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Substrates comprising frothed benefit agents for enhanced substrate benefits

Inactive Publication Date: 2013-06-20
KIMBERLY-CLARK WORLDWIDE INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a method for applying a benefit agent to a substrate using a dryer. The close proximity of the chemistry applicator to the dryer surface improves chemical mass efficiency and energy efficiency. The benefit agent is applied as a foam layer that acts as a diluter, reducing the amount of heat required to remove water from the foam during the drying process. The foam layer is more appropriately described as a collapsed foam film layer that has a unique cellular structure and voids of air entrapped. The benefit agent can be applied to various substrates, such as tissue, and can be applied to both sides of the substrate. The additive composition may be in the form of a polymer dispersion or solution. The technical effects of the invention include improved efficiency, reduced energy consumption, and increased softness and bulk in the substrate.

Problems solved by technology

However, the spraying process has low chemical mass efficiency levels (40% to 70%) due to waste of the additive composition caused by a boundary layer of air near the dryer's surface and relatively high dryer temperatures.
Further, modifying any additives to include additional solid particles and short fibers that improve the overall softness of a substrate is somewhat limited.
Because many of these particles are larger than the spray nozzles, clogging of the nozzles is an issue that prevents the additive dispersion from being properly applied onto the dryer surface.

Method used

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  • Substrates comprising frothed benefit agents for enhanced substrate benefits
  • Substrates comprising frothed benefit agents for enhanced substrate benefits
  • Substrates comprising frothed benefit agents for enhanced substrate benefits

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0136]Commercial HYPOD® dispersion was diluted with water to a 30% HYPOD® solid level and then frothed by the Gaston unit. The stable froth was applied to the hot drum surface of the 60 inch calendar dryer. The cured HYPOD® dispersion was creped off the dryer surface. Spunbond basesheets were creped using the froth process of the present invention as described herein. The HYPOD® coated basesheets were then printed with Cyan ink wherein 100 parts of the ink were mixed with 4.5 parts of the cross-linker by weight. The samples were hand printed using an anilox roller of 10.8 bcm (billion cubic microns).

[0137]Froth Process Conditions:[0138]% Solids in dispersion: 10-30% HYPOD 8510®[0139]Dryer Temperature: 260-300 deg F.[0140]Dispersion Flow rate: 100-500 cc / min[0141]Mixer Speed: 20%-60%[0142]Blow ratio: 5-30

[0143]Image analysis was performed on the SEM images to quantify surface ink coverage on both the untreated spunbond and the spunbond treated with the benefit agent of the present in...

example 2

[0144]Commercial HYPOD 8510® polyolefin dispersion was diluted with water to varied HYPOD 8510 solids levels with no or up to 50% additions of Lutensol® A 65 N ICONOL® 24 7 based on HYPOD 8510 solids. This chemistry was then frothed by the Gaston Systems foam unit and the stable froth was applied to the hot surface of a 60 inch dryer. The basesheet was then pressed onto the collapsed foam coated dryer surface, creped off the dryer surface, and wound up on a reel drum.

[0145]Basesheets namely cellulose based towel, hydroknit®, spunbond were used to create stretchy materials using the process by controlling the creping blade geometry and / or the draw ratio.

Froth Process Conditions:

[0146]% Solids in dispersion: 5% -30% HYPOD 8510 ®[0147]Dryer Temperature: 230-300 deg F.[0148]Dispersion Flow rate: 50-500 cc / min[0149]Mixer Speed: 20-60%[0150]Blow ratio: 5-30

Mechanical Testing—% Hysteresis:

[0151]Testing was performed using MTS tensile tester model # Insight Model EL1. A 3″ inch wide test sp...

example 3

[0153]Bulk was measured by quantifying the basis weight (gsm) and bulk (cc / g) by measuring the weight and the thickness of the material. The results are as shown in Table 5.

TABLE 5Code NumberBasis Weight (gsm)Bulk (cc / g)Control Spunbond1213Spunbond A Frothed1627Spunbond B Frothed2525

Test Methods

(1) In-Hand Ranking Test for Tactile Properties (IHR Test):

[0154]The In-Hand Ranking Test (IHR) is a basic assessment of in-hand feel of fibrous webs and assesses attributes such as softness. This test is useful in obtaining a quick read as to whether a process change is humanly detectable and / or affects the softness perception, as compared to a control. The difference of the IHR softness data between a treated web and a control web reflects the degree of softness improvement.

[0155]A panel of testers was trained to provide assessments more accurately than an average untrained consumer might provide. Rank data generated for each sample code by the panel were analyzed using a proportional haza...

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Abstract

The present invention provides a nonwoven substrate comprising a fibrous web defining a surface; and a layer of a benefit agent wherein said benefit agent is selected from an additive composition, an enhancement component and combinations thereof; wherein said benefit agent is frothed and bonded to the fibrous web surface through a creping process and wherein said nonwoven substrate demonstrates improvements selected from enhanced tactile feel, enhanced printing, a decrease in hysteresis, an increase in bulk, an increase in elasticity / extensibility, an increase in retractability, a reduction in rugosities and combinations thereof when compared to an untreated substrate.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application is a continuation-in-part of U.S. application Ser. No. 13 / 330,440 filed Dec. 19, 2011 which was a continuation-in-part of U.S. application Ser. No. 12 / 979,852 filed Dec. 28, 2010.FIELD OF THE INVENTION[0002]The present invention relates to a creped nonwoven substrate comprising a frothed polymer and additional softness enhancers that demonstrate enhanced tactile feel, enhanced printing, a decrease in hysteresis, an increase in bulk, an increase in elasticity / extensibility, an increase in retractability, a reduction in rugosities and other beneficial product use benefits when compared to an untreated substrate.BACKGROUND OF THE INVENTION[0003]Absorbent nonwoven products such as paper towels, tissues, diapers, and other similar products are designed to have desired levels of bulk, softness and strength. For example, in some tissue products, softness is enhanced by a topical additive composition such as a softening agent to t...

Claims

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Application Information

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IPC IPC(8): D04H13/00
CPCD04H13/007Y10T428/24455B32B2307/75B32B2555/00B32B2555/02A61K8/0208B32B5/022B32B5/20B32B5/245B32B37/12B32B38/145B32B2305/20A61K8/96A61K9/70Y10T428/24446B32B2307/51D06N3/0047D06N2205/045D06M15/227D06M15/233D06M23/04D06N2205/023D06N3/0029D04H1/58D04H1/64
Inventor QIN, JIANABUTO, FRANCIS P.CALEWARTS, DEBORAH J.DESAI, KEYUR M.HAMMONDS, YVETTE L.JURENA, JEFFREY F.KRAUTKRAMER, CANDACE D.LOYD, ADRIENNE R.SHAWVER, SUSAN E.WALDROUP, DONALD E.
Owner KIMBERLY-CLARK WORLDWIDE INC
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