Absorbent article, and non-woven material with fluid management properties.

Abstract

Absorbent article, and nonwoven material with fluid management properties. Nonwoven mats with excellent fluid management characteristics are disclosed. The nonwoven mats are made from a combination of binder fibers and structural fibers. The structural fibers are made of multicomponent hollow fibers. The structural fibers include first zones of polymeric components that alternate with zones of second polymeric components around the circumference of the fiber. The first zone of polymeric components is made of a polymer with a melting temperature lower than that of the polymer contained in the second polymeric component zone. In this way, the fibers have a three-dimensional conformation that produces a significant void volume within the nonwoven mat.

Description

/ 39 Absorbent article, and non-woven material with fluid management properties. Related patent applications

[001] The present application is based on and claims priority over the U.S. Provisional Patent Application Serial No. 63 / 175,871, filed April 16, 2021, which is incorporated herein by reference. FUNDAMENTALS

[002] Desired performance goals for absorbent personal hygiene products include low product leakage and a dry feel for the user. However, absorbent articles often fail before the product's full absorbent capacity has been utilized. Absorbent garments, such as incontinence garments and disposable diapers, often leak at the legs and waist. Leakage can be due to a variety of product deficiencies, one of which is insufficient fluid absorption by the absorbent system, especially on the second or third liquid insult.

[003] For example, the initial absorption rates for conventional absorbent structures can deteriorate once they have received liquid surges in their structures. The disparity between liquid delivery and absorption rates can result in excessive accumulation on the fabric surface before the liquid is absorbed by the absorbent core. During this time, the accumulated liquid can leak from the diaper's leg openings and soil the user's outer clothing and bedding. Attempts to alleviate leakage have included providing physical barriers with design features such as elastic folds at the legs and altering the amount and / or configuration of the absorbent material in the area of ​​the structure where liquid surges typically occur.

[004] Nonwoven materials, such as carded blankets and spunbonded blankets, have been used as side body linings in products Petition 870230088780, dated 06 / 10 / 2023, page 11 / 66 / 39 absorbent pads. Specifically, very open porous lining structures were employed to allow liquid to pass quickly through them and to help keep the body's skin separate from the wet absorbent pad beneath the lining.

[005] In addition to using a porous body side liner, many absorbent articles are also equipped with a peak layer. Peak layers can be made with thick, raised fabric structures that have a significant amount of empty space. Peak layers are positioned between the body side liner and the absorbent structure. Peak layers are designed to absorb liquids quickly in order to draw them away from the body so that they can be absorbed by the absorbent structure. Peak layers can provide absorbent personal hygiene products with faster fluid uptake and better drying.

[006] Maintaining dryness when using absorbent articles is important for several reasons, including greater comfort. Maintaining dryness also promotes better skin health. Although various past designs have provided great advances in technique, further improvements are still needed in the construction of absorbent articles so that liquids are captured and separated from the user in order to maintain a feeling of dryness. More particularly, improvements are needed in the design of expanding materials with excellent liquid absorption capacity and other liquid absorption properties. SUMMARY

[007] In general, the present disclosure relates to an expanding material made of multicomponent polymeric fibers which may also be hollow. The multicomponent fibers may include alternating polymeric zones around the cross-section of the fiber which have different thermal properties and cause the fiber to have a spiral-like shape, making the fibers well suited for use in blankets. Petition 870230088780, dated 06 / 10 / 2023, page 12 / 66 / 39 liquid absorbents. Non-woven blankets made in accordance with this disclosure, for example, have characteristics of high thickness, possess a significant amount of empty space and are suitable for absorbing liquids quickly to move the liquids from the side lining of the body to the absorbent structure.

[008] For example, in one embodiment, the present disclosure relates to an absorbent article comprising a body side lining, an outer cover, and an absorbent structure positioned between the body side lining and the outer cover. According to the present disclosure, the absorbent article further includes a peak layer positioned between the body side lining and the absorbent structure. The peak layer comprises a nonwoven mat containing a mixture of binder fibers and structural fibers. The structural fibers are designed to provide thick, void bulk. The binder fibers are designed to hold the structure together and provide strength. The structural fibers comprise multicomponent fibers.More specifically, the structural fibers have a cross-section that includes at least one first polymeric component zone comprising a first polymeric component and a second polymeric component zone comprising a second polymeric component. The first polymeric component comprises a first polymer having a higher melting point than the second polymeric component. In one embodiment, the first polymeric component and the second polymeric component both comprise polyester polymers, such as polyethylene terephthalate polymers. In one aspect, the cross-section of the structural fibers may include a plurality of first polymeric component zones that are separated by one or more second polymeric component zones. For example, in one embodiment, the cross-section of the structural fibers may include two to four first polymeric component zones and two to four second polymeric component zones. Petition 870230088780, dated 06 / 10 / 2023, p. 13 / 66 / 39 zones of secondary polymeric components, in which the first zones of polymeric components alternate with the second zones of polymeric components around the perimeter or circumference of the fiber.

[009] In one aspect, structural fibers may comprise hollow fibers. In addition, fibers may have a spiral-like conformation. For example, structural fibers may have more than about 1 crimp per inch, such as more than about 1.5 crimps per inch, such as more than about 2 crimps per inch, and generally less than about 8 crimps per inch, such as less than about 5 crimps per inch, such as less than about 3 crimps per inch.

[0010] Structural fibers may be present in the nonwoven fabric in an amount of about 20% by weight to about 60% by weight, as well as in an amount of about 35% by weight to about 45% by weight. Binder fibers, on the other hand, may be present in the nonwoven fabric in an amount of about 40% by weight to about 80% by weight, as well as in an amount of about 55% by weight to about 65% by weight. In one aspect, a greater amount of binder fibers is present in the nonwoven fabric compared to structural fibers on a weight percentage basis.

[0011] In one aspect, the binder fibers may include a mixture of different binder fibers with different sizes. For example, nonwoven fabric may contain primary binder fibers and secondary binder fibers. The primary binder fibers may have a denier of about 3 to about 10, as well as from about 4 to about 8. The secondary binder fibers, on the other hand, may be smaller than the primary binder fibers and may have a denier of about 0.1 to about 3, as well as from about 0.5 to about 2. In one aspect, the primary binder fibers may be contained in the nonwoven fabric in an amount of about 20% to about 75% by weight, as well as in an amount of about 30% to about 50% by weight. Petition 870230088780, dated 06 / 10 / 2023, p. 14 / 66 / 39 second binding fibers, on the other hand, may be present in the nonwoven blanket in an amount of about 5% to about 40% by weight, as well as in an amount of about 15% to about 25% by weight.

[0012] Binder fibers form bonding sites within the peak layer at crossing sites where binder fibers cross with other fibers. In one aspect, binder fibers comprise bicomponent fibers. Binder fibers may be made of one or more polyolefin polymers. For example, in one embodiment, the binder fibers include a core made of a polypropylene polymer surrounded by a sheath made of a polyethylene polymer.

[0013] The nonwoven fabric that forms the peak layer in the absorbent article may generally have a basis weight of about 20 g / m2 to about 120 g / m2, such as from about 40 g / m2 to about 100 g / m2. In one aspect, the nonwoven fabric may be a carded fabric. Furthermore, the nonwoven fabric may be bonded through air to cause the binding fibers to bond to the intersecting fibers without compressing the fabric.

[0014] The binder fibers and structural fibers may have any suitable length that provides void volume and integrity. In one aspect, the binder fibers and structural fibers may have an average length of about 30 mm to about 65 mm, as well as about 32 mm to about 60 mm. In order to improve the fluid handling properties of the expanding material, in one embodiment, the fibers in the nonwoven mat may be treated with a hydrophilic finish.

[0015] The nonwoven blanket or peak layer made in accordance with this disclosure may have several advantageous properties. For example, the nonwoven blanket may have a relatively high volume of voids which can be indicated by measuring air permeability. The air permeability of the nonwoven blanket, for example, may be greater than about 500 cfm / ft², as greater than about 600 cfm / ft², as greater than about 650 cfm / ft², Petition 870230088780, dated 06 / 10 / 2023, p. 15 / 66 / 39 as greater than approximately 700 cfm / ft2, as greater than approximately 750 cfm / ft2. The air permeability of the nonwoven blanket or peak layer is generally less than approximately 1500 cfm / ft2.

[0016] Nonwoven fabric and peak layer may also have strength and elongation properties that make the material suitable for use in high-speed processing. For example, nonwoven fabric may have strength and elongation properties that prevent bottlenecks during processing. For example, the tensile strength in the machine direction of nonwoven fabric may be greater than about 5,000 gf, such as greater than about 6,000 gf, such as greater than about 7,000 gf, such as greater than about 7,500 gf, such as greater than about 7,800 gf. gf, such as greater than about 8,000 gf, such as greater than about 8,200 gf, such as greater than about 8,400 gf, such as greater than about 8,600 gf, such as greater than about 8,800 gf, and generally less than about 12,000 gf.The machine-directed elongation of the nonwoven blanket is generally less than about 50%, such as less than about 45%, such as less than about 40%, such as less than about 38%, such as less than about 37%, such as less than about 36%, such as less than about 35%, and generally greater than about 20%, such as more than about 25%, such as more than about 30%.

[0017] The thickness of the nonwoven mat or peak layer may vary depending on the specific application. In one embodiment, the thickness of the nonwoven mat or peak layer is less than about 6 mm, such as less than about 5.5 mm, such as less than about 5 mm, such as less than about 4.5 mm, such as less than about 4 mm, and generally greater than about 2 mm, such as greater than about 3 mm, such as greater than about 3.2 mm, such as greater than about 3.4 mm, such as greater than about 3.6 mm, such as greater than about 3.8 mm.

[0018] In addition to absorbent articles, this disclosure also includes Petition 870230088780, dated 06 / 10 / 2023, page 16 / 66 / 39, addresses nonwoven fabrics with fluid management properties. The nonwoven fabric can be made from a mixture of binder fibers and structural fibers as described above. The nonwoven fabric can be used not only in absorbent articles but also in other applications where fluid management characteristics are desired. For example, the nonwoven fabric can also be used as a filter element in filter devices.

[0019] Other features and aspects of this publication are discussed in more detail below. BRIEF DESCRIPTION OF THE FIGURES

[0020] A full and informative disclosure of this disclosure is set forth, in particular, in the remainder of the descriptive report, including reference to the attached figures, in which: Figure 1 is a perspective view of one embodiment of a nonwoven blanket made in accordance with the present disclosure; Figure 2 is a perspective view with cut portions of an embodiment of a feminine hygiene product made in accordance with the present disclosure; Figure 3 is a perspective view of another embodiment of an absorbent article made in accordance with the present disclosure; Figure 4 is a schematic cross-sectional view of one embodiment of a fiber structure that can be used in accordance with the present disclosure; with Figure 5 is a representation of the results obtained in the example described below; Figure 6 is a representation of the results obtained in the example described below; Figure 7 is a representation of the results obtained in the example described below; graphic graphic graphic of of of some some some of of the Petition 870230088780, dated 06 / 10 / 2023, page 17 / 66 / 39 Figure 8 is a graphical representation of some of the results obtained in the example described below; Figure 9 is a graphical representation of some of the results obtained in the example described below; Figure 10 is a graphical representation of some of the results obtained in the example described below; Figure 11 is a graphical representation of some of the results obtained in the example described below; Figure 12 is another graphical representation of some of the results obtained in the example below; and Figure 13 is a plan view of a modality of structural fibers that can be incorporated into the product of the present disclosure.

[0021] The repeated use of reference characters in this descriptive report and in the drawings is intended to represent features or elements that are the same as, or analogous to, the present invention. DEFINITIONS

[0022] As used herein, the term nonwoven fabric or nonwoven blanket refers to a blanket that has a structure of individual polymeric and / or cellulosic fibers or yarns that are interwoven, but not in a manner identifiable as in a knitted fabric. Nonwoven fabrics or blankets have been formed from many processes, such as, for example, meltblowing processes, spunbonding processes, bonded carded blanket processes, those used to make fabrics and towels, etc.

[0023] As used herein, the term staple fiber means fibers that have a fiber length generally in the range of about 0.5 to about 150 millimeters. Staple fibers may be cellulosic or non-cellulosic fibers. Some examples of suitable non-cellulosic fibers that may be used include, but are not limited to, hydrophilically treated polyolefin fibers, polyester fibers, nylon fibers, acetate fibers. Petition 870230088780, dated 06 / 10 / 2023, page 18 / 66 / 39 of polyvinyl and its mixtures. Hydrophilic treatments may include durable surface treatments and treatments on polymer resins / mixtures. Staple cellulosic fibers include, for example, pulp, thermomechanical slurry, synthetic cellulosic fibers, modified cellulosic fibers and the like. Cellulosic fibers can be obtained from secondary or recycled sources. Synthetic cellulosic fibers such as, for example, rayon, viscose rayon and lyocell can be used. Modified cellulosic fibers are generally composed of cellulose derivatives formed by substitution of the appropriate radicals (e.g., carboxyl, alkyl, acetate, nitrate, etc.) by hydroxyl groups along the carbon chain.

[0024] As used herein, bonded carded webs refer to nonwoven webs formed by carding processes as are known to those skilled in the art and further described, for example, in U.S. Pat. No. 4,488,928 to Ali Khan et al., which is incorporated herein by reference thereto. Briefly, carding processes involve starting with a mixture of, for example, staple fibers with binder fibers or other bonding components in a bulky ball that is combed or otherwise treated to provide a generally uniform basis weight. This web is heated or otherwise treated to activate the adhesive component, resulting in a thick, integrated nonwoven material.

[0025] As used herein, the term hydrophilic generally refers to fibers or films, or to the surfaces of fibers or films, that are wettable by aqueous liquids in contact with the fibers. The term hydrophobic includes those materials that are not hydrophilic as defined. The phrase naturally hydrophobic refers to materials that are hydrophobic in their chemical composition state without additives or treatments that affect hydrophobicity.

[0026] The degree of wetting of the materials can, in turn, be Petition 870230088780, dated 06 / 10 / 2023, page 19 / 66 / 39, described in terms of contact angles and surface tensions of the liquids and materials involved. The appropriate equipment and techniques for measuring the wettability of particular fiber materials or mixtures of fiber materials can be provided by the Cahn SFA-222 Surface Force Analyzer System or an equivalent system. When measured with this system, fibers with contact angles less than 90° are designated wettable or hydrophilic, and fibers with contact angles greater than 90° are designated non-wettable or hydrophobic.

[0027] As used herein, the terms personal hygiene product and absorbent article refer to any article capable of absorbing water or other fluids. Examples of some absorbent articles include, but are not limited to, absorbent personal hygiene articles such as diapers, training diapers, absorbent underwear, adult incontinence products including fitted underwear, belted pads, male pads, protective underwear, fitted underwear, feminine hygiene products (e.g., sanitary napkins, pads, liners and the like), swimwear and so forth. Materials and processes suitable for forming such absorbent articles are well known to those skilled in the art.

[0028] Disposable absorbent products are designed to be removed and discarded after a single use. Single use means that the disposable absorbent incontinence product will be discarded after being used once, rather than being washed or cleaned for reuse, as is typical of normal fabric underwear.

[0029] As used herein, the dtex of a fiber is the number of grams of fiber per ten kilometers and is a direct measure of linear density. In comparison, denier is the mass in grams of fiber per 9,000 meters. Petition 870230088780, dated 06 / 10 / 2023, page 20 / 66 / 39

[0030] As used herein, the “stretch” or “stretch ratio” of a fiber is defined as the ratio between the final length of the fiber and the original length of the fiber.

[0031] The elongation of a fiber and the toughness of a fiber, which is a measure of the specific strength of the fiber, are measured according to ASTM Test D76 and / or ASTM Test D2101.

[0032] Air permeability as used in this document is tested according to ASTM Test D-737 (current test as of 2022). The test parameters used are a gauge head of 20 cm² and a pressure of 125 Pa. The test can be conducted using a TEXTEST FX 3300 air permeability tester available from ATI Corporation.

[0033] The tensile strength and elongation of a nonwoven blanket can be measured in the machine direction or in the transverse direction. As used herein, tensile strength is the peak load value, i.e., the maximum force produced by a sample when it is pulled to rupture. Elongation is the percentage elongation at rupture. Samples for tensile strength tests are prepared by drying and then molding the cut test specimens to a width of 25 mm and a length of approximately 152 mm. The instrument used to measure tensile strengths can be an MTS Criterian 42 and MTS TestWorks™ for Windows Ver. 4 (MTS Systems Corp., Research Triangle Park, NC). The load cell is selected depending on the strength of the sample being tested so that the peak load values ​​are between 10 and 90 percent of the full-scale load of the load cell.The gauge length is 76 mm and the jaw length is 76 mm. The load application speed is 305 mm / minute and the rupture sensitivity is set to 70%, with preset tilt points at 70 and 157 g. The sample is placed in the instrument jaws and centered with the longer dimension parallel to the direction. Petition 870230088780, dated 06 / 10 / 2023, page 21 / 66 / 39 of the load application. The test is then started and ended when the specimen breaks. Six (6) representative specimens are tested, and the arithmetic mean of all individual specimens tested is the tensile strength for the product. DETAILED DESCRIPTION

[0034] It must be understood by those skilled in the art that the present discussion is a description of exemplary embodiments only and is not intended to limit the broader aspects of the present disclosure.

[0035] In general, the present disclosure is directed to a fibrous material that possesses excellent fluid management characteristics. The fiber material has significant strength and integrity and also possesses a significant void volume for fluid absorption. The fiber material can be used in all different types of applications. In one particular embodiment, the fiber material can be used as a peak layer in an absorbent article.

[0036] Resilient peak layers provide absorbent personal hygiene articles with faster fluid uptake and better drying. Effective peak layers, for example, are able to absorb liquids quickly and transfer them to an absorbent core designed to store the liquids away from the user's skin. The peak layers work in conjunction with the absorbent core to keep the user dry and prevent leaks at the waist and legs. For example, peak layers have fluid handling properties that can effectively disperse liquids that reach and saturate a given target insult area. Peak layers increase the absorbent article's ability to move liquid away from the target insult area in order to limit saturation and improve the article's overall fluid management performance, especially during multiple insults.

[0037] In general, absorbent articles include a side lining of Petition 870230088780, dated 06 / 10 / 2023, page 22 / 66 13 / 39 body, an outer cover, and an absorbent core positioned between the body's side liner and the outer cover. Peak layers are typically positioned between the absorbent core and the body's side liner in order to provide fluid handling benefits. In the past, effective expansion materials typically required large quantities of material. Furthermore, many expansion materials made in the past had limitations regarding absorbent capacity and / or the ability to rapidly absorb substantial amounts of fluid.

[0038] The expansion materials made according to this disclosure possess excellent liquid absorption properties. Furthermore, due to the specific fibers selected for use in the construction of the nonwoven blanket, the expansion materials made according to this disclosure can have the same or better absorption properties with a reduced basis weight compared to previous materials. Consequently, the materials made according to this disclosure are very efficient in absorbing liquids. The ability to use less material in the manufacture of the blankets not only reduces the cost of the product but also makes the material more sustainable and environmentally friendly.

[0039] The expanding materials made in accordance with this disclosure also provide better dryness for the user of absorbent personal hygiene articles.

[0040] As described above, the material of the present disclosure that can be used as a peak layer is a fiber material in the form of a nonwoven mat. Referring to FIG. 1, for example, for illustrative purposes only, a nonwoven mat 20 made according to the present disclosure is shown. The nonwoven mat 20 contains at least two different types of fibers. More particularly, the nonwoven mat 20 includes structural fibers combined with binder fibers. In one aspect, the nonwoven mat 20 is made exclusively of structural fibers and binder fibers and Petition 870230088780, dated 06 / 10 / 2023, page 23 / 66 / 39, does not contain any other fiber or filler material. The structural fibers and the binder fibers can both be made of thermoplastic polymers.

[0041] In one aspect, nonwoven web 20 can be a carded web, particularly a bonded carded web. In this respect, nonwoven web 20 can be made of structural fibers and binder fibers which are staple fibers. In the production of a carded web, bales of the fibers can optionally be placed in contact with a collector that separates the fibers. The fibers are then fed through a combing or carding unit which further separates and optionally aligns the staple fibers along a direction, such as the machine direction (longitudinal direction) so as to form a fibrous nonwoven web. Once the web is formed, the web is then bonded using one or more bonding methods. According to this disclosure, the web contains binder fibers that facilitate the bonding of the fibers where they cross to give integrity and strength to the web.In one aspect, for example, carded webs can be bonded using air bonding. Air bonding, for example, controls the level of compression or collapse of the nonwoven web during the bonding process. In air bonding, heated air is forced through the web to melt at least one component within the web to cause the formation of bonding sites. The component that is melted can be a portion of the binder fibers. For example, the binder fibers may include a polyethylene polymer and a polypropylene polymer where the lower melt polyethylene component forms a sheath that surrounds a polypropylene core. The sheath polymer may melt during air bonding and cause the binder fibers to bond to other fibers at crossing points in the web where the binder fibers intersect other fibers. During air bonding, the nonwoven web can be supported on a forming wire or drum. Petition 870230088780, dated 06 / 10 / 2023, page 24 / 66 / 39 Additionally, a vacuum can optionally be drawn through the blanket for better process control.

[0042] Through the process described above, the structural fibers within the blanket become trapped or entangled with the bonded binding fibers and provide a void structure within the blanket that greatly increases liquid absorption.

[0043] The structural fibers selected for use in the fibrous material of the present disclosure may be multicomponent fibers formulated from polymers with different thermal properties that produce a fiber with a spiral-like conformation. For example, FIG. 13 represents an embodiment of structural fibers 22 that can be used in the nonwoven blanket of the present disclosure. The structural fibers, for example, provide the nonwoven blanket 20 with an “elastic” characteristic. In this way, the blanket 20 is not only resilient to compressive forces but also recovers when compressed. In this way, the nonwoven blanket 20 maintains its thickness and void volume under pressure, allowing fluid to enter the nonwoven blanket very quickly while maintaining space between the other components of the absorbent article, such as a liner and an absorbent core, in order to prevent rewetting.In this way, the fibers of the expanding material structure of the present disclosure provide better drying when incorporated into an absorbent article.

[0044] For example, referring to FIG. 4, an embodiment of a cross-section of a fiber structure 22 that can be used according to the present disclosure is shown. According to the present disclosure, the fiber 22 includes at least one first polymer component zone 24 and at least one second polymer component zone 26. As shown in FIG. 4, the two polymer component zones can alternate around the perimeter or circumference of the fiber. In the embodiment illustrated in FIG. 4, the fiber 22 includes three first polymer component zones 24 and Petition 870230088780, dated 06 / 10 / 2023, p. 25 / 66 / 39 three second polymer component zones 26. The first polymer component zones 24 alternate with the second polymer component zones 26. In general, the fiber 22 may include at least 1 and about 2 to about 5, such as about 3 to about 4 first polymer component zones 24 and at least 1 and about 2 to about 5, such as about 3 to about 4 second polymer component zones 26. The polymer fiber 22 may also be hollow and may include an axial passage 28.

[0045] The first polymer component zone 24 is made from a first polymer component, while the second polymer component zone 26 is made from a second polymer component. The first polymer component, for example, may have a lower melting point or softening point than the second polymer component. Constructing the fiber 22 with different polymer zones of polymers with different melting properties causes the fiber to have a three-dimensional shape which, when incorporated into a nonwoven mat, produces resilience and void volume. For example, the fiber 22 may have a spiral-like conformation. The fiber 22, for example, may have more than about 1 crimp per inch, such as more than about 1.5 crimps per inch, such as more than about 1.75 crimps per inch.The fiber typically has fewer than about 10 crimps per inch, such as fewer than about 6 crimps per inch, or fewer than about 4 crimps per inch. The crimp characteristics of the fiber can be measured according to the ASTM D3937 test (last revised in 2021).

[0046] Fiber 22 can be made from all different types of polymers, provided that the different polymeric components have different melting temperatures and are capable of producing fibers with a three-dimensional shape. For example, in one embodiment, fiber 22 can be made exclusively from polyolefin polymers. For example, the first Petition 870230088780, dated 06 / 10 / 2023, p. 26 / 66 / 39 The polymeric component may comprise a polyethylene polymer, while the second polymeric component may comprise a polypropylene polymer. Alternatively, fiber 22 may be made from polyester polymers. In yet another embodiment, fiber 22 may be made from a combination of a polyolefin polymer and a polyester polymer.

[0047] Polyester polymers that can be used to construct fiber 22 include polyalkylene terephthalate polymers. Polyalkylene terephthalate polymers, for example, can be derived from an aliphatic or cycloaliphatic diol, or mixtures thereof, containing from 2 to about 10 carbon atoms and an aromatic dicarboxylic acid. Examples of polyalkylene glycols that can be used include polyethylene terephthalate polymers and / or polybutylene terephthalate polymers.

[0048] Polyester polymers can be produced with comonomers. For example, a comonomer acid or a comonomer diol can be used in the production of the polyester polymer. In one embodiment, however, the polyester polymers used to produce fiber 22 do not contain any comonomers.

[0049] In one aspect, the first polymeric component comprises a first polyethylene terephthalate polymer, while the second polymeric component comprises a second polyethylene terephthalate polymer, wherein the first polyethylene terephthalate polymer has a lower melting point than the second polyethylene terephthalate polymer. The difference in melting point between the two polymers may be greater than about 5°C, such as greater than about 10°C, such as greater than about 15°C, such as greater than about 20°C and generally less than about 150°C, such as less than about 100°C, such as less than about 70°C.

[0050] If desired, one or more fillers may be incorporated into the fiber structure 22. The filler particles, for example, may be Petition 870230088780, dated 06 / 10 / 2023, p. 27 / 66 / 39 incorporated into the first polymeric component, the second polymeric component, or both polymeric components. The filler particles may have an average particle size smaller than about 2 microns, such as smaller than about 1 micron, such as smaller than about 0.75 microns, such as smaller than about 0.5 microns, and generally larger than about 0.001 microns. Fillers that may be incorporated into fiber 22 generally include white fillers. For example, filler particles that may be incorporated into the fiber include titanium dioxide fillers, barium sulfate fillers, and the like. Fillers can be incorporated into the fiber in an amount less than about 10% by weight, such as in an amount less than about 5% by weight, such as in an amount less than about 3% by weight, such as in an amount of less than about 2% by weight.When added to polymers to form fibers, filler particles may be present in the fiber in an amount greater than about 0.1% by weight, as well as in an amount greater than about 0.5% by weight.

[0051] Structural fibers generally have a relatively small size for use in the production of nonwoven fabric 20 according to the present disclosure. For example, structural fibers may have a size less than about 30 denier (denier per filament), such as less than about 25 denier, such as less than about 20 denier, such as less than about 18 denier. The fiber size may generally be greater than about 1 denier, such as greater than about 3 denier, such as greater than about 5 denier. In one aspect, structural fibers may have a size of about 4 denier to about 15 denier, such as a size of about 6 denier to about 12 denier. In an alternative embodiment, the fibers may have a size of about 12 denier to about 18 denier.

[0052] Structure 22 fibers are basic fibers. In this respect, structure 22 fibers can have an average fiber length of about 30 Petition 870230088780, dated 06 / 10 / 2023, p. 28 / 66 / 39 mm to approximately 65 mm, including all 1 mm increments between them. For example, the fibers of structure 22 may have an average fiber length greater than approximately 32 mm, such as greater than approximately 35 mm, such as greater than approximately 38 mm, such as greater than approximately 45 mm, such as greater than approximately 48 mm, and generally less than approximately 60 mm, such as less than approximately 55 mm.

[0053] Structural fibers may be present in the nonwoven blanket 20 as shown in FIG. 1 generally in an amount of about 20% by weight to about 60% by weight, including all 1% increments thereafter. For example, structural fibers may be present in the nonwoven blanket 20 in an amount greater than about 30% by weight, such as in an amount greater than about 35% by weight, such as in an amount greater than about 40% by weight, and generally in an amount less than about 60% by weight, such as less than about 55% by weight, such as less than about 50% by weight, such as less than about 45% by weight. In one aspect, for example, structural fibers are present in the nonwoven blanket 20 in an amount not greater than about 42% by weight.Due to the characteristics of structural fibers, for example, fewer structural fibers may be needed to produce nonwoven fabric and still have significant void space and resilience that provides sufficient liquid absorption capacity.

[0054] As described above, structural fibers are combined with binder fibers to construct the nonwoven mat 20. Binder fibers can also be constructed from multiple polymers. In general, binder fibers contain a thermoplastic polymer on the fiber surface that has a melting temperature lower than the melting temperature of the polymers used to produce the structural fibers.

[0055] Similar to structural fibers, binder fibers can also be short fibers having an average fiber length of about 30 Petition 870230088780, dated 06 / 10 / 2023, p. 29 / 66 / 39 mm to approximately 65 mm. For example, the binder fibers may have an average fiber length greater than approximately 32 mm, such as greater than approximately 35 mm, such as greater than approximately 38 mm, such as greater than approximately 40 mm, such as greater than approximately 45 mm, and generally less than approximately 60 mm, such as less than approximately 55 mm.

[0056] In one aspect, binder fibers can be single-component fibers made from a single polymer. The polymer used to produce binder fibers, for example, can be a polyethylene polymer.

[0057] In an alternative embodiment, the binder fibers are bicomponent fibers. Bicomponent fibers, for example, may have a high-melting-point component or polymer combined with a lower-melting-point component or polymer in a side-by-side arrangement or in a sheath / core arrangement. In a sheath and core arrangement, for example, the higher-melting-point component forms the fiber core while the lower-melting-point polymer or component forms the fiber sheath. The lower-melting-point component provides an efficient means of binding the fibers to other fibers, while the higher-melting-point component helps maintain the structural integrity of the fiber.

[0058] The lower melting point polymer, for example, may be a polyethylene polymer or a polyester polymer. The polyester polymer, for example, may be a polyethylene terephthalate polymer that includes a comonomer (a “CoPET”). The higher melting point polymer, on the other hand, may be a polypropylene polymer or a polyester polymer, such as a polyethylene terephthalate polymer. The binding fibers that may be used include, for example, a polyethylene / polyethylene terephthalate fiber, a copolymerized polyethylene terephthalate / polyethylene terephthalate fiber, or a polyethylene / polypropylene fiber.

[0059] In one embodiment, the binding fibers are made Petition 870230088780, dated 06 / 10 / 2023, page 30 / 66 / 39 exclusively of polyolefin fibers. For example, in one aspect, the component or core with the highest melting point may be made of a polypropylene polymer. The polypropylene polymer may be a polypropylene homopolymer or a random copolymer containing polypropylene. The random copolymer may be, for example, a propylene-butylene copolymer or a propylene-ethylene copolymer.

[0060] The sheath or surface polymer, on the other hand, may comprise a polyethylene polymer, such as a linear low-density polyethylene or a high-density polyethylene polymer. In yet another embodiment, the sheath polymer may be a random copolymer of ethylene and propylene.

[0061] In a sheath and core arrangement, the core polymer generally comprises from about 20% to about 80% by weight of the fiber, as well as in an amount of about 40% to about 60% by weight. Similarly, the sheath polymer may be present in the fiber in an amount of about 20% to about 80% by weight, as well as in an amount of about 40% to about 60% by weight.

[0062] The binder fibers incorporated into the nonwoven blanket 20 as shown in FIG. 1 may also be drawn fibers. For example, the binder fibers may have a stretch ratio greater than about 2, such as greater than about 2.4, and generally less than about 5, such as less than about 4, such as less than about 3.5. The dtex of the fibers may vary depending on the specific application. In general, the dtex may be from about 3 to about 12.5, including all increments of 0.5 between them. In one aspect, higher dtex fibers may be used wherein the binder fibers have a dtex of about 6.5 to about 12.5. Alternatively, smaller size binder fibers with a dtex of about 3 to about 6 or about 0.5 to about 2 may be used.

[0063] The size of the binding fibers can also be measured in Petition 870230088780, dated 06 / 10 / 2023, p. 31 / 66 / 39 denier. For example, binder fibers may have a denier of about 0.1 to about 12, including all increments of 0.1 in between. The denier of binder fibers, for example, may be greater than about 0.5, as well as greater than about 1, as well as greater than about 2, as well as greater than about 3, as well as greater than about 4, as well as greater than about 5, and generally less than about 10, as well as less than about 9, as well as less than about 8.

[0064] Binder fibers are generally present in nonwoven fabric 20 as shown in FIG. 1 in an amount of about 40% by weight to about 80% by weight, including all 1% by weight increments in between. For example, binder fibers may be present in nonwoven fabric 20 in an amount greater than about 45% by weight, as in an amount greater than about 50% by weight, as in an amount greater than about 55% by weight, and generally less than about 70% by weight, as in an amount less than about 65% by weight.

[0065] In one embodiment, the nonwoven fabric may include binder fibers of different sizes. For example, the nonwoven fabric may contain first binder fibers having a denier of about 3 to about 10. The first binder fibers, for example, may have a denier greater than about 4, such as greater than about 5, and less than about 8, such as less than about 7. The first binder fibers may be combined with second binder fibers having a smaller size. The secondary binder fibers, for example, may have a denier of about 0.1 to about 3, as well as from about 0.5 to about 2. For example, the secondary binder fibers may have a denier greater than about 0.8, such as greater than about 1, such as greater than about 1.2 and less than about 2.5, such as less than about 2.3, such as less than about 2, such as less than about 1.8, as well as less than about 1.6.The first binding fibers may be present in the nonwoven blanket in an amount of approximately 20%. Petition 870230088780, dated 06 / 10 / 2023, p. 32 / 66 / 39 to approximately 70% by weight. For example, the first binding fibers may be contained in the nonwoven blanket in an amount greater than approximately 30% by weight, such as in an amount greater than approximately 35% by weight, and in an amount less than approximately 50% by weight, such as in an amount less than approximately 45% by weight. Secondary binder fibers, on the other hand, may be present in the nonwoven blanket in an amount greater than about 5% by weight, such as in an amount greater than about 10% by weight, such as in an amount greater than about 15% by weight, such as in an amount greater than about 18% by weight, and in an amount less than about 30% by weight, such as in an amount less than about 25% by weight, such as in an amount less than about 23% by weight.

[0066] The combination of binder fibers with different sizes can provide various advantages and benefits.Lower denier fibers, for example, have a larger surface area for bonding. Thus, based on the amount of low-denier bonding fibers incorporated into the web, the low-denier bonding fibers can impact the web's strength and elongation properties. In this way, the web's strength and elongation can be controlled to produce webs that are easy to process and do not exhibit narrowing problems when laminated to other layers. It has also been found that incorporating some lower-denier fibers into the nonwoven web can prevent dust generation, especially when the web is cut.

[0067] Binding fibers generally have a tenacity greater than about 2 Nm / kg, such as greater than about 2.25 Nm / kg, and generally less than about 4.5 Nm / kg, such as less than about 4 Nm / kg, such as less than about 3.5 Nm / kg. Binding fibers generally have an elongation less than about 350%, such as less than about 325%, such as less than about 300%, such as less than about 290%, and generally greater than about 150%, such as greater than about 170%, such Petition 870230088780, dated 06 / 10 / 2023, p. 33 / 66 / 39 as exceeding approximately 175%, as well as exceeding approximately 180%.

[0068] The structural fibers and the binder fibers can be blended to form the nonwoven mat 20 as shown in FIG. 1. In one aspect, the fibers can be well blended so that the nonwoven mat 20 has a substantially homogeneous fiber distribution. The basis weight of the resulting nonwoven mat 20 can vary depending on the specific application. Nonwoven mats made according to the present disclosure can be used in all different types of applications, including use as a surge layer in an absorbent article, can be used as a filter layer in a filter device, or can be used in various other applications. In general, the basis weight can be from about 12 g / m2 to about 250 g / m2, including increments of 1 g / m2 in between.When used as a protective layer, for example, non-woven blanket 20 may have a basis weight generally greater than about 30 g / m2, such as greater than about 35 g / m2, such as greater than about 40 g / m2 and generally less than about 110 g / m2, such as less than about 90 g / m2, such as less than about 80 g / m2, such as less than about 70 g / m2 g / m2, such as less than about 60 g / m2.

[0069] In one aspect, the nonwoven blanket as shown in FIG. 1 may further include a hydrophilic treatment to further improve the fluid handling properties of the blanket. The hydrophilic treatment agent of the present disclosure may be selected from the group consisting of polyethylene glycol laurates, polyethylene glycol lauryl ethers and combinations thereof. Examples of polyethylene glycol laurates include, but are not limited to, polyethylene glycol monolaurate 400, polyethylene glycol monolaurate 600, polyethylene glycol monolaurate 1000, polyethylene glycol monolaurate 4000, polyethylene glycol dilaurate 600 and combinations thereof. Examples of suitable polyethylene glycol lauryl ethers include, but are not limited to, polyethylene glycol lauryl ether 600. Petition 870230088780, dated 06 / 10 / 2023, page 34 / 66 / 39

[0070] In addition to PEG laurates and PEG lauryl ethers, other polyethylene glycol derivatives may be used as hydrophilic treatment agents for the personal care products described herein. As used herein, the term polyethylene glycol derivatives includes any compound containing a polyethylene glycol fraction. Examples of other suitable PEG derivatives include, but are not limited to, PEG monoesterates such as PEG 200 monoesterate and PEG 4000 monoesterate; PEG dioleates such as PEG 600 dioleate and PEG 1540 dioleate; PEG monooleates such as PEG 600 monooleate and PEG 1540 monooleate; PEG monoisoesterates such as PEG 200 monoisoesterate; and PEG 16 octylphenyl.

[0071] In certain respects, the hydrophilic treatment agents described in this document, such as polyethylene glycol 600 lauryl ether and / or polyethylene glycol 600 monolaurate, may be used in combination with each other or with other viscoelastic agents. Examples of other viscoelastic agents that may be used in combination with the hydrophilic treatment agents include, but are not limited to, sodium citrate, dextran, cysteine, Glucopon 220UP (available as a 60% (by weight) alkyl polyglycoside solution in water from Henkel Corporation), Glucopon 425, Glucopon 600, Glucopon 625. Other suitable viscoelastic agents are described in U.S. Patent No. 6,060,636.

[0072] The hydrophilic treatment agent can be applied in varying amounts, depending on the desired results and application. Typically, the hydrophilic treatment agent is applied to the base fiber in an amount of about 0.1% to about 3%, about 0.1% to about 2%, or about 0.1% to about 1%, by weight of the base fiber.

[0073] The nonwoven blankets made according to the present disclosure have an excellent balance of properties that make the blankets well suited for use as expansion layers in articles. Petition 870230088780, dated 06 / 10 / 2023, p. 35 / 66 / 39 absorbents. Nonwoven blankets made in accordance with this disclosure, for example, may have a significant amount of void volume. An indication of the void volume is the measurement of the blanket's air permeability. Nonwoven blankets made in accordance with this disclosure, for example, may have an air permeability greater than about 500 cfm / ft². The air permeability of the blankets, for example, can be greater than about 550 cfm / ft², greater than about 600 cfm / ft², greater than about 650 cfm / ft², greater than about 700 cfm / ft², greater than about 750 cfm / ft², greater than about 800 cfm / ft², greater than about 850 cfm / ft², greater than about 900 cfm / ft². The air permeability of spider webs is generally less than about 1,500 cfm / ft².

[0074] Nonwoven blankets made in accordance with this disclosure can also have a good balance between strength and elongation. For example, the strength in the machine direction of the blanket can be greater than about 5,000 gf, such as greater than about 6,000 gf, such as greater than about 7,000 gf, such as greater than about 7,500 gf, such as greater than about 7,800 gf, such as greater than about 8,000 gf, such as greater than about 8,200 gf, such as greater than about 8,400 gf, such as greater than about 8,600 gf, such as greater than about 8,800 gf, and generally less than about 12,000 gf.The machine-directed elongation of the nonwoven blanket may be less than about 50%, such as less than about 45%, such as less than about 40%, such as less than about 38%, such as less than about 37%, such as less than about 36%, such as less than about 35%, and generally greater than about 20%, such as more than about 25%, such as more than about 30%.

[0075] The thickness of the nonwoven blanket can vary depending on the specific application and the type of fibers used to form the blanket. In general, the thickness is greater than about 2 mm, as well as greater than about 2.5 mm. Petition 870230088780, dated 06 / 10 / 2023, p. 36 / 66 / 39 mm, as greater than about 3 mm, as greater than about 3.2 mm, as greater than about 3.4 mm. The thickness of the blanket is generally less than about 8 mm, such as less than about 6 mm, such as less than about 5.5 mm, such as less than about 5 mm, such as less than about 4.8 mm, such as less than about 4.5 mm, such as less than about 4 mm. In one embodiment, the thickness of the blanket is from about 3.5 mm to about 4 mm with a basis weight of about 70 g / m2 to about 90 g / m2, such as from about 75 g / m2 to about 85 g / m2.

[0076] As described above, the nonwoven blanket 20 as shown in FIG. 1 is particularly suitable for use as a peak layer in an absorbent article. The nonwoven blanket can be used in all different types of absorbent articles for personal hygiene including, but not limited to, diapers, training diapers, incontinence garments, sanitary napkins, bandages and the like.

[0077] For example, disposable absorbent articles include feminine hygiene pads, such as the pad 10 shown in FIG. 2. The pad or filling 10 includes a side liner 14 and an outer baffle or cover 15 extending to a perimeter of the pad 12. The pad 10 may include an absorbent core 13 and a transfer layer or peak 17 made in accordance with the present disclosure disposed between the body side liner 14 and the outer baffle or cover 15. The absorbent core 13 may include an optional core wrap 16. In one aspect of the present disclosure, the pad 10 may include a scatter layer 40 positioned between the transfer layer or peak 17 and the absorbent core 13. Many products also have an adhesive strip 39 to help keep the product in place during use by adhering it to the user's underwear.

[0078] The disposable absorbent article may also be a diaper or training diaper, such as the training diaper shown in FIG. 3 Petition 870230088780, dated 06 / 10 / 2023, page 37 / 66 / 39 in a partially imprisoned state. The pants 120 define a pair of longitudinal terminal regions, also referred to herein as a frontal region 122 and a posterior region 124, and a central region, also referred to herein as the crotch region 126, extending longitudinally between and interconnecting the frontal and posterior regions 122, 124. The diaper 120 also defines an inner surface 128 adapted for use (e.g., positioned in relation to the other components of the pants 120) to be positioned towards the user, and an outer surface 130 opposite the inner surface. The illustrated trousers 120 include a chassis 132 which includes an outer cover 140 and a body side lining 142 which can be joined to the outer cover 140 in an overlapping relationship to them by means of adhesives, ultrasonic bonding, thermal bonding or other conventional techniques.The chassis 132 may further include a peak layer as per the present disclosure (not shown) and an absorbent structure (not shown) disposed between the outer cover 140 and the side liner 142 to absorb liquid body exudates exuded by the user and may further include a pair of containment flaps 146 attached to the side liner of the chassis 142 to inhibit the lateral flow of body exudates.

[0079] The peak layer according to the present disclosure can help absorb, slow down, and diffuse waves or jets of liquid that may be rapidly introduced into the absorbent article, as shown in FIG. 2 or FIG. 3. The peak layer is generally located between the body side liner and the absorbent core. In one aspect, the peak layer may be attached to one or more of the various components of the absorbent article, such as the absorbent core, the body side liner, or an envelope that may enclose the absorbent core.

[0080] The outer covering of the absorbent article may be made of a liquid-impermeable material. For example, in one aspect, the outer covering may be formed from a non-woven polypropylene sheet. Petition 870230088780, dated 06 / 10 / 2023, p. 38 / 66 / 39 connected by wiring.

[0081] The body side liner, on the other hand, is permeable to liquids and can be made of materials that are suitably compliant and soft when placed adjacent to the user's skin. The body side liner can be manufactured from a wide variety of blanket materials, such as synthetic fibers, natural fibers, a combination of natural and synthetic fibers, porous foams, cross-linked foams, perforated plastic films, or the like. Various woven and non-woven fabrics can be used for the body side liner. For example, the body side liner can be made from a meltblown or spun blanket of polyolefin fibers. The body side liner can also be a bonded-carded blanket composed of natural and / or synthetic fibers.

[0082] A suitable liquid-permeable body side liner is a two-component nonwoven mat with a basis weight of about 27 g / m2. The two-component nonwoven mat may be a two-component spunbond mat, or a two-component carded bonded mat. Suitable two-component staple fibers include a two-component polyethylene / polypropylene fiber. In this particular embodiment, the polypropylene forms the core and the polyethylene forms the fiber sheath. Other fiber orientations, however, are possible.

[0083] The material used to form the absorbent structure, for example, may include cellulosic fibers (e.g., wood pulp fibers), other natural fibers, synthetic fibers, woven or nonwoven sheets, woven fabric or other stabilizing structures, superabsorbent material, binders, surfactants, selected hydrophobic materials, pigments, lotions, odor control agents or the like, as well as combinations thereof.In one particular embodiment, the absorbent blanket material is a matrix of cellulosic down and superabsorbent hydrogel-forming particles. The down-type cellulose may comprise a mixture of down-type cellulose. A preferred type of down is... Petition 870230088780, dated 06 / 10 / 2023, page 39 / 66 / 39, identified with the trade name CR 1654, available from US Alliance Pulp Mills, of Coosa, Ala., USA, and is a bleached highly absorbent wood pulp containing primarily softwood fibers. As a general rule, the superabsorbent material is present in the absorbent mat in an amount of about 0 to about 90% by weight based on the total weight of the mat. The mat may have a density within the range of about 0.1 to about 0.45 grams per cubic centimeter.

[0084] Superabsorbent materials are well known in the art and can be selected from natural, synthetic, and modified natural polymers. Superabsorbent materials can be inorganic materials, such as silica gels, or organic compounds, such as cross-linked polymers. Traditionally, a superabsorbent material has the capacity to absorb at least approximately 15 times its weight in liquid and, suitably, is capable of absorbing more than approximately 25 times its weight in liquid. Suitable superabsorbent materials are readily available from various suppliers. For example, FAVOR SXM 880 superabsorbent is available from Stockhausen, Inc., of Greensboro, NC, USA; and Drytech 2035 is available from Dow Chemical Company, of Midland, Michigan, USA.

[0085] In addition to cellulosic fibers and superabsorbent materials, the structures of absorbent pads may also contain adhesive elements and / or synthetic fibers that provide stabilization and fixation when appropriately activated. Additives such as adhesives may have the same appearance or different appearances from cellulosic fibers; for example, said additives may be in the form of fibers, particles or liquid; the adhesives may have a curable or thermally hardening property. Said additives may reinforce the integrity of the total absorbent structure and may provide, alternatively or complementarily, adhesion between the facing layers of the folded structure. Petition 870230088780, dated 06 / 10 / 2023, page 40 / 66 / 39

[0086] Absorbent materials can be formed into a woven structure using various conventional methods and techniques. For example, absorbent matting can be formed using a dry forming technique, an air deposition technique, a carding technique, a fusion or spunbond technique, a wet forming technique, a foam forming technique, or similar techniques, as well as combinations thereof. Layered and / or laminated structures may also be suitable. Methods and apparatus for carrying out such techniques are well known in the art.

[0087] The absorbent mat material may also be a coforming material. The term coforming material generally refers to composite materials comprising a mixture or a stabilized matrix of thermoplastic fibers and a second non-thermoplastic material. As an example, coformed materials may be manufactured by a process in which at least one melt-spun die head is disposed near a chute through which other materials are added to the mat as it forms. These other materials may include, but are not limited to, fibrous organic materials such as woody or non-woody pulp such as cotton, rayon, recycled paper, paper pulp, and also superabsorbent particles or fibers, inorganic absorbent materials, treated polymeric staple fibers and the like. Any of a variety of synthetic polymers may be used as the melt-spun component of the coforming material.

[0088] This disclosure can be better understood with reference to the following examples. Example #1

[0089] Several different bonded carded mats were constructed and tested as a peak layer in an absorbent article. The bonded carded mats were compared with expansion layers contained in commercial products. Petition 870230088780, dated 06 / 10 / 2023, p. 41 / 66 / 39

[0090] Carded and air-bonded webs were constructed. In particular, 60% by weight of a binder fiber was combined with 40% by weight of a structural fiber to produce a bonded carded web having a basis weight of 80 g / m2. The binder fiber included a polypropylene core surrounded by a polyethylene sheath.

[0091] The structural fibers were multicomponent hollow fibers made of polyester polymers. The structural fibers were similar to the structural fiber illustrated in FIG. 4. In particular, the structural fibers included first zones of polymeric components alternating with zones of second polymeric components. The fiber included three first zones of polymeric components and three second zones of polymeric components around the circumference of the fiber. The first polymeric component and the second polymeric component were both non-comonomerizing polyethylene terephthalate polymers. The first polymeric component had a lower melting temperature than the second polymeric component. The fibers contained titanium dioxide particles. The nonwoven mats were hydrophilic due to the staple fibers that produced the mats being treated with a hydrophilic finish.

[0092] In a first set of experiments, nonwoven blankets as described above were incorporated into absorbent articles made from a commercial asset. In particular, the absorbent articles manufactured from a commercial asset contained an elastic material. The expanding material in the commercially manufactured absorbent article was replaced by the nonwoven blanket as described above. The nonwoven blanket was placed between a side body lining and an absorbent core. The commercially manufactured absorbent article was tested for fluid uptake and rewetted and compared with the absorbent articles that were modified to include the nonwoven blanket as described above.

[0093] The following test was conducted to determine the intake of Petition 870230088780, dated 06 / 10 / 2023, page 42 / 66 / 39 liquids and rehydration. SUMMARY

[0094] This test categorizes the amount of fluid remaining near the surface of the diaper immediately after an insult, as well as quantifying the amount of fluid not retained by the superabsorbent under high pressure after a longer wait and multiple insults. For successful use, the product must quickly aspirate fluid through the layers of the absorbent core, in addition to retaining the fluid to ensure it does not flow back out when subjected to high pressure. Load volumes and fluid delivery rates are predefined based on previous consumer studies with the product. These values ​​may vary from product to product. 1.0 Equipment and Supplies

[0095] 1.1 Top-loading electronic scale capable of reading 0.001 grams.

[0096] 1.2 Saline solution, 0.9 + 0.005% (w / w) aqueous isotonic saline solution.

[0097] 1.3 Countdown timer, readable down to 0.1 seconds

[0098] 1.4 Rectangular Plexiglass Plate (Dimensions length = 300 mm long and 100 mm wide) including an open cylinder located in the central area of ​​the plate (the inner diameter of the cylinder is 38 mm and the height is 125 mm)

[0099] 1.5 Two weights of 4 kg each

[00100] 1.6 Verigood blotting paper, white, 100 lb, 475 by 600 mm (19 by 24 inches), long paper, 250 sheets per ream, cut to the specified size of 88 x 300 mm + / - 13 mm (3.5 by 12 inches)

[00101] 1.7 Polycarbonate sheet (3 675 mm thick) cut to 114 mm wide x 432 mm long (4.5 by 17 inches) and weighing 177 grams. Petition 870230088780, dated 06 / 10 / 2023, page 43 / 66 / 39

[00102] 1.8 Polyethylene Funnel, 4 oz (113.4 g) capacity

[00103] 1.9 Low-tack double-sided tape or fastening material to secure the product to the surface.

[00104] 1.10 Stopwatch, readable in 0.1 seconds

[00105] 1.11 Ruler 2.0 Sample Preparation

[00106] 2.1 Based on the product size, determine the size and rate of the insult in the table below.

[00107] 2.2 Weigh the product with an accuracy of 0.01 grams and record it; discard samples outside the weight range determined by the applicant, if applicable. 3.0 Configuration Procedure

[00108] 3.1 Ensure that the saline solution is at room temperature.

[00109] 3.2 Have three countdown timers set for 30 seconds, 2 minutes and 15 minutes. 4.0 Test Procedure

[00110] 4.1 Place the product on a flat surface and secure the top and bottom ends with double-sided tape so that the product is stretched and the absorbent core is flat.

[00111] 4.2 Place the plate with the open cylinder over the stretched product so that the upper edge of the plate is aligned with the edge of the absorbent core. Place the funnel on top of the open cylinder on the plate.

[00112] 4.3 Weigh a sheet of blotting paper on a scale readable to three decimal places. Record the weight of the paper.

[00113] 4.4 Pour the specified amount of saline solution into the funnel according to the size of the product to be tested, following the instructions in the table below. Simultaneously activate the timer.

[00114] 4.5 Stop the timer as soon as the liquid passes Petition 870230088780, dated 06 / 10 / 2023, page 44 / 66 / 39 completely from the cylinder into the product (there is no liquid on the surface of the product). Start the timer set to 30 seconds and the timer set to 15 minutes.

[00115] 4.6 Record the capture time.

[00116] 4.7 After waiting 30 seconds, remove the plate with the cylinder open. Place the pre-weighed blotting paper over the product and then place the polycarbonate plate on top of it.

[00117] 4.8 Start the timer set to 2 minutes.

[00118] 4.9 After waiting 2 minutes, remove the polycarbonate sheet and blotting paper. Place the sheet back on the product with the open cylinder and leave it on the product during the waiting time.

[00119] 4.10 Weigh the blotting paper to the nearest thousandth and record the weight.

[00120] 4.11 Mark the two ends along the blotting paper where the fluid extends. Measure this distance in centimeters along the length and width of the blotting paper. Multiply these two distances to obtain the (spread) area of ​​the fluid. Record the spread.

[00121] 4.12 After waiting 15 minutes, place the weight on both sides of the cylinder on the plate. Pour the specified amount of saline solution, as per the table below, into the funnel placed in the cylinder. Simultaneously, start the timer and begin the countdown set for 15 minutes.

[00122] 4.13 Stop the timer as soon as the liquid has completely passed through the cylinder and entered the product (there is no liquid on the surface of the product). Record the second sampling time. Leave the plate with the cylinder open and the weights on the product during the waiting time.

[00123] 4.14 Weigh two sheets of blotting paper and record the weight to three decimal places. Petition 870230088780, dated 06 / 10 / 2023, pages 45 / 66 / 39

[00124] 4.15 After waiting 15 minutes, remove the weights and the rectangular board with the cylinder. Place the pre-weighed blotting paper on the product, then place the polycarbonate sheet and the two weights on top of it. Start the timer set for 2 minutes.

[00125] 4.16 After waiting 2 minutes, remove the weights, the polycarbonate plate, and the blotting paper. Immediately weigh the blotting paper on a scale readable to three decimal places and record the weight.

[00126] 4.17 Mark the two ends along the blotting paper where the fluid extends. Measure this distance in centimeters along the length and width of the blotting paper. Multiply these two distances to obtain the (spread) area of ​​the fluid. Record the spread. 4.18 Remove the product from the surface. Weigh the product and record the weight. Product Size N Step 1 Step 2 Step 3 Step 4 Step 5 2T / 3T 3T / 4T 4T / 5T Rate (ml / s) 9 ml / s 10 ml / s 12 ml / s 15 ml / s 15 ml / s 15 ml / s 15 ml / s 15 ml / s 15 ml / s Volume (ml) 40 50 60 70 85 100 80 100 110 Target Location (cm) (measured from the center) 4 5.5 6.5 7.5 8.5 9.5 8.5 9 9.5

[00127] In the first set of experiments, the following samples were constructed: Sample #1: HUGGIES SNUG & DRY brand diaper; Sample #2: HUGGIES SNUG & DRY brand diaper in which the expanding material has been replaced by non-woven fabric made in accordance with this disclosure; Sample #3: HUGGIES LITTLE MOVERS brand diaper; Sample No. 4: Modified HUGGIES LITTLE MOVERS brand diaper in which the expanding material has been replaced by non-woven fabric made in accordance with this disclosure.

[00128] Referring to FIGS. 5 and 6, the results obtained in the liquid intake and rewetting test are shown. As illustrated, the diapers modified with the nonwoven blanket of the present disclosure dramatically improved the handling properties of Petition 870230088780, dated 06 / 10 / 2023, page 46 / 66 / 39 fluids.

[00129] A subsequent set of experiments was conducted, in which diapers were made on a pilot line with different expanding materials. In particular, the nonwoven blanket as described above, made according to the present disclosure, was compared with a commercially available expanding material and also compared with an expanding material made of 100% hollow single-component polyethylene terephthalate fibers. The following samples were constructed: Sample #5: HUGGIES SNUG & DRY brand diaper; Sample #6: HUGGIES SNUG & DRY brand diaper including the expansion material of this disclosure; Sample #7: HUGGIES SNUG & DRY brand diaper containing an expanding material made of 100% polyethylene terephthalate fibers; Sample #8: HUGGIES LITTLE MOVERS brand diaper; Sample #9: HUGGIES LITTLE MOVERS brand diaper including the expansion material of this disclosure; Sample #10: HUGGIES LITTLE MOVERS brand diaper containing an expanding material made of 100% polyethylene terephthalate fibers; Sample #11: Diaper made with COSY lining containing the expansion material described in this disclosure; Sample #12: Diaper made with COSY lining containing expanding material made of 100% polyethylene terephthalate fibers.

[00130] FIGS. 7-12 illustrate the results obtained from the liquid uptake and rewetting tests of Sample No. 5 through Sample No. 12. As shown in the graphs, the nonwoven blanket made according to the present disclosure, containing only 40% by weight of Petition 870230088780, dated 06 / 10 / 2023, p. 47 / 66 / 39 polyester, provided rewetting results that were comparable to an expanding material made of 100% polyethylene terephthalate fibers. Example #2

[00131] Several different bonded carded mats were constructed in accordance with the present disclosure and compared with a commercial nonwoven mat that has been used as a peak layer. In this example, the mats were constructed and tested for air permeability.

[00132] The following connected carded blankets were tested: Sample No. 13: Comparative nonwoven blanket containing 30% by weight of polyethylene terephthalate fibers (6 denier), 35% by weight of binder fibers (1.5 denier) and 35% by weight of binder fibers (5.3 denier); Sample No. 14: 40% by weight of structural fibers as described in Example No. 1 (9 denier), 60% by weight of binder fibers as described in Example No. 1 (5.3 denier); Sample No. 15: 40% by weight of structural fibers described in Example No. 1 (9 denier), 40% by weight of binder fibers as described in Example No. 1 (5.3 denier), and 20% by weight of binder fibers having a smaller size (1.5 denier). The three samples above were tested for air permeability and the following results were obtained:______________________________ Sample No. Air Permeability (cfm / ft2) 13,450 14,955 15,751

[00133] As shown above, the nonwoven blankets made according to the present disclosure had dramatically improved air permeability compared to the comparison sample. Air permeability is directly related to void volume and liquid absorption capacity. Petition 870230088780, dated 06 / 10 / 2023, pages 48 / 66 / 39

[00134] The tensile strength in the machine direction and the elongation in the machine direction were also measured for Sample No. 15 above. The nonwoven blanket exhibited an excellent combination of properties that would indicate that the warp would be easy to process without choking problems. In particular, Sample No. 15 had a tensile strength in the machine direction of 8.877 gf and an elongation in the machine direction of 34%.

[00135] These and other modifications and variations of the present invention may be practiced by those skilled in the art without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. Furthermore, it should be understood that the details of the various embodiments may be modified in whole or in part. In addition, persons of ordinary skill in the art will note that the description presented is for illustrative purposes only and should not be construed as a limitation of the invention, which is described in more detail in the appended claims. Petition 870230088780, dated 06 / 10 / 2023, pp. 49 / 66

Claims

1 / 6 CLAIMS 1.Absorbent article (10), comprising: a side lining (14) of the body; an outer cover (15); an absorbent structure positioned between the side lining (14) of the body and the outer cover (15); and a peak layer (17) positioned between the side lining (14) of the body and the absorbent structure, the peak layer (17) including a nonwoven mat including a mixture of binder fibers and structural fibers, the structural fibers including multicomponent fibers, the structural fibers having a cross-section wherein the cross-section of the structural fibers includes a first polymeric component zone including a first polymeric component and a second polymeric component zone including a second polymeric component, wherein the first polymeric component has a lower melting temperature than the second polymeric component, characterized in that the binder fibers form bonding sites within the peak layer (17).

2. Absorbent article (10) according to claim 1, characterized in that the fibers of the structure include a plurality of first zones of polymeric components that are separated by one or more zones of second polymeric components.

3. Absorbent article (10) according to claim 1, characterized in that the first polymeric component comprises a first polyester polymer and the second polymeric component comprises a second polyester polymer.

4. Absorbent article (10) according to any of the preceding claims, characterized in that the first polymeric component and the second polymeric component both comprise polyethylene terephthalate polymers. Petition 870260051690, dated 29 / 05 / 2026, page 12 / 23 2 / 6 5. Absorbent article (10) according to any of the preceding claims, characterized in that the fibers of the structure comprise crimped fibers, including fibers that have 39 to 394 crimps per meter (1 to 10 crimps per inch).

6. Absorbent article (10) according to any of the preceding claims, characterized in that the fibers of the structure comprise hollow fibers.

7. Absorbent article (10) according to any of the preceding claims, characterized in that the fibers of the structure contain filler particles.

8. Absorbent article (10) according to any of the preceding claims, characterized in that the structural fibers are present in the nonwoven blanket in an amount of 20% to 60% by weight, such as in an amount of 35% to 45% by weight, the binding fibers being present in the nonwoven blanket in an amount of 40% to 80% by weight, such as in an amount of 55% to 65% by weight.

9. Absorbent article (10) according to any of the preceding claims, characterized in that the binding fibers comprise bicomponent fibers.

10. Absorbent article (10) according to claim 9 characterized in that the bicomponent fibers are made of polyolefin polymers.

11. Absorbent article (10) according to claim 9 or 10, characterized in that the bicomponent fibers include a coating layer surrounding a core, the coating layer including a polyethylene polymer, the core including a polypropylene polymer.

12. Absorbent article (10) according to any of the preceding claims, characterized in that the non-woven blanket Petition 870260051690, dated 29 / 05 / 2026, p. 13 / 23 3 / 6 has a basis weight of 20 g / m2 to 120 g / m2, such as 40 g / m2 to 100 g / m2.

13. Absorbent article (10) according to any of the preceding claims, characterized in that the nonwoven blanket comprises a carded and air-bonded blanket.

14. Absorbent article (10) according to any of the preceding claims, characterized in that the binder fibers and structural fibers have an average fiber length of 30 mm to 65 mm, such as 35 mm to 60 mm.

15. Absorbent article (10) according to any of the preceding claims, characterized in that the binder fibers comprise first binder fibers and second binder fibers, the first binder fibers having a denier of 3 to 10, such as 4 to 8, the second binder fibers having a denier of 0.1 to 3, such as 0.5 to 2.

16. Absorbent article (10) according to claim 15, characterized in that the first binding fibers are present in the nonwoven blanket in an amount of 20% to 75% by weight, as well as in an amount of 30% to 50% by weight, the second binding fibers being present in the nonwoven blanket in an amount of 5% to 40% by weight, as well as in an amount of 15% to 25% by weight.

17. Absorbent article (10) according to any of the preceding claims, characterized in that the nonwoven blanket has an air permeability greater than 2.54 m / s (500 cfm / ft2), greater than 3.05 m / s (600 cfm / ft2), greater than 3.30 m / s (650 cfm / ft2), greater than 3.81 m / s (750 cfm / ft2) and less than 7.62 m / s (1500 cfm / ft2).

18. Absorbent article (10) according to any of the preceding claims, characterized in that the nonwoven blanket has a tensile strength in the machine direction greater than 49.0 N (5000 gf), such as greater than 73.5 N (7,500 gf), such as greater than 78.5 N (8,000 gf), such as greater than 82.4 N (8,400 gf), such as greater than 86.3 N (8,800 gf) and less than 117.7 N (12,000 gf).

19. Absorbent article (10) according to any of the preceding claims, characterized in that the nonwoven blanket has an elongation in the machine direction of less than 50%, such as less than 45%, such as less than 40%, such as less than 38%, such as less than 37%, such as less than 36%, such as less than 35% and more than 20%.

20. Absorbent article (10) according to any of the preceding claims, characterized in that the non-woven blanket has a thickness of 2.5 mm to 5.5 mm.

21. Absorbent article (10) according to any of the preceding claims, characterized in that the reinforcing layer further comprises a hydrophilic finish applied to the fibers contained in the nonwoven blanket.

22. Nonwoven material with fluid management properties comprising: a nonwoven mat including a blend of binder fibers and structural fibers, the structural fibers including multicomponent fibers, the structural fibers having a cross-section wherein the cross-section of the structural fibers includes a first polymeric component zone including a first polymeric component and a second polymeric component zone including a second polymeric component, the first polymeric component including a first polyester polymer and the second polymeric component including a second polyester polymer, characterized in that the binder fibers include basic bicomponent fibers, and the binder fibers form bonding sites within the nonwoven mat at crossing sites where the binder fibers cross other fibers, the nonwoven mat including a carded mat having a basis weight of 20 g / m2 to 120 g / m2,and wherein the first polymeric component has a lower melting temperature than the second polymeric component, according to the article defined in claim 1.

23. Nonwoven material according to claim 22, characterized in that the structural fibers include a plurality of first polymeric component zones that are separated by one or more second polymeric component zones, and wherein the first polymeric component and the second polymeric component both comprise polyethylene terephthalate polymers, the first polymeric component having a lower melting temperature than the second polymeric component, and wherein the structural fibers comprise hollow fibers.

24. Nonwoven material according to claim 22 or 23, characterized in that the bicomponent fibers include a sheath layer surrounding a core, the sheath layer comprising a polyethylene polymer, the core comprising a polypropylene polymer.

25. Nonwoven material according to any one of claims 22 to 24, characterized in that the binder fibers and structural fibers have an average fiber length of 30 mm to 65 mm, such as 32 mm to 60 mm.

26. Nonwoven material according to any one of claims 22 to 25, characterized in that the expansion layer further comprises a hydrophilic finish applied to the fibers contained in the nonwoven mat.

27. Nonwoven material according to any one of claims 22 to 26, characterized in that the binder fibers comprise first binder fibers and second binder fibers, the first binder fibers having a dtex of 3.33 to 11.11 (denier of 3 to 10), such as 4.44 to 8.89 dtex (denier of 4 to 8), the second binder fibers Petition 870260051690, dated 05 / 29 / 2026, p. 16 / 23 6 / 6 having a dtex of 0.11 to 3.33 (denier of 0.1 to 3), as well as 0.56 to 2.22 dtex (0.5 to 2 denier), and wherein the first binder fibers are present in the nonwoven web in an amount of 20% to 75% by weight, as well as in an amount of 30% to 50% by weight, with the second binder fibers being present in the nonwoven web in an amount of 5% to 40% by weight, as well as in an amount of 15% to 25% by weight.

28. Nonwoven material according to any one of claims 22 to 27, characterized in that the nonwoven blanket has an air permeability greater than 2.54 m / s (500 cfm / ft2), greater than 3.05 m / s (600 cfm / ft2), greater than 3.30 m / s (650 cfm / ft2), greater than 3.81 m / s (750 cfm / ft2) and less than 4.62 m / s (1500 cfm / ft2).

29. Nonwoven material according to any one of claims 22 to 27, characterized in that the nonwoven fabric has a tensile strength in the machine direction greater than 49.0 N (5000 gf), such as greater than 58.8 N (6000 gf), such as greater than 73.5 N (7500 gf), such as greater than 78.5 N (8000 gf), such as greater than 82.4 N (8400 gf), such as greater than 86.3 N (8800 gf) and less than 117.7 N (12000 gf), and in that the nonwoven fabric has an elongation in the machine direction less than 50%, such as less than 40%, such as less than 38%, such as less than 37%, such as less than 36%, such as less than 35% and more than 20%. Petition 870260051690, dated 05 / 29 / 2026, pp. 17 / 23

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