Air-laid web with hollow synthetic fibers

a technology of synthetic fibers and air-laid webs, which is applied in the field of air-laid webs with hollow synthetic fibers, can solve the problems of not teaching the use of hollow fibers in an absorbent core, forming a bulky layer of barges, and forming a large amount of barges

Inactive Publication Date: 2004-06-03
INVISTA NORTH AMERICA R L
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The problem that Ito sought to solve was leakage due to an insufficient absorbing capacity in the first absorbing layer.
The fabric is a multilayer layer composition that can be used as a top sheet in a diaper, but it does not teach the use of hollow fibers in an absorbent core.
Additionally, the bulky layer of Barge is formed by a carding process.
There is no teaching on the use of air forming with wood pulp

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0042] In Example 1, four different web compositions were prepared by means of the air-laid procedure described previously, in which the amount of polyester fiber varied from 0 to 40% by weight of the total web and varying the denier of polyester fiber and its cross-section (solid or hollow).

[0043] Where the data indicates that there is no polyester means that the composition of the web comprised 10% bicomponent fibers and 90% wood pulp fibers. The results are set forth in Table 1, which shows the improved initial loft using a hollow fiber at a 40% level.

1TABLE 1 Initial loft (no loading), in. % PET 0 10 20 40 Solid 3 den 1.4 1.6 -- --Solid 6 den 1.4 1.6 1.6 1.7 Hollow 6 den 1.4 1.6 1.8 2.3 Solid 15 den 1.4 1.6 -- --

[0044]

2TABLE 2 Loft under compression, in. (10% PET) Load, lb 0 0.5 2 4 10 15 25 No PET 1.4 1.3 1.2 1.1 0.9 0.7 0.5 Solid 3 den 1.6 1.5 1.3 1.2 1 0.9 0.8 Solid 6 den 1.6 1.5 1.3 1.2 1 0.95 0.85 Solid 15 den 1.6 1.5 1.4 1.3 1.1 1 0.9 Hollow 6 den 1.6 1.5 1.3 1.2 1 0.9 0.8...

example 2

[0049] The web wet / dry strength ratio in the machine direction (MD) and cross direction (CD) of various webs was compared. The first web has no synthetic fiber (no PET), the second and third webs have solid fiber and the last web has hollow fiber. The solid and hollow fiber webs contained 10% bicomponent, 80% wood pulp and 10% polyester (of either 3 denier solid, 15 denier solid, or 6 denier hollow). The results are set forth in Table 7.

7TABLE 7 Wet / Dry Strength (%) MD wet / MD dry MD wet / CD dry No PET 0.40 0.42 10% solid 3 den 0.60 0.62 10% solid 15 den 0.59 0.61 10% hollow 6 den 0.60 0.63

[0050] The results show that webs having synthetic fibers are an improvement over the web with no PET, while the web with hollow fiber had results comparable to solid fiber webs.

example 3

[0051] The liquid acquisition test compared 6 den solid PET with 6 den hollow PET. The results are set forth below in Tables 9 and 10, and illustrate that the hollow fiber prevented any overflow. The most desirable behavior is to have instant penetration - no overflow and little or no leakage. Failing that, one wants as little overflow as possible, and to have the onset of overflow delayed as long as possible.

8TABLE 9 Overflow, ml Time, second 0 2 4 6 8 10 12 14 16 18 Solid PET 0 0 0 0 6 13 21 29 34 34 Hollow PET 0 0 0 0 0 0 0 0 0 0

[0052] As the results show, the hollow fiber web had no overflow even after 18 seconds, indicating instant liquid penetration. This is a very desirable result for disposable diapers, for example.

9TABLE 10 Leakage, ml Time, second 0 2 4 6 8 10 12 14 16 18 Solid PET 0 0 0 0 3 10 17 24 30 34 Hollow PET 0 0 0 0 2 13 26 40 52 53

[0053] Comparing the total of Overflow and Leakage, the hollow fiber webs are superior to solid fiber webs.

[0054] Table 11 shows the i...

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Abstract

The present invention relates to a single layer air-laid composition comprising: hollow synthetic fiber, absorbent and a binder system. The hollow fiber comprises from about 10 to about 50 percent by weight of said composition. The hollow synthetic fiber has a denier of between about 2 to about 18. The hollow synthetic fiber is selected from the class of polyolefins, polyesters, polyamides, acrylics, as well as mixtures and copolymers thereof. The absorbent comprises from about 40% to about 80% of the weight of said composition. The absorbent is a natural absorbent, or a synthetic absorbent, or a mixture of these. The natural absorbent is selected from the class of wood pulp fluff, cotton, cotton linters, and regenerated cellulose fibers, or a mixture of these. The synthetic absorbent is selected from the class of agar, pectin, guar gum, and synthetic hydrogel polymers. The binder fiber comprises from about 3 to about 15 percent by weight of said composition.

Description

[0001] This application is a continuation-in-part of U.S. Ser. No. 10 / 345,001 filed Jan. 15, 2003 in the name of Mabrouk Ouedemi, which was itself a continuation-in-part of U.S. Ser. No. 09 / 896,799 filed Jun. 29, 2001.[0002] 1) Field of the Invention[0003] The present invention relates to a single layer air-laid composition useful as an absorbent core in diapers, incontinent pads, sanitary napkins and other absorbent pads needed for body fluids. In particular, the present invention comprises a composition of an absorbent comprising wood pulp and optionally a super absorbent polymer, a binder system, and up to 50% hollow synthetic fibers based on the total composition weight. The composition of the present invention has an improved loft, compression resistance and fluid intake rate superior to existing composites based on natural absorbents and non-hollow synthetic fibers.[0004] Diapers, incontinent pads, sanitary napkins, and other absorbent pads used for uptaking bodily fluids gene...

Claims

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Application Information

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IPC IPC(8): D04H1/407D04H1/4291D04H1/43D04H1/4334D04H1/435D04H1/4382D04H1/4391D04H1/54
CPCD04H1/54D04H1/42D04H1/407D04H1/4291D04H1/43D04H1/4334D04H1/435Y10T442/699Y10T442/637Y10T442/69D04H1/43828D04H1/43835D04H1/43832D04H1/43914
Inventor QUEDERNI, MABROUKLATTEN, PAUL L.
Owner INVISTA NORTH AMERICA R L
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