes a fluff
pulp, such as a Southern bleached softwood kraft pulp, that has not been
treated with or
otherwise coupled to a carboxylic acid. In this regard, a user can determine
an amount of TMA
reduction by the carboxylic acid coupled to the fiber matrix of the absorbent
materials
described herein relative to the chosen control.
In an embodiment, an amount of TMA not sequestered by the absorbent material
and
allowed to equilibrate within the gaseous headspace (TMAg) is compared to an
amount of TMA
not sequestered in a control experiment that is allowed to equilibrate within
the control gaseous
headspace (TMAc). The reduction in gaseous concentration of free TMA measured
in the
headspace above the absorbent material relative to that of a control may be
expressed as percent
reduction of free TMA (% TMAred). This percent reduction can be calculated
with the
following equation.
% TMAred = (TMA c - TMAg / TMA) >< 100 %
It should be noted that fluid containing TMA, such as a fluid used to insult
an absorbent
material or absorbent article, that resides on a side or other portion of the
closed container may
skew TMA reduction results. Such TMA-containing fluid that does not contact an
absorbent
material or absorbent article may result in increased volatilization of TMA
from the TMA-
containing solution into the gas headspace of the closed container. Such
increased TMA
volatilization may result in higher relative gaseous TMA concentrations than
if the TMA-
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containing solution were insulted directly onto the absorbent material or
absorbent article
incorrectly indicating a capability (or lack thereof) of the absorbent
material or absorbent article
to sequester TMA.
Feminine Hygiene Product Evaluation Protocol
The feminine hygiene testing protocol generates data using standardized
methods that
can be used to compare the performance of one product to another. Testing
includes Product
Weight, Rewet Performance, and Liquid Distribution.
Measuring physical attributes such as product weight, basis weight and density
provides
baseline information for comparing one product to another.
Basis weight and density of an absorbent product affect liquid absorption,
liquid
wicking throughout the pad, and pad integrity. Basis weight and density
uniformity throughout
the pad or intentional profiling within portions of the pad, impact product
performance.
Rewet testing provides evidence of dryness against the skin after an absorbent
structure
has been insulted with fluid. Rewet values are influenced by the speed liquid
is absorbed into
the structure, how well liquid is wicked away from the point of insult, and
how well liquid is
retained within the product. Liquid distribution testing quantifies the amount
of fluid wicking
from the point of insult out to the ends of an absorbent product. These are
both important
properties when analyzing absorbent feminine hygiene product performance.
Intake and rewet assays for feminine care products assess the fluid management
capabilities of feminine hygiene products while laid on a flat board. Fluid
used in this test is a
menstrual fluid simulant. Results of the standardized assays allow comparison
of products in
their ability to intake fluid, mitigate rewet or flow back of fluid, and/or
the distance wicked by
fluid.
Equipment and Materials Needed
Equipment and materials needed for Feminine Hygiene Testing are as follows:
rewet
& liquid di sill buti on template for marking the pads; basis weight ¨ density
template; filter
paper, cut into 7.5cm x 6.2cm rectangles; peristaltic pump - calibrated to
0.33 mLs/min, with
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3 cams for 3 tubes; weight, rectangle, 0.46 psi or equivalent; synthetic
menstrual fluid,
laboratory timers, balance sensitive to 0.01 g; scissors; ruler; weighing
dish; 4 - 250m1 plastic
beakers; stainless steel tube holders; Samco Series 70 press or equivalent;
position template &
die cutter; cutting board; standard silicone tubing.
For intake and rewet assays, materials needed are as follow: absorbent pad,
insult block;
3 or 5 ml syringe; timer; stopwatch; Synthetic Menstrual Fluid (SMF) ¨
Processed Swine Blood
(PSB) ¨ see below for detailed process for preparation of SMF; filter paper,
Whatman #3 size
11cm; weight to generate 0.55 psi - standardized pressure setup; balance
sensitive to at
least 0.001 g; ruler; 250m1 plastic bottle; 50-nil test tubes.
Test Procedures:
Product weight variability
Step 1: Weigh all feminine hygiene products using the standard test
spreadsheet and
a balance to determine an average weight, standard deviation and coefficient
of variation.
Step 2: As you weigh the pads, write the weight of each pad somewhere on the
wrap
or directly on the pad.
Step 3: Stack pads in ascending/descending order by weight.
Step 4: If wraps do not come off easily and testing will be performed with
wraps on,
carefully remove and weigh at least five wraps.
Step 5: Enter the individual values in the standard test spreadsheet in order
to calculate
adjusted average product weight.
Step 6: After weighing samples to determine adjusted average product weight,
select
6 -12 pads (depending on number of replicates you are testing) that have a
product weight
closest to the adjusted average product weight and set them aside for rewet &
liquid distribution
testing.
Pad Preparation for Rewet & Liquid Distribution
Step 1: Take the pads set aside for rewet & liquid distribution testing and
separate them
into two groups:
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= Group One: 3-6 pads to be tested
= Group Two: 3-6 pads to be use for tare weight
Step 2: Loosen and open wrap unfolding samples so they can be laid flat with
wings
spread.
Step 3: Allow samples to lay flat for some time (4-8 hours) to allow them to
breathe
and flatten out. Applying some light weight can help to hasten this process.
Step 4: Locate the center of the sample by finding the center of the wings and
mark the
products for dosing.
Using Rewet & Distribution Template to Prepare for Testing
Step 1: The Rewet & Distribution Template is thin Plexiglas and has two slits
that are
used to mark and divide samples into three sections. A small hole in the
center of the template
designates the center of the template and also where it should be positioned
on a feminine
hygiene pad. Once this is in place over the dosing point, lines can be drawn
on the pad with a
marker using the slits as guides.
Position the template over the length and width of the pad aligning the center
hole of
the template over the center mark or dosing point of the pad.
Step 2: Mark the pad (and the wrap if applicable) using a permanent marker by
tracing
inside the slits of the template. This will divide the pad into three
sections. If necessary, use a
ruler to extend lines on the pad onto the plastic wrap.
Step 3: Label each section of the sample with a replicate number and a
position
identification:
For TESTING replicate #1, each section is labeled as follows: #1F (front), #1M
(middle) and #1B (back). If the front of the pad cannot be discerned from the
back of the pad,
label as follows: #1 End-A, #1 Middle and #1 End - B). For TARE replicate #1,
each section
should be preceded with the letter "T" (for tare) ¨ T#1F, T#1M, T#1.
Step 4: After marking all pads, select the ones to be used for TARE WEIGHT and
cut
along the lines made using the template.
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Step 5: Weigh and record the weights of each section.
An average TARE weight for each section is calculated and applied to the
DISTRIBUTION ¨ PAD SECTION of the work sheet in order to determine liquid
distribution.
Liquid Distribution is accomplished after testing is complete when wetted
sections are cut,
weighed and recorded in the spreadsheet. (Wet Weight, g. ¨ Dry Weight, g =
Rewet, g).
The average of each section (Front = 3.04g, Middle = 3.01g, Back = 8.59g) is
added to
the Distribution ¨ Pad Sections as "start weight,
Preparing Filter Papers
Before actual testing begins, condition filter papers at ambient room
temperature/humidity for at least two hours.
Count and weigh three sets of ten 7.5cm X 6.2cm filter papers per sample being
tested.
As the filter papers are weighed, write the weight (g.) on the filter paper
and record it.
Label the filter papers according to the position where they will be applied
to the pad
after it has been dosed with synthetic menstrual fluid.
Priming and Calibration of the Peristaltic Pump
Step 1: The pump is calibrated to deliver 20mLs of synthetic menstrual fluid
over 60
minutes. If samples are very small, a smaller dose of 10mLs over 30 minutes
can also be used.
A second pump is also set up for an even smaller dose of 5mLs over 30 minutes.
Verify operation and calibration of the peristaltic pump by filling a 250m1
beaker with
approximately 50mLs of synthetic menstrual fluid.
Step 2: Pre-weigh three separate 250m1 beakers and labeled them A, B and Cs.
Step 3: Record the weight of each beaker as a TARE weight.
Step 4: Place the three inlet (also labeled A, B and C) ends of the tubes into
the
menstrual fluid.
Step 5: Place the outlet ends into an empty 250m1 beaker.
Step 6: To prime the pump, turn it on and allow it to run long enough to rinse
out DI
water or air trapped in the lines from previous testing or sitting for long
periods of time.
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Step 7: Once the pump is primed and the tubes are full of synthetic menstrual
fluid,
confirm there's at least 40mLs of fluid left in the main 250m1 beaker to use
for calibration and
testing.
Step 8: Carefully remove each tube and place the each one of the outlet tube
ends into
the three correspondingly labeled pre-weighed beakers. (Tube A into Beaker A,
Tube B into
Beaker B etc.)
Step 9: Set the timer for three minutes and start the pump to run ¨ you will
see a small
amount of the fluid enter into each beaker.
Step 10: When the timer stops, carefully remove the tubes from the beakers and
weigh
each beaker recording the weights as Gross Weight, g.
Step 11: Subtract Tare weights from Gross weights to calculate Net weights of
each
individual line and record the Net Weight to confirm calibration.
All three tubes need to be confirmed as calibrated prior to testing. If there
are
discrepancies in the Net value of any tube greater than 10%, run the
calibration again following
the same steps mentioned above.
Step 12: If all three tubes are accurately calibrated, thread them through
corresponding
stainless steel tube holders in preparation for testing
Rewet and Liquid Distribution Test
Step 1: Weigh and record the weight of each pad.
Step 2: Place the pads to be tested on the counter inside the feminine hygiene
test
cabinet, and position them so the dosing tube is lcm above the marked insult
point of the pad.
If edges of pad curl, tape the pads to the countertop using lab tape so they
lay flat.
Step 3: Set the lab timer for 1 hour and start the pump.
Step 4: Close the feminine hygiene test cabinet.
Step 5: At the end of the one hour dosing application, allow samples to rest
for 20
minutes.
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Step 6: At the end of the 20 minute rest period, position filter paper stacks
on top of the
corresponding sections of samples by starting in the middle, then placing the
other two stacks
at the front and back of the pad so they touch the middle stack.
Step 7: Set individual timers for five minutes.
Step 8: Place a rectangular weight on top of the filter papers and pads and
start the 5
minute timer.
Step 9: At the end of 5 minutes, remove weight.
Step 10: Weigh filter paper stacks and record the wet weight for each one.
Step 11: Weigh the entire wet pad and record the weight.
Step 12: Cut each sample one at a time along the lines (drawn) on the pads
being as
precise as possible.
Step 13: Weigh each wet pad section (141F, 141M and #1113) and record weight.
Repeat
this process with all other replicates until testing is complete.
Calculations:
Rewet Value ¨ The amount of liquid absorbed by filter papers after dosing.
Rewet, g
= wet filter papers, g minus dry filter paper, g.
Liquid Distribution ¨ The total amount of liquid absorbed by each (cut)
section of a
pad: Front, Middle and Back. Liquid Distribution, g = weight of each section +
rewet value of
each section minus the average dry product weight of each (tare) section.
Step 14: Failure occurs if there is run off from the pad onto the countertop.
It is
acceptable if run-off goes into the wings and/or side channels.
Step 15: After testing is finished, flush all peristaltic pump lines with DI
water
Step 16: Store remaining synthetic menstrual fluid in refrigerator
Intake and Rewet for Feminine Hygiene Product
Preparation of SMF from Processed Swine Blood (PSB)
Step 1: Processed swine blood arrives in bags.
Step 2: Gently knead the bag to mix the contents.
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Step 3: Cut off an edge of the bag and pour the contents into a 250m1 plastic
bottle.
Step 4: Remove the label from the bag and place it on the 250m1 plastic
bottle.
Step 5: From the 250m1 plastic bottle, fill a 50-ml test tube approximately 40-
ml. Place
the excess PSB back into the fridge. Since the viscosity of the blood can
change over time, it
is important to remove small quantities at a time.
Step 6: Allow the PSB to come to room temperature for approximately 1 hour.
Step 7: Take the viscosity reading of the PSB. Viscosity can change between
bags and
overtime within each bag. The viscosity of the blood can change the intake
time.
Step 8: While testing, a second 50-ml test tube can be filled with PSB to
allow to come
to temperature.
Feminine Hygiene Product Sample Preparation
Step 1: A prototype should contain a backsheet and the pad. Measure product
absorbent
core length and width.
Step: 2 Mark center of absorbent core length and width with an -X". The -X"
will be
the insult point.
Step 3: For commercial products that have wings, the center should be the
middle of
the wings.
Intake and Rewet Testing Procedure for Feminine Hygiene Products:
Step 1: Place protruding side of the insult block on the product so the hole
is centered
over the insult point.
Step 2: Weigh three filter paper for the "Before rewet- weight and record
their initial
weight.
Step 3: Prime the syringe with menstrual fluid simulant.
Step 4: Draw 2 mL of PSB into the syringe, ensuring there are no air bubbles.
Step 5: Place the tip of the syringe over the insult point on the product,
resting the
syringe on the insult block, but not adding any pressure onto the block.
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Step 6: Start dispensing the menstrual fluid simulant, targeting a dose rate
of 5 mL/3
seconds. Simultaneous, start the stopwatch and 10 minute timer.
Step 7: Stop stopwatch when fluid is absorbed.
Step 8: When the 10 minutes timer ends, repeat steps 3-6 two more times.
Step 9: After the third round of the 10 minutes timer ending, remove the
insult block.
Step 10: Place three rewet filter paper on top of the product, covering
majority of the
fluid.
Step 11: Place the weight on top of the filter paper. Start a timer for 2
minute.
Step 12: When the 2 minute timer ends, remove the weight and filter paper from
the
product.
Step 13: Weigh the filter paper for the -After rewet" weight and record the
weight.
Step 14: If wicking distance is desired, measure the length and width of the
PSB on the
sample.
Step 15: Record the length and width of fluid distance wicked.
Step 16: Fold the product and dispose of it in a biohazard waste bucket.
Step 17: Clean the acrylic intake rewet board with disinfectant solution.
EXAMPLES
EXAMPLE 1. FABRICATION OF COMPOSITE FABRICS
The crosslinked fiber layer of the present Example was fabricated by using lab
scale
air-laying equipment. Crosslinked fibers in dry loose fluff form were fed into
a chamber with
blunt blends blades to disperse the fibers further. Air was supplied to the
chamber to push
crosslinked fibers through a wire mesh onto a tissue laid on a 14 in x 14 in
forming wire. The
air-laid crosslinked fiber mat was then sandwiched between blotter papers and
pressed at 12000
psi. Pressed mats were cut to dimensions of 12 in x 12 in, then stored for
later use. Resin
bonded carded web and spunbond materials were prepared by cutting the
nonwovens to the
same dimensions as the crosslinked fiber mat, 12 in x 12 in. Staple fibers
were prepared by
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putting the loose, dry staple fibers into 2 L of water and subjecting the
mixture to 1500 rpm in
a British Disintegrator to disperse the staple fibers. A 12 in x 12 in lab
scale wet-laying piece
of equipment was prepared by placing a forming wire over the drainage area and
sealing the
equipment such that water did not leak out. The staple fiber-water slurry was
mixed with low
velocity air impingement for 2 minutes. After 2 minutes, air impingement was
stopped and the
water was drained, depositing staple fibers onto the forming wire. The wet-
laid staple fiber
mat was sandwiched between blotter papers and dried at 105 C for 15 minutes.
To prepare the two layers of crosslinked cellulose fiber and nonwoven/staple
fiber for
hydroentanglement, the air-laid crosslinked cellulose fiber mat was removed
from blotters and
placed onto either a resin bonded carded web, a carded web, spunbond, or wet-
laid staple fiber
mat such that the crosslinked cellulose fiber mat was immediately positioned
on the
nonwoven/staple fiber layer.
Hydroentanglement of samples was performed with lab scale hydroentanglement
equipment including of a conveyor belt, forming wire on top of the conveyor
belt, jet strip
positioned over the conveyor belt to extrude water jets, and a pump to control
the pressure of
water jets coming out of the jet strip. The forming wire was positioned over
the conveyor belt
such that it was not under the jet strip. The combined mat of crosslinked
fiber and
nonwoven/staple fiber was placed onto the forming wire such that it was not
directly under the
jet strip and the crosslinked layer was directly facing the jet strip while
the nonwoven/staple
fiber layer was directly contacting the forming wire. The water pump was
turned on to provide
water jets at a low pressure, below 100 psi. One pass was defined as the
material to be
hydroentangled being moved through the water jets in one direction from one
end to the
opposing end without stopping or changing direction of the conveyor belt. The
conveyor belt
was manipulated to subject the crosslinked fiber and nonwoven/staple fiber mat
to four passes
at the low pressure condition to pre-wet the fibers. The pressure of the water
jets was then
manipulated to achieve pressures listed in Table 2 and the crosslinked fiber
and
nonwoven/staple fiber mat is subjected to one pass at that pressure. E.g.,
hydroentanglement
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of sample 10, a crosslinked fiber mat on top of a resin bonded carded web,
consisted of 4 pre-
wetting passes followed by one pass at 200 psi. Once samples were
hydroentangled, they were
restrained between two Teflon mats and dried in an over at 105 C for 15-20
minutes.
Table 2 shows different combinations of crosslinked fiber and nonwoven
material
hydro-entangled at varying pressures. As the hydro-entanglement pressure
increased, the
degree of crosslinked cellulose fiber penetration into the nonwoven increased.
In Table 2, the
nonwoven was either resin bonded carded web: A web included of synthetic
fibers that have
been bound by a resin; a spunbond web formed of filaments from a melt process;
or staple
fibers, which are synthetic fibers laid down as a mat and not bonded by any
mechanism.
Table 2. Composition of composite fabrics and hydro-entanglement pressures.
Name Crosslinked Nonwoven Nonwoven Hydro-
Fiber Basis Type Basis Weight
entanglement
Weight (g/m2) (g/m2)
Pressure (psi)
Sample 10 110 Resin bonded 40
200
carded web
Sample 11 110 Resin bonded 40
600
carded web
Sample 12 110 Resin bonded 40
1000
carded web
Sample 14 40 Spunbond 15
200
Sample 15 40 Spunbond 15
400
Sample 18 110 Staple fiber 40
200
(unbonded)
Sample 19 110 Staple fiber 40
600
(unbonded)
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EXAMPLE 2. DIAPER CONSTRUCTS AND PROPERTIES
Referring to Table 3, various BCWs can be combined with a crosslinked
cellulose fiber
to produce a range of densities for the resulting composite structures.
Despite the difference
in densities, all composite fabrics including BCW and crosslinked cellulose
fiber showed
improved rewet and intake values.
Table 3. Compositions of composite fabrics.
Material Basis Weight Caliper (mm) Density (g/cm3)
(ghn2)
TABCW/110 159 1.48 0.099
HelixTM Airk-F
RBCW/110 HelixTM 146 1.53 0.095
Air*)+
RBCW/110 HelixTM 143 2.76 0.052
Air*4
Two diaper constructs were formed for this Example, referred to as ADL and
core-wrap
constructs. The base diaper for the constructs was Commercial Diaper 1, a
diaper with a
nonwoven acquisition layer, a crosslinked cellulose fiber under the nonwoven,
and a fluffless
core with channels. Commercial Diaper 2 has a multi-layer core design and was
used as a
comparison for core-wrap diaper constructs using a composite fabric of the
present disclosure.
For the ADL construct, the nonwoven and crosslinked cellulose fiber were
removed
and the replacement material was cut to the dimensions of the nonwoven layer.
For the core-wrap construct, the nonwoven and HelixTM fiber were removed. The
core
was removed and wrapped by either a composite fabric material.
Example 2 shows that nonwoven used in the composite structure can be through-
air
bonded or resin bonded. Example 2 also shows the magnitude of improvement in
absorbent
properties are unique to using crosslinked fiber as the cellulosic fiber
layer. The nonwoven
can range from 7700 ¨ 18500 1PRP flow rate and maintain performance when
utilized in the
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crosslinked fiber containing composite. Composites with a basis weight of 150
gsm 10%
can range in density from 0.052 ¨ 0.099 &in' and have no change in diaper
construct
performance.
EXAMPLE 3. DIAPER CONSTRUCTS AND PROPERTIES
Referring to Table 4, a series of TABCW and crosslinked cellulose fiber
composite
fabrics were made.
Material Attributes ¨ Basis Weight, Caliper, Density
At roughly the same basis weight and hydro-entanglement conditions, HelixTM as
the
fiber component increases the caliper of the composite by ¨14%. Using the Groz-
B jet strip
increases the caliper of the composite by ¨14%.
Table 4. Material attributes.
Material Basis Weight Caliper Density
(wm2) (mm) (g/cm3)
TABCW/HelixTm A 110 153 1.57 0.098
gsm
TABCW/HelixTm Ae+ (a) 150 1.38 0.109
110 gsm
TABCW/HelixTm Air1-11)+ 150 1.58 0.095
110 gsm with Groz-B 64
NW/HelixTM Air -P 50gsm 90 1.02 0.15
NW/HelixTM Air44 150 0.65 0.13
1 lOgsm
TABCW is a through-air bonded carded web that serves as the nonwoven portion
of
the composite.
Two diaper constructs were formed for this experiment, referred to as ADL and
core-
wrap constructs. The base diaper for the constructs is Commercial Diaper 1, a
fluffless core
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diaper with a nonwoven acquisition layer and a HelixTM fiber distribution
layer under the
nonwoven. Commercial Diaper 2 has a multi-layer core design and was used as a
comparison
for core-wrap diaper constructs using a composite fabric of the present
disclosure.
For the ADL construct, the nonwoven and HelixTM fiber distribution layer were
removed and the replacement material was cut to the dimensions of the nonwoven
layer.
For the core-wrap construct, the nonwoven and HelixTM fiber distribution layer
are also
removed. The core is removed and wrapped by either a composite material of the
current
disclosure.
Diapers Constructed:
TABCW/HelixTm 110 gsm core-wrap
TABCW/HelixTm 110 gsm ADL
TABCW/HelixTm Air + 110 gsm ADL
TABCW/ HelixTM Air + 110 gsm core-wrap, Groz-B 64 jet strip
NW/ HelixTM Air + 50 gsm core-w-rap
The no load saddle wicking test and flat acquisition under load test are as
described in
test method section.
FIG. 9 is a bar graph showing a comparison of wicking distance from insult
point of a
composite fabric of the present disclosure in ADL diaper constructs in a no
load saddle wicking
test. Statistically, the deconstructed control diaper wicked less distance
towards the back. Both
the HelixTM (not shown) and HelixTM Air + composite fabrics wicked more
distance than the
control. The HelixTM composite fabric was able to wick further towards the
front than the
HelixTM Air + composite fabric. Increased wicking distance indicates better
utilization of the
core.
FIG. 10 is a bar graph showing a comparison of a composite fabric of the
present
disclosure in ADL diaper constructs with respect to intake times for the flat
acquisition under
load test. Deconstructing and reconstructing the control diaper has no
significant impact on
the intake time. Crosslinked fiber including composites had significantly
lower times for
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intakes 2 and 3. There was no significant difference in intake times when
He1ixTM (not shown)
and HelixTM Air + were used as the fiber component of the composite structure
in the diaper
constructs.
FIG. 11 is a bar graph showing a comparison of a composite fabric of the
present
disclosure in ADL diaper constructs with respect to rewet values for the flat
acquisition under
load test. Decreased rewet values were shown for intakes 1, 2, and 3, with the
rewet value for
intake 3 being dramatically smaller than in Commercial Diaper 1.
FIG. 12 is a bar graph showing a comparison of average wicking distances of
the diaper
for a composite fabric of the present disclosure in ADL diaper constructs, as
compared to
Commercial Diaper 1. The composite fabric in ADL diaper constructs wicked
significantly
further than the control diaper. HelixTM (not shown) as the crosslinked fiber
component of the
current disclosure wicks further in intake 1 than the HelixTM Air + version.
However, the
wicking distance from doses 2 and 3 are not statistically different between
the two crosslinked
fiber constructs.
FIG. 13 is a bar graph showing a comparison of average intake times of diapers
including composite fabrics of the present disclosure in core-wrap diaper
constructs in a no
load saddle wicking test. All diapers including composite fabrics of the
present disclosure had
significantly improved intake times versus the control Commercial Diaper 2.
There was no
significant difference between intake times of diapers including HelixTm (not
shown) or
HelixTM Ale+ containing composites. HelixTM Air + as the fiber component in
the composite
shows no significant difference when hydro-entangled with different jet
strips.
FIG. 14 is a bar graph showing a comparison of wicking distance from insult
point of
a composite fabric of the present disclosure in core-wrap diaper constructs in
a no load saddle
wicking test. All diaper constructs including the composite fabrics of the
present disclosure
showed significantly improved wicking distances versus the control. HelixTM
(not shown) as
the fiber component in the composite shows improved wicking distance versus
the HelixTM
Air + as the fiber component.
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FIG. 15 is a bar graph showing a comparison of a composite fabric of the
present
disclosure in core-wrap diaper constructs with respect to intake times from
the flat acquisition
under load test. All diaper constructs including the composite fabric of the
present disclosure
showed significant improvement in intake time versus the control.
FIG. 16 is a bar graph showing a comparison of a composite fabric of the
present
disclosure in core-wrap diaper constructs with respect to rewet values from
the flat acquisition
under load test. All diaper constructs including the composite fabrics of the
present disclosure
showed significant improvement over the control diaper.
FIG. 17 is a bar graph showing a comparison of average wicking distances of a
composite fabric of the present disclosure used in a core-wrap diaper design.
The diaper
construct including the core-wrap was a more simplified design compared to the
Commercial
Diaper 2's multi-layer core design. All diaper constructs employing the
composite fabrics of
the present disclosure showed improved wicking distance towards the front for
doses 1 and 2.
When HelixTM is used as the crosslinked cellulose fiber component in the
composite fabric, the
test fluid immediately wicked the full distance of the core of the diaper. All
crosslinked fiber
composite containing diaper constructs showed significantly improved wicking
distances
versus the control diaper.
Example 3 showed that there was no significant difference in diaper construct
performance when entangling HelixTm Air + with a different patterned jet
strip. Composites
with HelixTM exhibit improved wicking versus HelixTM Air44 in all diaper
constructs.
Improved wicking occurs through all insults or the first two insults.
Table 5. ADL Application ¨ Flat Acquisition Under Load
Commercial 150
gsm Average Commercial Fluff
Diaper 1 NW/HelixTM Air + Core Products
1st Intake (s) 36.4 43.0 46.8
2nd Intake (s) 45.4 30.9 84.1
3rd Intake (s) 47.5 25.8 98.8
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1 Rewet (g) 0.20 0.19 0.16
2nd Rewet (g) 0.22 0.20 0.38
3rd Rewet (g) 0.86 0.34 6.07
1" Wicking 25.7 27.3 21.6
Distance (cm)
2nd Wicking 30.6 32.7 27.4
Distance (cm)
3rd Wicking 34.1 36.7 33.1
Distance (cm)
Table 6. Core-wrap application - Flat Acquisition under Load
Commercial 90 gsm Average
Commercial
Diaper 2 NW/HelixTM Air*4 Fluffless Core
Products
1" Intake (s) 92.5 32.4 86.3
211d Intake (s) 262.9 17.9 264.5
3rd Intake (s) 314.7 15.6 318.6
1" Rewet (g) 0.16 0.19 0.15
2nd Rewet (g) 2.49 0.26 2.85
3rd Rewet (g) 16.34 2.97 12.39
1" Wicking 18.2 23.2 20.8
Distance (cm)
2nd Wicking 26.0 31.8 27.6
Distance (cm)
3rd Wicking 34.7 37.5 33.2
Distance (cm)
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EXAMPLE 4. LAB CARDED STAPLE FIBER COMPOSITES
Table 7. Intake Times of Lab Carded Staple Fiber Composites in Flat
Acquisition Under Load
test
Sample Intake 1 (s) Intake 2 (s) Intake 3 (s)
Commercial 61.0 198.4 217.6
Diaper 2
NW/ HelixTM 32.4 17.9 15.6
50gsm
Staple Fiber 36.0 26.6 18.1
Rayon Fiber 48.8 32.8 22.4
Table 8. Rewet Values of Lab Carded Staple Fiber Composites in Flat
Acquisition Under Load
test.
Sample Rewet 1 (g) Rewet 2 (g) Rewet 3 (g)
Commercial 0.13 0.68 9.38
Diaper 2
NW/Helix' M 0.19 0.26 2.97
Airg-P 50gsm
Staple Fiber 0.21 0.41 3.50
Rayon Fiber 0.16 0.44 2.90
Table 9. Wicking Distances of Lab Carded Staple Fiber Composites in Flat
Acquisition Under
Load test
Sample Wicking Wicking Wicking
Distance 1 Distance 2 Distance 3
(cm) (cm) (cm)
Commercial 21.1 27.7 32.3
Diaper 2
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NW/HelixTM 23.2 31.8 37.5
Airg+ 50gsm
Staple Fiber 24.4 34.2 38.0
Rayon Fiber 27.4 36.9 38.3
The above three tables shows when the nonwoven layer was comprised of unbonded
staple fibers, formed by the carding process and followed by subsequent
hydroentanglement
with HelixTM Ait0+ fibers, the resulting composite still performed comparably
to the
composite when formed with a pre-bonded nonwoven web. Both petroleum-based
staple fibers
and cellulose derived staple fibers were used as the nonwoven layer in this
Example.
Composites made with the carded staple fibers were made into core-wrap
prototypes following
the same procedure described in Example 2. When compared with the composite
made with a
pre-bonded nonwoven web, the carded web composites exhibit a similar intake
time trend in
the Flat Acquisition Under Load test. Additionally, both the rewet values and
wicking
distances of the carded web composites are within value ranges previously
measured with the
pre-bonded nonwoven composites. The variety of staple fibers that can be used
in the
nonwoven portion of the composite allows for flexibility in sourcing of raw
materials for
manufacturing of the composite.
EXAMPLE 5. FLUFFLESS CORE AND FLUFF CORE DIAPER COMPARISONS
The present Example shows that the benefit offered by the hydroentangled
crosslinked
fiber and nonwoven composite fabrics of the present disclosure for the core-
wrap application
(see, e.g., FIG. 4). Further benefits can be observed if the basis weight of
crosslinked fiber is
increased.
As an ADL, the crosslinked fiber composite reaches parity in saddle wicking
results.
The crosslinked fiber composite stands out in flat acquisition under load,
improving intake
times, rewet values, and early wicking distances. It is possible to make
multiple grades of
material by varying the basis weight.
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FIG. 18 is a bar graph showing average intake times of fluffless diapers in a
no load
saddle wicking test for a diaper using the composite fabric in a core-wrap
configuration
compared to averages of commercial fluffless core diapers. The composite
fabric was able to
significantly improve intake time of fluid in the core-wrap application for
the no load saddle
wicking test.
FIG. 19 is a bar graph showing a comparison of wicking distances from insult
point for
a diaper using the composite fabric in a core-wrap configuration compared to
averages of
commercial fluffless core diapers. The composite fabric was able to increase
wicking
distances compared to the average wicking distance of commercial fluffless
core diapers.
FIG. 20 is a bar graph showing a comparison of fluffless diaper intake times
in a flat
acquisition under load test for a diaper using the composite fabric in a core-
wrap configuration
compared to averages of commercial fluffless core diapers. The composite
fabric was able to
significantly improve the intake time for all three fluid insults in the core-
wrap application.
FIG. 21 is a bar graph showing a comparison of fluffless diaper rewet values
in a flat
acquisition under load test for a diaper using the composite fabric in a core-
wrap configuration
compared to averages of commercial fluffless core diapers. The composite
fabric was able to
significantly improve the second and third rewet values in the core-wrap
application.
FIG. 22 is a bar graph showing a comparison of average wicking distances of
fluffless
diapers in a flat acquisition under load test for a diaper using the composite
fabric in a core-
wrap configuration compared to averages of commercial fluffless core diapers.
The composite
fabric was able to increase wicking distances for all three fluid insults in
the flat acquisition
under load test in the core-wrap application.
FIG. 23 is a bar graph showing a comparison of fluff core diapers from insult
point of
diaper constructs in a no load saddle wicking test for a diaper using the
composite fabric in an
ADL configuration compared to averages of commercial fluff core diapers. The
composite
fabric was able to increase wicking distance against the average wicking
distance of
commercial fluff core diapers in the no load saddle wicking test.
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FIG. 24 is a bar graph showing a comparison of wicking distances of a diaper
using the
composite fabric in an ADL configuration compared to averages of commercial
fluff core
diapers. The composite fabric was able to significantly increase wicking
distances against the
average wicking distances of commercial fluff core diapers in the flat
acquisition under load
test, for all three fluid insults.
EXAMPLE 6. DIAPER AND ADULT INCONTINENCE PRODUCT (WET-LAID
COMPOSITE) ¨ CONSTRUCTS AND PROPERTIES
Described below is a pilot approximation of commercially available hybrid
carded pulp
technology. Production of the HelixTM in nonwovens composite on a wet-laid
pilot line began
with fiber stock preparation. Dry HelixTM Air -P fibers were added to a stock
tank of water and
diluted to a concentration of <2%. The stock tank was constantly stirred with
an agitator that
did not damage the quality of the fibers. The stock was pumped from the stock
tank to the
headbox of the wet-laying system. Along the way, the stock was further diluted
with water to
improve formation of the fibers as they were deposited onto the forming wire.
The diluted
stock then entered the headbox and was distributed onto the forming wire to
form a web of
HelixTM Air + fibers. Water was then drained from the web from either gravity
or vacuum
slits below the forming wire. When the web was sufficiently dry, it was
transferred from the
forming wire onto a pre-bonded nonwoven web. The nonwoven web width was
equivalent or
greater in width as compared to the Helix"' Air'-h web. The bi-layered
nonwoven and fiber
web were pre-hydroentangled with low pressure water jets to help keep the two
layers together.
The water jets first came in contact with the fibrous side of the web to push
the fibers into the
nonwoven. After pre-hydroentanglement, water was removed via vacuum slits. The
web was
then threaded through a heated can dryer system where minimal heat was applied
to help
dewater the web to approximately 50% solids content. The partially-dried web
was then wound
into a roll and wrapped in plastic to prevent further moisture loss. The
plastic wrapped rolls
were then saved for further hydroentanglement.
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Rolls were loaded onto an unwind stand and unwound such that the nonwoven side
of
the web contacted the carrier web and the fiber side of the web was faced
towards the
hydroentanglement jet heads. The carrier web brought the unbonded HelixTM in
nonwovens
material through at least two hydroentanglement jet heads to further push the
HelixTM
fibers into the nonwoven, bonding the two layers together. The composite
structure was
dewatered via vacuum slits and passed through a through-air drying system to
completely dry
the composite to greater than 90% solids content. The dry composite was wound
into a roll for
further use.
While a 2-step process for making the composite fabric is described in the
present
Example, a person of skill in the art would understand that a 1-step process
can be readily
carried out.
Referring to Table 10, the composite material used in this Example was formed
of a
fiber layer composed of 100% HelixTM Air + and the nonwoven layer was a
through air bonded
carded web. Sample Codes 1-4 were tested for their performance as an ADL;
samples 5 and 6
were tested for their performance as a core-wrap.
Table 10. Test composite material compositions.
Sample Code (4) Composite basis HelixTM Air(9+ BW Nonwoven
BW
weight (BW, g/m2) (g/m2) (g/m2)
1 150 110 40
2 140 110 30
3 120 80 40
4 110 80 30
5 90 50 40
6 80 50 30
Commercial baby diapers and a commercial adult incontinence product were
selected
as commercial comparatives for prototypes. The ADL from each product was
removed and
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replaced with composite fabric of the exact same dimensions: Codes 1-4 were
tested in each
commercial product.
The intake times of the Commercial Comparative Diapers in a flat acquisition
under
load test were obtained. Commercial Comparative Diapers 1 and 4 had the
fastest intake times.
In an ADL diaper construct, with Code 1, 2, 3, or 4 composite fabric samples
replacing the
ADL of Commercial Comparative Diapers 1, 2, 3, or 4, in a flat acquisition
under load test,
composite fabric sample Code 1 exhibited a noticeably reduced intake time
compared to
Comparative Diapers 2 or 3, respectively. A reduction in intake time compared
to Comparative
Diaper 1 was seen for all ADL diaper constructs using Codes 1, 2, 3, and 4
composite fabric
samples. A reduction in intake time compared to Comparative Diaper 4 was seen
for ADL
diaper constructs using Codes 1, 3, and 4 composite fabric samples, and for
intakes 1 and 3 in
the case of an ADL diaper construct using a Code 2 composite fabric sample.
For the intake times of embodiments of core-wrap diaper constructs, with Code
5 or 6
composite fabric samples wrapping the absorbent core of Commercial Comparative
Diaper 1,
in a flat acquisition under load test, both Code 5 and 6 composite fabric
samples provided a
significant reduction in intake time compared to Commercial Comparative
Diapers 1 and 5.
Commercial Comparative Diapers 1 and 4 have the lowest rewet values at Rewet 3
among the Commercial Comparative Diapers, in a flat acquisition under load
test. Across
Commercial Comparative Diapers 1-4, code 1 composite fabric offered
improvement in rewet
values, and this was particularly noticeable in rewet 3. An improvement in
rewet values at
Rewets 2 and 3 compared to Commercial Comparative Diaper 5 was also observed,
in
particular in core-wrap diaper constructions where a Code 5 or 6 composite
fabric sample
wraps the absorbent core of Commercial Comparative Diaper 1, in a flat
acquisition under load
test.
For the average total wicking distance in embodiments of ADL diaper
constructs, using
Code 1, 2, 3, or 4 composite fabric samples to replace the ADL of Commercial
Comparative
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Diaper 1, in a flat acquisition under load test, the wicking distances were
improved compared
to those of Commercial Comparative Diaper 1.
For the average total wicking distance in embodiments of core-wrap diaper
constructs,
using Code 5 or 6 composite fabric samples to wrap the absorbent core of
Commercial
Comparative Diaper 1, in a flat acquisition under load test, the wicking
distances were
improved compared to those of Commercial Comparative Diapers 1 and 5.
The intake times for ADL constructs using Code 1, 2, 3, and 4 were improved
compared
to the intake times of Comparative Diaper 4, in a no load saddle wicking test.
Core-wrap diaper constructs made with Code 5 and Code 6 composite fabric
samples
show improvement in intake times 2 and 3 compared to Commercial Comparative
Diaper 5, in
a no load saddle wicking test.
In an ADL diaper construct, the wicking distances using Code 1, 2, 3, or 4
composite
fabric samples were improved (i.e., greater than) to those of the Commercial
Comparative
Diaper 3 and Commercial Comparative Diaper 1.
In a core-wrap diaper construct, the wicking distances using Code 5 or 6
composite
fabric samples to wrap the absorbent core were improved (i.e., greater than)
compared to those
of the Commercial Comparative Diapers 1 and 5.
For a comparison of average intake times of ADL adult incontinence product
constructs
in a no load saddle wicking test, using Code 1, 2, 3, or 4 composite fabric
samples to replace
the ADL of a Commercial Comparative adult incontinence product, the ADL adult
incontinence product constructs made with Code 1, 2, 3, and 4 composite fabric
samples
showed improvement (i.e., lower intake times) in intake times 2 and 3 compared
to the
Commercial Comparative adult incontinence product.
For a comparison of wicking distances from insult point (front and back) and
total
wicking distance of ADL adult incontinence product constructs in a no load
saddle wicking
test, using Codes 1, 2, 3, or 4 composite fabric samples to replace the ADL of
a Commercial
Comparative adult incontinence product, the ADL adult incontinence product
constructs made
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with Codes 1, 2, 3, and 4 composite fabric samples show improvement (i.e.
greater wicking
distances) in wicking distances when compared to the Commercial Comparative
adult
incontinence product.
In the present Example, for the majority of commercial baby diaper
comparatives, Code
1 showed improvement in intake times and wicking distance for flat acquisition
under load
tests. For Commercial Comparative Diaper 1, the composite fabrics could assist
absorbent
cores with very high SAP content utilize more of the absorbent core than
conventional ADLs.
In both the flat acquisition under load and no load saddle wicking tests, ADL
diaper constructs
containing Codes 1, 2, 3, or 4 composite fabrics showed a significant increase
in wicking
distance.
EXAMPLE 7: SEQUESTRATION OF TMA WITH HELIX IN NONWOVENS
HelixTM in Nonwovens sheets were cut into lg pieces and compared with
fiberized fluff,
formed into pads, placed in sealed containers, and insulted with
trimethylamine solution. The
fiberized fluff is treated with a chemical to sequester trimethylamine.
Comparative fluff pulp sheets were cut into strips and then fiberized in a
Kamas mill.
The fluff pulp was then formed into 2-inch diameter pads with an average
weight of
0.94 0.02g. These pads were compressed in a Carver press to a pressure of
2000psi.
Testing containers were constructed out of Kirkland 500mL water bottles, which
were
selected due to their compressibility. 16 gauge needles were driven through
plastic lids of the
water bottles, glued in place, and sealed with silicone caulking. Rubber
tubing was placed
around the hilt of the needles to allow for an airtight seal between the hilt
and measurement
devices.
The compressed fluff rounds were introduced into the testing containers,
insulted with
15g of solution, sealed, and then the headspace above was tested for TMA after
2 hours.
Referring to Table 11, TMA solutions were tested at a concentration of 0.053%
by weight.
Normal vaginal fluid not associated with bacterial vagin osi s has
trimethylamine levels
0.0005% by weight according to literature values.
Table 11. TMA solutions.
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g DI water tL 25% solution
% by weight TMA solutions
25x literature 300 639 0.053
The concentration of trimethylamine in the headspace of the containers was
tested
above both pulps two hours after insult. 105SE model Sensidyne tubes were
used. These
tubes are labelled for use with ammonia, but are able to be used with
trimethylamine, as well.
The actual trimethylamine concentration is found by multiplying the Sensidyne
reading by a
conversion factor of 0.5.
Three samples of each material were tested. The trimethylamine concentrations
in
headspaces above pads were compared for the Helix in Nonvvovens composite and
fluff pulp.
Referring to Table 12, it was found that the Helix in Nonwovens composite
decreased the
headspace concentration of TMA more than the fluff pulp.
Table 12. TMA Headspace Test.
Sample Nonwoven Helix' TMA TMA Present
Basis Air + Concentrati (ppm)
Weight Basis on (%)
(gsm) Weight
(gsm)
NW/HelixTM 40 110 0.053 0.33
Air 110 gsm
NW/HelixTM 40 80 0.053 0.33
Airg-P 80 gsm
NW/HelixTM 40 50 0.053 0.66
Airg-P 50 gsm
BlissTM N/A N/A 0.053 17
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EXAMPLE 8. FEMININE HYGIENE PRODUCT EVALUATIONS
A NW/ HelixTM Air -F composite fabric having a basis weight of 150 g/m2 was
evaluated in a flat sheet configuration and served as an absorbent core for
use in a sanitary pad.
The non-woven side faced the incoming liquid. Compared to 7 Commercial
Comparative
sanitary pads, referring to FIG. 25, the composite fabric had the most even
fluid distribution.
The basis weight of composite or the He1ixTM Air -F fraction did not appear to
have an effect
on distribution.
Table 13. Feminine hygiene product dimensions.
Product Absorbent Core
(L x W) (cm x cm)
Commercial Comparative Sanitary Pad 1 19.5 x 7.2
Commercial Comparative Sanitary Pad 2 20.5 x 6.2
Commercial Comparative Sanitary Pad 3 22 x 7
Commercial Comparative Sanitary Pad 4 19 x 7.4
Commercial Comparative Sanitary Pad 5 22 x 6.6
Commercial Comparative Sanitary Pad 6 18.3 x 6.7
Commercial Comparative Sanitary Pad 7 17.4 x 7
NW/ HelixTM AirC04 composite fabric 20 x 7
FIG. 26A is a schematic diagram illustrating an example feminine hygiene
product
2600A including an absorbent composite 2610A, in accordance with embodiments
of the
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present disclosure. Absorbent composite 2610A can be or include the composite
fabrics formed
by physically entangling a crosslinked cellulosic fiber layer and a nonwoven
polymer layer, as
described in more detail in reference to FIG. 1, as an example of composite
fabric 110 of FIG.
1. Example feminine hygiene product 2600A also includes a liquid impermeable
backsheet
2605 and topsheet 2615, as described in more detail in reference to FIG. 4. In
contrast to
conventional feminine hygiene products, described in reference to the
comparative examples
of FIG. 27A and 27B, example feminine hygiene product 2600A can omit a
dedicated
acquisition-distribution layer (ADL), at least in part because composite
fabric 2610A can
perform the same or similar function with improved results, described below.
Example feminine hygiene product 2600A defines an inner surface 2620 and an
outer
surface 2625, relative to the orientation of donning and the expected
direction of incidence of
liquid insult. To that end, topsheet 2615 can be or include nonwoven material
or another liquid-
permeable material, such as a spunbond (SB) material or a through air bonded
carded web
(TABCW), or a perforated film. In some embodiments, topsheet 2615 can receive
an embossed
pattern or a pattern of perforations to facilitate or otherwise improve
capillary action and/or
wicking/distribution of liquid from the inner surface toward the absorbent
composite 2610A.
As such, the embossing and/or perforations can be propagated into and/or
through the
absorbent composite 2610A.
As illustrated in FIG. 26A, composite fabric 2610A can adopt a core-wrap
configuration as described in more detail in reference to FIG. 28A. FIG. 26B,
in contrast,
illustrates a multilayer configuration where an absorbent composite 2610B
includes one or
more stacked layers of the physically entangled composite fabric described in
reference to FIG.
1, in accordance with embodiments of the present disclosure. To that end, the
stacked layers
can be disposed relative to inner surface 2620 with crosslinked cellulose
material physically
contacting backsheet 2605.
In reference to FIGs. 29-32 that present data generated by comparative testing
of
example feminine hygiene products 2600A and/or 2600B in accordance with
embodiments of
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the present disclosure, FIGs. 27A-27B are schematic diagrams illustrating
cross sections of
comparative example 1 and comparative example 2, respectively. Comparative
example 1 and
comparative example 2 represent existing commercial feminine hygiene products
considered
to be market leaders in North American and Asian markets, respectively.
FIG. 27A illustrates an example commercial feminine hygiene product 2700 as
available in the North American market. Example commercial feminine hygiene
product 2700
includes a backsheet 2705, a cellulosic material layer 2710 that includes
super-absorbent
polymer 2715 dispersed in the cellulosic material layer 2710, an acquisition
distribution layer
2720 formed of a spunlace material, and a liquid permeable topsheet 2725
formed of perforated
film material. FIG. 27B illustrates an example commercial feminine hygiene
product 2750 as
available in the East Asian market. Example commercial feminine hygiene
product 2750
includes a backsheet 2705, a cellulosic material layer 2710 that includes
super-absorbent
polymer 2715 dispersed in the cellulosic material layer 2710, an acquisition
distribution layer
2730 formed of a through air bonded carded web (TABCW) material, and a liquid
permeable
topsheet 2725 formed of TABCW material. Additionally, example commercial
feminine
hygiene product 2750 includes two spunlace layers interposed between the
cellulosic layer
2710 and the ADL 2730 and between the cellulosic layer 2710 and the backsheet
2705. Average
physical characteristics of example commercial feminine hygiene products 2700
and 2750 are
described in Table 14, in comparison to exemplary embodiments of the present
disclosure.
Data in Table 14 were tabulated from six examples of each product
configuration.
Table 14: Average Material Data for Comparative Examples and Exemplary
Embodiments
Attribute (mean value) Comparative Comparative Example 1
Example 2
* n=6 Example 1 Example 2
Absorbent Structure Mass (g) 2.70 4.60 3.30
3.85
Cellulose Mass (g) 1.30 3.70 2.20
2.57
Petrochemical Mass (g) 1.40 0.9 1.10
1.28
Absorbent Structure Caliper (mm) 1.83 2.22 2.35
2.35
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Advantageously, incorporating a smaller mass of petrochemical materials
improves the
overall sustainability of feminine hygiene products by reducing the use of
petroleum that, on a
global scale, represents an annual reduction of non-renewable resource usage
on the order of
thousands or millions of tons. Additionally, replacing petrochemical materials
with cellulosic
materials represents a replacement of a non-sustainable material with a
renewable resource. In
some embodiments, example feminine hygiene products 2600A and 2600 B include
from about
0.5 g to about 5 g of cellulosic material, from about 1.0 g to about 5 g of
cellulosic material,
from about 1.5 g to about 5 g of cellulosic material, from about 2.0 g to
about 5 g of cellulosic
material, from about 2.5 g to about 5 g of cellulosic material, from about 3.0
g to about 5 g of
cellulosic material, from about 3.5 g to about 5 g of cellulosic material,
from about 4.0 g to
about 5 g of cellulosic material, or from about 4.5 g to about 5 g of
cellulosic material, including
fractions and interpolations thereof Understandably, while additional
absorbent material will
increase the overall volumetric capacity of example feminine hygiene product
2600A or
2600B, generally wearer experience is impaired with increasing product weight.
As such, a
lower mass can be desirable, balanced against the reduction of performance on
acceptance and
retention of liquid that results from reducing the quantity of absorbent
material.
In some embodiments, example feminine hygiene products 2600A and 2600 B
include
from about 3.0 g to about 0.1 g of petrochemical material, from about 2.5 g to
about 0.1 g of
petrochemical material, from about 2.0 g to about 0.1 g of petrochemical
material, from about
1.5 g to about 0.1 g of petrochemical material, from about 1.0 g to about 0.1
g of petrochemical
material, and from about 0.5 g to about 0.1 g of petrochemical material,
including fractions and
interpolations thereof. As previously described, from a sustainability
perspective,
petrochemical materials can be sought to be excluded from example feminine
hygiene product
2600A or 2600B to as great an extent as possible. Beyond a threshold value,
however, structural
and functional performance of products are impaired at the expense of wearer
experience. For
at least this reason, a petrochemical mass that is too low or zero can impair
performance and
result in larger sizes and weights, making feminine hygiene products feel
bulky and large.
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Advantageously, Examples 1 and 2 exhibit a reduced mass of petrochemical
materials relative
to comparative example 1, without introducing the same additional amount of
cellulosic
material as in comparative example 2. In this way, the improved performance of
example
feminine hygiene products 2600A and 2600B can be seen to represent an improved
approach
for transitioning from petrochemical materials to cellulosic materials, in
that performance is
significantly improved with a smaller increase in product mass.
Advantageously, omitting dedicated ADL materials from example feminine hygiene
products 2600A and 2600B, as described in more detail in reference to FIGs.
26A-26B and
FIGs. 28A-28B can permit a larger portion of the absorbent structure to
comprise cellulosic
material without increasing characteristic dimensions, referred to as the
"caliper," at the
expense of wearer experience. A thinner caliper, where caliper describes the
thickness of
components of the products, improves wearer experience by reducing the
perception of wearing
the product (e.g., during motion, when stretching, when seated, or when
standing). Reducing
the caliper by too great an extent, however, increases rewet and increases
intake time by
constraining fluid motion in the transverse direction between backsheet 2605
and topsheet
2615. In some embodiments, example feminine hygiene products 2600A and 2600 B
have an
absorbent structure caliper from about 3.0 mm to about 0.1 mm, from about 2.5
mm to about
0.1 mm, from about 2.0 mm to about 0.1 mm, from about 1.5 mm to about 0.1 mm,
from about
1.0 mm to about 0.1 mm, and from about 0.5 mm to about 0.1 mm, including
fractions and
interpolations thereof As such, experiments with example feminine hygiene
product
configurations resulted in performance data described in reference to FIGs. 29-
32 for material
and dimension data described in Table 14. As demonstrated in Table 14,
exemplary
embodiments of the present disclosure, as described in more detail in
reference to FIGs. 26A-
26B and 28A-28B, exhibit comparable dimensions and weight relative to
comparative example
1 and comparative example 2. As such, data in Table 16, below, as well as the
graphs presented
in FIGs. 29-32, present direct comparisons between comparable products. In
this way, the
improvements to standard assay measures reported represent a significant and
unexpected
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improvement to shared properties of intake time, rewet, wicking distance, or
the like, in terms
of both average performance and consistency between products.
To that end, FIG. 28A is a schematic diagram of a cross section of example
feminine
hygiene product 2600A illustrating material layers of absorbent composite
material 2610A. As
illustrated, in place of a dedicated ADL layer as is conventional in
commercial products,
example feminine hygiene product 2600A includes a core-wrap configuration of
composite
material formed from a nonwoven layer 2810 and a crosslinked cellulose layer
2805, wrapped
around an absorbent core 2815. In some embodiments, the composite material is
formed by
physically entangling nonwoven layer 2810 and crosslinked cellulose layer
2805, which forms
an interfacial region 2820 making the nonwoven layer 2810 and crosslinked
cellulose layer
2805 mechanically inseparable in a dry state. In some embodiments, the
composite material is
at least partially wrapped around an absorbent core 2815. In some embodiments,
the composite
material is at least partially folded to form hollow core (e.g., omitting
absorbent core 2815) or
folded such that crosslinked cellulose layer 2805 contacts itself Absorbent
core 2815 can be
or include a cellulosic fluff pulp material, a superabsorbent polymer, a
synthetic absorbent
material, or combinations thereof, as described in more detail in reference to
FIGs. 8A-8C. The
composite material can be wrapped completely around absorbent core 2815 or can
be partially
wrapped around absorbent core 2815, defining a gap that can be covered as
described in more
detail in reference to FIGs. 5B-7B. FIG. 28A is not drawn to scale, such that
relative thicknesses
of layers 2805 and 2810 and interfacial region 2820 are illustrated to
facilitate visual
interpretation, rather than to demonstrate exact or relative dimensions.
As described in more detail in reference to FIG. 26B, FIG. 28B is a schematic
diagram
illustrating a cross section of example feminine hygiene product 2600B,
including absorbent
composite material 2610B formed of multiple stacked layers of composite formed
of
crosslinked cellulose layer 2805 physically entangled with nonwoven layer
2810, with
interfacial region 2820 formed therebetween. Example feminine hygiene product
2600B is
illustrated including two layers of composite material. In some embodiments,
example
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feminine hygiene product 2600B includes one layer, two layers, three layers,
four layers, five
layers, six layers, or more, of composite material. As described in reference
to FIGs. 29-32,
absorbent capacity increases with increasing layer number, making a higher
number of layers
beneficial up to a point that the caliper of the absorbent structure and the
perceived size and
weight of the example feminine hygiene product 2600B affects wearer comfort.
To that end,
the number of layers is selected to provide improved performance on the series
of standardized
assays described above without adding caliper or mass to a point that would
impair wearer
experience.
In some embodiments, example feminine hygiene product 2600B includes two
layers
of composite material, including two nonwoven layers 2810, two cellulose
layers 2805, and
two interfacial regions 2820, and outperforms both comparative example 1 and
comparative
example 2 on intake time, rewet, and wicking distance assays, as described in
more detail in
reference to FIGs. 29-32. With more layers of composite material, the
likelihood of perceived
weight and size causing discomfort increases. With fewer layers, the
likelihood of impaired
performance during liquid insult increases. As illustrated, nonwoven layer
2810 is oriented
toward inner surface 2620 (e.g., facing topsheet 2615) and cellulose layer
2805 faces backsheet
2605. In this way, nonwoven layer 2810 can serve to distribute liquid through
interfacial region
2820 to cellulose layer 2805 absorbing liquid wicked away from topsheet 2615
with improved
performance over comparative examples. For layers nearer to backsheet 2605,
liquid is
received from layers nearer to topsheet 2615. In this way, while liquid insult
can occur at a
relatively concentrated region of an innermost layer of composite fabric
(relative to inner
surface 2620), the region of liquid transfer can increase with increasing
layer number toward
backsheet 2605, as absorbance in each respective layer includes a wicking
component in a
lateral direction and a longitudinal direction. In some embodiments, the
orientations described
above can be reversed, such that cellulose layers 2805 can be oriented toward
inner surface
2620 and nonwoven layers 2810 oriented toward outer surface 2625.
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In some embodiments, one or more layers of composite material are oriented in
alternating or different configurations than those shown in FIG. 28B. For
example, layers can
be oriented such that at least one cellulose layer 2805 contacts another
cellulose layer 2805,
forming a dual-layer composite material with nonwoven layers 2810 facing both
topsheet 2615
and backsheet 2605. In some embodiments, as when more than two layers of
composite
material are included, combinations of the two orientations described above
can be included.
For example, with three layers of composite material, a first layer and a
second layer can be
stacked with cellulose layer 2805 of the first layer contacting nonwoven layer
2810 of the
second layer, with a third layer oriented such that the cellulose layers 2805
of the second and
third layers contact each other.
Table 15 describes comparison data for performance of example feminine hygiene
products 2600A and 2600B without topsheet 2615 on a series of assays described
above in
reference to absorbent article testing procedures. Table 15 is provided to
demonstrate that both
structures exhibit comparable performance for the suite of tests. Data in
Table 15 are not
representative of the performance of composite fabric in a complete feminine
hygiene product,
as such the data are not directly comparable to those of FIGs. 29-32. Instead,
data in Table 15
demonstrate that the inclusion of composite fabric in one or more
configurations can provide
comparable performance of feminine hygiene products over a suite of assays
representative of
typical hygienic use.
Table 15: Performance Data of Example Absorbent Composites 2610A-B
Assay Absorbent Composite Absorbent
Composite
N = 6, mean (std. dev) 2610A 2610B
Intake Time -First [Sec] 9.5 (0.5) 9.3 (1)
Intake Time -Second [Sec] 24.7 (5) 24.5 (2.5)
Intake Time -Third [Sec] 54.2 (15) 54.3 (11)
Rewet Mass [g] 0.71 (0.18) 0.72 (0.19)
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Wicking Distance-Longitudinal [cm] 9.8 (0.9) 9.8 (0.5)
Wicking Distance - Lateral [cm] 5.8 (0.8) 6.0 (0.5)
Table 16: Performance Data for Exemplary Embodiments and comparative examples
Sample\Assay Intake Intake Intake Rewet Wicking Wicking
N = 6 Time- Time- Time- Mass [g] Distance-
Distance-
mean First Second Third Longitudinal
Lateral
(std. dev) [Sec] [Sec] [Sec] [cm] [cm]
Negative 28.74 142.24 538.73 0.859 7.0 (0.0)
3.3 (0.3)
Control (2.92) (11.62) (45.38) (0.085)
Comparative 19.40 15.75 34.13 0.777
Example 1 (10.1) (4.11) (12.24) (0.1) 9.1
(0.2) 5.4 (0.2)
Example 1 12.61 9.72 13.69 0.181
(4.94)) (2.64) (3.92) (0.07) 9.8 (0.0)
6.0 (0.3)
Comparative 10.74 226.48 494.58 1.160
Example 2 (2.80) (111.24) (98.45) (0.115) 8.1
(0.4) 4.4 (0.2)
Example 2 5.88 13.79 25.77 0.583
(0.62) (3.14) (5.92) (0.062) 9.2
(0.5) 5.6 (0.4)
Fig. 29 is a graph of intake time data demonstrating improvement of a shared
property
between a negative control product without cellulosic materials, comparative
example 1,
comparative example 2, and example 1 and example 2 in accordance with
embodiments of the
present disclosure. Data for the graph in FIG. 29, reproduced in the first
three columns of Table
16, include statistical measures developed from six replicate assays of each
product, such that
the bar height represents the average intake time and the error bars represent
one standard
deviation. As described above in reference to the absorbent article testing
procedures, intake
time assays include three sequential intake time tests to simulate repeated
liquid insults on the
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same feminine hygiene product. In this way, the performance of the product
under typical and
extended wear conditions can be assessed. In FIG. 29, the control product is
representative of
commercially available light-weight feminine hygiene products that are
constructed using
synthetic materials, such as absorbent synthetic polymers, nonwoven
acquisition distribution
layers, or the like, without including cellulosic materials. Data for the
control product is
provided as an indirect comparison for the improvement to intake time
performance of
embodiments of the present disclosure. Comparative example 1 and comparative
example 2,
as described in Table 14, incorporate cellulosic materials as part of
absorbent structures but do
not include the composite fabric as described in more detail in reference to
FIG. 1. As such,
comparative example products 1 and 2 represent direct comparisons for a shared
property to
demonstrate the improved performance of embodiments of the present disclosure.
A lower intake time reflects faster distribution of liquid insults from the
inner surface
of a product (e.g., topsheet 2615) to absorbent materials that accept and
retain liquid, keeping
the wearer drier and more comfortable. Negative control product exhibits
comparable
performance to comparative example 2, with intake time increasing with each
progressive
insult, reaching a peak intake time of about 500 seconds for the third intake.
In contrast,
comparative example 1 and both examples 1 and 2 exhibit significantly reduced
intake times
relative to negative control. Relative to comparative example 2, example 2
exhibits
significantly improved intake times for each intake, including approximately
20X
improvement on second and third intakes. Furthermore, example 2 outperforms
comparative
example 1, despite incorporating additional internal structures and with
different topsheet 2615
materials.
In this way, intake time for a first intake of example feminine hygiene
products 2600A
or 2600B can be less than or about 30 seconds, less than or about 29 seconds,
less than or about
28 seconds, less than or about 27 seconds, less than or about 26 seconds, less
than or about 25
seconds, less than or about 24 seconds, less than or about 23 seconds, less
than or about 22
seconds, less than or about 21 seconds, less than or about 20 seconds, less
than or about 19
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seconds, less than or about 18 seconds, less than or about 17 seconds, less
than or about 16
seconds, less than or about 15 seconds, less than or about 14 seconds, less
than or about 13
seconds, less than or about 12 seconds, less than or about 11 seconds, less
than or about 10
seconds, less than or about 9 seconds, less than or about 8 seconds, less than
or about 7 seconds,
less than or about 6 seconds, less than or about 5 seconds, less than or about
4 seconds, less
than or about 3 seconds, less than or about 2 seconds, and less than or about
1 seconds,
including fractions and interpolations thereof Intake time for a second intake
of example
feminine hygiene products 2600A or 2600B can be less than or about 250
seconds, less than or
about 240 seconds, less than or about 230 seconds, less than or about 220
seconds, less than or
about 210 seconds, less than or about 200 seconds, less than or about 190
seconds, less than or
about 180 seconds, less than or about 170 seconds, less than or about 160
seconds, less than or
about 150 seconds, less than or about 140 seconds, less than or about 130
seconds, less than or
about 120 seconds, less than or about 110 seconds, less than or about 100
seconds, less than or
about 90 seconds, less than or about 80 seconds, less than or about 70
seconds, less than or
about 60 seconds, less than or about 50 seconds, less than or about 40
seconds, less than or
about 30 seconds, less than or about 20 seconds, less than or about 10
seconds, less than or
about 9 seconds, less than or about 8 seconds, less than or about 7 seconds,
less than or about
6 seconds, less than or about 5 seconds, less than or about 4 seconds, less
than or about 3
seconds, less than or about 2 seconds, and less than or about 1 seconds,
including fractions and
interpolations thereof Intake time for a third intake of example feminine
hygiene products
2600A or 2600B can be less than or about 550 seconds, less than or about 525
seconds, less
than or about 500 seconds, less than or about 475 seconds, less than or about
450 seconds, less
than or about 425 seconds, less than or about 400 seconds, less than or about
375 seconds, less
than or about 350 seconds, less than or about 325 seconds, less than or about
300 seconds, less
than or about 275 seconds, less than or about 250 seconds, less than or about
225 seconds, less
than or about 200 seconds, less than or about 175 seconds, less than or about
150 seconds, less
than or about 125 seconds, less than or about 100 seconds, less than or about
75 seconds, less
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than or about 50 seconds, and less than or about 25 seconds, less than or
about 10 seconds, less
than or about 9 seconds, less than or about 8 seconds, less than or about 7
seconds, less than or
about 6 seconds, less than or about 5 seconds, less than or about 4 seconds,
less than or about
3 seconds, less than or about 2 seconds, and less than or about 1 seconds,
including fractions
and interpolations thereof
FIG. 30 is a graph of performance assay data of intake time for comparative
example 1
and example 1, highlighting improved intake time performance of example
feminine hygiene
products 2600A and 2600B relative to comparative products from the North
American market,
in accordance with embodiments of the present disclosure. As shown, example 1
outperforms
comparative example 1 on all three intake tests. Advantageously, example 1
exhibits a reduced
intake time on all three intakes that is lower than the average intake time
for first intake of
comparative example 1. Data of Fig. 30 demonstrate that incorporating
composite fabric 110
described in reference to FIG. 1 significantly improves performance on intake
time, which
directly reflects an improved wearer experience, while also omitting a
dedicated ADL layer
that is included in comparative example 1.
FIG. 31 is a graph of data from rewet mass assays for the same set of five
products, in
accordance with embodiments of the present disclosure. As previously
described, rewet mass
measures a quantity of liquid that is exuded from an absorbent article
following application of
a calibrated pressure. For that reason, a lower value of rewet mass reflects
an improved
retention of liquid under physically representative pressures, such as that of
average
bodyweight applied to a feminine hygiene product when seated. In this way,
rewet mass for
example feminine hygiene products 2600A or 2600B can be less than or about 1.5
grams, less
than or about 1.4 grams, less than or about 1.3 grams, less than or about 1.2
grams, less than or
about 1.1 grams, less than or about 1.0 grams, less than or about 0.9 grams,
less than or about
0.8 grams, less than or about 0.7 grams, less than or about 0.6 grams, less
than or about 0.5
grams, less than or about 0.4 grams, less than or about 0.3 grams, less than
or about 0.2 grams,
or less than or about 0.1 grams, including fractions and interpolations
thereof. With improved
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rewet mass, examples 1 and 2 outperform both negative control and comparative
examples 1
and 2, reflecting an improved wearer experience, while also omitting dedicated
ADL layers
that add material between absorbent components and topsheet 2615 that can
serve to retain a
portion of exuded liquid.
FIG. 32 is a graph of data from wicking distance assays for the same set of
five products,
in accordance with embodiments of the present disclosure. As previously
described, wicking
distance measures the performance of feminine hygiene products to accept and
distribute a
liquid insult during a prescribed period of time, in accordance with
embodiments of the present
disclosure. In this way, a longer wicking distance reflects improved
performance. As
examples 1 and 2 of example feminine hygiene product 2600A or 2600B omit a
dedicated
ADL, a person of ordinary skill would reasonably expect examples 1 and 2 to
exhibit impaired
performance relative to negative control and comparative examples 1 and 2,
each of which
include a dedicated ADL. Instead, FIG. 32 demonstrates that example 1
outperforms
comparative example 1 in both longitudinal and lateral directions, reflecting
improved wicking
performance in both characteristic directions. Similarly, example 2
outperforms comparative
example 2 in both longitudinal and lateral directions, reflecting improved
wicking in both
characteristic directions. Improved performance on wicking distance assays
reflects improved
wearer experience at least in part due to improved distribution of a localized
liquid insult
through the feminine hygiene product to increase retention capacity over a
time period that is
characteristic of a period of wearing a feminine hygiene product. In some
embodiments,
longitudinal wicking distance for example feminine hygiene products 2600A or
2600B is
greater than or about 0.5 cm, greater than or about 1.0 cm, greater than or
about 1.5 cm, greater
than or about 2.0 cm, greater than or about 2.5 cm, greater than or about 3.0
cm, greater than
or about 3.5 cm, greater than or about 4.0 cm, greater than or about 4.5 cm,
greater than or
about 5.0 cm, greater than or about 5.5 cm, greater than or about 6.0 cm,
greater than or about
6.5 cm, greater than or about 7.0 cm, greater than or about 7.5 cm, greater
than or about 8.0
cm, greater than or about 8.5 cm, greater than or about 9.0 cm, greater than
or about 9.5 cm,
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greater than or about 10.0 cm, greater than or about 10.5 cm, greater than or
about 11.0 cm,
greater than or about 11.5 cm, greater than or about 12.0 cm, greater than or
about 12.5 cm,
greater than or about 13.0 cm, greater than or about 13.5 cm, greater than or
about 14.0 cm,
greater than or about 14.5 cm, and greater than or about 15.0 cm, including
fractions and
interpolations thereof In some embodiments, lateral wicking distance for
example feminine
hygiene products 2600A or 2600B is greater than or about 0.5 cm, greater than
or about 1.0
cm, greater than or about 1.5 cm, greater than or about 2.0 cm, greater than
or about 2.5 cm,
greater than or about 3.0 cm, greater than or about 3.5 cm, greater than or
about 4.0 cm, greater
than or about 4.5 cm, greater than or about 5.0 cm, greater than or about 5.5
cm, greater than
or about 6.0 cm, greater than or about 6.5 cm, greater than or about 7.0 cm,
greater than or
about 7.5 cm, greater than or about 8.0 cm, greater than or about 8.5 cm,
greater than or about
9.0 cm, greater than or about 9.5 cm, greater than or about 10.0 cm, including
fractions and
interpolations thereof. Advantageously, data for example feminine hygiene
products 2600A
and 2600B, as illustrated in Table 16 and FIGs. 29-32, reveal improved
performance in terms
of average values and improved consistency as reflected by variability of
measured values. For
example, standard deviation values determined for each standard assay are
lower for both
Example 1 and Example 2 configurations, relative to the respective comparative
example and
negative control. In this way, embodiments of the present disclosure exhibit
improved
performance on average and more consistent performance, reflecting a
significant
improvement to wearer experience relative to conventional absorbent products
currently
available on the market.
By example and without limitation, embodiments are disclosed according to the
following enumerated Paragraphs:
Al. A composite fabric, comprising:
a nonwoven layer comprising polymeric fibers and/or filaments;
a crosslinked cellulose layer comprising crosslinked cellulose fibers; wherein
the
crosslinked cellulose layer is positioned opposed to the nonwoven layer; and
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an interfacial region between the nonwoven layer and the crosslinked cellulose
layer,
comprising physically entangled polymeric fibers and/or filaments from the
nonwoven layer
and crosslinked cellulose fibers from the crosslinked cellulose layer,
wherein the nonwoven layer and the crosslinked cellulose layer are
mechanically
inseparable in a dry state; and
wherein the composite fabric has a density of from 0.06 g/cm3 to 0.15 g/cm3
(e.g., 0.06
g/cm3, 0.12 g/cm3, 0.08 g/cm3, or 0.06-0.08 g/cm3).
A2.
The composite fabric of Paragraph Al, wherein the nonwoven layer and the
crosslinked cellulose layer overlap with one another and interpenetrate at the
interfacial region.
A3. The
composite fabric of Paragraph Al or Paragraph A2, wherein the crosslinked
cellulose layer and the nonwoven layer fully interpenetrate.
A4. The composite fabric of any one of the preceding Paragraphs, wherein
the
nonwoven layer has a first thickness, the crosslinked cellulose layer has a
second thickness,
and the interfacial region has a thickness less than or equal to the thickness
of the first or the
second thickness.
A5. The composite fiber of Paragraph Al, wherein the polymeric fibers
and/or
filaments comprises synthetic polymer fibers and/or filaments.
A6. The composite fabric of any one of the preceding Paragraphs, wherein
the
nonwoven layer comprises a bonded carded web fabric, a carded web, a spunbond
fabric, a
melt blown fabric, an unbonded synthetic fiber, or any combination thereof
A7. The composite fabric of any one of the preceding Paragraphs, wherein
the
crosslinked cellulose fibers comprise polyacrylic acid crosslinked fibers.
A8. The composite fabric of any one of the preceding Paragraphs, wherein
the
crosslinked cellulose layer is air-laid or dry-laid onto the nonwoven layer.
A9. The
composite fabric of any one of Paragraphs Al to A7, wherein the
crosslinked cellulose layer is wet-laid onto the nonwoven layer.
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A10. The composite fabric of any one of Paragraphs Al to A9, wherein the
crosslinked cellulose fibers from the crosslinked cellulose layer are hydro-
entangled into
polymeric fibers and/or filaments from the nonwoven layer in the interfacial
region.
Al 1. The composite fabric of any one of the preceding Paragraphs, wherein the
nonwoven layer has a dry basis weight of 15 g/m2 to 50 g/m2 in the composite
fabric.
Al2. The composite fabric of any one of the preceding Paragraphs, wherein the
crosslinked cellulose layer comprises a dry basis weight of 20 g/m2 to 185
g/m2 in the
composite fabric.
A13. The composite fabric of any one of the preceding Paragraphs, wherein
composite fabric is embossed, folded, pleated, and/or perforated, and wherein
the folded or
pleated composite fabric optionally comprises an absorbent material in a fold
or a pleat.
A14. The composite fabric of any one of the preceding Paragraphs, wherein the
composite fabric does not comprise latex, latex-bonded fibers, a hydroengorged
layer, a
pretreated nonwoven layer, lyocell, rayon, or any combination thereof
A15. The composite fabric of any one of the preceding Paragraphs, consisting
of the
nonwoven layer and the crosslinked cellulose layer, and an interfacial region
between the
nonwoven layer and the crosslinked cellulose layer.
A16. The composite fabric of any one of the preceding Paragraphs, wherein the
composite fabric neutralizes odor when subjected to biological fluids.
A17. An absorbent article, comprising the composite fabric of any one of the
preceding Paragraphs.
A18. The absorbent article of Paragraph A17, wherein the article comprises a
personal care absorbent product.
A19. The absorbent article of Paragraph A18, wherein the personal care
absorbent
product is selected from a diaper, an incontinence product, a feminine hygiene
product, a wipe,
a towel, and a tissue.
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A20. The absorbent article of any one of Paragraphs A17 to A19, wherein the
absorbent article comprises a fluid acquisition distribution layer comprising
the composite
fabric.
A21. The absorbent article of any one of Paragraphs A17 to A20, wherein the
composite fabric is disposed over an absorbent material, wherein the
crosslinked cellulose layer
faces the surface of the absorbent material, and the absorbent material
optionally comprises a
superabsorbent polymer.
A22. The absorbent article of any one of Paragraphs Al 7 to A19, further
comprising
an absorbent core.
A23. The absorbent article of Paragraph A22, wherein the absorbent core
comprises
a first layer of composite fabric overlying an absorbent material and a second
layer of
composite fabric underlying the absorbent material, wherein the absorbent
material optionally
comprises a superabsorbent polymer.
A24. The absorbent article of Paragraph A22, wherein the absorbent core
comprises
the composite fabric enveloping an absorbent material, wherein the absorbent
material
optionally comprises a superabsorbent polymer.
A25. The absorbent article of Paragraph A24, wherein the composite fabric
fully
envelops the absorbent material, wherein the absorbent material optionally
comprises a
superabsorbent polymer.
A26. The absorbent article of Paragraph A24 or Paragraph A25, wherein the
crosslinked cellulose layer contacts the surface of the absorbent material.
A27. The absorbent article of Paragraphs A17 to A20 and A22 to A25, wherein
the
absorbent article comprises an absorbent material, wherein either the nonwoven
layer or the
crosslinked cellulose layer contacts the surface of the absorbent material,
when the composite
fabric is folded or pleated.
A28. The absorbent article of any one of Paragraphs Al 8 to A27, wherein the
absorbent article is a diaper or an incontinence product.
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A29. The absorbent article of any one of Paragraphs A20, A21, A26 and A27,
wherein the absorbent article has an intake time decrease of at least 23% from
a first fluid
exposure to a second subsequent fluid exposure in a flat acquisition under
load test, when the
absorbent article comprises a fluid acquisition distribution layer comprising
the composite
fabric.
A30. The absorbent article of any one of Paragraphs A24 to A28, wherein the
absorbent article has an intake time decrease of at least 25% from a first
fluid exposure to a
second subsequent fluid exposure in a flat acquisition under load test, when
the absorbent
article comprises the composite fabric enveloping the absorbent core.
A31. The absorbent article of any one of Paragraphs A20, A21, and A28, wherein
the
absorbent article has an intake time decrease of at least 8% from a second
fluid exposure to a
third subsequent fluid exposure in a flat acquisition under load test, when
the absorbent article
comprises a fluid acquisition distribution layer comprising the composite
fabric.
A32. The absorbent article of any one of Paragraphs A24 to A28, wherein the
absorbent article has an intake time decrease of at least 12% from a second
fluid exposure to a
third subsequent fluid exposure in a flat acquisition under load test, when
the absorbent article
comprises the composite fabric enveloping the absorbent material.
A33. The absorbent article of any one of Paragraphs A20, A21, and A28, wherein
the
absorbent article has a wicking distance percentage of at least 60% after a
third fluid exposure
in a no load saddle wicking test when the absorbent article comprises a fluid
acquisition
distribution layer comprising the composite fabric.
A34. The absorbent article of any one of Paragraphs A24 to A28, wherein the
absorbent article has a wicking distance percentage of at least 60% after a
third fluid exposure
in a no load saddle wicking test when the absorbent article comprises the
composite fabric
enveloping the absorbent material.
A35. The absorbent article of any one of Paragraphs Al7 to A21 and A28,
wherein
the composite fabric comprises the nonwoven layer at a dry basis weight of 20
g/m2 to 50 g/m2
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(e.g., 30 g/m2 to 40 g/m2) and the crosslinked cellulose layer at a dry basis
weight of 70 g/m2
to 120 g/m2 (e.g., 80 g/m2 to 110 g/m2).
A36. The absorbent article of any one of Paragraphs A17 to A19, and A22 to
A28,
wherein the composite fabric comprises the nonwoven layer at a dry basis
weight of 20 g/m2
to 50 g/m2 (e.g., 30 g/m2 to 40 g/m2) and the crosslinked cellulose layer at a
dry basis weight
of 40 g/m2 to less than 70 g/m2 (e.g., 40 g/m2 to 60 g/m2, or 50 g/m2).
A37. The absorbent article of Paragraph A35, wherein the absorbent article has
a
wicking distance percentage of at least 60% after a third fluid exposure in a
no load saddle
wicking test when the absorbent article comprises a fluid acquisition
distribution layer
comprising the composite fabric.
A38. The absorbent article of Paragraph A36, wherein the absorbent article has
a
wicking distance percentage of at least 60% after a third fluid exposure in a
no load saddle
wicking test when the absorbent article comprises the composite fabric
enveloping the
absorbent material.
A39. An absorbent article, comprising:
a liquid-impermeable backsheet defining an inner surface and an outer surface;
an absorbent core, disposed on the inner surface of the backsheet, wherein the
absorbent
core comprises:
an absorbent material defining an upper surface and a lower surface of the
absorbent core; and
a composite fabric surrounding at least a portion of the upper surface and the
lower surface, comprising:
a nonwoven layer comprising polymeric fibers and/or filaments;
a crosslinked cellulose layer comprising crosslinked cellulose fibers,
wherein the crosslinked cellulose layer is positioned opposed to the nonwoven
layer; and
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an interfacial region between the nonwoven layer and the crosslinked
cellulose layer, comprising physically entangled polymeric fibers and/or
filaments from the
nonwoven layer and crosslinked cellulose fibers from the crosslinked cellulose
layer,
wherein the nonwoven layer and the crosslinked cellulose layer are
mechanically inseparable in a dry state; and
a topsheet overlying the upper surface of the absorbent core and contacting
the inner
surface of the backsheet.
A40. The absorbent article of Paragraph A39, wherein the composite fabric
fully
surrounds the upper surface and the lower surface of the absorbent core.
A41. The absorbent article of Paragraph A39, wherein the composite fabric
overlaps
on the upper surface or the lower surface of the absorbent core by at least a
portion of a width
of the composite fabric.
A42. The absorbent article of Paragraph A39, wherein the composite fabric
defines a
gap on the upper surface or the lower surface of the absorbent core, the
absorbent core further
comprising a cover layer disposed over the gap.
A43. The absorbent article of Paragraph A42, wherein the cover layer overlies
at least
a portion of the composite fabric, the composite fabric being disposed between
at least a portion
of the cover layer and the absorbent material.
A44. The absorbent article of Paragraph A42, wherein the cover layer underlies
the
composite fabric, and at least a portion of the cover layer is disposed
between the composite
fabric and the absorbent material.
A45. The absorbent article of any one of Paragraphs A42 to A44, wherein the
cover
layer is formed of the composite fabric.
A46. The absorbent article of any one of Paragraphs A42 to A45, wherein the
cover
layer comprises a spunbond meltblown spunbond (SMS) material.
A47. The absorbent article of any one of Paragraphs A42 to A45, wherein the
cover
layer comprises a spunbond (SB) material.
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A48. The absorbent article of any one of Paragraphs A39 to A47, wherein the
absorbent material comprises an absorbent synthetic polymer and a high-loft
through air
bonded carded web (TABCW).
A49. The absorbent article of any one of Paragraphs A39 to A47, wherein the
absorbent material comprises an absorbent synthetic polymer (e.g., SAP), a
fluff pulp, or any
combination thereof
A50. The absorbent article of Paragraph A49, wherein the absorbent material
comprises from 30% to 90% by weight of the absorbent synthetic polymer and
from 10% to
70% by weight of the fluff.
A51. The absorbent article of any one of Paragraphs A39 to A50, wherein the
polymeric fibers and/or filaments of the nonwoven layer of the composite
fabric comprises
synthetic polymer fibers and/or filaments.
A52. The absorbent article of any one of Paragraphs A39 to A51, wherein the
nonwoven layer and the crosslinked cellulose layer of the composite fabric
overlap with one
another and interpenetrate at the interfacial region.
A53. The absorbent article of any one of Paragraphs A39 to A52, wherein the
crosslinked cellulose layer and the nonwoven layer of the composite fabric
fully interpenetrate.
A54. The absorbent article of any one of Paragraphs A39 to A52, wherein the
nonwoven layer has a first thickness, the crosslinked cellulose layer has a
second thickness,
and interfacial region comprises a thickness less than or equal to the
thickness of the first or
the second thickness.
A55. The absorbent article of any one of Paragraphs A39 to A54, wherein the
nonwoven layer comprises a bonded carded web fabric, a carded web, a spunbond
fabric, a
melt blown fabric, or any combination thereof
A56. The absorbent article of any one of Paragraphs A39 to A55, wherein the
crosslinked cellulose fibers comprise polyacrylic acid crosslinked fibers.
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A57. The absorbent article of any one of Paragraphs A39 to A56, wherein the
crosslinked cellulose fibers from the crosslinked cellulose layer are hydro-
entangled into
polymeric fibers and/or filaments from the nonwoven layer in the interfacial
region.
A58. The absorbent article of any one of Paragraphs A39 to A57, wherein the
nonwoven layer has a dry basis weight of 15 g/m2 to 50 g/m2 in the composite
fabric.
A59. The absorbent article of any one of Paragraphs A39 to A58, wherein the
crosslinked cellulose layer comprises a dry basis weight of 20 g/m2 to 185
g/m2 in the
composite fabric.
A60. The absorbent article of any one of Paragraphs A39 to A59, wherein the
composite fabric does not comprise latex, latex-bonded fibers, a hydroengorged
layer, a
pretreated nonwoven layer, lyocell, rayon, or any combination thereof
A61. The absorbent article of any one of Paragraphs A39 to A60, wherein the
article
comprises a personal care absorbent product.
A62. The absorbent article of Paragraph A61, wherein the personal care
absorbent
product is selected from a diaper, an incontinence product, and a feminine
hygiene product.
A63. The absorbent article of any one of Paragraphs A39 to A62, wherein the
composite fabric fully envelops an absorbent material, wherein the absorbent
material
optionally comprises a superabsorbent polymer.
A64. The absorbent article of any one of Paragraphs A39 to A63, wherein the
crosslinked cellulose layer contacts the surface of the absorbent material.
A65. The absorbent article of any one of Paragraphs A39 to A64, wherein the
absorbent article has an intake time decrease of at least 25% from a first
fluid exposure to a
second subsequent fluid exposure in a flat acquisition under load test.
A66. The absorbent article of any one of Paragraphs A39 to A65, wherein the
absorbent article has an intake time decrease of at least 12% from a second
fluid exposure to a
third subsequent fluid exposure in a flat acquisition under load test.
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A67. The absorbent article of any one of Paragraphs A39 to A66, wherein the
absorbent article has a wicking distance percentage of at least 60% after a
third fluid exposure
in a no load saddle wicking test when the absorbent article comprises the
composite fabric
enveloping the absorbent material.
A68. The absorbent article of any one of Paragraphs A39 to A67, wherein the
composite fabric comprises the nonwoven layer at a dry basis weight of 20 g/m2
to 50 g/m2
(e.g., 30 g/m2 to 40 g/m2) and the crosslinked cellulose layer at a dry basis
weight of 40 g/m2
to less than 70 g/m2 (e.g., 40 g/m2 to 60 g/m2, or 50 g/m2).
A69. A feminine hygiene product, comprising:
a composite fabric comprising:
a nonwoven layer comprising polymeric fibers and/or filaments;
a crosslinked cellulose layer comprising crosslinked cellulose fibers, wherein
the crosslinked cellulose layer is positioned opposed to the nonwoven layer;
and
an interfacial region between the nonwoven layer and the crosslinked cellulose
layer, comprising physically entangled polymeric fibers and/or filaments from
the nonwoven
layer and crosslinked cellulose fibers from the crosslinked cellulose layer,
wherein the nonwoven layer and the crosslinked cellulose layer are
mechanically inseparable in a dry state.
A70. The feminine hygiene product of Paragraph A69, further comprising an
absorbent core comprising an absorbent material.
A71. The feminine hygiene product of Paragraph A69 or Paragraph A70, wherein
when subjected to a fluid insult, the composite fabric distributes the fluid
to a front portion, a
middle portion, and a back portion of the feminine hygiene product.
A72. The feminine hygiene product of Paragraph A71, wherein the front portion,
middle portion, and back portion each comprises an amount of fluid within 20
wt% to 45 wt %
of each portion.
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A73. The feminine hygiene product of any one of Paragraphs A70 to A72, wherein
the composite fabric is disposed over the absorbent core.
A74. The feminine hygiene product of any one of Paragraphs A70 to A72, wherein
the composite fabric envelops at least a portion of the absorbent material.
A75. A method of making a composite fabric of any one of Paragraphs Al to A15,
comprising:
supplying polymeric fibers and/or filaments;
supplying crosslinked cellulose fibers;
air-laying or wet-laying the crosslinked cellulose fibers to provide a
crosslinked
cellulose layer on a nonwoven layer of polymeric fibers and/or filaments,
wherein the
crosslinked cellulose layer is positioned opposed to the nonwoven layer; and
physically
entangling the polymeric fibers and/or filaments from the nonwoven layer and
the crosslinked
cellulose fibers from the crosslinked cellulose layer to provide the composite
fabric, wherein
the composite fabric comprises an interfacial region between the nonwoven
layer and the
crosslinked cellulose layer, wherein the nonwoven layer and the crosslinked
cellulose layer are
mechanically inseparable in a dry state.
A76. The method of Paragraph A75, wherein physically entangling the polymeric
fibers and/or filaments from the nonwoven layer and the crosslinked cellulose
fibers from the
crosslinked cellulose layer comprises hydro-entangling the crosslinked
cellulose fibers into the
polymeric fibers and/or filaments.
A77. The method of Paragraph A75 or Paragraph A76, wherein the polymeric
fibers
and/or filaments is in the form of a bonded carded web fabric, a carded web, a
spunbond fabric,
a melt blown fabric, an unbonded synthetic fiber, or any combination thereof
A78. The method of any one of Paragraphs A75 to A77, wherein the polymeric
fibers
are synthetic.
A79. The method of any one of Paragraphs A75 to A78, wherein the nonwoven
layer
is a top layer, and the crosslinked cellulose layer is a bottom layer.
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A80. The method of any one of Paragraphs A75 to A78, wherein the nonwoven
layer
is a bottom layer, and the crosslinked cellulose layer is a top layer.
A81. The method of any one of Paragraphs A75 to A80, wherein the crosslinked
cellulose layer is pre-formed prior to entangling with the nonwoven layer,
and/or the nonwoven
layer is pre-formed prior to entangling with the crosslinked cellulose layer.
A82. The method of any one of Paragraphs A75 to A80, wherein the crosslinked
cellulose layer is not pre-formed prior to entangling with the nonwoven layer,
and/or the
nonwoven layer is not pre-formed prior to entangling with the crosslinked
cellulose layer.
A83. A feminine hygiene product, comprising:
a composite fabric comprising:
a nonwoven layer comprising polymeric fibers and/or filaments;
a crosslinked cellulose layer comprising crosslinked cellulose fibers, wherein
the crosslinked cellulose layer is positioned opposed to the nonwoven layer;
and
an interfacial region between the nonwoven layer and the crosslinked cellulose
layer, comprising physically entangled polymeric fibers and/or filaments from
the nonwoven
layer and crosslinked cellulose fibers from the crosslinked cellulose layer,
wherein the nonwoven layer and the crosslinked cellulose layer are
mechanically
inseparable in a dry state.
A84. The feminine hygiene product of any one of Paragraph A83, further
comprising:
an absorbent core including a superabsorbent polymer,
wherein the composite fabric is wrapped at least partially around the
absorbent core
with the crosslinked cellulose layer physically contacting the absorbent core.
A85. The feminine hygiene product of any one of Paragraphs A83 to A84, wherein
the nonwoven layer is a first nonwoven layer, the crosslinked cellulose layer
is a first
crosslinked cellulose layer, and the interfacial region is a first interfacial
region, the composite
fabric further comprising:
a second nonwoven layer;
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a second crosslinked cellulose layer; and
a second interfacial region between the second nonwoven layer and the second
crosslinked cellulose layer, comprising physically entangled polymeric fibers
and/or filaments
from the second nonwoven layer and crosslinked cellulose fibers from the
second crosslinked
cellulose layer,
wherein the second nonwoven layer and the second crosslinked cellulose layer
are
mechanically inseparable in a dry state, and wherein the second crosslinked
cellulose layer is
mechanically coupled with the first nonwoven layer.
A86. The feminine hygiene product of any one of Paragraphs A83 to A85, further
comprising an average intake time on a first intake of less than or equal to
about 15 seconds,
as measured by a standardized intake time method.
A87. The feminine hygiene product of any one of Paragraphs A83 to A86, further
comprising an average intake time on a second intake of less than or equal to
about 15 seconds,
as measured by a standardized intake time method.
A88. The feminine hygiene product of any one of Paragraphs A83 to A87, further
comprising an average intake time on a second intake of less than or equal to
about 10 seconds,
as measured by the standardized intake time method.
A89. The feminine hygiene product of any one of Paragraphs A83 to A88, further
comprising an average intake time on a third intake of less than or equal to
about 30 seconds,
as measured by a standardized intake time method.
A90. The feminine hygiene product of any one of Paragraphs A83 to A89, further
comprising an average intake time on a third intake of less than or equal to
about 15 seconds,
as measured by the standardized intake time method.
A91. The feminine hygiene product of any one of Paragraphs A83 to A90, further
comprising an average rewet mass of less than or equal to about 0.75 grams, as
measured by a
standardized rewet performance method.
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A92. The feminine hygiene product of any one of Paragraphs A83 to A91, further
comprising an average rewet mass of less than or equal to about 0.20 grams, as
measured by
the standardized rewet performance method.
A93. The feminine hygiene product of any one of Paragraphs A83 to A92, further
comprising an average wicking distance in a longitudinal direction of greater
than or equal to
about 9.2 cm, as measured by a standardized liquid distribution method.
A94. The feminine hygiene product of any one of Paragraphs A83 to A93, further
comprising an average wicking distance in a longitudinal direction of greater
than or equal to
about 9.8 cm, as measured by the standardized liquid distribution method.
A95. The feminine hygiene product of any one of Paragraphs A83 to A94, further
comprising:
a topsheet comprising a nonwoven material, the topsheet mechanically coupled
with
the composite fabric and defining an inner surface of the feminine hygiene
product; and
a liquid impermeable backsheet mechanically coupled with the composite fabric
and
defining an outer surface of the feminine hygiene product.
A96. The feminine hygiene product of any one of Paragraphs A83 to A95, wherein
the topsheet comprises a perforated film material or a through air bonded
carded web
(TABCW).
A97. The feminine hygiene product of any one of Paragraphs A83 to A96, further
comprising:
a first spunlace layer interposed between the topsheet and the composite
fabric; and
a second spunlace layer interposed between the liquid impermeable backsheet
and the
composite fabric.
A98. The feminine hygiene product of any one of Paragraphs A83 to A97, further
comprising an average intake time on a second intake of less than or equal to
about 225 seconds,
as measured by a standardized intake time method.
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A99. The feminine hygiene product of any one of Paragraphs A83 to A98, further
comprising an average intake time on a third intake of less than or equal to
about 490 seconds,
as measured by a standardized intake time method.
MOO. The feminine hygiene product of any one of Paragraphs A83 to A99, further
comprising an average rewet mass of less than or equal to about 1.15 grams, as
measured by a
standardized rewet performance method.
A101. The feminine hygiene product of any one of Paragraphs A83 to A100,
further
comprising an average wicking distance in a longitudinal direction of greater
than or equal to
about 8.2 cm, as measured by a standardized rewet performance method.
A102. The feminine hygiene product of any one of Paragraphs A83 to A101,
further
comprising an average wicking distance in a lateral direction of greater than
or equal to about
4.5 cm, as measured by a standardized liquid distribution method.
A103. The feminine hygiene product of any one of Paragraphs A83 to A102,
further
comprising a total mass of composite fabric of less than or equal to about
4.00 g.
A104. The feminine hygiene product of any one of Paragraphs A83 to A103,
further
comprising a total mass of cellulosic material of greater than or equal to
about 1.50 g.
A105. The feminine hygiene product of any one of Paragraphs A83 to A104,
further
comprising a total mass of petrochemical material of less than or equal to
about 1.30 g.
While illustrative embodiments have been illustrated and described, it will be
appreciated that various changes can be made therein without departing from
the spirit and
scope of the disclosure.
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